Eton Eey QC Trainer International Certification & Training KSA(+966-599-807084) PAK (+92-334-7497876) www.qctrainer.com Email: ss_aakash@yahoo.com | With ARAMCO Engineering Standard & Procedure : SHAHID ALT CSWIP 3.1 (Instructor) Celli: 00966-599-807084 Cell#: 0092-334-7497876 35_aakash@yahoo.com Web: www.qctrainer.com: QC Trainer innematonal Certiicaton & Tanna Arne sare Pak na S787) ‘wwweacrainecom What is QA/QC? mal 85_sakash@yahoo.com 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 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 waming if ‘contractor doesn’t comply or violate with the standard procedure. ‘What is RFI? When an RFI will be raised? ‘Request for Inspection (RFT), RFI shall be raised only when the status of the preliminary inspection is satisfactory, and the works (items) are hold ot 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, Its 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 ASME3 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 me UIIso QC Trainer iematonal Gerteaton & Tarnng ‘ent moro Px 234575) wr cvarercom ‘Regarding Saudi Aramco Abbreviations Emat $_sesn@yhoo.com 1. SAE Su ame Egg str 18 8 Gaon Sone rom) ‘2, SAEP (Saudi Aramco Engineering Procedures). 19. WPB,WCB,LCB,LCC,LC1,LC2,LC3 (Materials Grades). 2 Selo dome npcton nes). 10. MAGP Ot lowe opting Psu) 4. SATR(Saudi Aramco Test Report). 21, SMYS (Specified Minimum Yield Strength). 5. SATIP (Saudi Aramco Typical Inspection Plan). 22. FCS (Field Change Sheet). * 6. CSD (Consultant Services Department). 23. CAR (Corrective Action Request). 2. Saonrfnud acamcs Prlert Mmagenest ear 24 eestor pet 2 St Sud Aone pectin Deparnent) 2 Ne han conor tego). 2 ssc natn sant eae 26. Pe (npg ert Or 50, Soe nt Amc tnd Dg 27, As iran tnd etn ater) 1. seed for sco. 2m aon sent cl ete 22 snp sna amor econ Pan > Av Amato ara stan) 13. SAMSSs(Saudi Aramco Material System Specifications). fe See eee Oestnactvn Testing seer On eae em a © Ginter on etna ra es ethane SS 998i Soc Bw. Nev meenie 15 Owe nfo err ol prow essen ne 117. UPC Uniform Plumbing Code). PID Loperntion Unapertion Leported SATIP (Saudi Aramco Typical Inspection Plan) SAES (Saudi Aramco Engineering Standard) ] SAEP (Saudi Aramco Engineering Standard} Pr» odo SAIC (Saudi Aramco Inspection Check List) | SATR (Saudi Aramco Test Report) Received NTI from Construction Team:~ Intemally Checking and Not Proceed the Next Step Before RFI time With NTI (ISO Drawing, MTC, SATR-W-2006 ete), 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 ete Pre icp” In prousy Pad Hold (RPP) . s SAEP-1143 (RT) SAT RW 2006 +> WeohTAN Lepert SAEP-1144 (MT) Loo}: - wat Grductios, SAEP-1145 (PT) 08 +- Tucks iq SAEP-1146 (UT) Tete qe Weld tobias Copa SAEP-1150 Inspection Coverage on Projects dwlae RPO . is Well Cetus Raise (Issue), Replied (Action) Open & Closed NCR (Non-Conformance Report) PAR (Preventive Action Request) Surveillance Report Contactor Internal NCR ARAMCO NCR (Reduce 2-Points in PQI) (Reduce 7-Points in PQI) SO After ‘Two Contactor Intemal NCR for Same Violation: Escalate to raise the ARAMCO NCR Al RAMCO NCR Mean Log Book Entry Before getting MCC should be close the all open NCRs.QC Trainer vernational Cerifeaton & Training Saoss-9.90706) PRK 823947457876) vw etainer com Ene 2 sakash@yehoo.com PQP (Project Quality Plan) or QCP Quality Control Procedure) Construction Scope of Work IFC Package Material Arrival MTO, MTC, Outboud Certificate (As per Drawing) NTI For Material Receiving Inspection (QC Mechanical /Piping Inspector) Standard: ASME-XT Design Code: 31.1, 31.3 Project specifications Heat No. Grade Specification Class SAP No. Dimensional Inspected & Release for Construction Construction / Execution Department Fabrication Preparation (ISO Drawing, MTO, Outbound) Consumable WPS Calibration Welders NTI for Cutting & Fitup to QC Piping Inspector 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) MN. QC Trainer international Cerificalon & Traning A(t 640708) PAK (a TUEPTD) www qtrainer.com SATIP, SAIC & STAR malt $5 sakash@yehoo.com SATIP-W-O11-01 Welding of On-Plot Piping (ASME 31.1, 31.3) [1] SAIC-W-2005 | Pre-Welding Inspection (Shop & Field) of Plant Piping 2_| SAIC-W-2006 | In-Process Welding Inspection 3__| SAIC-W-2007 | Post-Welding Visual Inspection (Plant Piping) [4 | SAIC-W-2015 | Selection of Welds for NDE (On-Plot Piping & Structures) Control of Welding Consumables - Plant Piping (Site Storage, Pia Neelcag eta Handling, Conditigning & Issuance) oe 2 6 _| SAIC-W-2013 | Weld Repair Inspection SATIP-W-012-01 Welding of Pipelines (API-1104, ASME 31.4, 31.8) Pre-Welding, In-Process & Final Inspection (Pipelines) | Inspection of Repair on Weld Joints or Base Metal by Welding (Prior to Weld ee SAIC-W-2051 | Acceptance) for Pipelines 3 SAIC-W-2044 | Receiving Inspection of Welding Consumables (Pipelines) 4 SAIC-W-2046 _| Control of Welding Consumables (Storage, Handling, Issuance & | Conditioning) - Pipelines [5 SaIc-W-2037_| W-2037 7 SAIC-W-2036 [6 SAIC-A-2009 | Verify Test Equipment (Safety Assessment) Unspection & Procedure review of Socket Welded Joints Inspect/Verify Piping & Weld Modifications* After Initial Welding | Acceptance (Modifications, Repair and Rework) SATIP-M-001-01 Welding of Pipelines (AWS D1.1) Inspection of Structural Welding (Per AWS D1.1) (ea SAIC-M-2012 | pre-Welding, In-Process & Final Inspection (Pipelines) SATR [1 SATR-W-2006 Daily Weld Fit-Up Insp. Report (For SAEP-1160 Database) 2 SATR-W-2007 | Daily Weld Fit-Up And Production Report (Shop Weld)-Pipeline [3 SATR-W-2010 | Welding Consumables Issuance Report 4 | SATR-W-2009 __| Welding Rod Oven Calibration/Verification Report SATR-W-2013 SATR-W-2019 Data Base Reporting For Production Weld & Welding Repair Rate Assessment SATR-W-2013 Weekly Welder Repair Rate Report, | SATR-W- 2019 Weekly & Cumulative Weld Status Report Welding Consumable Receiving Insp Report ASME 31.1 (Pressure Piping, Power Piping) ASME 31.3 (Process Pipin; ASME 31.4 (Pipeline Tran: 1s) portation Systems for Liquids and Slurries) ASME 31.8 (Gas Transmission and Distribution Piping Systems) Info: Pressure Vessel Inspections s (API 510) Risk Based Inspection (API 580/ ASME PCC-3) Piping Inspections (ANSI B 31.3 / 31.4, API 570) Welding Inspection (CSWIP 3.1 / API 577)QC Trainer Intemational Geniicaton & Taming GA Dee 708 PAK is2Sb4eSr7 Welding On SS (Austenitic Stainless steel) Emalt $_sakash@yahoo.com ¥_ 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 $0-ppm. Gray duet tape is prohibited (chlorides) Y Austenitic & nickel alloy material fabrication areas are separated from CS areas (upwind to prevent cross contamination) Y Wind velocity in the weld area for GTAW, GMAW, or gas shielded FCAW shall not exceed 8 kph 2.2m) Y Oil, moisture, scale, rust, paint (except approved weld-able primers), metallic coatings (e.g. zine) 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 @ continuous chromium-oxide, passive film. Both are acid treatments and neither will remove grease or oil. Welding of Tie Join 3-Days continuously raising the RFI for subjected Joint. For Welding suitable Time is 12°clock of day time. (Mary. peat tump ef Ley) Average T& Suitable Temperature is: 45°¢ (Recorded Three Days Temperature) Due to Elongation: (Contraction & Expansion) Tie-in joint is a concept of ASME B31.8 and it was considered as a factor in some design aspects and wwe use it in piping (designed based on ASME B31.3) for separating boundary of different subcontractors in test packages. Punch List Definitions Category Punch ‘A’ Items ; Items to be completed prior to Pressure Test (Hydro/Pneumatic) & Service. Category Punch 'B' Items ; Items to be completed after Pressure Test (Hydro/Pneumatic) & Service. Bal pane essure Lest | Note 1. Initial punch list shall be carried out by contractor prior package submission to SAPMT & SAPD. SAPID will list additional punch items (If not listed by contractor/SAPMT) for Category A & B items. ‘The purpose of this sheet to provide you the guidelines for punch list categorization and not listed all the requirements of standards and international standards. It is user responsibility to verify the standard requirements and shall not limited to below categorized items. Visual test packages like open vent and drain lines shall not have any punch B' Items and All items shall be listed for Category A’ Items,: QC Trainer Intemational Geriicaton & Trang Sa96s-090- 207084 PAK 82994-7457876) ‘wswactrainer com Welding Consumable a cale nanan Welding Consumable Control Room Non Stop electricity should be available. Humidity: 40 °¢ to 50° Temperature: 5-60°C (Ideal Temp 25°e to 30°c) Monitor & Fulfill the Requirements: Available trained ROD Issuer Hygrometer placed on appropriate place and should be Calibrated Al Equipment should be calibrated Safety Equipment should be installed. S488 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 SAKA KK INSTRUCTIONS: DO NOT USE ELECTRODE OR FILLER MAT'L "LOTS" on SA Projects for production welding until PML tests verify composition. At the latest, test the first produetion 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)/ . Asi- cs SPA-5.6 Copper & Alloy Electrodes , a SFA-5.7 Copper & Alloy Rods & Electrodes AS3- SFA-5.9 Bare SS Electrodes & Rods AS4-SS 5.11 Nickel & Alloy Electrodes (SMAW) ASS ALS 12 Tungsten & Alloy Electrodes C el 13 Surfacing Electrode (SMAW) A S.4 - CY - Blectrede 14 Nickel & Alloy Bare Electrodes & Rods A Sop Cy - beds 21 Bare Electrodes & Rods, Surfacing SS Electrodes (FCAW) & SS Flux Cored Rods (GTAWIAS* 10 + Low-Alloy Electrodes & Fluxes (SAW) Low-Alloy Electrodes & Rods (GMAW) loy Electrodes (FCAW) *(SPA = Specification of filler analysis) ASME SEC II C - Specification for Welding rods, Electrodes & Filler metals rote CHEMICAL ANALYSIS (PMI ... "BUTTON" aL Details vary per Spec. Refer to Fig. | - Pad for Chemical Analyses [ of Undiluted Weld Metal iQC Trainer infematonal Centicaton & Training ‘Sere orng rant PMI (Positive Material Identification) SAES-A-206 mats sakash@yabo om API -s78 There are two globally accepted analytical methods for simple on-site Positive Material Identification: X-ray Fluorescence (XRF) and Optical Emission Spectroscopy (OES), Hand Held Spectrometer is used for performing PML PMI by XRF Metal Analyzer X-MET8000 PMI: Positive Material Identification ~ Verification that the nominal chemical composition of an alloy material is as specified and ordered. The term applies to programs, processes, procedures, and tests in accordance with this standard. PMI Testing: Any physical evaluation or test of a material, meeting the requirements of this standard, to confirm that the material which has been or will be placed into service is consistent with the selected or specified alloy material, 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 Il, 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 TIC for each element. (Consumable = 412.6% Variation accepted) Results showing Copper Content greater than 0.7% indicate unacceptable "cross contamination" The elements of the basic alloy materials to be verified shall be in accordance with Table 2. Table 2 “Basic Alloy Elements to be Verified Carbon-Molybdenum, Manganese | Molydenum, and Chromium Molybdenum-Vanadium steels Regular carbon grade stainless T Chromium, Molybdenum and Vanadium, Chromium, Nickel and Molybdenum [sees Low and high carbon stainless Chromium, Nickel, Molybdenum and |_steels _| Carbon Chromium, Nickel, Molybdenum, Titanium and Niobium Nickel, Iron, Copper, Chromium, | Nickel-based alloys Molyodenum, Tungsten, Vanadium and Copper, as applicable |” stablized stainless steelsQC Trainer sacs gore pac ase aeer) Consumable: (ASME Sec-II-C) malt $5 2akash@yenoo.com 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 Approv: ‘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 Nev = Sous Welding Consumables shall have a SAP ID number to show their purchase from an approved vendor for specific consumable. Drying & Re-Drying ASI ASS Low Hydrogen Blecirode Low Hydrogen Blectrode [60XX c TOXX & 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:- AS1 ASS Alloy Low Hydrogen Electrode Alloy Low Hydrogen Electrode 60XX, TOXX & 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 6! 4-Hr in Portable Oven minimum 6! 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 ‘Smm for 1G/IF Position 4mm for other Position Non-Low Hydrogen Electrode 5mm for All Position « Low Hydrogen Electrodev viv QC Trainer {ntemational Gerifoaton & Tranng NSAoES 59 g0OR4) PAK aR T4TE7) won tra Exposure Limitat Drying: 120C - 250C (2-H) Not be exposed if.- Store: 120€ - 200C Minimum 4-Hr Open in Atmosphere i 8-Hr in Portable Oven minimum 65°C Lincoln currently recommends a 3-year shelf life in certain brands of SMAW clectrodes. 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 £6010 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) | “ [Mhoriaied or Zireonated ‘Use on DE+ve -d (Orange) and Lanthanated (( old) 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) "Major Inspection of Material Receiving Major Inspection of Material (Pipe) % Size ¥ Welded Seam Y Condition Y Inside Dia ¥ Type/ Specification / Schedule Y Outside Dia Y Storage Y Length |v Heat Number _ ¥_ Wall Thickness 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QC Trainer iseratona Gefcaton& Taring ‘ccm sren a nso) DUTIES BEFORE WELDING CHECK ACTION Eat te slath@yateo.com [Application Standard Approved WPS / POR & Drawing (welling package) Have been approved and WPS is available to welders (and inspectors) ee Composition & Condition: Metal) Traceability |! 8¢cordance with drawing/WPS>Identified and can be traced to atest certificate 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 storedicontrolled as | Welding consumables |. ecified by the QC Procedure Jeller qualifications | !entification of welders qualified for each WPS to be used. PSUs Gunicasionl Ail vel dt ata Ncaion SuneeS TCC aa eT (in date) preparations | In accordance with WPS (and/or drawings)Edge Preparation: ae In accordance with WPS/drawings tack welds are to good workmanship standard me and to code/WPS Weld faces ate fiee from defects, contamination and damage Preheat (ifrequited) 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 Lo entire complete job or contract. DUTIES DURING WELDING (CHECK ACTION) . . Ensure weather conditions are suitable/comply with Code ] ened eens | (Conditions will not affect welding) ‘Welding process [Un accordance with WPS Preheat Temperature _ | (ifrequired) Minimum temperature is being maintained in accordance with WPS Inter-pass temperature | Maximum temperature is in accordance with WPS ding consumables | Inn accordance with WPS and being controlled as Procedure ‘Welding parameters | Current, volts, travel speed are in accordance with WPS. Root run ‘sually 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 | Each weld is marked with the welders identification and is identified in accordance with __| drawingsveld map - Weld appearance Ensure welds are suitable for all NDT (profile, cleanness etc)- SPF | Visually inspect welds and sentence in accordance with Code Dimensional survey | Check dimensions are in accordance with drawing/Code Drawings insure any modifications are included on as-built drawings Ensure all NDT is complete and reports are available for records |’ Monitor in accordance with the Procedure (if required) Monitor for compliance with Procedure (check chart record) | test (if required) Ensure test equipment is calibrated Monitor test to ensure compliance | Pre with Procedure/Code. Ensure reports/records are available Documentation | Ensure all reports/records are completed and collated as required Records | Repa Pressure/load: QC Trainer IRerratonal Coaicaton & Trang ‘nti dpsorns Pease are ASME_SECTIONS Eat ankasnyaoo com (ASME_ = American Society of Mechanical Engineers) SECTION-I | Rules for Construction of Power Boilers SECTION I | Materials Part A - Ferrous Material Specifications Part B -Nonferrous Material Specifications Part C_ - Specifications for Welding Rods, Electrodes, and Filler Metals [pat D = Properties (Customary) | Part E Properties (Metric) [SECTION- I Subsection NCA [SECTION-IV (Rules for Construction of Heating Boilers SECTION-V [Nondestructive Examination -SECTION-Vi_“ Recommended Rules _for the Care and Operation of Heating Boilers Recommended Guidelines for the Care of Power Boilers Rules for Construction of Pressure Vessels Division 1 Division 2- Alternative Rules Division 3- Alternative Rules for Construction of High Pressure Vessels Welding and Brazing Qualifications SECTION Fiber - Reinforced Plastic Pressure Vessels SECTION XI _/ Rules forin service Inspection of Nuclear Power Plant Components SECTION XI Rules for Construction and Continued Service of Transport Tanks ME B 31.3 - Process Piping ASME B 31.1 - Power Piping ASTM- American Society of Testing Materials AWS D1.1- American Welding Society (Structural Welding) AWS D16 - American Welding Society (Structure $$ Welding) [ASME BI6.1 Cast iron pipes flanges & Hanged fittings Flanges [ASME 16.5 | Carbon siee! pipes flanges & flanged fittings. (Up to 24”) ‘ASME B16.47 Large Diameter steel flanges. (Above 24”) ESS ASME B16.9 Steel butt welding fittings fittings "ASME B16.28 Butt-welded short radius elbows & returns bends. f an © B16.20/ API-601_| Metallic gaskets for pipe flanges- Spiral wound |Seibaesee BI6.21 ‘Non metallic gasket 1 Socket & Threaded ASME B16.11 Forged steel socket welding & threaded fittings fittings cai [ASME Bi6.10 Face 10 face & end to end dimension of valves. | Valves 7 7 Flanged -welded ends steel valves (Pressure & Temperature | ASME B16.34 eae oes t Ball, Plug & Butter fly Valves As per ASME B31.3, what is the maximum weld reinforcement allowed? [Wallihickness | Max. Weld Reinforcement [Less than 6 mm 15mm aad [mm 4mm SimmQC Trainer Intemational Geriicaton & Taming SA(+06 896007086 PAK vs2-94. 747678) A= Number: Eat te aath@yeten.com A—Nuibers are used to identify the weld metal chemical composition of ferrous metals Cc ANALYSIS 1 NO. Types of weld deposit c cr Mo Ni Ma Si 1] Mild steel 0.20 = 1.60 1.00 2 | Carbon-Molybdenum 015050 04-065 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 [04-150 | = 1.60) 2.00 [5 Chrome (6% to 10.5%)-Mo_| 0.15 | 60-103 104-150 | — 1.20 2.00 6 Chrome-Martensitie [oasis 70,70 E 20 1.00 7 Chrome-Ferritic Tots 1.0 10 3.00 8 Chrome-Nickle 0.15 40 7515 [2.50 1.00 ‘9 Chrome-Niekle 0.30) 40 15-37 | 2.30 1.00 TO Nickle t0 4% 0. 0.55 0.80-4.0_| 1.70 1.00 11 Mn-Mo 0.17 [025-075 [0.85 [125-225 [1.00 [2 Ni-Cr-Mo 013 [150 0.25-0.80_|1.25-280_|0.75-2.25 [1.00 Wb 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) P= Numbers | Types of Material Carbon-Manganese steel Carbon - 4 % Mo. (Alloy Steel [1% Cr % Mo. (Alloy Steel) 24% Cr— 1 %Mo, 5 Cr. (Alloy Steal) [High Alloy Martensitic stainless steel [High Alloy Ferritic stainless steel = Austenitic stainless steel. 9 ___ Nickel steel | Quenched & Tempered Steel TAI & Al base Alloys Cu & Cubase Alloys eS 3 Ti & Ti base Alloys 6 Zi & Zr base Alloys 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. [Fo Numbers] Gass. OF Filler Metals F=Nos._| Gass. Of Filler Metals = Boi - 21-25 | Al & Al base alloys. { a a AY 31-37 | Cu & Cubase alloys. - Glnloic Wom 41-45 Ni & Ni base alloys. Low hydrogen electrode. S134 Ti & Ti alloy | All stainless steel Electrode. (SMAW) _| 61 Zr & Zralloys © Bare wires/Core wires of CS, SS &LAS | 71—72 | Hard-facing weld metalQC Trainer iMtematonal Gerificaton & Traning KS8(+056 696607004 PAK (5294-77878) ‘www qciainer com What are the different types of Base Material with Grade? Material STAN lesan Tnterpase th Grade Filler We | Pre Heat Temp | PWHT P No. wn SEMEN DIR coca Max | ‘A106 Gr. A-0.28 % (SUBSE 050% | cs A108 Gr. C= 0.95% | ER-708-2 <20mm : 10°C . 19>599°C Pret | meen | enat, | mo10- | ceraaeae | are | ERTS ISL Gr A-53 GB | | 5 TERSOS- e i B00" esitcs) asascrertes | ER E-70181 | Max 10°C 50;Cll genet A316 | | iss ERSIOL | E316 A3I6H SS P Noe | (astmsiz) | 4 Spa ER30BL E308L | | ‘toc a77°C NA 304,308,310, 308L | HODI7 3 | | 347,348 ER 3478 | E347 | A 32M ERS | 847 ep | Dissinilar CSASSt0 SS-304L | ERNICrS | Tee TC NA Meterial (BM T=<12mm) | | _CSA-53 to SS-304L | ms Ts mane | | 104°C to 760° 335-711 | | 260°C icy, (A335-P-22 | paptet ea tact Alloy a 730°C to | S00°¢ | 00 ‘Aluminum Sm ay Gre Aluminum "sp 241 Gr 6083 25 Welder Qualification:- ASME See-IX & SAEP-324 must be qualified ICC'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: lo. 14, S4 64 Pipe — Groove : ic ; OD cr a 2G BH * Pibe— Raloding { ; Mb -E teat oe 5G EV,0 -* NIG. pect 7 Pobe~ Fixe? x wade. Rotel 7 eS al dtc) Y NOOK Feat Lit 4 Vetind yap) 2Gand$SG All * Cats Hwignday ee a Thickness: ele gee Pte Qualification based on 2T formula = PXS4 = AU PosQC Trainer Intemational Gerifoaton & Tanne ON So 08 PAK oS 787) ‘www.qctrainer com Email 85_aakash@ychoo.com Performance Qualification — Position and Diameter Limitations (Within the Other Limitations of QW-303) | rte guans iatan Tet crsoe Tee Mate and Pipe Over28Pipez 4 im (G10 mm) watt etton ‘(610 an) 99. ob. Pe and Pipe 1 F Finaw : | Fa ea i ae eH x By Net fy | sm — crore “ fo F Nee) Ho | Gand 46 fe Fivae a | 26, rand a6 aM HTN 2 at LL Spedal aston ($9 ss soe sor a fot | * : eave on * - uty ce # : Ho es seein : t ‘aL fot 2) Spec one (5 SF Net 2) Pips — sve pete) a " a a aesise a au a wc ors (9) se soe we 1 : - F Pipe — Fer et) es . Bio I Special Pads (SP) Sr | we Qw-452.3. > Groove Weld Diameter Limits OD of Test Coupon in (mm) op geeneaii (om) Min Max a 1%" Welded Test Unlimited Ea 7A" Welded Test Unlimited 1" to 2% " (73mm) LS" iv Unlimited [_24" 73mm) to above 243 2A" (73mm) Unlimited GENERAL NOTES: (2) Type and numberof tts reared shal be in accordance with eas. ©) 2% in (73 mm) 0.0. ithe equvalen: of NPS 2% (DN 65) Thickness Range Qualification for WQT = OD Qualified, in (mm) t Coupon i az ze zi L <10mm ail 1.5mm 2 T Deposit Thickness 10mm to 13mm [ Unlimited Process Used on base of Material Thickness: SMAW = Allabove 3mm GTAW Thin Section <10mm GMAW/FCAW: Typically 3 t0 30mm SAW = 15 to 150mm or above |. QC Trainer ‘Rlamatonal Cenfenton & Tang Iara to Pax eau Te GTAW process is mandatory for all Lines that will be less than 24” in Ena ts skash@yaoo.con Dia, 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 [ (ome Pale Maal Sar sutrave Presse) B >0.2%-0.4% Level B ee] esi | | tn | tn tre C. 0.4% - 0.5% Level C i Sowa | ‘Sra | MAESeStenee nme D. > 0.5% Level D, Revoke ale | eR tina eet | Mei Se a a [a [aceite] amir | | sms ar | | oar Triana [© | seetiote7 | taxman | see teens | tent € Walla eortng says L ‘Sd aa > ‘wot | Above 8% | Above | bevel Welle conaeenty atin ar | Semaine seeeere enone (Length) = RT Rejeoted / RT Done x 100 Joint (Qty)Nos. = RT Rejected / RT Done x 100 7. Level A, B & C Welders Y Inall cases, Welder performance should target “A” Classification results with the lqwest possible Linear & Joint Repair Rates achievable. Y Continuing Process Improvement, Cost Effectiveness is acceptable for Cat. A & B welders, Y Cat, C welders are not cost effective and require close supervision) 8. Level DV lers: ¥ Welders may exceed the 7.5% joint WRR weekly for a ma 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, um period of 2-3 weeks with close ( ‘Tack Weld: Thickness = — 3.2t04.8 7 Length 2 12.5 t0.25.4/ 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 15* seconds cooling under gas flow will result in zero oxidationan QC Trainer {ntemational Cerifoaton & Training oaoss-s99.007084 mak s2.394-7087976) ‘wws.gctraner com Ea: s_sakash@yahoo.com Preheat: " Preheat Temperature not be less than 10C Preheat Temperature shall be established over a minimum distance 75mm of each side. ‘Temperature Equalization mint = 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 = 52°C Maximum Interpass Temperature: Pipe, Reducer, Elbo, Tee= 25°C 3.45 315C Structural = 10°C 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 ics = <20mm Not required 2 320mm 593-649 +-Hr 3__| Alloy Steel (P-4& 5) [213mm ‘704-746 2-H _| High Alloy Steel (P-6) [All Thickness: | 732-788 [2-H [5 Nickel Alloy (P-9 A&B) >20mm_ | 593-635, [4-Hr Note: P No. 7 (High Alloy Ferritic stainless steel) & 8 (Austenitic stainless steel.) Not Done PWHT Heating & Cooling Rate in PWHT is :- 222°C/Hr _after 316°C in shall be applied a minimum of 300 mm on either side of the weld that is to be PWHTed. The ‘ation 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 e of the joint unless the internal surface is also insulated. ‘Thermocouple Requirement: (J & K Types) PipeDia = = = 305mm (12) or Less PipeDia = = 305 t0 610 PipeDia = 610 and above 4No. In this chart, ‘X-axis represents temperature and Y-axis represents Time, In X-axis each line to line distance represents 10Deg C In Y-axis each line to line distance represents half an hour, That means the time between 2 and 3 represents one hour. ‘The graph contains several lines, AB, BC, CD, AE 1) AB is RATE OF HEATING curve 3) CD is RATE OF COOLING curve BC is SOAKING TEMPERATURE 14) AE is ROOM TEMPERATURE curve When you check the WPS you can see the required values for each of these.QC Trainer Intemational Gerificaton & Trang NSA oes 40730 PA onaSH747075) \nwwaetrainercom mat ss_aakaen@yahoo.com In Fillet Weld Convexity:- Width of weld face W<8mm W> 8 to<25mm W> 25mm 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 O- (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% Weld Repair: Y 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 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. Afier welding: Maximum gap of 50% engagement is acceptable. Note: Ata 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 mim. 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.QC Trainer Intemational Gerificaton & Traring NEAR sm 40O%4 PRK 8234777) vwvietrainer.com NOTE: Internal tapering (ASME B31.3) by machining, back Ena $8 aalaan@yanoo com 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). For Socket Welding: 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. PIKOTEK Buttering / Weld buildup:- Buttering or weld build-up on the prepared surfaces shall not exceed the lesser of Y 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. 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: LS 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: LSD (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.QC Trainer Iiemational Geriieaton & Training IKGh( 066600207086 Pak ($25394-747675) \www-qcrainer. com Line Class:- (SAES-L-105) 3CS1P First Pressure rating Secon: Pipe Material Third = Corrosion Allowance Forth Service An example of a complete piping line class designator is "3CSIP", This designator specifies an ASME pressure class 300, carbon steel piping system with 1,6 mm corrosion allowance designed for general Ema $5, sakash@yehoo.com process service with no changes to the base piping line class material specification. 5.1 The standard consists of three parts: Part I, supplements ASME B31.4/8 design Code and covers the applicable piping defined in SAFS-1-100 for non-process facilities such as pump stations, terminals, water treatment and water injection plants, bulk air fueling terminals, tank farms, and wellhead piping. Flowlines, trunklines, transmission lines, plant cross-country pipelines, and sub-sea pipelines are excluded. Part Il, supplements / refineries and petrochemical plants. Part Ll covers utility and non-metallic piping for process and non-process facilities. Table 9.1 - Piping Line Classes Index for Part I (Non-process Facilities) SME B31.1/3 design Code and covers the applicable piping defined in SAES-L-100 for process facilities such as steam generation plants, GOSPs, gas plants, NGL plants, off-shore platforms, — DESIGN TEMP] VALVE service | MATERIAL | pee ON oe | ME | VALNE [wore (CARBON STEEL PIPING - NON SOUR SERVICES General ydrocarbon | Impecttesed | ASMEBI63 | AGCto 12NC | Trim 12 lowtnp) | Carns! | Flange ating” ASME B31431.8 General iycrocarton | Cabonstel | ASMEBI63 | I®Cw IN| Tam’ | ERWaad X63 | Flange rating’ | se pemaited | ASMEB3I.AS18 DCSE Wellhead Piping | Carbon sel) APT@AS000RI | SC BTC | Trim ® L ASME B3L4518 | Ca Rha Gas Carbon seal | APL6A ODOR | BCT TPC] Trim Ne Wellicad Piping ASME 318 ‘CARBON STFE. PIPING -SOUR SERVICES: Sou Caibonsteel | ASMEBIGS ] -ISCw@IONC] Timi |) $$Ceunizonmenss | 18013156 | Flange rating! PerSAESLAI33 | ERWand X65 | ASMEB314318 ‘re permitted | Sourserices | Carbon sel | ASMEBI6S | ISCw SNC] Trim 1 | a) HiConvitonments | HICResisant | Flange rating? | per SAES-L133 18015156 | ASMEBSLASLS | | ERW and X65 | sermitted l STAINLESS STEELS [TSA Gone enkn | SUBULSS | ASMEBICS | aOCw IC] Timi] SAIP —] | Coworive sevice Flange rating! | ASME B3L4B1.8 | Spor TIGRIS | ASMEBIGS | Cw INC] Tam Id SSS ~ Conrosive Services Flange rating! | 38p0r ASMEBSLABL8 WW Conoshe process Sea SuperDuplee | ASMEBIGS | OCwo ane | Tams] Water, Wasea Water, ange rating!QC Trainer Code Of Pipe & Fittings item CS (Carbon Steel) [SS (Stainless Steel) | DS (Duplex Steal) aoe ASTM-106 ‘ASTM-312 ‘ASTM-790 a ASME-36.10 ASME-36.19 ASME-36.19 : ] ASTM-234 ASTM-403 ASTM-815 ney ASME-169 | __ASME-169 ASME-16.9 TEE | ASTMA234 ‘ASTM-405 ‘ASTM-182 |__ASME-16.9 ASME-16.9 ASME-16.9 ae ‘ASTM-105 ‘ASTM-182 ‘ASTM-182 EES ASME-165 | __ASME-16.5 ASME-16.5 ma ] ASTM-234 ASTM-403 T ASTM-240 REDUCER | _asMeigo | _ASMP-169 ASME-16.9 “Dol T AS oe ASTM-105 ASTM-182, | = ASTM-182 SOCKOLET | _ASME-16.11 ASME-16.11 ASME-16.11 ‘ASTM-106 7 ‘ASTM-312 ASTM-790 Ra | 1 ASME-36.19 ASME-36.19 aa ASTM-234 ASTM-403 ASTM-815 |___ASME-16.9 | __ASME-36.19__ | __ASME-36.19 LTCS ASTM A 333 GR. 6 pecification & Grade with as example Heat No. of CS Material item Specification & Grade Heat No. | 85625, | PIPE ea SB602 | ’ ts 290558 _ELBOW - A-234 | (WPHY-60) 782363 Te aa . HAD feet I Seinoaal BHY, R53, R4AVA, BIG REDUCER A234, (WPHY-60) | 782363, WELDOLET a Weldolet (225663) THREDOLET A-105 | SOCKOLET Thredolet (UXRL) NIPPLE z CAP| ° i 1 i & ~w QC Trainer : al aN en NI eee St en NA ae be Salt me ENA alti fal | " sle«[? 3] ri we Re [SOCKET WELD & THREADED TYPE 7434 Baba af] Pus a Pe A LIZ ad A Eee MG ime Sa [eel ef a — Aae Traines 055.599.9070) Pak (182994.7687070) ‘ww getaior com [ FITTINGS: | 1, | Elbow (Bendsy | To Joint the Two Pipe - Pipe Cut an Angle of 45 or 90 By Radius: | | By Types: hort Radius Equal Elbow Long Radius Reducing Elbow Extra Long Radius 2. Tee ‘Used to make a Branch Line at Right Angle to the Main line i Equal Tee _ Reducing Tee - 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. Concentric reducer is used in pump suction. (Yes / No). Explain. Answer: No. Air pockets may form if concentric reducer is used at pump suction, which results in Cavitations, and cause damage to Pump. To avoid this problem, Eccentric Reducer with Flat Side Up (FSU)is used in Pump Suction. Olets Small Bore Fittings Olet use for connecting Main Line to Branch Line Sock olet Thread olet Weld olet Sweep olet (Like Weld olet but use for other then 90° Angle 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 (6. Flanges "1-Otifice Flange (hole for instruments) ‘heck Vaive (Non Return Valve) Two Types: (Lift Check Valve, Swing check Valve) Not Handle no need to operate: Installation Direction required > all Valve: 90° Angle required for Work 3- Safety Valve 4+- Globe Valve: Installation Direction required > ~ Butterily Valve: Only move his Plate in 90° Angle (Both Side) 6- Gate Valve (No Direction required for installation) Needle Valve we can check the Temperature or Pressure by this hole, Neck Weld Flange: Long Neck Weld Flange 3-Slip on Flange 4-Blind Flange 5-Socket Weld Flange o-Male & Female Flange / angue & Groove