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

Inspection of Repair on Weld Joints or Base Metal by

SAIC-W-2013 WELD-
Welding (Prior to Weld Acceptance)
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 GENERAL REQMTS (See Note 1, Attachment 1, SAIC-W-2008, SAIC-W-2016 & SAIC-W-2036 Related to Repairs)
QUALITY PLAN
SA Inspector was notified before Repairs. (RT results, etc).
An agreed upon system shall be set in place on all projects.
REQUIREMENT
Prime Contractor shall witness repair
A1
excavation by Sub Contactor. SA Inspector shall have a chance to
NDE Kickoff
witness any such excavation of repairs. "GLASS WINDOW POLICY"
Meeting
exists regarding repairs.
Topic
Weld did not meet code or standard acceptance criteria.
NDE PROCESS CONTROL SAES-W-011,
PROCEDURE details Repair Practice. This was strictly Para.
followed regarding repair verification, weld ID, NDE & repair markings, 18.7
A2
NDE reporting, & disposition of repairs. Prime QUALITY PLAN
Contractor & Sub, NDE Service Provider follow protocol
NDE markings are verified, and correct joint was REQUIREMENT
repaired by qualified welders with approved JCCs.

SAEP-1160 Database and recording of repairs and status:

A) Meets SAEP-1160 Sect 6 Weld Tracking. (SAIC-W-2008)
B) Backlogs are tallied and reported. QUALITY PLAN
A3 C) SA OID/NDTU has received any RT Film
(original & repairs) D) Tracer welds are REQUIREMENT
selected and tested for repair joints Repair is actually
reported in Database & documented.

B Repair of Welds Rejected by Radiography or Other NDE Methods

Weld cut-out was performed on welds that has been repaired twice.
SAES-W-011,
B1 Note: Exception to this is when additional repair attempts are allowed by
Para. 18.1
Saudi Aramco Inspector.

Cracked welds (except for crater cracks) are repaired by cut-out unless a
SAES-W-011,
B2 repair is approved by CSD. Crater cracks are ground out & MT examined
Para. 18.2
(or PT).

C Repair of Welds due to Base Metal or Welding Consummables (Tie-Ins to Existing Equipment or Piping, etc)

Cracks related to base metal or welding consumables shall be SAES-W-011,

C1
evaluated by CSD BEFORE any repair attempt. See Note 2 in C2. Para. 18.2

Page 1 of 5
 If a repair to a crack is approved, Repair & Inspection Procedure was
reviewed & approved by CSD prior to excavation of defects.
Note 1: Additional checklist items shall be added to this
checklist to include conditions & inspection reqmts and acceptance
criteria for repair of weld. See examples below.
Note 2: When tie-in welds to
existing piping in services such as Hydrogen, Caustic, Sulphur Recovery, SAES-W-011,
C2
Acid Gas, Wet H2S, other services as covered in API 571, etc ... Para. 18.2
Weldability shall be considered as well as additional cleaning beyond the
25mm rule, ph testing for process saturated surfaces, and crack
preventive measures such as "FULL OR PARTIAL BAKE OUTs" &
increased PREHEAT TEMPSs ... as outlined in API 571.
Determine reason for cracking (Weld
Service environment)

Page 2 of 5
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

Weld Repair Inspection SAIC-W-2013 WELD-

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

Repair of Parent material mechanical damage, pitting marks: The

extent of repair allowed is as per parent material specification / code. If
C3 needed the section of parent material / item with damage shall be ASME Sec II
replaced. All the repair shall follow the approved project repair
procedure / method statement.

Consumable related repairs have been identified & corrective action

has been taken regarding WPS Parameter monitoring & removal of
existing consumables (same lot, batch number) to prevent reoccurrence.
Furthermore, Quality Manager has taken action regarding SAIC-W-2009,
SAES-W-011,
C4 Attachment 1 regarding Acceptable Storage Practices & maintaining a
Para. 18.2
Dry Environment for Electrodes. NCR was
issued & defective consumables were removed from site
Root cause and corrective actions implemented was determined and
agreed upon by the authorized SA Inspector covering Repairs.

D ASME B31.3 CODE REQUIRED CONSIDERATIONS, WELDER & QUALITY INSPECTOR RESPONSIBILITY (DEFECT EXCAVATION)

Action: Construction & Quality Mgrs shall ensure that Welders & Inspectors perform the following checks with due diligence in a spirit of cooperation
& getting Costly Repair done right on FIRST REPAIR ATTEMPTS. The need for a 2nd Repair Attempt indicates a failure and a Quality system
breakdown (lack of knowledge, diligence & communication), especially related to NDE findings (markings, repair instruction). Second Repair Attempts
(costly, inefficient) are easily preventable. In all cases, 2nd repair excavations shall be attended by Stakeholders & their Supervision who shall witness
& determine that excavations & rewelding are successful (retrain welders, Inspectors as needed).
SA INSPECTORS SHOULD NEVER HAVE TO BE APPROACHED IN ORDER TO
APPROVE A 3RD WELDING REPAIR ATTEMPT.
ASME B31.3, Para 328.6 Weld Repair:
A) A weld defect to be repaired shall be removed to sound metal.
B) Repair welds shall be made using a
SAES-W-011,
D1 qualified welding procedure. C) Repair
Section 3.2
welds shall be made recognizing that the cavity to be repaired may differ
in contour & dimensions from the original joint.
WELDER & INSPECTOR ACHIEVE RESULTS (FIRST REPAIR)

INSPECTOR VERIFIES THAT THE DEFECT HAS BEEN REMOVED.

1. Inspector verifies NDE marks & joint ID are
accurate (excavation). 2. Inspector uses
face shield to witness excavation (safe practice).
3. Welder excavates "in careful stages" (defect location)
ASME B31.3,
4. Inspector checked that defects were "Chased until removed".
5. Inspector rechecks excavated area vs. exact
Para. 328.6
film defect location. 6. Inspector
D2
conferences with welder & both make the call for any further excavation
Weld Repair
based on a) welder intimate knowledge b) the excavation dimensions &
contour favor total cut out c) excavation does not accurately match NDE
Considerations
results or d) "Nothing was found". Decision: Was the
excavation successful? Can a repair weld be made after clean up
grinding & NDE (root opening size, slope, etc). Additionally NDT may
be requested as needed to confirm the removal defective areas (MT,
UT and RT )

EXCAVATION CONTOUR IS WELDABLE (NO CUT-OUT REQ'D):

1. Sound Metal shall be visible in the area identified by ASME B31.3,
the repair. 2. Inspector checks contour of
excavation prior to NDE to verify that any steep sharp angles/slopes are Para. 328.6
D3 contour ground (weldable). 3. Verify
clean metal after regrinding (use magnification as needed) Weld Repair
This is especially critical on 2nd repair attempts, and this
is often the very reason a second repair was required. Considerations

Page 3 of 5
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

Weld Repair Inspection SAIC-W-2013 WELD-

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
INSPECTOR VERIFIES EXCAVATION IS ACCEPTABLE.
ASME B31.3,
1. Sound Metal is visible in the area identified by the repair.
2. Inspector witnesses NDE (MT or PT) of the
Para. 328.6
excavated area. 3. Where a root opening
D4
exists, Inspector verifies Post-Cleaning thoroughly removes residues
Weld Repair
(MPT particles, PT developer) by flushing or use of compressed air AND
Preheating while brushing to remove residual contaminants that can
Considerations
affect weld repair quality.
SA INSPECTOR WAS NOTIFIED & WITNESSED 2ND REPAIR
SAES-W-011,
ATTEMPT (EXCAVATION & REWELDING) ... WITNESS POINT!
D5 Section
ANY SUPPLEMENTAL NDE IS PERFORMED (AS
18
REQUESTED).

E REWELDING OF EXCAVATIONS (WPS & NDE)

Repair procedure may utilize a welding procedure previously approved

SAES-W-011,
E1 by CSD in conjunction with a separate method statement or it may be a
Para. 18.4
separate detailed welding procedure.

SAES-W-011,
Replacement weld (Cut-out) was inspected as a repair by the use of
Para. 18.5 &
the relevant Inspection Checklist covered in the applicable SATIP for
E2 SAEP-
Welding. Per SAEP-1160, Change weld ID (RW suffix).
1160,
Suffix shall no longer be identified as R1, R2.
Section 6 Table
All repaired welds shall be inspected using the original testing method.
SAES-W-011,
E3 Additional test methods may also be required, if deemed necessary by
Para. 18.5
the authorized Saudi Aramco inspector.

SAES-W-011,
E4 Approved WPS applicable to the weld repair is available on site.
Para. 7.1.8
Welding is performed by Qualified welders and in possession of the SAEP-324,
E5
applicable Job Clearance Cards). Para. 6.2.5

F Casual Repairs Based on Workmanship & Weld Profile, Visual or NDE Examination Results (See also SAIC-W-2007)
SAIC-A-2007
Welds (Piping, Structural) are evaluated per Visual Acceptance Crtieria
F1 As
of SAIC-W-2007 (ASME B31.3, AWS D1.1 code welds)
Referenced
Undercuts are ground to a smooth contour with the adjacent metal
SAES-W-011,
F2 surface. NOTE: Weld build-up performed on undercuts that exceed the
Para. 11.6
allowable limits indicated in the applicable code (SAIC-W-2007)

SAES-W-011,
F3 Arc strikes are removed by grinding.
Para. 11.6

SAES-W-011,
F4 MPT or PT, as applicable, is carried out after grinding of arc strikes.
Para. 11.9

SAES-W-011,
F5 Crater cracks are removed by grinding. (MT/PT)
Para. 18.2

Gouges and other indications of careless workmanship are removed by SAES-W-011,

F6
grinding Para. 11.6

Repair of welds for alignment purpose should not be allowed with out
written approval of Aramco. All these repair welds shall undergo Project weld
F7
PWHT/NDT/HT/Pressure testing as per the Approved repair procedure / repair procedure
Method statement

Temporary welded attachments or temporary tack welds are removed by

SAES-W-011,
F8 grinding. NOTE: Attachments are cut off no closer than 3 mm to the base
Para. 11.7
metal surface, prior to the required grinding.

MPT or PT, as applicable, is carried out after repair by grinding or SAES-W-011,

F9
re-welding on the ground areas. Para. 11.9
REMARKS:

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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

Weld Repair Inspection SAIC-W-2013 WELD-

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

NOTE 1: Use this checklist in conjunction with SAIC-W-2016 (Assessment of Weld Repairs). Weld Repair Reporting shall follow new
SAEP-1160, Section 6 Details. See Attachment 1 - SAEP-1160 DATABASE, PROCESS CONTROL TRACKING (By Weld)
See also SAIC-W-2036 for Weld Modification or Re-Work After Weld Acceptance. Know the difference and the reqmts.
REFERENCE DOCUMENTS:
1. SAES-W-011, Welding Requirements for On-Plot Piping, (30 March 2005)
2. SAEP-324, Certification Review and Registration of Project Welders and Brazers, (30 June, 2003)
3. SAEP-1160, Tracking & Reporting of Welding, NDT and Pressure Testing for Capital Projects (17 July 2006)
4. API RECOMMENDED PRACTICE 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry (First Edition, Dec. 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

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