Saudi Aramco Inspection Checklist: Pre-Welding Inspection (Shop & Field) of Plant Piping SAIC-W-2005 15-Dec-09 Weld

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
Pre-Welding Inspection (Shop & Field) of Plant Piping SAIC-W-2005 15-Dec-09 WELD-
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 Requirements (Pre-Welding)
Approved Welding Procedure(s) or WPS are available/posted at the weld

site.
Note: All attachments (A, B) and cover pages to WPS are SAES-W-011,
A1
posted. Page A1 (WPS Approval Request) is signed by SA Inspection. Para. 7.1.8
WPS & Special Process Control Procedures
are approved.
Welder(s) have been issued Job Clearance Card, and that range of
SAEP-324,
A2 qualification shown matches the application of WPS being used.
Sec. 5
SAES-L-310,
Section 7,
Inspectors highlight any special features or precautions listed in the spec
concerning Welding & other special processes such as NDE criteria Last Bullet Item
A3 (Line Class, Service Category or SA reqmts.)
*Best Practice: Tool-Box Meeting or Pre-Job Conference covers (Welding Specs)
approved Welding Specs & any special requirements & Special
Process Control
(Pre-Welding)
All weld joints shall be marked for identification as follows:SAEP-1160 &
SAEP-1160,
SAIC-W-2008.
Section 6 &
A4 a) by weld number and by welder symbol.
SAES-W-011,
b) with suitable weather-proof marking material.
Section 16
c) easy visibility location, and durable for a time suitable to SAPID.
Weld number & Welder symbol are to be marked adjacent to welds. SAES-W-011,
Note: Use suitable weather-proof permanent Para. 16.1
markers & materials, such as certified low-chloride (50ppm) markers for
A5
Stainless steel Note: This is an assigned unique SAEP-1160,
weld ID number to be tracked by database & shall remain intact during Table
the construction process 6.1
Isometric Piping Dwgs for work have been reviewed & approved:
A) Process Control Procedure for Welding is
SAES-L-310,
followed relative to checks on mat'ls (Traceability, marking,
Section 7,
dimensional) using latest approved* drawing revisions. *Document
Control system exists.
A6 Bullet Item
B) Fab Shops have been approved per SAIC-L-2031. Shops follow
& Special
strict mat'l & consumable controls as outlined in Procedure
Process Control
C) Equipment checks for welders (checks are established)
(Pre-Welding)
SAIC-L-2031 was utilized prior to Kickoff of
Construction.
Welding power supplies are calibrated SAES-W-011,
Note: Sch Q requires a 6 month interval (max). Process control Section 19 &
A7 procedures shall detail intervals. BS
7570 is used for validation when Charpy Impacts are specified. Sch Q,
Note : See SAIC-W-2011 checklist. Attch-IV Para-6
Page 1 of 32
ITEM
No.
B WELD JOINT EDGE PREP (Includes Cutting & Arc Gouging Method, Joint Edge Buttering, & Cleaning Method)
Stainless steel and nonferrous materials shall be cleaned with grinding

wheels or stainless steel brushes not previously used on other materials.. SAES-W-011,
B1
Use Attachment 1. Para. 11.4.3
Lessons Learned (CuNi - SS segregation)
Thermal cut surfaces of stainless steel and non-ferrous materials shall be SAES-W-011,
B2
ground to bright (unoxidized) material prior to welding. Para. 11.3.2.4
A minimum of 1.5 mm depth shall be removed by grinding/machining

from thermally cut or gouged surfaces of air-hardenable materials (e.g., SAES-W-011,
B3
Chrome-Moly steels or P-No 3 / 4 / 5). Additional NDE required on cut Para. 11.3.2.3
surfaces is at the option of the authorized SA inspector.
Ragged and irregular edges shall be ground or machined to bright metal.

SAES-W-011,
B4 Thermally cut or gouged surfaces for all materials, including carbon
Para. 11.3.2.1
steels, shall be power brushed or ground prior to welding.
All holes cut for set-on nozzles, bosses, or branch connections shall be
SAES-W-011,
B5 ground smooth and the diameter of the hole shall be ± 1.6 mm of the
Para. 11.3.2.1
inside diameter of the set-on member.
Re-cut or re-beveled Fittings shall have cut surfaces examined for SAES-W-011,
B6
laminations before welding. Perform MT or PT. Para. 11.3.3
Oil, moisture, scale, rust, paint (except approved weldable primers),
metallic coatings (e.g. zinc) or other foreign matter, has been removed SAES-W-011,
B7
from weld surfaces at least 25mm adjacent to weld joint. Para. 11.3.1
Butt joint Internal misalignment shall not exceed 1.5 mm.

NOTE: Internal tapering (ASME B31.3) by machining, backwelding, or a SAES-W-011,
combination may be used to correct any misalignment. Para. 9.3
B8
If external surfaces of the components are not aligned, the weld &
shall be tapered between them. [ASME B31.3, Para. 328.4.3 (2).
Buttering or weld build-up on the prepared surfaces shall not exceed the
lesser of ⅓ of the base metal thickness or 10mm without the approval of
CSD. If the buttering or buildup exceeds this, then the following
SAES-W-011,
requirements shall apply. a) The buttering
Para. 11.3.5.1
B9 operation shall be witnessed by Saudi
SATIP-W-
Aramco Inspection.b) The buttering shall be inspected by RT, and PT or
011-01 Item 3.5
MT after completion of the build-up but before final welding of the joint.
Note.repairs shall be performed per SAIC-W-2033
Note: Inspect Piping ends for Cleanliness int/ext FBE Coating:

A) Solvent Clean oil residues. Applicable SATIP
B) Chloride Content Testing (ID & OD) for External FBE
B10
& Internal FBE C) Feathering of COATING
Internal FBE Coating & Surface Preparation
Coated & clad or overlayed surfaces are protected from welding arc,
associated weld spatter, and damage from ground clamps or other SAES-W-011,
B11
associated equipment. Take appropriate action for protection to provide Para. 11.11
cover & ensure proper selection of grounding locations is inspected.
C WELD JOINT DETAIL
All pressure-containing welds shall be made with multiple passes.

SAES-W-011,
C1 Socket welds shall be welded in two passes SAES-W11
Para. 9.1
Para 11.19 (SAIC-W-2037)
Page 2 of 32
ITEM
No.
All nozzles, branch, and tee connections shall be made with full SAES-W-011,
C2
penetration groove welds only. Para. 9.2
Internal misalignment of butt joints shall not exceed 1.5 mm. Internal
SAES-W-011,
C3 tapering in accordance with ASME B31.3 (Par 328.4.3 ) by machining,
Para. 9.3
backwelding, or a combination may be used to correct the misalignment.
SAES-W-011,
C4 Permanent backing rings or strips shall not be used.
Para. 9.4
Full penetration groove joint included angles < 30 degrees, except SAES-W-011,
C5
portions of compound bevels, shall not be used without approval. Para. 9.7
For nozzles with re-pads, the nozzle attachment weld shall be SAES-W-011,
C6
completed & inspected (SAIC-L-2010 PMI ) prior to installing the re-pad. Para. 9.8
Every Weld joint conforms with an approved WPS (Joint Detail):
a. Base material & b. Thickness & c. Bevel type & d. Root Gap
SAES-W-011,
e) Special
Para.
C7 surface preparation instructions (Low-Alloys, etc)
7.1.1
Adequate field instruction
(detail or written notes) exist.
Minimum distance between parallel butt welds shall be 20 mm or SAES-W-011,
C8
three times the wall thickness of the joint, whichever is greater. Para. 11.16.1
Pressure containing welds (e.g., nozzles and other attachments) shall be

separated from other pressure containing welds by no less than 20 mm
or three times the joint thickness, whichever is greater.
SAES-W-011,
C9 NOTE: RT of the butt welds is required when minimum
Para. 11.16.2
separation is not achieved. Inspection approval is required For joints
other than butt welds, other appropriate inspection methods shall be
used, depending on the geometry and material.
D Welding Environment (Planning & Weather Checks)
Wind shields or tents shall be required when wind is strong enough to

affect arc stability or shielding gas coverage or when deemed necessary
by SA Insp. GTAW, GMAW, or gas-shielded FCAW shall not be used for
field or yard fabrication unless adequate windshield is used. Wind
SAES-W-011,
D1 velocity in the weld area for GTAW, GMAW, or gas shielded FCAW shall
Section 11.2
not exceed 8 kph (2.2 m/s)
keep other side pipe
ends closed when working with any weld process.
Welding is not done if surfaces are wet, damp, exposed to rain, or when
SAES-W-011,
D2 welders are exposed to inclement conditions such as wind blown sand,
Para. 11.2.2
dust, rain.
For field welding, remote Current controls shall be used if welding is

SAES-W-011,
D3 more than 30 m from welding power source or when welders are working
Para. 19.1
in "remote" locations (e.g., on an elevated piperack).
E Welding Consumables … Use also SAIC-W-2032
Check WPS application & consumable Filler metal size, type & class
conform with the WPS. Note.Change in filler metal or deposit
chemistry from A-No. 1 (based on ASME SEC IX) to A-No. 2 and vice- SAES-W-011,
E1
versa is not permitted without approval obtained through welding Para. 7.4.5
procedure review process. Change from A-No. 1 to A-No. 2 is not
permitted for sour service without requalification.
Page 3 of 32
ITEM
No.
Filler Metal and other weld consumables at weld site are controlled as
As Referenced
per SAIC-W-2032 (4 & 8 hr rules, reconditioned rod use, etc).
E2
Welders have issue slips at site. Check these to SATR-W-
SAIC-W-2032
2010.
Welding consumables shall be the same brand, type, maximum size as

indicated on WPS & PQR for welding processes as follows: SAES-W-011,
A) GMAW electrode specified on WPS with impact toughness reqmt Para. 7.4.4,
E3
B) SAW flux specified Para.
C) FCAW electrode specified 7.4.8
D) WPS/PQR with "G" designation consumable (AWS A 5.5 Table 2)
F Workmanship, Technique & Preheating (Pre-Job Awareness)
Welders & Fitters know the requirements for Preheating & Tack Welding
SAES-W-011,
F1 before the first tack weld is made. See Attachment
Section 11 & 12
2.
GTAW Practices (Consumable Control, Technique, Purging) are
SAES-W-011,
F2 acceptable and in place before work & follow Attachment 3.
Section 11
G Preheat
If a weld joint is wet or has surface moisture or condensation, it shall be

dried by heating for a distance of 100 mm from the weld joint and shall SAES-W-011,
G1 Preheat temperature selected/used is sufficient to prevent cracking &
be warm to the hand before welding unless a greater preheat Para. 12. 3
achieve req'd hardness value OR at least the greater as follows:
temperature is required.
A) 10°C (50 F).
B) Required/recommended preheat listed in ASME B31.3 Tables.
C) Pre-heat temps from SASD AE-036451 (8 pgs) for ASME P-No. 1
materials, including API grades up to and including X60.
D) Preheat value listed in Tables 3A and 3B for SMAW process. SAES-W-011,
G2
E) Temperature determined by CSD for steels with SMYS above 60 ksi, Para. 12.1
(incl API grades X65 or greater) or for matl without ASME P-No.
F) Temperature as specified in the approved welding procedure.
Note:Preheat is clearly specified in the WPS or Process Control
Procedure to give clearshall
Preheat temperatures & available field instruction
be established for WORK
over a minimum distance of
SAES-W-011,
G3 75 mm on eachFlanges, fittings
side of the and
weld. pipingtemperature
Preheat often requirespecified
different (WPS,
preheat
temps due to differing Para. 12.5
etc) is obtained prior toCarbon Equivalent
& maintained Values.
during Know these reqmts.
welding.
Temperature-indicating crayons, thermocouples, or contact pyrometers

shall be used to measure preheat & interpass temps. SAES-W-011,
G4
Temperature indicating crayons are prohibited for any weld joint to be Para. 12.4
coated, or that will have a heat-shrink sleeve installed on it.
On wall thickness exceeding 25mm, preheat is done from the same side
as the welding. Heat source is removed for 1 minute prior to measuring SAES-W-011,
G5
the temperature. (allow temperature equalization). Para. 12.6
Perform frequent checks to maintain preheat temps during welding
REMARKS:
ATTACHMENTS:
Attachment 1 - Stainless Steel Practices (PFI-ES-43, From SAIC-L-2031, Section F)
Attachment 2 - SAES-W-011 TECHNIQUE, WORKMANSHIP & PREHEATING
Attachment 3 - GTAW PRACTICES (CONSUMABLE CONTROL, TECHNIQUE, PURGING)
Attachment 4 - HEAT INPUT MEASUREMENT REQUIREMENTS
REFERENCE DOCUMENTS: 1. SAES-W-011, Welding Requirements for On-Plot Piping, (30 March, 2005)
2. SAES-W-016, Welding of Special Corrosion-Resistant Materials, (30 March 2005)
3. 12-SAMSS-007, Fabrication of Structural and Miscellaneous Steel (3 September 2006)
Page 4 of 32
ITEM
No.
2. SAEP-324, Certification Review and Registration of Project Welders and Brazers, 1 July 2008
2. SAES-W-011, Welding Requirements for On-Plot Piping, (30 March 2005)
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
Page 5 of 32
Attachment 1 - Stainless Steel Practices (PFI-ES-43, From SAIC-L-2031, Section F)
APPLY 100% IN WELD SHOPS,
Austenitic Stainless Steel & Nickel Alloy Shop (Per SAIC-L-2031) Check
F FIELD APPLICATION IS AS
Cross-Contamination Measures (Shop & Field) any Fail
SHOWN
Stainless Steel & Nickel Alloy Weld Shops address material Handling & Storage,
Field use as
F1 Fabrication & Shipping per Piping Fabrication Institute (PFI) Standard ES-43. PFI-ES-43, Sec 1
applicable
Stainless Steel & Nickel Alloy Shops are safely & properly ventillated (ANSI Z49.1).
F2 Adequate air movers lift toxic fumes. Check for Confined spaces in the field*. PFI-ES-43, Sec 1 *Check in field
Handle Austenitic stainless steel & nickel alloys with nylon slings or equipment protected
F3 PFI-ES-43, Sec 2.1 Check in field
with a non-contaminating buffer mat'l.
Conduct a visual exam of both internal & external surfaces to detect existing contamination
or gouges caused by contact with contaminating material.
F5 Fittings are stored on pallets or shelving constructed of non-contaminating material PFI-ES-43, Sec 2.3 N/A field
F6 Storage areas for these matls are separate from areas where CS material is stored. PFI-ES-43, Sec 2.4 N/A field
F7 SS material stored outdoors was covered (water repellent sheet, etc). PFI-ES-43, Sec 2.5 Check in field
CS strapping is used if a durable, non-contaminating mat'l (clean wood, cardboard, cloth,
F8 paper & SS buffer) isolates the strapping from contact with the stainless steel or nickel alloy. PFI-ES-43, Sec 2.6 Check in field
Gray duct tape (high chlorides) is absolutely prohibited
F9 Walking on austenitic SS or nickel alloy material is not allowed. PFI-ES-43, Sec 2.7 Check in field
Contact surfaces of tools & equipment* containing CS, zinc, copper or their alloys are Check in field
F10 PFI-ES-43, Sec 3.1
covered in noncontaminating matl. (Shall be adequate to prevent cross-contamination) *scaffold, etc
Tools (grinding wheel, wire brush, etc) are color coded and used ONLY for each
specific metal. Hawiyeh Lessons Learned (copper contamination / SS)
Grinding discs, abrasive discs & belts are "labelled for SS" and made of resin-bonded
alumina, silicon carbide or zirconium carbide. (No Sulphurized items)
F13 Only 300 series SS brushes are used on austenitic & nickel alloys. PFI-ES-43, Sec 3.4 Check in field
All material removal & cleaning tools are marked to identify that they are to be used on
F14 specific austenitic & nickel alloy materials only. Marking is visible while a tool is in use. PFI-ES-43, Sec 3.5 Check in field
(Purple & other color codes). Different grades of alloys use new/ different tools.
Austenitic & nickel alloy material fabrication areas are separated from CS areas (upwind to Field avoids
prevent cross contamination). contamination
Suitable methods prevent cross contamination by CS shavings, grinding dust, and zinc dust Check in field
F16 from coating operations by Enclosure, separation & location of work areas OR Engineering PFI-ES-43, Sec 3.6 Field shielding
controls & ventillation assure cleanliness & safety as suitable
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)
Pressure-sensitive & adhesive-backed tape is removed (along with any adhesive residue)
using a suitable solvent or abrasive.
Cutting fluids or oils are low halogen, low sulphur & are completely removed from all
surfaces prior to any welding or forming.
Shipping of materials uses new packing matls & shipping protectors such as PVC caps, Check in field
plugs, & new adhesive tapes. No harmful substances are used in shipping. staging areas
Certified chloride-free marking or color coding has a water soluble chloride content
below 50 ppm (measured after drying). Weld ID is marked per SAIC-W-2008
F22 ID tags & Attachment devices used are made of noncontaminating materials. PFI-ES-43, Sec 4.3 Check in field
Austenitic stainless steel & nickel alloys are handled in a manner that will minimize the risk
of material becoming contaminated. Small segments use caution (controls)
F24 Alloys on same load as CS matl are segregated by wood bracing or other suited matl. PFI-ES-43, Sec 4.4 Check in field
NOTES: 1) Prevent costly cross contamination repairs* (*Cleaning/passivation per ASTM A380 methods shall be CSD approved).
2) Where cross contamination occurs, do not allow welding. If rust is not yet visible, Water-wet with pure Demin/distilled water to
form rust using clean soaked rag on suspect areas. Wet-dry cycles allows test areas to remain dry for a total of 8 hrs in a 24-hr test period. (Pass)
shows no evidence of rust stains or corrosion product. Fact: Once cross-contamination occurs, rust will remain until repaired.
3) Copper Contamination in SS (From CuNi electrodes, grinders, etc) exists when PMI Cu values exceed 0.7% - See Hawiyah LL).
Attachment 1 - Stainless Steel Practices (Photo Examples for Inspector Awareness)
F-11 & F12 … Color Coding of cutter & grinders (yellow tape = 316L mat'l only) & discs used for SS works
F-10 … Examples of Approved Shop with acceptable "buffer material" to prevent Cross contamination
Tungsten Sharpeners are required to prevent Tungsten Tip Contamination (Piranha Model shown)
Creative yet simple Jigs & Restraints with buffer mat'l prevent welding distortion and cross contamination
Item F-10 … Inspector Caution: Prevent Copper Contamination of Stainless Steel at grounding points …
Ground Clamps must be similar metallurgy or as shown here, quality 316L SS overlay welds were made.
Adjustable Non-metallic pipe roller supports designed specifically for Stainless Steel
Typical GTAW (Tig) rig with portable pallet making a weld. Note the taped ends using an approved tape low in
chlorides (Never allow gray duct tape in SS Shop). Lastly, 316L electrodes without color code ends
Attachment 1 - Stainless Steel Practices (Photo Example of Approved SS Shop)
Attachment 1 - Stainless Steel Practices (Photo Examples of CS Contamination of SS piping)
Note 1: Passivation Cleaning per ASTM A380 is now required (or CSD approved other
method) Note 2: Examples are from Vendor supplied skid-mounted Pumps
(Associated piping)
Attachment 1 - Stainless Steel Practices (Hawiyeh Lessons Learned CuNi - SS Contamination)
Lessons Learned Summary: Always make sure everything in a SS & Non-Ferrous Material Shop & in the field
is color
field is color coded / segregated, especially CuNi electrodes (coat them green on the ends). Take steps
early to completely segregate and color code all materials, electrodes, and especially Tools such as
cutting wheels, grinders, brushes FOR EACH SPECIFIC MATERIAL USED ON THE JOB. Note the unusual
discoloration of the Copper Contaminated 316L SS welds in the CSD photos below. In the final analysis,
PMI results showing Copper Content greater than 0.7% indicate unacceptable "cross contamination".
Photo below shows both ERCuNi & ER316L Electrodes - Highlighting need for color coding electrode ends

Summary Notes: Following #6 Recommedation, Simulation Samples (info only) were taken at Khurais.
Samples showed PMI results for 316L SS greater than 0.7% Copper indicated a Copper Contamination. As
Certain fittings have up to 0.7% Copper content, this is above the 0.4% noted in the CSD report. CuNi tacks in a
316L joint are very easily picked up by PMI due to dilution. Also, the use of a grinder previously used on CuNi,
then afterwards used on 316L SS showed a PMI test failure. Prevent cracking and failures!
ATTACHMENT 2 - SAES-W-011 TECHNIQUE, WORKMANSHIP & PREHEATING

SEE ATTACHMENT 3 FOR ADDITIONAL DETAILS

ATT. 3 - GTAW PRACTICES (CONSUMABLE CONTROL, TECHNIQUE, PURGING)
GTAW CONSUMABLES (CONTROL & SURVEILLANCE)
Welders shall prevent tungsten electrode contact with work (including molten pool). If this happens, welders shall extinguish the arc &
repair/replace the electrode by means listed below in Tungsten Repair section. If weld is to be of RT quality then the tungsten inclusion shall
be ground out (repair). Power source & current used shall be specified on the WPS & shall be that used in the field.
Tungsten electrode & Consumable Preparation & Redressing/Repair: Tungsten electrode preparation (before welding) and repair
or redressing of contaminated and/or oxidized tips is an area frequently overlooked by organizations unfamiliar with proper shop practices.
Contaminated electrodes produce an erratic arc & dirty, contaminated welds of inconsistent quality. 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. Use
of silicon carbide type* grinding wheels results in contamination of tungsten & inconsistent tip quality. *Prohibited per CSD.
Quality Step (CSD approved, Required for shop approval): Procedures & surveillance shall ensure proper shop & field practices:
1. Properly prepare new tungsten electrodes by using diamond type cutting equipment specifically designed for Tungsten (Piranha, etc)
These commercially available and inexpensive tungsten cutters/grinders utilize diamond technology to provide clean, contamination free,
separation and grinding finish that prevents splintering/shattering of tips, prevents cross contamination, provides precise tip geometry for
desired weld shape, size, and penetration for consistency in welding (Cost savings in time, fewer repairs, extended electrode life).
2. QC surveillance shall ensure that the following GTAW practices regarding Tungsten consumables are carried out on SA Projects
A) Issue of properly prepared Tungsten electrodes (AWS A5.12 specification) is included in Consumable control measures. Use Issue slips
B) Prohibited are: 1) The unacceptable practice of field grinding tungsten. 2) The improper methods of removing contaminated or oxidized
tungsten tips such as breaking with wire cutters, breaking by hand with a hammer, or grinding off with silicon carbide wheel.
C) Early identification of welders using improper techniques (retrain and monitor welders until they produce quality results).
D) Redressing of contaminated or oxidized tips is done at a specified location using proper tip geometry.
Filler metal contamination: See Section 5 below for detailed In-Process GTAW Surveillance
IN-PROCESS MANUAL GTAW TECHNIQUE SURVEILLANCE
FOR MANUAL GTAW TECHNIQUE, there are SIX (6) basic areas for In-Process Surveillance (Page 3 covers purging practice):
Poor Practice shall be identified and corrected ASAP as part of an ongoing effort toward Continuing Process Improvement on IK Projects.
(1) ARC INITIATION & EFFECTS (5 types GTAW equipment are listed below): GTAW equipment for specific P-No is listed below.
High Frequency (HF) Start: Use for all P-No GTAW manual welds, mandatory* for P-No 5 & above, including dissimilar welds.
Use high frequency start & post-purge gas flow for the torch. SAES-W-011, Para 5.2.1 & SAES-W-016 Para 6.2 Also, a remote contactor
and current level control (pedal or torch mounted) is required. Pre-set power source current start/rise and decay/stop controls triggered by
a foot switch (remote foot pedal rheostat) or torch mounted control (finger control rheostat) is an acceptable alternative for remote control.
Note: GTAW for P-No 1, P-No 3 & P-No 4 materials shall utilize HF Start (above) or equipment below Except Touch or Scratch start.
Pulse Start/Capacitor Discharge: Used for machine or automatic welding (DC), not for manual GTAW
Automatic Pulsed (GTAW-P): When used for root pass welding of single-sided joints, welding shall be performed with the same make
and model of welding system using same equipment and/or program settings as those used in procedure quals. Comment: The need to
specify make & model, program, equipment settings & pulse waveform is based upon the effects these variables have on welding arc
performance, especially sidewall fusion and out-of-position welding. Studies verify considerable variation in arc characteristics when one
make or model of welding system is compared to another. Variation can lead to welding defects difficult to detect by RT (API 582 Par 5.2.1)
Touch or scratch start (Prohibited by CSD): With power source energized, contactor closed, & shielding gas flowing from cup, torch
is lowered toward the work piece until the tungsten electrode contacts with work piece. The torch is quickly withdrawn a short distance
to establish the arc. Depending on the instantaneous short circuit current capability of the welding power source, the current through the
welding electrode upon arc initiation may cause damage to the weld or the electrode. This is corrected by limiting the current upon arc start.
Touch starting has a tendency for electrodes to stick to the work causing electrode contamination & tungsten transfer.
Touch & Retract Starters: Touch and retract starters are similar to contact starting in that the tip of the electrode is lowered to make
contact with the work piece. However, the controls in this starter do not allow current to flow until the electrode begins to be withdrawn,
thus striking the arc. This eliminates the tendency for electrode contamination. Another variation involves a low current to be passed thru
the electrode, which heats the electrode tip and allows the arc to more easily be initiated upon retraction. Acceptable method per CSD
(2) CURRENT SELECTION (WPS ESSENTIAL VARIABLE) & CURRENT CONTROLS
Selection: Direct current electrode negative (DCEN*) & Direct current electrode positive (DCEP**) are two types of direct current used in
GTAW. WPS terminology using DCSP* or straight polarity and DCRP** or reverse polarity is no longer standard terminology. *DCEN = DCSP
A) DCEN produces the greatest heat, deep joint penetration & faster welding. This is the most common configuration in SA, almost all WPS.
B) DCEP (DCEP = DCRP or reverse polarity) is extremely limited in use (3mm & less extremely thin aluminum & magnesium alloys)
C) AC is used in GTAW process at Saudi Aramco in similar applications to DCEP such as for P- No 23 Aluminum materials (ER4043 filler)
D) PROGRAMMED CURRENT - Combines AC & DC. Variable Polarity or VP is a type of programmed current. Not used in SA applications.
Programmable controllers: Programmable controllers control weld sequence, pulse, arc voltage, arc length, and other parameters)
Current Controls (See also HF Start): Current Control Mechanisms are listed below for GTAW process:
Remote foot pedal type & Finger control type rheostats - Arc control in DC welding machines uses a rheostat in welding circuit.
Contactor - A device that opens and closes an electrical circuit (Used in Touch Start Methods)
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VERIFY that current type, current controls, electrode type, & shielding gas match a CSD approved WPS. - See Table below
(3) TORCH MANIPULATION (TECHNIQUE & APPLICATION): Notes for inspector awareness are identified with an asterisk *
Walking the Cup*: A technique for manipulating the torch when manually welding groove & fillet welds. With this technique, the electrode
extension is adjusted* to allow the proper arc length* while the edge of the cup* rests on the side of the joint. The torch is manipulated in a
manner to swing the tip of the tungsten back & forth across the side of the joint by “walking-the-cup” on each edge of the joint. The left or
right edge of the gas nozzle/cup is in constant contact with the members giving the cup a walking motion on the weld joint. One limitation of
this technique is that it is very difficult* to walk-the-cup when welding pipe less than 2 in. [50 mm] in diameter*.
Dragging the Finger: A technique used in manual welding of all types of joint configurations. It can be used when welding all diameters
of pipe & tubing. A fingerstall is made by overlapping a “sleeve” of fiberglass mat’l approx 8 in. [200 mm] long. Fingerstall is placed over the
middle finger & should extend about 1 in. [25 mm] beyond the end of the finger. A Fingerstall stabilizes the hand holding the torch as it is slid
along during welding and provides added insulation and protection for the welder.
Brace Technique: Used in manual welding of vessels, very large pipe diameters and structures. In this technique, the welder stabilizes
the torch by resting his wrist, arm or elbow as far away from the weld zone as possible & sliding the wrist in the direction of welding.
Freehand Technique: This technique should be used only when no other technique is feasible. Very few welders create quality welds
without technique to stabilize the torch. Uncontrolled torch motion can lead to tungsten contact with work or filler. Ensure only the best
welders make joints in difficult field locations where freehand technique is used. Also increase surveillance and NDE as needed.
(4) WORK PIECE MANIPULATION
Planning for production: During the planning of welding operation sequence & qualifying welding procedures & welders, the welding
engineer must establish in which welding position the joint will be welded in production. Shop handling practices are found in SAIC-L-2031.
Manual Manipulation: For small pipe welds that can be rotated, it may be economical to make the welds using pipe rollers. Weld the top
quarter, then manually rotating the pipe & completing the weld in quarters. Other ways the weld joint can be manually positioned are by
physically moving the component or using lifting devices such as overhead cranes or universal balance positioners (manually operated).
(5) FILLER METAL ADDITION (For manual GTAW, only cut length Filler Wire is covered. Wire feed or autogenous welding is not allowed)
Filler Metal Addition: When retracting weld filler rod from the pool, care shall be exercised to ensure the hot end of the rod is not
removed from within the welding torch’s protective gas envelope. If the end of the filler wire should become oxidized, then the oxidized end
shall be cut prior to using the remaining wire. Typically a pair of cutting pliers* is used in this process. (*Prohibited for cutting tungsten).
When welding a root pass, filler metal is normally held in one position and not manipulated. When welding filler and cover passes, filler metal
may be manipulated a slight amount based on joint opening. During welding, the welder must be careful not to touch the filler wire to the
tungsten electrode, since the electrode would become contaminated (Repair or replace).Prior to using filler wire, verify that the type of the
filler wire matches the filler material specified on the welding procedure. Additionally, assure cleanliness of filler material (no visible rust,
discoloration, or evidence of atmospheric contamination such as dust or residues. GTAW Filler metals shall be issued & stored in a portable
container such as a capped PVC tube. Welder training assures that approved consumable id and storage procedures are followed.
(6) EXTINGUISHING THE ARC: Care is taken to avoid forming crater cracks, porosity & start/stop weld defects. Perform close visual check
Welders can achieve this in several ways. After the arc has been extinguished, it is good practice to flow the shielding gas from the torch
over the end of the weld to permit this area to cool* under the protective gas. At the same time, this allows the tungsten electrode to cool
under the shielding gas and prevents its oxidation. Filler material ends are maintained under shielding gas to prevent their oxidation OR
any oxidized filler metal ends shall be cut (cutting tool pliers) each time arc is extinguished & filler becomes oxidized (every tack, stop, etc).
*Inert gas flow time over an extinguishing arc follows the "15 second rule" = Zero Contamination ... QC surveillance point*
Note: 15* seconds cooling under gas flow will result in zero oxidation. Time is dependent on application & can be less to achieve quality.
Decreasing the Current (Down Slope, Down Ramp): Decreasing current is one of the most effective methods for extinguishing the
arc. In this method, the size of the weld pool is decreased by decreasing the current with a foot or hand controlled rheostat.
Weld Tie-In: Moving the arc up and over to the side of the joint (while remaining in the joint) or over the previous pass or back stepping is
effective in minimizing disturbance of the final weld pool. A gradual breaking of the arc will reduce the possibility of porosity & crater crack.
Page 28 of 32
Filling the Crater: A small quantity of filler can be added just as the electrode is withdrawn (& cools under gas) to compensate for weld
pool solidification shrinkage & provide a little extra filler material to help prevent a shrinkage cavity.
Inspect completed welds for undercut, underfill, excess penetration or reinforcement, crater cracks, & porosity
GTAW PURGING PRACTICES
Acceptance Criteria (Oxidation)
The purge shall achieve actual oxygen levels inside or exiting the joint (via the vent) never greater than 50 ppm O2 (maximum 0.005%) prior
to and during welding, as measured with an O2 analyzer with low-level read-out capability. The actual oxygen levels achieved in
production shall be measured periodically (i.e., at the start of production work for each welder, and thereafter, on a random basis for the
number of joints to be performed). Analyzers shall be used for all joints if excessive internal oxidation is observed on any joints based on
the visual appearance of the oxide tint. Use the AWS C5.5 Figure 40 Oxidation Table for guidance, comparison & reporting.
1. 12 ppm O2 = No oxide tint ... ACCEPTABLE
2. 60-70 ppm O2 = Slight oxide tint visible ... Unacceptable
3. 70-90 ppm O2 = Slightly more visible oxide tint ... Unacceptable
4. 200 ppm O2 = Dark oxide tint ... Unacceptable
5. 250 ppm O2 = Almost Black oxide tint ... Unacceptable
6. 500 ppm O2 = (0.05%) = Black or “sugared” ... Unacceptable ... Likely will be a "Cut out" or weld metal repair
Comment: Discoloration (oxide tint) is dark at 200 parts per million or ppm O2, with a discernible tint at 60-70 ppm .
Welding procedure shall cover “additional testing” or disposition of those welds found with “oxide tint” or discoloration.
If no such procedure exists: See Disposition Below
Disposition of Oxidized Root Pass & Welds
“Welds with internal oxidation, based on visual appearance of oxide tint as Inspected, shall be repaired or treated by CSD approved method
Treat or Passivate using an approved method such ASTM A380 practice or other CSD approved method.
PURGE DAM DETAILS
Purge Dams shall follow the detailed practices of AWS D10.11, Recommended Practices for Root Pass Welding. Due to a common problem
of leakage with proprietary dissolvable water-soluble dams, these shall be avoided whenever possible. If purge dams are to be used but
cannot be retrieved after welding, then proprietary dissolvable (water soluble paper such as rice paper, etc) dams shall be used and the
following stringent conditions for their application shall apply:
A) In addition, water-soluble approved “low chloride” glues* shall be used to hold the dams in place (Elmer’s glue is accepted in our Industry
for this exact purpose) or proprietary water soluble adhesive tape shall be applied to purge dams. Dams shall be located far enough from
the joint to prevent their failure during the welding process, usually 150-300 mm.
B) Before decreasing purge gas pressure and closing the weld joint, a “visual inspection window” shall be left open for Inspection to
verify acceptable root pass condition. This is an extremely quick inspection with a mini-light that determines any root oxidation.
Inspector specifies a 25 mm visual "window" & identifies visible oxide tint. Pass/Fail.
COMMENTARY: Currently, tape is being used in many instances on large bore pipe to hold these dams in place ... This is the only way the
dams “stay put”. Dams using rice paper often allow a high rate of gas escape & require multiple layers “glued” together to maintain purge.
Page 29 of 32
Page 30 of 32
Attachment 4 - HEAT INPUT MEASUREMENT REQUIREMENTS
USE SATR-W-2011
1. Use a calibrated Volt/amp meter. Check readings adjacent to source & Work (without disturbing welder)
2. Welding Machines are calibrated per SAIC-W-2011 Checklist. SA Witness Point.
3. Have a Test Form to list values against welds made. Determine Acceptable Limits before Testing
4. Take valid readings. (10 Degree, 90 Degree Rule). Travel speed (& SMAW bead width) is critical.
5. Procedure shall have a disposition for retraining & disposition for unacceptable results.
TAKE H.I. MEASUREMENTS (Use the 10 degree - 90 degree rule)

Measurements in either 90 degree quadrant is used to validate H.I. Results (Pass/Fail)
Notes for H.I. Measurements
1. Take measurements for the
voltage & amperage when the
welder is welding in those two
quadrants shown in the sketch.
2. Travel speed measurements
are also taken in the same two
quadrants shown in the sketch.
3. 100% checks of Heat Input is
required for all welders until
they establish their ability to
meet WPS Heat Input Values.
4. Testing may be reduced to a
random check once the Saudi
Aramco authorized inspector
has accepted initial results.
5. Highly recommended is the
practice & testing of welders
during qualification and before
any production work to assure
sound welds within H.I. Limits

Saudi Aramco Inspection Checklist: Pre-Welding Inspection (Shop & Field) of Plant Piping SAIC-W-2005 15-Dec-09 Weld

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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

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

A General Requirements (Pre-Welding)

Approved Welding Procedure(s) or WPS are available/posted at the weld

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Stainless steel and nonferrous materials shall be cleaned with grinding

A minimum of 1.5 mm depth shall be removed by grinding/machining

Ragged and irregular edges shall be ground or machined to bright metal.

Butt joint Internal misalignment shall not exceed 1.5 mm.

Note: Inspect Piping ends for Cleanliness int/ext FBE Coating:

C WELD JOINT DETAIL

All pressure-containing welds shall be made with multiple passes.

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Pressure containing welds (e.g., nozzles and other attachments) shall be

D Welding Environment (Planning & Weather Checks)

Wind shields or tents shall be required when wind is strong enough to

For field welding, remote Current controls shall be used if welding is

E Welding Consumables … Use also SAIC-W-2032

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Welding consumables shall be the same brand, type, maximum size as

F Workmanship, Technique & Preheating (Pre-Job Awareness)

If a weld joint is wet or has surface moisture or condensation, it shall be

Temperature-indicating crayons, thermocouples, or contact pyrometers

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Contractor / Third-Party Saudi Aramco

QC Inspector PID Representative

QC Supervisor Proponent and Others

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

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Attachment 1 - Stainless Steel Practices (Photo Examples for Inspector Awareness)

Attachment 1 - Stainless Steel Practices (Hawiyeh Lessons Learned CuNi - SS Contamination)

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

ATTACHMENT 2 - SAES-W-011 TECHNIQUE, WORKMANSHIP & PREHEATING

SEE ATTACHMENT 3 FOR ADDITIONAL DETAILS

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

TAKE H.I. MEASUREMENTS (Use the 10 degree - 90 degree rule)

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