SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

In-Process Welding Inspection
PROJECT TITLE

SAIC NUMBER

DATE APPROVED

QR NUMBER

SAIC-W-2006
WBS / BI / JO NUMBER

25-May-05

WELD-

CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) LAYOUT DRAWING NUMBER SCHEDULED INSPECTION DATE & TIME SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO INSPECTION LEVEL

EQUIPMENT DESCRIPTION REV. NO. PURCHASE ORDER NUMBER

EQPT CODE

SYSTEM ID.

PLANT NO.

EC / PMCC / MCC NO. QUANTITY INSP. MH's SPENT TRAVEL TIME

ACTUAL INSPECTION DATE & TIME SAUDI ARAMCO ACTIVITY NUMBER CONTRACTOR INSPECTION LEVEL

SAUDI ARAMCO USE ONLY

WORK PERMIT REQUIRED?

ITEM No. A A1

ACCEPTANCE CRITERIA Joint preparation & cleanliness: Weld number and Welder symbol are marked adjacent to the weld joint. (NOTE: Markings shall be made with a suitable weather-proof marking material.) Weld joint identification markings conformed with the requirements of the approved Weld Joint Identification System per SAIC-W-2008. (NOTE: Project QA/QC and PID may attach the weld numbering system as Attachment 1 to this checklist. ) An approved Welding Procedure (WPS) is available at the weld site. (NOTE: Page A1 of the Welding Procedure Approval Request requires signature by the Saudi Aramco Inspection Agency. ) Welder(s) have been issued Job Clearance Card, and that range of qualification shown matches the application of WPS being used. Oil, moisture, scale, rust, paint (except an approved weldable primer), metallic coatings (e.g. zinc) or other foreign matter, has been removed from the weld surface and at least 25mm of the adjacent base metal surface. Coated and clad or overlaid surfaces are protected from the welding arc, associated weld spatter, and damage from ground clamps or other associated equipment. Stainless steel and nonferrous material is cleaned with grinding wheels or stainless steel brushes, not previously used on other materials. Welding Environment: Wind shields or tents are installed when the wind is strong enough to affect arc stability or shielding gas coverage. The wind velocity in the weld area for GTAW, GMAW, or gas shielded FCAW shall not exceed 8 kph (2.2 m/s). Welding is not done during inclement weather e.g., wind blown sand, rain etc. For field welding, remote Current controls shall be used if the welding is more than 30 m from the welding power source or when the welders are working in "remote" locations (e.g., on an elevated piperack). Welding power supplies for use in welding where impact toughness test is required by the code or standard are verified to have been validated within 1 year in accordance with BS 7570. Welding Consumables Filler metal size, type and classification conform with the WPS. (NOTE: A change in filler metal or deposit chemistry from A-number 1 (based on ASME SEC IX) to A-number 2 and vice-versa is not permitted without approval .)

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

SAES-W-011, Para. 16.1 SAES-W-011, Para. 16.2

A2

A2

SAES-W-011, Para. 7.1.8 SAEP-324, Sec. 5 SAES-W-011, Para. 11.3.1

A3

A4

A5

SAES-W-011, Para. 11.11 SAES-W-011, Para. 11.4.3

A6 B B1 B2 B3

SAES-W-011, Para. 11.2.1 & 11 2 3 SAES-W-011, Para. 11.2.1 SAES-W-011, Para. 11.2.2 SAES-W-011, Para. 19.1

B4

B5

SAES-W-011, Para. 19.2

C1

SAES-W-011, Para. 7.4.5

Page 1 of 4

SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

In-Process Welding Inspection
PROJECT TITLE

SAIC NUMBER

DATE APPROVED

QR NUMBER

SAIC-W-2006
WBS / BI / JO NUMBER

25-May-05

WELD-

CONTRACTOR / SUBCONTRACTOR

ITEM No. C2

ACCEPTANCE CRITERIA Filler Metal and other weld consumables at weld site are maintained as per SAIC-W-2032. Welding consumables shall be of the same brand, type and maximum size as indicated on the WPS for the following welding processes: a. GMAW electrode to be used for procedures with impact toughness requirements b. SAW flux c. FCAW electrode d. WPS/PQR using any consumable with a "G" designation (ASME SEC IIC) per SAES-W-011, Para. 7.4.8. Preheat Wet or damp weld joints are surface dried by heating to a distance of 100mm from the toe, and are hand warm before welding. The actual preheat temperature was selected and used by the fabricator that is sufficient to prevent cracking and to achieve the required hardness,or, shall not be less than the greater of the following: a) 10C. b) The required or recommended preheat listed in ASME B31.3. c) Pre-heat temperatures from Std. Drg. W-AE-036451for all ASME P-No. 1 materials, including API grades up to and including X60. d) The preheat listed in Tables 3A and 3B for the SMAW process. e) Temperature determined by CSD for steels with specified minimum yield strengths above 60 ksi, (including API grades X65 or greater) or for materials not listed as an ASME P-number. f) Temperaturee as specified in the approved welding procedure. The preheat temperature shall be established over a minimum distance of 75 mm on each side of the weld. Temperature-indicating crayons, thermocouples, or contact pyrometers shall be used to measure preheat and interpass temperatures. Temperature indicating crayons have not been used for any weld joint that is to be 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 and heat source removed fro 1 minute prior to measuring the temperature. Back Purging & Shielding Gas Inert gas is used for GTAW or GMAW root passes on single-sided groove welds, on ASME P-No. 5 materials and higher. For P-No. 5 materials and higher, back purging is maintained until at least 10mm of the weld deposit thickness is completed. Nitrogen as a backing gas for austenitic stainless steel, is not used. Shielding gases conformed to the following requirements: a. Carbon dioxide (CO2): Federal Specification BC-C-101, Type B or Compressed Gas Association CGA G-6.2, Type F. b. Argon (Ar): Compressed Gas Association CGA G-11.1, Grade A. c. Other gases and gas mixtures with approval from CSD. Back purge for carbon and low alloy steel has reduced the oxygen level to below 1%. (NOTE: Verification is made by the use of oxygen analyzer. )

REFERENCE Project Quality Plan

PASS

FAIL

N/A

RE-INSP DATE

C3

SAES-W-011, Para. 7.4.4

D D1

SAES-W-011, Para. 12. 3

D2

SAES-W-011, Para. 12.1

D3

SAES-W-011, Para. 12.5 SAES-W-011, Para. 12.4 SAES-W-011, Para. 12. 4 SAES-W-011, Para. 12. 6

D4

D5

D6 E E1 E2 E3

SAES-W-011, Para. 11.14.1 SAES-W-011, Para. 11.14.2 SAES-W-011, Para. 11.14.3

E4

SAES-W-011, Para. 6.7

E5

SAES-W-011, Para. 11.14.4

Page 2 of 4

SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

In-Process Welding Inspection
PROJECT TITLE

SAIC NUMBER

DATE APPROVED

QR NUMBER

SAIC-W-2006
WBS / BI / JO NUMBER

25-May-05

WELD-

CONTRACTOR / SUBCONTRACTOR

ITEM No. E6 F F1

ACCEPTANCE CRITERIA Back purge for stainless steel and nickel alloys has reduced the oxygen level to below 0.05%. Root Pass The direction of welding conforms with the WPS. (NOTE: If the WPS is not qualified in the vertical position, then the direction of welding shall be vertical-up. ) Each weld pass is thoroughly cleaned and all slag or other foreign matter removed before the next pass is deposited. NOTE: See WPS remarks for cleaning method, e.g. mechanical brush. Root pass is deposited without backing for WPS qualified for singlesided groove welds without backing. The GTAW process shall be used for the root pass of butt welds without backing in piping and nozzles of 50.8mm nominal diameter or less. (NOTE: Exempted are vent and drain piping open to the atmosphere or Category D piping. ) Hot Pass & Weld-Out The direction of welding conforms with the WPS. (NOTE: If the WPS is not qualified in the vertical position, then the direction of welding shall be vertical-up. ) Each weld pass is thoroughly cleaned and all slag or other foreign matter removed before the next pass is deposited. NOTE: See WPS remarks on cleaning method, e.g. mechanical brush. SAW Flux fused during welding shall not be reused (i.e., fluxes that use recrushed slag are not acceptable). The maximum allowable SMAW electrode sizes that can be used are given below. a) Low hydrogen electrodes - 5 mm for the 1G/1F position; 4 mm for all other positions. b) Non-low hydrogen electrodes - 5 mm for all positions. Remote Current controls are used if the welding is more than 30 m from the welding power source or when the welders are working in "remote" locations (e.g., on an elevated pipe rack). The heat input (HI) of each production weld is calculated (using the formula below) if notch-toughness tests are specified, and then confirmed not to exceed the heat input limits listed in the WPS's. HI (kj/cm) = Voltage X Amperage X 60/Travel Speed (cm/min) Adjacent weld beads shall be staggered and not started from the same location. All full penetration joints requiring double sided welding shall be ground or gouged to sound metal and inspected by penetrant testing (PT) or magnetic particle testing (MT) prior to welding the reverse side, unless exempted by SAES-W-011, Para. 7.4.11as follows: a) For automatic or mechanized processes if additional PQR testing is conducted. b) For other special processes, approved by CSD, on butt joints where the production weld will be radiographed. Unless specified otherwise, the maximum interpass temperature are: a. 177C for P-No. 8 and P-No. 4x materials and b. 315C for P-1 steels. Unless specified in the WPS, back welding is done using the same process, consumables and preheat as the fill passes.

REFERENCE SAES-W-011, Para. 11.14.5

PASS

FAIL

N/A

RE-INSP DATE

SAES-W-011, Para. 7.4.7.1 SAES-W-011, Para. 11.4.1 SAES-W-011, Para. 7.4.10 SAES-W-011, Para. 5.2.3

F2

F3

F4

G G1

SAES-W-011, Para. 7.4.7.1 SAES-W-011, Para. 11.4.1 SAES-W-011, Para. 6.5.2 SAES-W-011, Para. 11.1

G2

G3

G4

G5

SAES-W-011, Para. 19.1

G6

SAES-W-011, Para. 19.4 SAES-W-011, Para. 11.13

G7

G8

SAES-W-011, Para. 11.3.4

G9

SAES-W-011, Para. 12.7 SAES-W-011, Para. 11.17

G10

Page 3 of 4

SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

In-Process Welding Inspection
PROJECT TITLE

SAIC NUMBER

DATE APPROVED

QR NUMBER

SAIC-W-2006
WBS / BI / JO NUMBER

25-May-05

WELD-

CONTRACTOR / SUBCONTRACTOR

ITEM No. G11 G12

ACCEPTANCE CRITERIA Forced or accelerated cooling of welds is prohibited without the specific approval of CSD. All slag, flux, weld spatters, and undercuts are removed from the completed weld and surrounding areas.

REFERENCE SAES-W-011, Para. 11.18 SAES-W-011, Para. 11.4.2

PASS

FAIL

N/A

RE-INSP DATE

REMARKS:

ATTACHMENTS: 1. Attachment 1 - Weld Joint Identification/Markings (NOTE: This will be attached by the Project QA/QC & PID ) REFERENCE DOCUMENTS: 1. 2. 3. 4. 5. 6. SAES-W-011, Welding Requirements for On-Plot Piping, (30 October, 2002) SAEP-324, Certification Review and Registration of Project Welders and Brazers, (30 June, 2003) Std. Dwg. W-AE-036451, Pre-Heat Levels for Welding Carbon Steel, Rev 2 ASME B31.3, Process Piping, (2002) ASME SEC II Part C Specifications for Welding Rods, Electrodes, and Filler Metals, (1 July, 2001) ASME SEC IX - Qual. Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators, (7/12001)

Contractor / Third-Party
Construction Representative*
Work is Complete and Ready for Inspection: Name, Initials and Date: Name, Initials and Date:

Saudi Aramco
PMT Representative
T&I Witnessed QC Record Reviewed Work Verified

QC Inspector
Performed Inspection Name, Initials and Date: Work / Rework May Proceed

PID Representative
T&I Witnessed Name, Initials and Date: QC Record Reviewed Work Verified

QC Supervisor
Quality Record Approved: Name, Sign and Date: *Person Responsible for Completion of Quality Work / Test

Proponent and Others

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

Y = YES

N = NO F = FAILED

Page 4 of 4