SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3
SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Review of WPS & Process Control Procedure (Pipelines)
PROJECT TITLE

SAIC-W-2038
WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

30-Jun-08
DATE APPROVED
QR NUMBER

WELDCONTRACTOR / SUBCONTRACTOR

EQPT CODE

SYSTEM ID.

PURCHASE ORDER NUMBER

PLANT NO.

EC / PMCC / MCC NO.

QUANTITY INSP.

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

SAUDI ARAMCO TIP NUMBER

SAUDI ARAMCO ACTIVITY NUMBER

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

WORK PERMIT REQUIRED?

PASS

FAIL

N/A

Instructions for Approval (Responsibilities) ... Quality Managers shall see Notes 1 & 2 at end of this checklist

A1

For shop and all field fabrication IK, NEW WPSs & PQRs are
prepared* and submitted using the correct SA Welding Forms:
A) Attachment 1 - SAES-W-011/012 WELDING PROCEDURE
SPECIFICATION (ATTACHMENT A, PAGES A1, A2, A3, A4, A5)
B) Attachment 2 - SAES-W-011/012 WELD & LINE DESCRIPTION
TABLE (ATTACHMENT B).
For New Procedures (Master Set), follow Attachment 3 rules.
C) If previous CSD-approved WPS is reused. See Section C.

SAES-W-012,
Para. 7.1.2

A2

All WPSs & PQRs shall conform to the latest edition of the relevant
Code (API STD 1104 or ASME SEC IX, as appropriate).

SAES-W-012,
Para. 7.2.1

A3

Complete Weld Table (Attachment B) listing all mat'ls, thicknesses, &

weld joint types for individual line designations, shall be submitted along
with the WPS & PQR documents for each job.

SAES-W-012,
Para. 7.1.3 & 4

A4

PQRs shall include certified copies/facsimiles of all test records for IK

qualification, (the TPI testing agency that issued the test record shall
certify the copies).

SAES-W-012,
Para. 7.1.10

A5

Originals of all test records, mill certificates, etc. including records from
independent test laboratory are available for review by SA.

SAES-W-012,
Para. 7.1.11

A6

Welding of qualification test coupons shall be monitored by either an

approved independent test laboratory or independent TPI. Monitoring
shall include verification of accuracy of the recorded parameters.

SAES-W-012,
Para. 7.2.5 a)

A7

PQR mechanical tests and examinations shall be performed by

approved independent test laboratory, unless Fabricator is specifically
approved by OID to perform their own tests.

SAES-W-012,
Para. 7.2.5 b)

A8

For all automatic welding & any process with pulsing, the WPS shall
include all applicable equipment and controller parameter settings.

SAES-W-012,
Para. 7.2.6

Procedure Variables to be checked in detail:

B1

Procedure Variables meet the detailed reqmts of SAES-W-012, Section

7.4 & 7.5. Use Attachment 5 as a thorough review aid.

SAES-W-012,
Section 7.4

B2

Welding Procedure Qualification Hardness testing is required (sour

service applications) with maximum allowable hardness VHN 250 per
SASD AB-036386. Use Attachment 5 as a review aid.

SAES-W-012,
Para. 7.5.1

Review & Submittal of Existing WPS (CSD Previously Approved) ... Quality Manager Checklist (Action & Review)

C1

After approval by CSD, the package of welding procedures,

qualification test records, & weld maps/tables may be approved for
additional jobs by Inspection Dept. Project assigned Inspector will
authorize the use of existing CSD-approved welding procedures if scope
& essential variables are acceptable for the new application. Follow
directions below for Existing WPS Package approval.

Page 1 of 4

SAES-W-012,
Para. 7.1.1

RE-INSP DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

Review of WPS & Process Control Procedure (Pipelines)
PROJECT TITLE

ITEM
No.

SAIC NUMBER

SAIC-W-2038
WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

30-Jun-08
DATE APPROVED
QR NUMBER

5-Nov-08

WELD-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

Review & Submittal of Existing WPS (CSD Previously Approved) ... Quality Manager Checklist (Action & Review)

C2

CSD APPROVAL COVER SHEET LISTS APPROVAL STATUS &

CONDITIONS WITH ALL CSD COMMENTS. SUBMIT THIS COVER
SHEET ALONG WITH DETAILS OF THE INTENDED APPLICATION:
A) Complete Page A1, Request Welding Procedure Approval
It must be complete in entirety (Design Details) & Project Specific.
B) Complete Attachment B, Weld & Line Description Table
Service description & line class information details are provided.
Note 1: New Application is compared against CSD-approved docs.
Note 2: If the CSD approval cover sheet is not available, the WPS
cannot* be approved by PID. Request a copy from CSD providing the
CSD Log Number on all requests. * CSD Notes are mandatory .
C) All existing WPS, PQR, Attachments (A1, B) are submitted as one
package (Incl. NEW Attachment A1, B) for approval.

SAES-W-012,
Para. 7.1.1

C3

Each Weld and Line Description Table (Att. B) must be complete and
show line designations (service), materials, joints, & WPS used for
the NEW APPLICATION.

SAES-W-012,
Para. 7.1.4

RE-INSP DATE

Note: CSD HAS IDENTIFIED 6 SELECTED VARIABLES FOR CLOSE REVIEW OF WPS (MOST COMMON CAUSE OF WPS REJECTION)
C4

Check Material requirements (compare old & new application), using

ASME IX, WPS (QW-403) for P-No, Group No., Spec & Grade

SAES-W-012,
Para. 7.1.1

C5

Per QW 403 & 450, Check Thickness range, comparing the old and new
application.

SAES-W-012,
Para. 7.1.1

C6

Per QW 403, Check Pipe Diameter range, comparing the old and new
application.

SAES-W-012,
Para. 7.1.1

C7

Per QW 407 & Service Application (Form Page A1), Check PWHT,
comparing the old and new application.

SAES-W-012,
Para. 7.1.1

C8

Check Service & Materials (scope) for Hardness Reqmts, comparing the
old and new application.

SAES-W-012,
Para. 7.1.1

C9

Check for Charpy Impact requirements, comparing old and new

applications, carefully checking test temperature and impact test values ...
Ranges often vary & require requalification.

SAES-W-012,
Para. 7.1.1

Note: The following revisions apply to all existing WPS. QA/QC Mgrs. shall take immediate action for revision as needed.

C10

Existing P-No. 1 WPS (GTAW/SMAW) without Heat Input reqmt:

Revise without requalification of procedure, follow request below:
A)
Specify in WPS Technique Section (QW 410), under Maximum weave
width, the following: 3 x electrode diameter.
Note 1: Revisions are legibly handwritten or typed, signed & dated.
Note 2: Bead widths over 5 x electrode diam. (excess weave width) can
adversely affect weld quality (poor technique). Instruct welders to follow 3
x electrode diameter, & never exceed 5 x electrode dia.
Note 3:
If Heat Input measurement is req'd , Heat Input reqmts will control
weave width (technique). Ensure that travel speeds are closely monitored
along with proper bead width for good HI values. Note 4: Weave widths
exceeding 5 x dia. result in quite significant reduction in notch toughness
test results. (This is unacceptable).

As referenced,
Contact CSD on
any welding
technical
questions
SAES-W-012,
Para. 7.1.1

C11

NOTICE: ERRORS EXIST IN SAES-W-012 PREHEAT TABLES.

NEW & EXISTING WPS SHALL BE REVISED PER ATTACHMENT 6.
Background: The 28 February 1998 edition was revised and the following
"copy and paste error" was made in welding standards. Preheat Values of
Table 4A/4B (Vertical Down SMAW Butt Welds) are identical to Table
3A/3B (Vertical Up SMAW Butt Welds).This is incorrect as higher preheat
is needed for vertical down position.
Utilize
February 1998 Table 4A/4B immediately on project .
See Attachment 3 of this Checklist for correct table values.
This will result in higher preheats. Train welders accordingly.

As referenced,
Attachment 3,
Contact CSD as
needed to verify
SAES-W-012,
Para. 7.1.1

Page 2 of 4

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

Review of WPS & Process Control Procedure (Pipelines)
PROJECT TITLE

SAIC NUMBER

SAIC-W-2038
WBS / BI / JO NUMBER

C12

This exists for every type welding joint covered by a WPS.

A) See SAIC-W-2037 for socket welding requirements.
B) See SAIC-L-2015, SAIC-W-2037 for seal welded thread jts
C) See SAIC-L-2013 for welding of branch connections.
D) See SAIC-L-2144 for Pipeline repair sleeve applications.
1) Instructions are available at all sites where welding is done.
2) Instructions can be written in or attached to WPS or may be in a
Welding Process Control Procedure covering all welding activity.
3) Those responsible for implementation are adequately trained.

As referenced,
Attachment 3,
Contact CSD as
needed to verify
SAES-W-012,
Para. 7.1.1

C13

WPS using ER70S-6 filler mat'l (GTAW, GMAW Process) are

revised without WPS requalification (unless impact tests are req'd) as
directed below (CSD has approved this direction):
A) Substitute ER70S-2 for ER70S-6 (GTAW Process)
B) Substitute ER70S-3 for ER70S-6 (GMAW Process)
See Attachment 4.

As referenced,
Attachment 4,
Contact CSD as
needed to verify
SAES-W-012,
Para. 7.1.1

C14

WPS using Internal & External Field applied FBE Coatings shall be
CSD approved. The process shall be GMAW STT or GTAW to assure the
following criteria: All weld joints including adjacent areas to be FBE coated
either Internal or External shall be ground smooth and free from burrs,
weld spatter, sharp edges. Weld toes shall be merged smoothly and
rounded with no sharp undercuts. Weld cap or internal root protrusion
shall not be more than 1.5 mm. WPS provides adequate field
instruction.

SAES-H-201,
Para. 7.2.2

C15

CSD approved WPS with essential variables that include the restriction
of electrodes (Per Attachment 5) are "noted":
A) G Designated Electrodes are restricted to the exact brand & type
specified on the PQR & WPS.
B)
WPS & PQR with Impact Toughness Reqmts use the same brand name
& type GMAW electrode, SAW flux & FCAW electrode.
C)
Change in filler metal or deposit chemistry from A-No. 1 to A-No. 2
(ASME SECT IX) Note: Requalify Sour Service Procedures
WPS Notes shall specify that substitutions are not allowed and exact
brand name and type consumable shall be used.
Plan Consumable substitution approvals by CSD. Do not wait until
designated & required consumables are gone.

SAES-W-012,
Section 7

30-Jun-08
DATE APPROVED
QR NUMBER

5-Nov-08

WELD-

CONTRACTOR / SUBCONTRACTOR

WELDING PROCESS CONTROL PROCEDURE (COVERS ALL WELDING RELATED ACTIVITY OTHER THAN THE WPS)

D1

Welding related activities other than the actual WPS are identified and
controlled (Special Construction Process) by Procedure. Option exists for
a single procedure (Welding Process Control) or multiple procedures
covering the remaining elements in Section D below.
A single Procedure is recommended for efficiency . All SAIC are
referenced in this procedure. Use the specific checklists.
SAEP-1160 Weld ID & Tracking System (Database) required.

D2

WPS & PQR (Review) for Welding Master Sets

SAIC-W-2038

D3

Review of Welder & Welding Operator Certs (Pipelines) & Review of

welder performance. See SAIC-W-2039 Att. 2

SAIC-W-2039

D4

Weld Repair Procedure (Including WPS)

SAIC-W-2040

D5

Weld Joint ID & Database (Status, Reporting) per SAEP-1160*

SATR-W-2008, SATR-W-2013, SATR-W-2018, SATR-W-2019 can be
eliminated if Database gives an acceptable report format

SAIC-W-2008

D6

Welding Machine Calibration per BS7500 for Pipelines

SAIC-W-2045,
SATR-W-2011

D7

Welding Consumable Control (Pipelines)

A) Receiving Inspection (SAIC-W-2044) (SATR-W-2020)
B) Storage & Handling (SAIC-W-2046)
C) Consumable Issuance & Control (SAIC-W-2055) (SATR-W-2010)
D) Calibration of Electrode Oven, Baking & Portable (SAIC-W-2055)
Note: Use SATR-W-2009 for Report Form (Calibration)
E) GTAW Tungsten Electrode use, care, restoration (SAIC-W-2049)
F) GTAW Purging Consumables (Gas, Purge Dams) (SAIC-W-2049)
SAIC-W-2049 Attachment 1 covers GTAW Consumables

SAIC-W-2055

D8

Procedure for Buttering and/or Weld Buildup

SAIC-W-2047

D9

Pre-Welding & Fit-Up Inspection (& How WPS is monitored)

Disposition for Repairs - Alignment Tolerances. See Note 3.

SAIC-W-2048
SATR-W-2006

Page 3 of 4

Schedule Q,
Attachment VI,
Special Process
Tables

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3
SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Review of WPS & Process Control Procedure (Pipelines)
PROJECT TITLE

30-Jun-08
DATE APPROVED
QR NUMBER

SAIC-W-2038

5-Nov-08

WBS / BI / JO NUMBER

D10

In-Process Welding Inspection (Heat Input Measurement)

SAIC-W-2049

D11

Post-Welding Visual Inspection

SAIC-W-2050
SATR-W-2007

D12

Inspection of Weld Repairs (Repair Verification)

SAIC-W-2051

D13

Production Weld & Welder Repair Rate Assessment

SAIC-W-2056

D14

Temperature Tie-In Welding

SAIC-W-2057,
SATR-W-2014

WELD-

CONTRACTOR / SUBCONTRACTOR

Remarks:
NOTES: 1) See Section "C" regarding Existing WPS (whether approved or not). Follow all specifics. Contact CSD on any technical matter
related to Welding. Contact your Project Inspection Representative on any checklist question for Welding. QA/QC Mgr. Action Required!
2) QA/QC Mgr shall ensure a detailed Welding Process Control Procedure per Section D is established. See item D1.
Certain procedure elements (heat input, wps monitoring, associated forms, etc) are also provided as applicable to scope.
3) Alignment Tolerances & Disposition of Repairs shall be addressed during Pipe Stringing. See SAIC-W-2048.
4) Structural steel welding (AWS D1.1 related) on Pipelines shall utilize SAIC-M-2012. See SAIC-M-2012.
ATTACHMENTS: 1 - SAES-W-011/012 WELDING PROCEDURE SPECIFICATION (ATTACHMENT A, PAGES A1, A2, A3, A4, A5)
Attachment 2 - SAES-W-011/012 WELD & LINE DESCRIPTION TABLE (ATTACHMENT B)
Attachment 3 - SAEP-352 Welding Master Set Preparation & Approval (Instructions)
Attachment 4 - NACE RP-0472 Table 2: Process/Filler Material Combinations Exempt from Weld Deposit Hardness Testing
Attachment 5 - WPS PROCEDURE VARIABLES (SAES-W-012, Section 7.4)
Attachment 6 - SAES-W-012 TABLE 4A/4B - PREHEAT TEMPS. VERTICAL DOWN SMAW BUTT WELDS (NOTICE OF ERROR IN SA STDS)
REFERENCE DOCUMENTS: 1. SAES-W-012, Welding Requirements for Pipelines, (31 December 2002)
2. SAEP-352, Welding Procedures Review and Approval, (31 May, 2003)

Contractor / Third-Party

Saudi Aramco

Construction Representative*

PMT Representative

Work is Complete and Ready for Inspection:

Name, Initials and Date:

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

Name, Initials and Date:

QC Inspector

PID Representative
Performed Inspection

Work / Rework May Proceed

Name, Initials and Date:

Name, Initials and Date:

QC Supervisor

Proponent and Others

Quality Record Approved:

Name, Sign and Date:

Name, Organization,
Initials and Date:

*Person Responsible for Completion of Quality Work / Test

Y = YES

Page 4 of 4

N = NO F = FAILED