Adw TR RTCF QP Me 002, Rev.1

RAS TANURA REFINERY CLEAN FUELS PROJECT
DOCUMENT REVIEW - COMMENT SHEET

DOCUMENT TITILE: WELDING CONTROL PROCEDURE(Doc # ADW-TR-RTCF-QP-ME-002, Rev. 1)
Sr.
No.
TRS Comment/Reference(by Mr. Abdul Kareem) dated 15-Oct-18 ADW Reply to comment(by Mr.Nazim) dated 21-Oct-18
1 Add contract no in the headline Incorporated

In sec. 8.8, revoked welder amy requalify in accordance with clause 8.1 if welder receives 40hrs of
2 training record singned by both TRS and Adwani and welder number will change to XXX TO XXXR Incorporated
3 After 9.10, make the minimum data requirment make as heading Incorporated
4 add in the section 12.3 weaving shall not be done more than 3times of electrode dia Incorporated
5 ins ection 13, add sec. 12.3 of SAES-W-011 Incorporated
6 In sec 13, add sec. 12.7 of SAES-W-011 Incorporated
7 In sec 15.2, add sections as per SAES-W-011, 11.4 Incorporated
8 In section 15.4.8, add the section completely as per SAES-W-011, 11.7 Incorporated
9 In sec 15.4, add sec. 11.15 of SAES-W-011 Incorporated

NAWAF MATTAR AL-ADWANI & TRADING, CONT. CO. LTD
CONTRACT No.: 10100-25330
DOCUMENT REVIEW COVER PAGE
TABLE OF CONTENTS
1. Scope…………………………………………………………………………..3
2. Definition……………………………………………………………………….3
3. Reference…………………………………………………………………………..4
4. Responsibilities……………………………………………………………………5
5. Procedures……………………………………………………………………….. 7
6. Approved Welding Procedures…………………………………………………..8
7. WPS & PQR -Review & Approval………………………………………………..9
8. Qualification of Welders…………………………………………………………. 10
9. Weld Identification Numbering System…………………………………………..12
10. Calibration…………………………………………………..……………………..15
11. WPS & Welder In-Process Monitoring…………………………………...……..17
12. Welding Defect Analysis & Prevention…………………………………………....19
13. Preheat & Inter Pass Temperature………………..…………….……………….22
14. Heat Input Measurement………………..…………………………..…………23
15. In - Process Welding Inspection………………..………..…………………...23
16. Post Welding Visual Inspection………………..……………………………. 27
17. Assessment of Production Weld (Status Report) & Repair Rate…….… 32
18. Buttering or Weld Build Up………………..…………………………….…….33
19. Inspection I Verification Of Weld Modification………………….…..……… 33
20. Welding Consumables Control……………..…………..……………………. 34
21. Work Flow………………………………………………………………………….35
ADW-TR-RTCF-QP-ME-002, Rev.1 Page 2 of 37

1. Scope
The purpose of this procedure is to describe the procedure and responsibilities

associated with welding activities and subsequently applicable NDT & Hardness testing
requirements for welding of piping as per Company standards, Specifications, ASME
B31.3 and ASME Sec IX etc, including Field fabrication and erection, repair and
modification performed by Al-Adwani Co. ltd for RAS TANURA REFINERY CLEAN
FUELS PROJECT.
2. Definitions
Company Saudi Aramco

Contractor Tecnicas Reunidas
Sub-Contractor Al-Adwani Co. Ltd
SPMT Site Project management Team
SQIT Site Quality Inspection Team
PQM Project Quality Manager
QR Quality Representative
PQP Project Quality Plan
API American Petroleum Institute
ASME American Society of Mechanical
Engineers
RFI Request for Inspection
NDT Non Destructive Testing
HT Hardness Testing
MT Magnetic Particle Testing
PMI Positive Material Identification
PT Penetrant Testing
PWHT Post Weld Heat Treatment
RT Radiographic Testing

SPC Single Point Contact

UT Ultrasonic Testing
WPS Welding Procedure Specification
3. REFERENCE
The following documents shall form a part of this specification in the manner extend
indicated herein
1. Schedule “Q” - Quality Requirement / Year of Issue

2. SAES-W-011 - Welding Requirements for On-Plot Piping
3. AE-036451 - Preheat Levels for welding carbon steel
4. SAEP-324 - Certification Review and Registration Project
Welders and Braziers
5. SAES-L-350 - Construction of plant piping
6. SAEP-352 - Welding Procedure Review and approval
7. SAES-A-206 - Positive Material Identification
8. SA4758-ENG - Job Clearance Card
9. SAEP-1160 - Tracking and Reporting of Welding, NDT and
Pressure Testing for capital Projects
10. ASME B31.3 - Process Piping
11. ASME Sec V - Non Destructive Examination
12. ASME Sec IX - Welding and Brazing Qualification
13. ASME B16.11 - Forged Fittings
14. ASME Sec II Part A - Ferrous Material Specification
15. ASME Sec II Part C - Specifications for Welding Rods, Electrodes & Filler
Metals
16. AWS D1.1 - Structural Welding Code-Steel

17. AWS A2.4 - Standard Welding Symbols

18. AWS A3.0 - Standard Terms and Definitions
19. API RP 582 - Welding Guidelines for Chemical, Oil, and Gas
Industries
20. APL 5L - Specification for Line pipes
4. Responsibility
4.1. Project Manager
Responsible for overall project package for Design, Procurement, Quality and
Construction.
4.2. Construction Manager

• Responsible for Overall site management, dissemination or execution of quality
procedures that meets project specification and project requirements.
• Establishment of construction organization, monitor job quality, schedule control

and overall project management.
4.3. Construction Supervisor

• Shall ensure that all site activities are performed in environmentally safe and
responsible manner accordance with HSE and follow-up all safety procedures,
permit to work, etc.
• Shall supervise piping works and ensure the compliance with established
construction schedule and project requirements as per applicable specifications,
standards and compliance to applicable codes and approved ITP.
4.4. QC Manager
• He has the overall responsibility to organize, implement, conduct and manage the
quality assurance program. He shall document all NCR’s and implement the
corrective actions. He shall coordinate with field engineering group, Project

superintendent, QC Inspectors to ensure that the Procedure / Inspection Test Plan

(ITP) are properly implemented. He will report to top management on the
performance of QMS and need for any improvement.
• Also he is responsible to report any deficiencies in the quality of work to the project
Manager. He has the authority to stop work in any area where discrepancies
remain uncorrected and shall cancel the stop work order and non-conformance
report upon satisfactory correction of noted deficiencies. The QC Manager shall
coordinate with the Project Construction group, Qc inspectors to ensure that the
Method Statement / Inspection Test Plan (ITP) are property implemented and
verify compliance with the relevant codes, standards and company (Saudi Aramco)
Specifications in accordance with the approved ITP and referenced SAIC.
4.5. QC Supervisor
Coordinate the Inspection activities and verify the QC report for Completion and
sign off the documents and verify compliance with the relevant codes, standards
and company (Saudi Aramco) specifications in accordance with the approved ITP
and referenced SAIC.
4.6. QC Inspector
Perform all inspections as per the approved ITP to ensure compliance to the
requirements of the IFC drawings and company standards, prepare Inspection
reports.
4.7. Document controller
Responsible for issue, maintain and controlling all documents required for
construction of final product including filing system and keep log of all completed

RFI and status of inspections and keep and maintain completed test packs and
have electronic format available for end of the job (EOJ) documents.
5. Procedure
5.1. All works shall comply with the respective requirements of company standards and
Specifications, ASME B31.3, ASME-IX, AWSD1.1 and approved construction
drawings, etc.
5.2. The QA/QC Manager with the support of QC Supervisor, in consultation with the
Construction Manager, shall select welding procedures required for the project
from the existing COMPANY approved procedures. If procedure is not available, a
new welding procedure shall be prepared in accordance with the standards and
project requirement.
5.3. Prior to start any welding operation, the welding procedure shall be qualified by a
company approved third party inspection agency and qualified procedure to be
submitted to company for approval.
5.4. All field and shop welding shall be carried out in accordance with, SAES-W-011,
ASME B31.3, and AWS D1.1 as applicable. Welders shall be qualified and
accepted in accordance with SAES-W-011 Para 8, No welding will be performed
prior to issuance of COMPANY job clearance cards. Copy of their qualification
cards shall be available at the field office and the original shall be with the welders.
Welding Inspector will be constantly monitoring the proficiency of the welders (SA
4758-ENG). Refer, SAEP 324 Para 5 and SAIC -W- 2008 for inspector duties.

5.5. For piping fabrication and piping erection the location of the weld shall be marked
on weld map drawings for identification purposes.
5.6. Welding supervisors will ensure that the applicable WPS with current revision is
available at all locations where welding is being performed.
5.7. The project welder tracking coordinator / NDT coordinator / welding Inspector is
responsible for tracking all issued JCC's welder performance and revoking of
JCC's either at section level for small to medium projects or on a single mega
projects.
6. Approved Welding Process

The following processes are approved for use with the restrictions and
requirements as listed.
6.1. Shielded Metal Arc Welding (SMAW).

6.2. Gas Tungsten Arc Welding (GTAW).
6.2.1. Except for ASME P-No. 1through P-No. 5A/58/5C base materials, all manual
GTAW shall use a high frequency start and post-purge gas flow for the torch. Filler
metal must always be added. autogenous welding is not permitted unless
specifically approved by CSD.
6.2.2. The GTAW process shall be used for all passes for butt welds in piping and set-in
fittings less than 25.4 mm nominal pipe size (NPS).
6.2.3. The GTAW process shall be used for the root pass of butt welds without backing
in piping and set-in fittings of 50.8 mm nominal pipe size or less, except for vent
and drain piping open to the atmosphere or Category D piping.
6.2.4. The GTAW process shall be used for the root pass of single-sided groove welds
without backing made with stainless steel or nickel-based consumables.

6.2.5. The use of flux-cored GTAW wires for the root pass of single-sided groove welds
of P-No. 8 or higher materials with or without backing gas is not permitted unless
specifically approved by company (CSD).
6.3. Gas Metal Arc Welding GMAW)

6.3.1. The GMAW short-circuiting (dip) mode shall not be used except for:
a) Structural attachments to the outside surface of the pipe, including seal welds.
b) Tacking (including continuous tacks) that will be completely removed by back
gouging and back welding.
c) The root pass and hot pass only for butt welds in P-No. 1 carbon steels.
d) The modified short circuit mode (RMD =Regulated metal deposition) of GMAW
shall use for root pass welding.
6.3.2. GMAW shall not be used for single-sided tee or corner joints (i.e., branch or nozzle
welds).
7. WPS & PQR – Review and Approval
7.1. All welding procedures to be used shall be submitted as a complete package to

company for the technical approval prior to the start of work. The welding
procedure shall include the Welding Procedure Request Form, Welding Procedure
Specifications (WPS), Qualification Test Records (PQR), and Weld Maps/weld
description Tables. All WPS's & PQR's shall conform to the latest edition of the
ASME Sec IX & SAES-W-011 Para 7.4. An identification system shall be used for
the WPS and revision number, the qualification test shall be performed by an
independent testing agency approved by COMPANY.

8. Qualification of Welders
8.1. All welders and welding operators shall be qualified in accordance with ASME sec
IX and SAEP-324. AII the qualification documents along with job clearance card
shall be submitted to company for approval.
8.2. The test records of all welders shall be available at all the times at all the work
location for review by the company.
8.3. The JCC's are valid only for the project for which they are issued.
8.4. The first three production welds for each newly certified welder shall be 100%
radiographed and only after the acceptance of the same, shall the welder be
allowed to continue on the project. If there is any defective weld, progressive
examination (as penalty) of two more welds shall be conducted and if both found
acceptable, the welder shall be inducted for further production. If any of the penalty
welds fail, the welder shall be disqualified and sent for further training and
documented evidence & record of satisfactory further training to be submitted to
company for review, he may be permitted for requalification. If both (2) penalty
welds fail, the welder shall be disqualified, Refer appendix Ill.
8.5. Expiration & renewal of qualification shall be in accordance with ASME sec IX QW-
322, All welder’s continuity records shall be updated by AL-ADWANI according to
qualifying organization accepted weld reports / third-party company performance
qualification records.
8.6. Welder performance weekly rejection rate percentage shall be calculated joint
basis and linear basis, it shall not exceed joint basis 5% and linear basis 0.2%. If
any welder exceeds the weekly repair rate above specified limit, his production
welding shall be stopped & welder may be considered candidate for re-training and
retesting.

8.7. Additional supervision / additional NDT is required until consistent results of 5%

WRR or less (joint repair rate) are achieved. If WRR target is not achieved within
2-3 weeks’ welder JCC to be revoked.
8.8. Revoked welder may re-qualify in accordance with clause 8.1 if welder receives
minimum 40hrs training record signed by both TRS and Adwani and the welder
number will changed to XXX to XXXR
8.9. Training must be documented copy of documentation shall submit along with new
JCC approval.

9. Weld Identification Numbering System

9.1. All welds shall be identified by a unique welder number and welder symbol. This
information shall be transferred to a weld map, which will be part of the final
documentation Weld maps may be constructed from piping isometric drawings or
similar sketches. Each weld will be marked with a unique ID number that will be
tracked by data base. Welder ID (symbol) will also be marked.
9.2. The following weld identification numbering system shall be used to identify and
track piping groove butt and socket welds as a minimum. Each weld shall be
identified by joint number, line number, and spool number.
➢ Piping Shop welds SW#XX/YY

➢ Piping Field welds FW#XX/YY
➢ Piping weld first repair Add "R1" at the end of weld number
➢ Piping weld second repair Add "R2" at the end of weld number
➢ Piping Re-weld Add "RW" at the end of weld number
➢ Tracer weld one Add "T1" at the end of weld number
➢ Tracer weld two Add "T2" at the end of weld number
Note: For further repairs on Tracer Welds, Progressive sampling as per ASME B 31.3
9.3. W-01- This number shall be given to a weld prior to production welding. If required
examinations are accepted no change is required.
9.4. W-01R1 - The W-01 weld has been completed and examination has revealed an
unacceptable discontinuity that was repaired. If subsequent examinations are
accepted no change is required.
9.5. W-01R2 - The W-01R1 weld repair has been completed and examination has
revealed an unacceptable Discontinuity. If subsequent examinations are accepted

no change will be made. No further repairs are permitted without concurrence of

COMPANY. If permitted the suffix R3 shall be used.
9.6. W-01RW - The unaccepted weld W-01R2 has been cut-out and the joint has been
re welded. The identification Methodology above is to be applied should further weld
repairs be necessary.
9.7. W-01T1 -The W-01 weld has been completed and examination has revealed the
weld is acceptable.
9.8. W-01T2 - An unacceptable weld discontinuity or HT tests have been rejected.

Progressive sampling is required in both cases and the tracer welds will be
identified. If subsequent tests are accepted no change is required. Repairs on tracer
welds will require further sampling in which case the suffix numbering system shall
progress accordingly as per ASME B31.3.
9.9. The following weld identification numbering system shall be used to identify and
track piping groove butt and socket welds as a minimum. Following data are
required to be collected, linked and maintained for each weld till the end of the
project.
9.10. W-01A- Additional joints of Isometric drawing revision, shall identified with the suffix
'A'. W-01S- For joints that are cut & re-welded due to modification, shall identified
with the suffix letter 'S'.
9.11. Minimum Data requirement for production welding
The following minimum data items associated with full penetration groove and Butt
welds and associated special processes for piping erection & fabrication equipment’s
are required to be collected, linked, and maintained for each weld to the extent it is
applicable

Weld Joint Identification
Isometric drawing number Design information

Weld joint number Assigned by contractor
Line number Design information
Line class Design information
Pipe diameter Design information
Spool number Design information
Wall thickness Design information
Schedule Design information
Material class/Grade Design information
Type of Joint Design information Groove or butt
NDT Required Design information - Indicate methods and extent
PMI required Yes/No
Heat Number Pipe to Pipe, Pipe to Fitting or Fitting to Fitting
Weld fit-up Inspection
Date of Inspection
SATR Number This number may be the same as IR no or .Quality record
SAIC Number This number may be the same as IR no or Quality record
number
number
In-Process Weld Inspection
Welder Identification Indicate approved welder or welders by identification symbol{s)
who are welding the joint.
WPS Identification Indicate the approved WPS(s) used to weld the joint.
WPS Parameters Verified - Yes/No. reference Inspection Checklist number
SATR Number This number may be the same as IR no or Quality record
SAIC Number This number may be the same as IR no or Quality record
number
number
Completed Weld Visual Inspection

Visual Inspection Indicate accept or reject per specified acceptance criteria
SAIC/SATR Number This number may be the same as IR no or Quality record number

Weld selection for NDT

Selected for NDT Yes/ No
Criteria for section for If NO" record the weld as completed and visually accepted
NDT are listed in the
SATR Number This number may be the same as IR no or Quality record number
applicable SATIP- W-
SAIC Number This number may be the same as IR no or Quality record number
011
NDT control and Identification

Date of NDT Request Indicate the date of NDT request made
NDT Report Number This number shall remain until final acceptance
Date of NDT Completed
Date of NDT results Date of initial NDT acceptance
Selection of Trace welds
Selection of Tracer Welds Two tracer welds will be selected for each rejected weld in a
Identify Original rejected 10% RT system (ref: ASME B31.3) I SAEP 1160
weld
Date of NDT Results Date of acceptance or rejection
Retests for Tracer

Selection of Tracer welds If any unacceptable, 2 additional welds shall be selected from
Date of NOT Welds the
Datesame lot
of acceptance or rejection
10. Calibration
10.1. Welding machine calibration

The welding power supplies shall be validated In accordance with clause 9 of BS
7570: 2000, schedule” Q", SATR-W-2011and SAES W-11 by an expert, ensure the
equipment’s which is using for calibration to be calibrated in accordance with national
standards. In general, all the power source control should be calibrated. If meters are
fitted, these should be validated in preference to other methods of setting the relevant

parameter. The requirements and method of power source and meter calibration will
depend on the type of power source whether it is a flat or drooping characteristics
power source. Table1 shows the calibration accuracies of standard grade power
sources. All Welding machines shall be calibrated in every 6 months as per project
schedule Q. Doubted or out of order machine must be check with calibrated clamp
meter after confirmation it can be re used.
Table 1 -Validation accuracies for standard grade power sources

Quantity Quantity
±10% of the true value
Current and voltage BS G38-10-1990
±10% of the true value. between 100 % and
25% of the maximum setting
Current and voltage (BS EN 60974-1 : ± 2.5% of the maximum setting, below 25% of
the maximum setting
Analogue meters Class 2.5 clause 3.5
Digital meters Current Voltage ±2.5% of maximum rated welding current
±2.5% of no-load voltage
10.2. Calibration of baking ovens and validation of quivers

Electrode Ovens shall be calibrated and certified by third party inspection agencies
as per the requirement of COMPANY procedures but not exceeding 6 months’
interval. Quivers (that are operating at minimum 65°C) will be validated by using
calibrated digital thermometers periodically every 6 months by the responsible
Welding Inspector.
10.3. Calibration of welding instruments

All welding machines, pyrometers, Clamp meters, Hygrometers, and Purging
monitors shall be calibrated and certified by third party inspection agencies as per
the requirement of Schedule “Q" and company specifications, but not exceeding 6
months’ interval.

10.4. Temperature Recorders

Temperature recorders shall be calibrated every three months and a current
calibration sticker shall be maintained on the recorder. The calibration frequency
may extend up to 12 months with the approval of company.
11. WPS & Welder in-Process Monitoring
11.1. WPS and Welder in Process Monitoring shall follow the requirements of approved
inspection and test plan.
11.2. During Welding approved WPS shall be available at site.
11.3. Each weld will be marked with a unique ID number that will be tracked by data
base. Welder ID (symbol) will also be marked.
11.4. Welding Inspectors shall be in possession of a complete set of Inspection tools

and in progress inspection shall be carried out to ensure weld joint ID markings,
fit-up & welding information is marked consistently on all production welds &
documented daily in the weld data base prepared in accordance with applicable
COMPANY standard requirements.
11.5. During the fabrication and erection of stainless steel and corrosion resistant
materials, the welding inspectors will monitor that the current working practices
are in compliance with the provisions of approved test plan and procedures.
11.6. Welding Inspectors will monitor compliance with the provisions of the above
requirements as well as with applicable standards.
11.7. During the execution of actual welding, the welding inspector shall check the
following:

11.7.1. Cleanliness of grooves- area to be welded should be free from oil, rust, scale and
other loose foreign.
11.7.2. Materials at least 50 mm from the weld area to assure sound welds.
11.7.3. All pre-heating shall be done as per the requirements of and relevant WPS.
11.7.4. The occurrence of unacceptable defects such as pinholes, blowholes, cracks etc.
11.7.5. Each weld pass shall be thoroughly cleaned and all slag or other foreign matter
removed before the next pass is deposited. All slag, flux, and spatter shall be
removed from the completed weld and surrounding areas.
11.7.6. Proper identification of welder I welding operators and weld numbers. Welder code
should be marked and placed on the side of weld work done, for SS material low
chloride (below 50ppm) marker shall be used.
11.7.7. Welding shall not be performed when the wind is strong enough to affect arc
stability or shielding gas coverage Wind velocity in the weld areas for GTAW.
GMAW or gas shielded FCAW shall not exceed 8 kph (2.2 m/s). Windshields or
tents shall be required when the wind or blowing sand is sufficient to adversely
affect weld quality. Contamination from the environment such as wind-blown sand
shall be prevented by the use of adequate shielding.
11.7.8. Welding shall not be done when surfaces are wet or damp or exposed to rain or
snow or when the welder I welding operators are exposed to inclement conditions.
Any wet or damp surfaces must be dried by heating and shall be warm to the hand
before welding.
11.7.9. All appropriate safety precautions shall be taken for each inspection method.

12. Welding defect analysis and prevention
Normally, the welding defects include: porosity, crack, incomplete penetration,

incomplete fusion, slag inclusion, tungsten inclusion, undercut, concavity, excess
penetration etc. These defects decrease the weld strength capacity and have to
be prevented during daily welding. ·Below is the analysis of the reasons causing
defects and the prevention methods.
12.1. Porosity: during the welding work, if the entrapped (into the weld metal) air does
not immediately escape, this will be get porosity. The following situation is likely to
be the causes for the porosity welders should take care to prevent porosity from
occurring:
12.1.1. Too much rust or oil around the bevel area, bevel area is not properly cleaned.
12.1.2. The fit up gap is too big, so fusion depth too deep to make the air difficult to escape.
12.1.3. Using the unqualified electrode or electrode not properly baked before using.
12.1.4. During welding the arc is too long, or welding speed is too fast, or voltage is too
high.
12.1.5. Too high shielding gas flow rate in GTAW/MIG process.
12.2. Crack: during the welding and cooling period, rapid temperature changes and un-
suitable operation is likely to be the causes for the occurrence of crack. Care
should be taken to the following to prevent crack occurrence during welding:
12.2.1. Choose the low hydrogen rod, completely clean oil, rust, water etc. from the groove
area to control the entrapment of hydrogen content into the metal during welding.
12.2.2. Keep the rod in dry storage area, use the correct rod. properly bake rod before use
and follow the welding consumable control procedure.

12.2.3. Properly preheat before welding if the weather is cool, if multiple layers welding
has to be applied, proper controls shall be given to the inter pass temperature and
cooling rate after welding.
12.3. Incomplete fusion& penetration: during welding, this may happen if the electrical
ampere is too low, the rod travel speed is too fast, bevel angle and width is not
proper, which leads the base metal nearby the bevel cannot be completely fused
and mixed with the molten electrode. Weaving shall not be done more than 3 times
of electrode dia. Preventive ways are:
12.3.1. Carefully clean the bevel area and remove the oil, rust etc.
12.3.2. Follow the WPS requirement to control bevel angle.
12.3.3. Clean the slag between layers completely.
12.3.4. Select proper electrical ampere and rod travel speed.
12.3.5. Pay attention to the rod weave range and avoid the rod eccentricity during welding.
12.4. Slag inclusion: This normally occurs due to the slag is difficult to be removed from
the fusion metal because low electrical ampere and slag does not have enough
time to float up due to the fast welding speed. Items below shall be kept in attention
to prevent slag defect from occurring.
12.1. Follow the WPS and control the root gap, bevel angle. root face, etc.
12.2. Clean the edge of the bevel completely, remove the attached slag if any, remove
oil, debris etc before the startup of weld.
12.3. Select proper electrical ampere, travel speed and wave range according to WPS.
12.4. If multiple layers welding are required, slags shall be removed carefully before the
next layer welding starts.
12.5. Tungsten inclusion: during the GTAW welding, if selected electrical ampere is too
high, the tungsten crystallization may be formed and stays in the weld seam during
cooling time, which results in tungsten fusion. Preventive measures is showed

below:
12.5.1. Select the good quality tungsten and select the tungsten with proper
diameter according to pipe diameter and pipe materials.
12.5.2. Select proper electrical ampere according to tungsten diameter.
12.5.3. Enforce the tungsten gas protection and prevent the tungsten from
burning.
12.5.4. During welding, attention shall be paid to avoid tungsten touching fusion
metal or welding wire.
12.5.5. Select the frequency of electrical arcing as high as possible.
12.6. Undercut: The main reason of undercut is the high electrical ampere and rod travel
speed during welding. So during welding, select the proper electrical ampere and
control the arc length and rod welding angel, and special attention should be paid
to control travel speed from being too fast.
12.7. Concavity: This is caused due to the frequent shut down of arc or the arc is too
long, wrong welding rod is selected and bevel gap is too big. The better way to
avoid it by the following steps:
12.7.1. Try best to reduce the arc shut down frequency.
12.7.2. Control the bevel gap following the approved WPS.
12.7.3. Before arc shut down, the rod should stay a little more time with proper
weave to make more rod fusion in the concavity, weaving width and
weaving method shall be controlled as per approved Welding procedure
specification.
12.8. Excess penetration: the welding electrical ampere too high or rod travel speed too
slow is the main reason; also the welder operation skill and the rod angle can cause
it happen. The correct preventive way includes:

12.8.1. Improve the welder skill by executing welder training.
12.8.2. Select welding element properly according to approved WPS.
12.8.3. Adjust the electrical ampere and travel speed according to the fusion
width.
12.8.4. Control the fit up gap, the rod angle and the inter pass temperature
according WPS requirement during welding.
13. Preheat and lnterpass Temperature
Preheat shall be in accordance with ASME 8 31.3 & SAES-W-011.

13.1. Preheat Temperature - minimum temperature in the weld joint preparation
immediately prior to the welding. Or in the case of multiple pass welds, the
minimum temperature in the section of the previously deposited weld metal,
immediately prior to the welding.
13.2. In multi-pass welding the interpass temperature must be checked before starting
each pass. The locations at which the interpass temperature must be checked are:
on the base metal surfaces to be welded (on the side to be welded), within three
inches of each weld joint edge and along the entire length of the joint to be welded.
13.3. The pre heat temperature shall be established over a minimum distance of 75 mm
of each side of the weld.
13.4. If the thickness exceeds 25 mm and pre heating to be done from the same side as
the welding, then the heat source shall be removed for 1 minute to allow for
temperature equalization prior to measuring the temperature.
13.5. Preheat to be applied all types of welding, including tack welds, repair welds, and
seal welds on threaded joints.

13.6. Electric element or heating torch may be used for achieving the required WPS
specified preheat temperature.
13.7. Temperature-indicating crayons, thermocouples, or calibrated contact pyrometers

shall be used to measure preheat and inter pass temperatures. Temperature-
indicating crayons shall not be used for any weld joint that is to be coated or that
will have a heat- shrink sleeve installed on it. Welding inspector shall conform pre
heating is carry out in accordance with the applicable approved WPS.
13.8. If a weld joint is wet or has surface moisture or condensation, it shall be dried by
heating for a distance of 100mm from the weld joint and shall be warm to the hand
before welding unless a greater preheat temperature is required.
13.9. Unless specified otherwise, the maximum interpass temperature shall be 177Cfor
P-No 8,P-No 3X and P-No 4X materials and 315C for P-1,P-3,P-4 and P-5 steels.
14. Heat Input Measurement
14.1. The heat input (HI) of each production weld must be calculated, if notch-toughness
tests are specified in design condition, and then confirmed not to exceed the heat
input limits listed in the welding procedure specifications.
14.2. The HI formula is:

HI (KJ/mm) = Voltage X Amperage X 60 / Travel speed (mm/min)
15. In process Welding Inspection
15.1. General
15.1.1. Limitations imposed by the essential variables of the procedure qualifications shall
be adhered to in production welding. No welding shall be carried out prior to
approve the WPS and issued approved welders JCC, Preparation and welding of

piping components shall be in accordance with the appropriate qualified WPS &
welders.
15.1.2. The surfaces to be welded shall be smooth, uniform and free from laminations,
tears, scale, slag, grease, paint and other deleterious material that might adversely
affect the welding.
15.1.3. Current return cables of welding equipment shall be connected directly to the pipe
on which the welding Is to be done. If the pipe size exceeds 16 inches at least two
welders shall weld simultaneously around the pipe circumference. Arcs shall be
struck only on fusion faces or on striking plates provided as an aid to arc starting.
Stray arc strikes shall be removed by grinding away all material which has been
affected by the arc heat. Where this results in the minimum thickness being below
tolerance, the limited thickness reduced section may be repaired welding then
grind smooth.
15.1.4. A circular cap to prevent entry of foreign material, of a design which will not
damage pipe ends, shall be used to cover the open ends of the pipe and shall be
placed on the line during interruptions in the work expected to last more than two
hours. Caps shall not be removed until recommencement of the work. All open
ends of pipe strings shall be capped off and sealed when welding is completed.
15.2. Root Pass, Hot Pass & Weld-Out
15.2.1. The direction of welding conforms to the WPS. Each weld pass is thoroughly
cleaned and all slag or other foreign matter removed before the next pass is
deposited.
15.2.2. The GTAW process shall be used for the root pass of butt welds without backing
in piping and set-in fittings of 50.8 mm nominal pipe size or less.

15.2.3. Temperature – indicating crayons, thermocouples or calibrated contact

pyrometers shall be used to measure pre – heat and interpass temperatures.
Temperature, indicting crayons shall not be used for any weld joints that is to be
coated or that will have a heat – shrink sleeve installed on it.
15.2.4. steel and non – ferrous materials Each weld pass shall be thoroughly clean and
all slag other foreign matter removed before the next pass is deposited.
15.2.5. All slags, flex and spatters shall be removed from the completed weld and
surrounding areas.
15.2.6. Stainless shall be clean with grinding wheels or stainless steel brushes not
previously used on other materials.
15.3. Maximum SMAW electrode sizes to be used.

15.3.1. The maximum allowable SMAW electrode sizes that can be used for this project
are given below:
i. Low hydrogen electrode
➢ 5 mm for 1G / 1F position
➢ 4 mm for other positions
ii. Non-Low hydrogen electrode
➢ 5 mm for all positions

➢ If SMAW welding is utilized for socket weld the largest size of electrode that is
permitted is 3.2 mm
15.4. Tack welds:
15.4.1. All tack welds shall be made by qualified welders.
15.4.2. All tacks or temporary welds shall be performed with the same care, materials,

electrodes, minimum preheat, and procedures that are used for permanent welds.
15.4.3. Tack welds shall be of sufficient size to maintain joint alignment. The tack
thickness is 3.2-4.8mm and length is 12.5-25.4mm. The minimum number of tack
welds are:
a) Pipe diameter of 101.6mm or less: three equally spaced tacks.
b) Pipe diameter above 101.6mm: minimum of four equally spaced tacks. The
designated inspector should determine if more tacks are needed.
15.4.4. Tack welds that are to be incorporated into the final weld shall be thoroughly
cleaned, prepared at each end, and inspected for cracks. Any cracked tacks shall
be removed before welding the joint.
15.4.5. If the tack welds are to be incorporated into the final root pass weld and are made
with a different process or electrode than the root pass, then the tack weld process
and electrode shall have been used as the root pass for an appropriate procedure
qualification.
15.4.6. Bridge tacks shall be done above the root area but within the groove area and
shall be completely removed prior to completion weld. If any tacks made outside
the groove will be MT/PT examined.
15.4.7. Arc strikes, gouges and other indications of careless workmanship shall be
removed by grinding.
15.4.8. Any Temporary welded attachments or temporary tack welds shall be ground off
attachments may be cutoff no closer than 3mm to base metal surface., prior to
the required grinding.
15.4.9. If any grinding reduces the base metal thickness to less than the design minimum,
the ground area shall be re-welded and ground flush with the original base metal
surface or the component shall be replaced.

15.4.10. For all materials inspection by magnetic particle or liquid penetrant methods of
areas shall be performed where temporary welds have been removed or weld
repairs to ground areas of the base material have been made or arc strikes after
repair grinding.
15.4.11. Coated and clad or overlaid surfaces shall be protected from the welding arc,
associated weld spatter, and damage from ground clamps or other associated
equipment.
15.4.12. All threaded joints and fayings surfaces shall be sealed welded by a continuous
fillet weld (Required weep holes shall be left un welded) connections or
attachments designed for periodic removal maybe exempted from seal welding.
15.4.13. Sealing compounds or tapes shall not be used on joints that are to be seal
welded.
15.4.14. Seal welding of threaded connections shall covered all exposed threads and
shall have a smooth contour between the two surfaces.
16. Post Welding Visual Inspection

16.1. After completion of welding, visual inspection Shall be accordance with applicable
Check list of approved ITP, SAES- W-011, ASME B31.3 and AWS D1.1as follows
16.1. All weld joints shall be marked for identification by a weld number and a welder
symbol. These identifications shall be made with a suitable weather-proof marking
material. The markings shall be placed in a location such that they will be easily
observed and remain visible for a time suitable to the inspector.
16.2. Groove welds shall be made with slight or minimum face reinforcement (cap). ln
the case of butt-weld, the face reinforcement shall not exceed above the limit of
specified in ASME B31.3.In height and have gradual transition to the plane of the
base metal surface, free from undercut. They shall be free of the discontinuities.
Welds shall be free from overlap

16.3. Arc strikes outside the area of permanent welds should be avoided on any base
metal. Cracks or blemishes caused by arc strike shall be ground to a smooth
contour and check to ensure soundness with dye penetrant method.
16.4. Slag shall be removed from all completed welds. Weld and adjacent base metal
shall be cleaned by means of brushing, grinding, chipping etc.
16.5. The faces of fillet welds may be slightly convex, flat or slightly concave, as specified
in the drawing, but shall meet the minimum designed throat dimensions and leg
length dimensions.
16.6. No skip or stitch welds are permitted.
16.7. The leg size of fillet welds shall be as per the construction drawing.
16.8. All slag, flux and spatter is removed from the weld and surrounding area.
16.9. All arc strikes, gouges and other surface imperfections shall be removed grinding
by emery disc (not by grinding disc).
16.10. Temporary attachments have been cut off no closer than 3 mm to the base metal,
then ground flush and NDT tested after removal.
16.11. Grinding does not reduce the base metal thickness to Less than the design
thickness and surface shall be smooth.
16.12. Surface irregularities, including weld reinforcement which inhibit accurate
interpretation of specified method of NDT shall be ground smooth.
16.13. Inspection of all welds includes a band of base metal at least 25mm both side.
16.14. Visual defects found in completed welds & at least 25 mm wide on each side of
the weld be within the allowable weld imperfections listed in ASME B 31.3.
16.15. Cracks shall not be permitted in any size. (Zero imperfection allowed).

16.16. Lack of fusion and incomplete penetration shall be evaluated per ASME B31.3.
16.17. Weld inclusions, surface porosity, undercut and weld reinforcement shall also be
evaluated per ASME B31.3.
16.18. Acceptance criteria of completed welds shall be as per ASME B 31.3 and SAES
W-011, refer below table for ASME B 31.3 acceptance limits.
16.19. Forced or accelerated cooling of welds is prohibited without specific approval of

CSD.
16.20. All Socket welds shall be at least two pass weld.
16.21. If SMAW welding is being utilized the largest size of the electrode that is permitted
is 3.2mm diameter.
16.22. The requirements for minimum separation between adjacent welds are listed in
16.23 & 16.24. The distance shall be measured between the edges of the adjacent
cap passes. These restriction don’t apply if one of the welds has been Post weld
heat treated prior to making second weld or both welds have been post weld heat
treated and inspected.
16.23. The minimum distance between paralleled butt welds shall be 20mm or three
times the wall thickness of the joint, whichever is greater.
16.24.Pressure containing weld (e.g.: Nozzles and other attachments) shall be

separated from other pressure containing welds by no less than 20mm or 3 times
the joints thickness, which are is greater. Radiography of the Butt welds is
required for the situation in which the minimum separation is not achieved for
joints other butt welds other appropriate inspection methods shall be used
depending on the geometry and material. The following are the exemptions.
16.24.1. Structural components and reinforcing pads.
16.24.2. Hot tap split tee and welds which cross the pipe longitudinal seam.



17. Assessment of Production Weld (Status Report) and Weld Repair Rate
17.1. The assessment of production weld and repair weld shall be evaluated by either
by visual or by NDE and declaration of defects shall be based on the construction
codes (refer to: ASME B31.3). The rejected weld will be identified and recorded
determination of acceptable weld repair rate as stated in the contractor procedure.
17.2. The target for maximum project repair rate (calculated on a joint basis) should
normally not exceed 5%.
17.3. Project weld repair rate and individual welder repair rate should not exceed
maximum weld repair rate agreed upon in the project. Progressive examination
shall be performed for every weld of the welder whose weld has failed in RT, root
cause or causes of weld defects shall be determined, evaluated and recorded.
17.4. Corrective actions on the root causes will be initiated to prevent reoccurrence of
the weld deficiencies.

18. Buttering or weld build-up
18.1. Buttering or weld build-up on prepared surfaces shall not exceed the lesser of 1/3
of base metal thickness or 10 mm, without the approval of COMPANY. If the
buttering or build-up exceeds this, then the following requirements shall apply:
18.2. The buttering operation shall be witnessed by COMPANY Inspection.
18.3. The buttering shall be inspected by RT and PT or MT after completion of the build-
up but before final welding of the joint. Buttering of joints between dissimilar metal
joints requires prior approval by COMPANY. (Through WPS review process).
19. Inspection / Verification of Weld Modification
19.1. If the line modification is required due to an engineering need, this modification
shall be recorded in accordance with Al-Adwani Procedure for Management of
Technical Documentation at site. All the subsequent quality records will follow the
provision of previous items concerning the weld database part of this procedure.
The rework may be required due to one of the following reasons:
19.2. Weld joint misalignment & damage.
19.3. Rework to achieve specified fabrication tolerances.
19.4. Rework for any drawing & piping specification revisions that may or may not affect
existing identified welds.
19.5. Rework due to unacceptable root pass.
19.6. Weld modification (Repair) of a previously welded joint requires shall be given a
unique welding 10 number and accepted by the QC inspector responsible for fit-
up.
19.7. The minimum distance between parallel butt welds shall be 20mm or 3 times wall
thickness of the joint, whichever is greater.
19.8. Distance shall be measured between the edges of the adjacent cap passes.

These restrictions do not apply if one of the welds has been PWHT'd prior to
making a second weld or both welds have been PWHT'd & inspected.
Radiography of butt weld is always required when minimum separation is not
achieved.
19.9. Welds requiring re-work shall be physically identified on site, marked & verified by
inspection prior to performing any repair I rework.
19.10. Method of identifying weld re-work follows a procedure.
19.11. Procedure or method statement for repair/rework will be submitted and approved
by COMPANY.
19.12. Weld map shall indicate the location of weld to be re-worked, all temporary
attachment locations/positions shall be captured on a weld map to coordinate
NDT done after removal of temporary attachments. Temporary attachments shall
be welded in accordance with approved welding procedure.
19.13. Welds requiring re-work by cutting and re-welding shall be prepared and
inspected with applicable code and standard care must be given as a new joint.
19.14. Applicable inspection checklist or a separate checklist shall be use for all repairs.
19.15. Welds requiring re-welding shall be inspected using the original testing method.
20. Welding Consumable control
Welding consumable control Procedure shall be prepared and got approved by

company prior to start the job. Refer Welding consumable control Procedure.

21. Work Flow

- Conducts refresher training course.
Welding Group - Conducts welder's qualification test in accordance with
SAEP-324 Para 6.2.1.
- Prepares test specimens & consumables for Refresher/Training/WPQT.
-- To monitor
Should passthe welding
three performancetests
(3) consecutive of each welder.
to automatically qualify for WPQT.
- If a welder passes 1 or 2 of the initial 3 weld tests, he will be allowed to

Refresher Training take 2 or more weld tests in order to qualify for WPQT.
Course
- If a welder does not pass any of the initial three (3) weld tests,
a Performance Warning shall be issued to him before he will continue
any further training.
QC Inspector - After completing the refresher training course the welder will be
endorsed for Qualification Test.

- Inspection of test specimens and ensure welders who will
- Re-training shall be in accordance with this procedure Para 3.8 prior
take the WPQT are capable and competent in taking the
to take the re-test qualification that requires written certification
test.
from the Welding Superintendent.
- Training performance records will be duly signed by
the QC Inspector, as a final assessment of each
welder prior taking the qualification test.

Welding Engineer
- responsible for the preparation of materials and consumables needed in
the qualification test.
- arrange the schedule for WPQT with the ARAMCO Independent
Inspection Agency or Welding Testing Center (WTC).
- prepares RFI for scheduled WPQT with the WTC Inspector /Con. QC
Inspector/Subcontractor QC Inspector.
- Records the details of the conducted refresher training course.
- A valid test certificate and the training performance records
Welder Performance of each candidate shall be kept ready for verification purposes
Welding
Supervisor of the Welding Testing Center (WTC).
Qualification Test /
Re-test
- Welding Testing Center (WTC) conducts the Welder
Qualification Test (WQT) in accordance with approved Test
Supplements to be witnessed Aramco Approved Third Party
and QC Inspector.

Visual - Visual Examination By Aramco Approved Third Party.

Examination
Unacceptable
Acceptable
- Radiographic Examination by the WTC in accordance with ASME
Radiographic B31.3 Table 341.3.2.

Examination
Unacceptable
Acceptable
Welding Engineer
- prepares JCC and other documents to be submitted to
Job Clearance TR / ARAMCO for approval / signature.

Card (JCC)
- prepares Welders Performance Qualification Report / Log for
proper monitoring and verification and submitted to the
Project Inspector.
- All- approved
Reviews JCC will be forwarded
certifications of welderstoprior
the Project
to start Inspector
of work. for
Project
proper issuance
- Issues JCC totothe
thequalified
qualifiedwelder’s
welders.prior the welders will take the
Inspector
initial production welding.
- Monitors the initial production welding of the welders.
Terminate Qualified
- Receives Identity Card from the Welding Engineer.
Welders
- Receives JCC from the Project Inspector prior to start of work.
- Certified by the WTC and qualified to take the initial production

- first 3 production welds shall be done for each welder who passed
welding.
in WQT prior to continue the production welding - carbon steel
Initial Field Testing
& stainless, respectively.
(3-Butt Welds) /
Unacceptable Additional Tests - A welder shall perform welding works in accordance with this
procedure in Par. 6.5.

1 or 2-Butt Welds
- additional test shall be made if required in accordance with
(See Par. 3.6.4 & 3.6.5)
ADW-TR-RTCF-QP-ME-002, Rev.1 ASME IX, QW-321.3(b). Page 36 of 37
- Other qualifications that qualified in initial production welding
Acceptable
- Each welder shall be allowed only to weld within the limit of his
(Field Testing)
qualification range.
Re-certification - Execution of such welding works shall be in accordance with this
procedure in item 6.5.
Production
Welding
- Monitors the production welds of each welder to ensure acceptable
welds.
- Welding and Non-Destructive System (WENDS)

Project Inspector
- Stores all welding production data of all welders who made
Unacceptable the welds.
Welds
- Generates such welding reports (i.e. Welders Performance
Re-training
(See Par. 3.6.7)
Reports, etc).
- Verifies the progress of the welding works and the Performance

WELDS of each welder.
(QC Group)
- Records and monitors the weld production of welders.

Welding
- Investigates the causes of such weld defects, evaluated
Engineer
and recorded.
Maximum 5%
Repair Rate
Weekly Basis (Linear Basis) & 5%

Rejection Rate (Joint Basis)
Borderline - If the repair rate of each welder is borderline, he will receive

Repair Rate
a written “Performance Warning”. If no improvements, a welder
will be pulled out temporarily from work for internal training.
Once completed the training, he will be sent back at the jobsite

High Repair
Terminate Rates to continue production welding.

Adw TR RTCF QP Me 002, Rev.1

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RAS TANURA REFINERY CLEAN FUELS PROJECT

DOCUMENT REVIEW - COMMENT SHEET

1 Add contract no in the headline Incorporated

5 ins ection 13, add sec. 12.3 of SAES-W-011 Incorporated

6 In sec 13, add sec. 12.7 of SAES-W-011 Incorporated

7 In sec 15.2, add sections as per SAES-W-011, 11.4 Incorporated

9 In sec 15.4, add sec. 11.15 of SAES-W-011 Incorporated

10 In sec 16, add sec. 11.18 of SAES-W-011 Incorporated

11 In sec 16, add sec. 11.19 of SAES-W-011 Incorporated

12 In sec 16, add sec. 11.16 of SAES-W-011 Incorporated

6. Approved Welding Procedures…………………………………………………..8

7. WPS & PQR -Review & Approval………………………………………………..9

9. Weld Identification Numbering System…………………………………………..12

11. WPS & Welder In-Process Monitoring…………………………………...……..17

12. Welding Defect Analysis & Prevention…………………………………………....19

13. Preheat & Inter Pass Temperature………………..…………….……………….22

14. Heat Input Measurement………………..…………………………..…………23

15. In - Process Welding Inspection………………..………..…………………...23

16. Post Welding Visual Inspection………………..……………………………. 27

17. Assessment of Production Weld (Status Report) & Repair Rate…….… 32

18. Buttering or Weld Build Up………………..…………………………….…….33

19. Inspection I Verification Of Weld Modification………………….…..……… 33

20. Welding Consumables Control……………..…………..……………………. 34

21. Work Flow………………………………………………………………………….35

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 2 of 37

The purpose of this procedure is to describe the procedure and responsibilities

Company Saudi Aramco

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 3 of 37

SPC Single Point Contact

1. Schedule “Q” - Quality Requirement / Year of Issue

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 4 of 37

17. AWS A2.4 - Standard Welding Symbols

4.2. Construction Manager

• Establishment of construction organization, monitor job quality, schedule control

4.3. Construction Supervisor

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 5 of 37

superintendent, QC Inspectors to ensure that the Procedure / Inspection Test Plan

4.7. Document controller

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 6 of 37

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 7 of 37

6. Approved Welding Process

6.1. Shielded Metal Arc Welding (SMAW).

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 8 of 37

6.3. Gas Metal Arc Welding GMAW)

7. WPS & PQR – Review and Approval

7.1. All welding procedures to be used shall be submitted as a complete package to

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 9 of 37

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 10 of 37

8.7. Additional supervision / additional NDT is required until consistent results of 5%

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 11 of 37

9. Weld Identification Numbering System

➢ Piping Shop welds SW#XX/YY

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 12 of 37

no change will be made. No further repairs are permitted without concurrence of

9.8. W-01T2 - An unacceptable weld discontinuity or HT tests have been rejected.

9.11. Minimum Data requirement for production welding

ADW-TR-RTCF-QP-ME-002, Rev.1 Page 13 of 37

Weld Joint Identification