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Revised paragraphs paragraphs are are indicated indicated in in the the right right margin margin Page Page 1 1 of of 5151 Primary contact: Niemeyer, Dennis Charles on 966-3-8760237
Primary contact: Niemeyer, Dennis Charles on 966-3-8760237
SAES-W-012
SAES-W-012
5
5 October
October 2009
2009
Welding Requirements for Pipelines
Welding Requirements for Pipelines
Welding Standards Committee Members
Welding Standards Committee Members
Awwami, Adnan N., Chairman Awwami, Adnan N., Chairman Rao, Sanyasi X., Vice Chairman Rao, Sanyasi X., Vice Chairman
Carrera, Rene L. Carrera, Rene L. Carswell, Raymond J. Carswell, Raymond J. Chiang, Howard Chiang, Howard Juraifani, Hatim H. Juraifani, Hatim H. Keen, Peter David Keen, Peter David
Muslim, Husain Muhammad Muslim, Husain Muhammad Nasir, Ghalib Taher
Nasir, Ghalib Taher Nasri, Nadhir Ibrahim Nasri, Nadhir Ibrahim Niemeyer, Dennis Charles Niemeyer, Dennis Charles
Sabti, Tareq Ibrahim Sabti, Tareq Ibrahim
Saudi Aramco DeskTop Standards
Saudi Aramco DeskTop Standards
Table of Contents Table of Contents 1
1 Scope...Scope... ... 22 2
2 Conflicts Conflicts and and Deviations...Deviations... ... 22 3
3 References...References... ... 33 4
4 General...General... ... 55 5
5 Approved Approved Welding Welding Processes...Processes... ... 66 6
6 Welding Welding Consumables...Consumables... ... 88 7
7 Welding Welding Procedures...Procedures... ... 1111 8
8 Welder Welder and and Welding Welding Operator Operator Qualification. Qualification. 1919 9
9 Joint Joint Details...Details... ... 2020 10
10 Technique Technique and and Workmanship...Workmanship... 20... 20 11
11 Preheat...Preheat... .. 2626 12
12 Postweld Postweld Heat Treatment.Heat Treatment... ... 2727 13
13 Production Weld Production Weld Hardness Testing...Hardness Testing... ... 3030 14
14 Inspection Inspection Access...Access... 31... 31 15
15 Weld Weld Identification...Identification... 31.... 31 16
Table of Contents (cont'd) Table of Contents (cont'd) 17
17 Repairs.Repairs... 39.. 39 18
18 Miscellaneous Miscellaneous Requirements...Requirements... ... 4040 19
19 Safety....Safety... 40... 40 Appendix
Appendix 11
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Conditioning, Storage,Conditioning, Storage, and Exposure oand Exposure of SMAW Ef SMAW Electrodes... lectrodes... 4141 Appendix
Appendix 22
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–
Conditioning, Storage,Conditioning, Storage, and Exposureand Exposure of of Wires and Wires and Fluxes...Fluxes... . 4444 Appendix
Appendix 33
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Preheat Temperatures Tables... 45Preheat Temperatures Tables... 45 AttachmeAttachment Ant A
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–
RequeRequest for st for WeldingWelding ProcedureProcedure Approval...Approval... 49.. 49 Attachme
Attachment Bnt B
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Weld and LineWeld and Line DescriptiDescription Table...on Table... ... 5050
1 Scope
1 Scope
1.1
1.1 This This standard standard specifies specifies the the welding, welding, heat heat treatment, treatment, Nondestructive Nondestructive TestingTesting (NDT), Charpy impact testing, and hardness testing requirements for welding (NDT), Charpy impact testing, and hardness testing requirements for welding pipelines and equipment (e.g., scraper traps) to
pipelines and equipment (e.g., scraper traps) to ASME B31.4ASME B31.4 andand ASME B31.8.ASME B31.8. It covers both onshore and offshore pipelines, including shop
It covers both onshore and offshore pipelines, including shop and fieldand field fabrication, repairs, and modificat
fabrication, repairs, and modification. ion. Distribution and other Distribution and other facilities whichfacilities which use
use ASME B31.4ASME B31.4 as the piping as the piping design code are also design code are also included. included. TheseThese requirements are in addition to the requirements of
requirements are in addition to the requirements of ASME B31.4,ASME B31.4, ASME B31.8,ASME B31.8, API STD 1104,
API STD 1104, andand ASME SEC IX.ASME SEC IX. For materials outside the scope of
For materials outside the scope of ASME B31.4ASME B31.4 or or ASME B31.8,ASME B31.8, CSD shallCSD shall determine if supplementary requirements are required.
determine if supplementary requirements are required. 1.2
1.2 Additional Additional requirements requirements may may be be contained contained in in Scopes Scopes of of Work, Work, Drawings, Drawings, or or other Instructions or Specifications pertaining to specific items of work. other Instructions or Specifications pertaining to specific items of work. 1.3
1.3 Any Any reference reference to to Consulting Consulting Services Services Department Department (CSD) (CSD) shall shall be be interpreted interpreted asas the CSD Welding
the CSD Welding Specialist or a Specialist or a representative designated by representative designated by CSD. CSD. AnyAny reference to "approval" shall be interpreted as written app
reference to "approval" shall be interpreted as written app roval.roval. 1.4
2
2 Conflicts Conflicts and and DeviationsDeviations 2.1
2.1 Any Any conflicts conflicts between between this this standard standard and and other other applicable applicable Saudi Saudi AramcoAramco Engineering Standards (SAESs), Materials Systems Sp
Engineering Standards (SAESs), Materials Systems Sp ecifications (SAMSSs),ecifications (SAMSSs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the resolved in writing by the Company or Buyer Representative through the Manager, Consulting Services Department of Saudi
Manager, Consulting Services Department of Saudi Aramco, Dhahran.Aramco, Dhahran. 2.2
2.2 Direct Direct all all requests requests to to deviate deviate from from this this standard standard in in writing writing to to the the Company Company or or Buyer Representative, who shall follow internal company procedu
Buyer Representative, who shall follow internal company procedu rere SAEP-302SAEP-302 and forward such requests to the Manager, Consul
and forward such requests to the Manager, Consul ting Services Department of ting Services Department of Saudi Aramco, Dhahran.
Saudi Aramco, Dhahran.
3 References
3 References
Unless stated otherwise, all Codes, Standards, and Drawings referenced in this Standard Unless stated otherwise, all Codes, Standards, and Drawings referenced in this Standard shall be of the latest issue (including revisions, addenda, and
shall be of the latest issue (including revisions, addenda, and supplements) and aresupplements) and are considered a part of this Standard.
considered a part of this Standard. 3.1
3.1 Saudi Saudi Aramco Aramco ReferencesReferences
Saudi Aramco Engineering Procedures Saudi Aramco Engineering Procedures
SAEP-302
SAEP-302 Instructions for Obtaining a Waiver of a Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Mandatory Saudi Aramco Engineering Requirement
Requirement SAEP-321
SAEP-321 Performance Qualification Testing and Performance Qualification Testing and Certification of Saudi Aramco Welders Certification of Saudi Aramco Welders SAEP-323
SAEP-323 Performance Qualification Testing of Contract Performance Qualification Testing of Contract Welders and Brazers
Welders and Brazers SAEP-324
SAEP-324 Certification Review and Registration of Project Certification Review and Registration of Project Welders and Brazers
Welders and Brazers SAEP-352
SAEP-352 Welding Procedure Review and Approval Welding Procedure Review and Approval SAEP-1140
SAEP-1140 Qualification of Saudi Aramco NDT Personnel Qualification of Saudi Aramco NDT Personnel SAEP-1142
SAEP-1142 Qualification of Non-Saudi Aramco NDT Qualification of Non-Saudi Aramco NDT Personnel
Personnel Saudi Aramco Engineering Standards
Saudi Aramco Engineering Standards SAES-A-206
SAES-A-206 Positive Material Identification Positive Material Identification SAES-B-064
SAES-B-064 Onshore and Nearshore Pipeline SafetyOnshore and Nearshore Pipeline Safety SAES-L-131
SAES-W-010
SAES-W-010 Welding Requirements for Pressure VesselsWelding Requirements for Pressure Vessels Saudi Aramco Materials System Specifications
Saudi Aramco Materials System Specifications 01-SAMSS-035
01-SAMSS-035 API API Line Line PipePipe 01-SAMSS-038
01-SAMSS-038 Small Direct Charge Purchases of PipeSmall Direct Charge Purchases of Pipe 01-SAMSS-333
01-SAMSS-333 High Frequency Welded Line Pipe High Frequency Welded Line Pipe Saudi Aramco Standard Drawings
Saudi Aramco Standard Drawings AB-036386
AB-036386 Hardness Testing for Welding Procedure Hardness Testing for Welding Procedure Qualifications
Qualifications AE-036451
AE-036451 Preheat Levels for Welding Carbon Steels Preheat Levels for Welding Carbon Steels Saudi Aramco Construction Safety Manual
Saudi Aramco Construction Safety Manual 3.2
3.2 Industry Industry Codes Codes and and StandardsStandards American Petroleum Institute American Petroleum Institute
API SPEC 5L
API SPEC 5L Specification for Line PipeSpecification for Line Pipe API STD 1104
API STD 1104 Welding of Pipelines and Related FacilitiesWelding of Pipelines and Related Facilities API RP2A-WSD
API RP2A-WSD Planning, Designing and Constructing Fixed Planning, Designing and Constructing Fixed Offshore Platforms-Working Stress Design Offshore Platforms-Working Stress Design American Society of Mechanical Engineers
American Society of Mechanical Engineers ASME B31.3
ASME B31.3 Process Piping Process Piping ASME B31.4
ASME B31.4 Liquid Petroleum Transportation Piping Systems Liquid Petroleum Transportation Piping Systems ASME B31.8
ASME B31.8 Gas Transmission and Distribution Piping Gas Transmission and Distribution Piping Systems
Systems ASME SEC II-C
ASME SEC II-C Welding Rods, Electrodes and Filler MetalsWelding Rods, Electrodes and Filler Metals ASME SEC V
ASME SEC V Nondestructive Examination Nondestructive Examination ASME SEC VIII
ASME SEC VIII Rules for Construction of Pressure Vess Rules for Construction of Pressure Vesselsels ASME SEC IX
ASME SEC IX Welding and Brazing QualificationsWelding and Brazing Qualifications American Society for Testing and Materials
American Society for Testing and Materials ASTM A707
ASTM A707 Standard Specification for Forged Carbon and Standard Specification for Forged Carbon and Alloy Steel Flanges for Low-Temperature Alloy Steel Flanges for Low-Temperature
Service Service ASTM A833
ASTM E747
ASTM E747 Standard Test Method for Controlling Quality of Standard Test Method for Controlling Quality of Radiographic Testing Using Wire
Radiographic Testing Using Wire Penetrameters
Penetrameters American Welding Society
American Welding Society AWS A2.4
AWS A2.4 Standard Welding SymbolsStandard Welding Symbols AWS A3.0
AWS A3.0 Standard Terms and DefinitionsStandard Terms and Definitions AWS A4.3
AWS A4.3 Standard Methods for Determination of theStandard Methods for Determination of the Diffusible Hydrogen Content of Martensitic, Diffusible Hydrogen Content of Martensitic, Bainitic, and Ferritic Weld Metal Produced by Bainitic, and Ferritic Weld Metal Produced by Arc Welding
Arc Welding AWS A5.01
AWS A5.01 Procurement Guidelines for Consumables Procurement Guidelines for Consumables AWS A5.32
AWS A5.32 Specification for Welding Shielding GasesSpecification for Welding Shielding Gases AWS D1.1
AWS D1.1 Structural Welding Code- Steel Structural Welding Code- Steel British Standards Institution
British Standards Institution BS EN ISO 14175
BS EN ISO 14175 Welding Consumables - Gases and Gas MixturesWelding Consumables - Gases and Gas Mixtures for Fusion Welding and Allied Processes for Fusion Welding and Allied Processes BS EN ISO 14344
BS EN ISO 14344 Welding and Allied Processes - Flux and Welding and Allied Processes - Flux and GasGas Shielded Electrical Welding Processes Shielded Electrical Welding Processes - Procurement Guidelines for Consumables Procurement Guidelines for Consumables BS EN50504
BS EN50504 Validation of Arc Welding Equipment Validation of Arc Welding Equipment Manufacturers Standardization Society of the Valve and Fittings Industry Manufacturers Standardization Society of the Valve and Fittings Industry
MSS-SP-75
MSS-SP-75 Specification for High Test, Wrought, Butt Specification for High Test, Wrought, Butt Welding Fittings
Welding Fittings National Association of Corrosion Engineers National Association of Corrosion Engineers
NACE SP0472
NACE SP0472 Methods and Controls to Prevent In-Service Methods and Controls to Prevent In-Service Cracking of Carbon Steel Welds in P-1 Cracking of Carbon Steel Welds in P-1 Material in Corrosive Petroleum Refining Material in Corrosive Petroleum Refining Environments
Environments
4 General
4 General
4.1
4.1 AWS A2.4AWS A2.4 "Standard Welding Symbols" shall be used "Standard Welding Symbols" shall be used for all welding details onfor all welding details on all drawings.
all drawings. 4.2
4.2 AWS A3.0AWS A3.0 "Standard Terms and Definitions" shall be used for all specifications"Standard Terms and Definitions" shall be used for all specifications and documents.
4.3
4.3 These These requirements requirements apply apply to to all all sub-contractors sub-contractors or or sub-vendors sub-vendors for for items items withinwithin the scope of this standard.
the scope of this standard. 4.4
4.4 The The ASNT ASNT term term Nondestructive Nondestructive Testing Testing (NDT) (NDT) has has been been used used in in this this standardstandard and shall be considered synonymous with the ASME term Nondestructive and shall be considered synonymous with the ASME term Nondestructive Examination (NDE).
Examination (NDE). 4.5
4.5 The The terms terms "shall," "shall," "should" "should" and and "may" "may" have have the the following following significance:significance: Provisions that use "shall" are mandatory unless specifically modified in Provisions that use "shall" are mandatory unless specifically modified in contract documents by the Engineer.
contract documents by the Engineer. The word "should" is used to recommend
The word "should" is used to recommend practices that are considered beneficialpractices that are considered beneficial but are not requirements.
but are not requirements. The word "may" in a
The word "may" in a provision allows the use of optional procedures or provision allows the use of optional procedures or practices that can be used as an alternative to the Standard requirement. practices that can be used as an alternative to the Standard requirement. 5
5 Approved Approved Welding Welding ProcessesProcesses
The following processes are approved for use with
The following processes are approved for use with the restrictions and requirements asthe restrictions and requirements as listed below:
listed below: 5.1
5.1 Shielded Shielded Metal Metal Arc Arc Welding Welding (SMAW).(SMAW). 5.2
5.2 Gas Gas Tungsten Tungsten Arc Arc Welding Welding (GTAW).(GTAW). 5.2.1
5.2.1 Except Except for for P-No. P-No. 1 1 base base materials, materials, all all manual manual GTAW GTAW shall shall use use a a highhigh frequency start, post-purge gas flow for the torch, and
frequency start, post-purge gas flow for the torch, and filler metal shallfiller metal shall be added.
be added. 5.2.2
5.2.2 The The GTAW GTAW process process shall shall be be used used for for all all passes passes for for butt butt welds welds andand socket welds in piping and nozzles less than 33.4 mm outside diameter socket welds in piping and nozzles less than 33.4 mm outside diameter (1" NPS).
(1" NPS). This does not apply to This does not apply to weldolets, sockolets, threadolets, andweldolets, sockolets, threadolets, and welding bosses.
welding bosses. 5.2.3
5.2.3 The The GTAW GTAW process process shall shall be be used used for for the the root root pass pass of of butt butt welds welds inin piping and nozzles of
piping and nozzles of 60.3 mm outside diameter (2" NPS) or less,60.3 mm outside diameter (2" NPS) or less, except for vent and drain piping open to the atmosphere or for carbon except for vent and drain piping open to the atmosphere or for carbon steel in low press
steel in low pressure water service. ure water service. This does not apply to socketThis does not apply to socket welds, weldolets, sockolets, threadolets, and welding bosses. welds, weldolets, sockolets, threadolets, and welding bosses. 5.2.4
5.2.4 The The GTAW GTAW process process shall shall be be used used for for the the root root pass pass of of single-sidedsingle-sided groove welds without backing made with
groove welds without backing made with stainless steel or nickel-basedstainless steel or nickel-based consumables.
5.2.5
5.2.5 The The use use of of flux-cored flux-cored GTAW GTAW wires wires for for root root pass pass of of single-sidedsingle-sided groove welds of P-No. 8 o
groove welds of P-No. 8 or higher with or without backing gas is notr higher with or without backing gas is not permitted unless specifically approved by CSD.
permitted unless specifically approved by CSD. 5.2.6
5.2.6 When When internal internal coatings coatings are are specified specified on on pipelines, pipelines, the the GTAW GTAW processprocess shall be used for the root pass of
shall be used for the root pass of butt welds for inaccessible pipingbutt welds for inaccessible piping diameters, i.e., thos
diameters, i.e., those below 24-inches diame below 24-inches diameter. eter. Other processes Other processes maymay be used if the level of weld spatter and the weld profile are acceptable be used if the level of weld spatter and the weld profile are acceptable
for coating or if measures in removing weld spatter are
for coating or if measures in removing weld spatter are proven to beproven to be effective.
effective. Internal copper shoes Internal copper shoes may be effective may be effective for controlling for controlling weldweld spatter.
spatter. 5.3
5.3 Submerged Submerged Arc Arc Welding Welding (SAW).(SAW). 5.4
5.4 Gas Gas Metal Metal Arc Arc Welding Welding (GMAW) (GMAW) [including [including Flux Flux Cored Cored Arc Arc WeldingWelding (FCAW)].
(FCAW)]. 5.4.1
5.4.1 The The GMAW GMAW short-circuiting short-circuiting (dip) (dip) mode mode shall shall not not be be used used except except for:for: a)
a) Structural Structural attachments attachments to to the the outside outside surface surface of of the the pipe,pipe, including seal welds.
including seal welds. b)
b) Tacking (including continuous tacks) that will be completelyTacking (including continuous tacks) that will be completely removed by backgouging and backwelding.
removed by backgouging and backwelding. c)
c) The The root root pass pass and and hot hot pass pass only only for for butt butt welds welds in in P-No. P-No. 1 1 carboncarbon steels.
steels. d)
d) Automatic/machine Automatic/machine welding welding using using the the GMAW GMAW process process in in thethe short-circuiting
short-circuiting or pulsing mode or pulsing mode requires approval by requires approval by CSD. CSD. AA computerized automated ultrasonic inspection system, approved computerized automated ultrasonic inspection system, approved by Inspection Department, must be used.
by Inspection Department, must be used. If the welding processIf the welding process is approved, it may be used
is approved, it may be used for all passes in material of anyfor all passes in material of any thickness, subject to the limits of the qualification code. thickness, subject to the limits of the qualification code. e)
e) The The modified modified short short circuit circuit mode mode of of GMAW GMAW may may only only be be used used for for root paas welding.
root paas welding. It is not applicable tIt is not applicable to fill passes.o fill passes. 5.4.2
5.4.2 GMAW GMAW and and FCAW FCAW shall shall not not be be used used for for the the root root pass pass on on single-sidedsingle-sided tee or corner joints (i.e., branch or noz
tee or corner joints (i.e., branch or nozzle welds).zle welds). 5.4.3
5.4.3 Flux-Cored Flux-Cored Arc Arc Welding Welding (FCAW).(FCAW). a)
a) The The FCAW FCAW process process shall shall not not be be used used for for the the root root pass pass on on fullfull penetration, groove joints that are welded from one side only penetration, groove joints that are welded from one side only
without backing (backing may be
without backing (backing may be used if it is removed after used if it is removed after welding and weld irregular profile is rectified).
b)
b) Self-shielded FCAW shall not be used without the specificSelf-shielded FCAW shall not be used without the specific approval of CSD.
approval of CSD. 5.5
5.5 Thermit Thermit Welding Welding using using a a copper copper alloy alloy is is permitted permitted for for attaching attaching electricalelectrical grounding or cathodic protection cables.
grounding or cathodic protection cables. Thermit welding shall not be Thermit welding shall not be used onused on stainless steel materials.
stainless steel materials. 5.6
5.6 Stud Stud Welding Welding is is permitted permitted for for attaching attaching insulation insulation fasteners fasteners and and heat heat conductors.conductors. 5.7
5.7 Other Other processes processes may may be be used used only only with with the the approval approval of of CSD. CSD. Depending Depending uponupon the process and application proposed, CSD may require testing in addition to the process and application proposed, CSD may require testing in addition to that specified by the Code.
that specified by the Code. 5.8
5.8 Welding Welding without without filler filler metal metal additions additions is is not not permitted.permitted. 6
6 Welding Welding ConsumablesConsumables
6.1 General
6.1 General
6.1.1
6.1.1 Electrodes, Electrodes, filler filler wires, wires, and and fluxes fluxes shall shall conform conform toto ASME SEC II-C.ASME SEC II-C. Other consumables may be used only with the approval of CSD and, Other consumables may be used only with the approval of CSD and, depending upon the process and application proposed, may require depending upon the process and application proposed, may require testing in addition to that specified by
testing in addition to that specified by API STD 1104API STD 1104 or or ASME SEC IX.ASME SEC IX. Approval to use other (unlisted in
Approval to use other (unlisted in ASME SEC II-C)ASME SEC II-C) consumables shallconsumables shall be obtai
be obtained througned through the weh the welding prlding procedure rocedure review preview process. ocess. For unliFor unlistedsted consumables, vendor literature, which shall include intended use and consumables, vendor literature, which shall include intended use and approximate chemistry and mechanical properties, shall be submitted approximate chemistry and mechanical properties, shall be submitted with the procedure.
with the procedure. 6.1.2
6.1.2 All All consumables consumables shall shall be be stored stored and and dried dried in in accordance accordance with with thethe
requirements of Appendix 1 for SMAW electrodes and Appendix 2 for requirements of Appendix 1 for SMAW electrodes and Appendix 2 for other consumables.
other consumables. 6.1.3
6.1.3 GTAW GTAW filler filler metal metal shall shall have have either either the the AWS/ASME AWS/ASME identification identification or or the manufacturer's identification marked on each ind
the manufacturer's identification marked on each individual rod by theividual rod by the manufacturer with tags ("flags"), stencil, or stamping.
manufacturer with tags ("flags"), stencil, or stamping. 6.1.4
6.1.4 Welding Welding consumables consumables shall shall be be selected selected based based on on their their mechanicalmechanical properties, compatibility with the materials
properties, compatibility with the materials to be joined, their to be joined, their suitability for the intended service, and consideration of polarity, suitability for the intended service, and consideration of polarity, position, and direction of welding.
position, and direction of welding. Welding consumables not meetingWelding consumables not meeting standard industry practice using the above criteria may b
standard industry practice using the above criteria may b e rejected bye rejected by Saudi Aramco.
6.1.5
6.1.5 Low Low hydrogen hydrogen consumables consumables (defined (defined as as less less than than or or equal equal to to 8 8 ml ml of of hydrogen per 100 g of deposited weld metal, measured in accordance hydrogen per 100 g of deposited weld metal, measured in accordance with
with AWS A4.3)AWS A4.3) shall be used except for applications listed below:shall be used except for applications listed below: a)
a) Cellulosic Cellulosic electrodes electrodes may may be be used used in in all all passes passes for for girth girth welds welds for for pipelines and equipment for grades up to and including X60 and pipelines and equipment for grades up to and including X60 and
wall thickness less
wall thickness less than or equal to 25 mm. than or equal to 25 mm. Cellulosic electrodesCellulosic electrodes shall not be used for hot tapping
shall not be used for hot tapping operation or for in-serviceoperation or for in-service welding.
welding. b)
b) Cellulosic electrodes may be used for the root and hot passes of Cellulosic electrodes may be used for the root and hot passes of single-sided groove welds without backing for pipelines and single-sided groove welds without backing for pipelines and equipment for all grades and wall thicknesses.
equipment for all grades and wall thicknesses. 6.1.6
6.1.6 Dissimilar Dissimilar metal metal welds welds (DMW) (DMW) are are defined defined as:as: i)
i) Any Any weld weld joint joint (excluding (excluding weld weld overlays overlays or or strip strip lining) lining) betweenbetween ferritic steel and either austenitic stainless steel, duplex stainless ferritic steel and either austenitic stainless steel, duplex stainless steel, or nickel-based alloys, or
steel, or nickel-based alloys, or ii)
ii) Use Use of of stainless stainless steel steel or or nickel-based fnickel-based filler iller metals metals on on ferritic ferritic steels.steels. DMWs shall be restricted as follows:
DMWs shall be restricted as follows: a)
a) DMWs DMWs are are not not permitted permitted for for any any welds welds exposed exposed to to sour sour service (welds in clad systems are acceptable if the DMW service (welds in clad systems are acceptable if the DMW interface with the ferritic steel is not in contact with the sour interface with the ferritic steel is not in contact with the sour fluid).
fluid). b)
b) DMWs are permitted for non-sour hydrocarbon service if DMWs are permitted for non-sour hydrocarbon service if made with a nickel-based consumable.
made with a nickel-based consumable. c)
c) Austenitic Austenitic stainless stainless steel steel consumables consumables may may be be used used only only for for the following applications and if the maximum design
the following applications and if the maximum design temperature is below 300°C:
temperature is below 300°C: 1)
1) External External structural structural attachments attachments (e.g., (e.g., pipe pipe supports).supports). 2)
2) Non-sour, Non-sour, non-hydrocarbon non-hydrocarbon (e.g., (e.g., water, water, air) air) services.services. 6.1.7
6.1.7 Other Other than than the the DMWs DMWs listed listed in in paragraph paragraph 6.1.6, 6.1.6, the the selection selection of of filler filler metal compositions for joining base materials of different P-Numbers metal compositions for joining base materials of different P-Numbers or compositions shall be as follows:
or compositions shall be as follows: a)
a) For For attaching attaching non-pressure non-pressure parts parts to to pressure pressure parts, parts, the the nominalnominal composition of the filler metal shall match the nominal
composition of the filler metal shall match the nominal composition of the pressure part.
b)
b) For other applications, the filler metal sFor other applications, the filler metal shall conform to either hall conform to either base metal composition or to an intermediate composition, base metal composition or to an intermediate composition,
whichever is the most appropriate for the application. whichever is the most appropriate for the application. 6.1.8
6.1.8 For For hydrocarbon hydrocarbon service, service, filler filler metal metal or or deposit deposit chemistries chemistries conformingconforming to A-number 2
to A-number 2 (ASME SEC IX)(ASME SEC IX), i.e., carbon-0.5% Mo, (e.g., E7010-, i.e., carbon-0.5% Mo, (e.g., E7010-A1 or E7018-E7010-A1 for SMAW) shall not be
A1 or E7018-A1 for SMAW) shall not be used unless specificallyused unless specifically approved by
approved by CSD. CSD. E7010-P1 may E7010-P1 may be used.be used. 6.1.9
6.1.9 All All electrodes electrodes shall shall be be purchased purchased with with certified certified lot lot testing testing inin accordance with
accordance with AWS A5.01AWS A5.01 or or BS EN ISO 14344.BS EN ISO 14344. The LotThe Lot classification shall be S2, T2, C2, F2
classification shall be S2, T2, C2, F2 or higher. The schedule of or higher. The schedule of testingtesting shall be "4 or I" or hi
shall be "4 or I" or higher for gher for AWS A5.01AWS A5.01 and "Schedule 4" or higher and "Schedule 4" or higher for
for BS EN ISO 14344.BS EN ISO 14344. 6.1.10
6.1.10 If If ER70S-6 iER70S-6 is s to to be be used for used for sour sour service service the chemistry the chemistry of of the wthe wireire shall not exceed the requirements of
shall not exceed the requirements of NACE SP0472NACE SP0472 (as follows):(as follows):
Carbon Carbon (C) (C) 0.10 0.10 wt% wt% max;max;
Manganese Manganese (Mn) (Mn) 1.60 1.60 wt% wt% max;max;
Silicon Silicon (Si) (Si) 1.00 1.00 wt% wt% max.max.
This must be verified for all lots of wire. This must be verified for all lots of wire. 6.1.11
6.1.11 If If a a consumable consumable has has an an AWS AWS classification classification which which has has a a minimumminimum tensile strength lower than the minimum required tensile strength of tensile strength lower than the minimum required tensile strength of the material being welded it is
the material being welded it is potentially under-matching. potentially under-matching. All of theAll of the lots of this type of consumable shall be checked to confirm that they lots of this type of consumable shall be checked to confirm that they have tensile and yield strengths exceeding th
have tensile and yield strengths exceeding the minimum required for e minimum required for the base material being welded.
the base material being welded. 6.2
6.2 Submerged Submerged Arc Arc Welding Welding FluxesFluxes 6.2.1
6.2.1 Active Active type type Submerged Submerged Arc Arc Welding Welding fluxes fluxes shall shall not not be be used used withoutwithout CSD approval.
CSD approval. The approval shall be The approval shall be obtained through the weldingobtained through the welding procedure review process.
procedure review process. The fabricator shall clearly identify theThe fabricator shall clearly identify the proposed use of active fluxes in their welding procedure submissions. proposed use of active fluxes in their welding procedure submissions. 6.2.2
6.2.2 Flux Flux fused fused during during welding welding shall shall not not be be reused reused (i.e., (i.e., fluxes fluxes that that useuse recrushed slag are not acceptable).
recrushed slag are not acceptable). 6.2.3
6.2.3 Reclaimed Reclaimed flux flux can can be be used used provided provided following following the the conditions conditions below:below:
Magnetically separated.Magnetically separated.
Mixed with the percentage of new flux recommended by the fluxMixed with the percentage of new flux recommended by the flux
manufacturer. manufacturer.
Baked out prior to use per Baked out prior to use per manufacturer recommendations.manufacturer recommendations.
6.2.4
6.2.4 SAW SAW fluxes fluxes that that the the flux flux manufacturer manufacturer recommends recommends for for single single passpass welding shall not be used
welding shall not be used for multiple pass welding.for multiple pass welding. 6.3
6.3 SMAW SMAW electrodes electrodes shall shall be be limited limited as as follows:follows: 6.3.1
6.3.1 F-Nos. F-Nos. 1 1 and and 2 2 electrodes electrodes shall shall not not be be used used on on materials materials requiringrequiring impact tests either by Code or job specification.
impact tests either by Code or job specification. 6.3.2
6.3.2 F-Nos. F-Nos. 1 1 and and 2 2 electrodes electrodes shall shall not not be be used used for for pressure-retainingpressure-retaining welds.
welds. 6.4
6.4 Shielding Shielding GasesGases 6.4.1
6.4.1 Shielding Shielding gases gases shall shall conform conform to to the the requirements requirements of of AWS A5.32AWS A5.32 or or BS EN ISO 14175.
BS EN ISO 14175. 6.4.2
6.4.2 The The requirements requirements for for other other gases gases and and gas gas mixtures mixtures shall shall be be submittedsubmitted to CSD for approval.
to CSD for approval. 6.5
6.5 The The following following table table gives gives the the minimum minimum strength strength levels levels for for consumables consumables that that cancan be used to weld the various grades of pipe.
be used to weld the various grades of pipe.
Pipe
Pipe Root ConsumableRoot Consumable Minimum Minimum
Fill Consumable Fill Consumable
Minimum
Minimum NoteNote X52 and below
X52 and below 60XX 60XX 70XX70XX
X60
X60 70XX 70XX 70XX70XX
Must have mill certs Must have mill certs for 70XX fill for 70XX fill consumable consumable showing that it showing that it
meets 75 KSI tensile meets 75 KSI tensile X65 X65 70XX 70XX 80XX80XX X70 X70 80XX 80XX 80XX80XX Notes: Notes:
This table applies to manual and semiThis table applies to manual and semiautomatic welding. automatic welding. It does not apply to automIt does not apply to automaticatic
GMAW welding. GMAW welding.
This table must be used This table must be used in conjunction with electrode selection requirements in Sectionin conjunction with electrode selection requirements in Section
6.1.5. 6.1.5.
7
7 Welding Welding ProceduresProcedures
7.1 Documentation
7.1 Documentation
7.1.1
7.1.1 All All welding welding procedures procedures to to be be used used shall shall be be submitted submitted to to Saudi Saudi AramcoAramco PMT or the proponent as a
PMT or the proponent as a complete package prior to complete package prior to the start of work the start of work (refer to
(refer to SAEP-352SAEP-352 for details)for details). . The package of The package of welding procedures,welding procedures, qualification test records, and Weld and
qualification test records, and Weld and Line Description Tables shallLine Description Tables shall be submitted for the technical approval by CSD.
be submitted for the technical approval by CSD. Only the weldingOnly the welding procedure will be approved.
procedure will be approved.
After technical approval by CSD the welding Weld and Line After technical approval by CSD the welding Weld and Line Description Table procedure may be approved by the Inspection Description Table procedure may be approved by the Inspection Department for other
Department for other appropriate applications on appropriate applications on future projects. future projects. TheThe project assigned inspector will authorize the use of CSD-approved project assigned inspector will authorize the use of CSD-approved
welding procedures if the scope and
welding procedures if the scope and essential variables (i.e., Code,essential variables (i.e., Code, material grade P and group number and thickness, PWHT and impact material grade P and group number and thickness, PWHT and impact requirements) are acceptable for the new application.
requirements) are acceptable for the new application.
Welding procedures for external structural supports that do not attach Welding procedures for external structural supports that do not attach to the pressure-containing component do not require CSD approval and to the pressure-containing component do not require CSD approval and they may be qualified to
they may be qualified to AWS D1.1.AWS D1.1. 7.1.2
7.1.2 The The forms forms for for the the WPSs WPSs and and PQRs PQRs shall shall be be as as suggested suggested in in thethe respective code being used.
respective code being used. 7.1.3
7.1.3 Welding Welding shall shall not not commence commence until until the the welding welding package package has has beenbeen approved for application by Saudi Aramco inspector and returned to approved for application by Saudi Aramco inspector and returned to the fabricator.
the fabricator. Any welding prior Any welding prior to the approval of to the approval of the weldingthe welding package is subject to rejection at the sole option of Saudi Aramco package is subject to rejection at the sole option of Saudi Aramco
inspector.
inspector. Any rework required as a Any rework required as a result of this rresult of this rejection shall be atejection shall be at the fabricator's expense.
the fabricator's expense. 7.1.4
7.1.4 After After approval approval by by Saudi Saudi Aramco Aramco inspector, inspector, the the fabricator fabricator shall shall issueissue copies of the approved Welding Procedures and Weld and Line copies of the approved Welding Procedures and Weld and Line Description Tables to the Saudi Aramco Inspector and
Description Tables to the Saudi Aramco Inspector and PMT prior toPMT prior to the start of fabrication.
the start of fabrication. 7.1.5
7.1.5 Approval Approval of of welding welding procedures procedures shall shall not not be be construed construed as as authority authority for for deviation from listed specifications or requirements of the relevant deviation from listed specifications or requirements of the relevant codes and standards and shall n
codes and standards and shall not relieve the contractor, fabricator, or ot relieve the contractor, fabricator, or vendor from correcting any deviations.
7.1.6
7.1.6 All All WPSs, WPSs, PQRs, PQRs, and and Weld Weld and and Line Line Description Description Tables Tables shall shall bebe available at the work site for review at a
available at the work site for review at any time by the authorizedny time by the authorized Saudi Aramco inspector.
Saudi Aramco inspector. 7.1.7
7.1.7 All All Welding Welding Procedure Procedure Specifications Specifications and and Welding Welding ProcedureProcedure Qualification Records shall be written in English.
Qualification Records shall be written in English. 7.1.8
7.1.8 For For in-Kingdom in-Kingdom contractors contractors the the PQRs PQRs shall shall include include either either the the originaloriginal testing certificates, a copy of the original certificates that has been testing certificates, a copy of the original certificates that has been certified by the testing agency, or a
certified by the testing agency, or a color copy of the originalcolor copy of the original certificates. For Out of Kingdom qualifications the contractor shall certificates. For Out of Kingdom qualifications the contractor shall stamp all PQR records certifying them to be true c
stamp all PQR records certifying them to be true c opies.opies. 7.1.9
7.1.9 Originals Originals of of all all test test records, records, mill mill certificates, certificates, etc., etc., including including recordsrecords from the independent test laboratory shall be made
from the independent test laboratory shall be made available for reviewavailable for review by Saudi Aramco upon request.
by Saudi Aramco upon request. 7.2
7.2 General General RequirementsRequirements 7.2.1
7.2.1 All All welding welding procedures procedures for for pipelines pipelines shall shall be be qualified qualified in in accordanceaccordance with
with API STD 1104API STD 1104 as required by the design codes,as required by the design codes, ASME B31.4ASME B31.4 andand ASME B31.8.
ASME B31.8. For other applications permitted by the design codFor other applications permitted by the design cod e,e, procedures may be qualified in accordance with
procedures may be qualified in accordance with ASME SEC IX.ASME SEC IX. AllAll automatic welding procedures shall be qualified in
automatic welding procedures shall be qualified in accordance withaccordance with API STD 1104.
API STD 1104. Procedures that comply with a previous edition butProcedures that comply with a previous edition but not the current edition of the relevant Code are not acceptable, even if not the current edition of the relevant Code are not acceptable, even if the Code permits
the Code permits such procedures. such procedures. Procedures no longer conforProcedures no longer conformingming to the latest Code edition shall be
to the latest Code edition shall be revised and re-qualified.revised and re-qualified. In sour service, procedures for "in Service" welding shall b
In sour service, procedures for "in Service" welding shall b e qualifiede qualified in accordance with
in accordance with API STD 1104API STD 1104 Appendix B. Appendix B. In sIn service ervice weldingwelding includes the attachment of repair sleeves and
includes the attachment of repair sleeves and hot tap sleeves.hot tap sleeves.
Qualification testing shall be performed of the same or higher carbon Qualification testing shall be performed of the same or higher carbon equivalent.
equivalent. 7.2.2
7.2.2 For For any any new new or or additional additional qualification qualification tests tests that that are are required, required, SaudiSaudi Aramco reserves the right to monitor any and
Aramco reserves the right to monitor any and all phases of theall phases of the procedure qualification, including welding of the coupons and procedure qualification, including welding of the coupons and
mechanical testing.
mechanical testing. Saudi Aramco may asSaudi Aramco may assign the monitoring sign the monitoring to anto an inspection agency.
inspection agency. 7.2.3
7.2.3 All All information information shown shown on on the the PQR, PQR, such such as as amperage, amperage, voltage, voltage, traveltravel speed, postweld heat treatment time and
speed, postweld heat treatment time and temperature, as applicable,temperature, as applicable, shall be actual data as reco
7.2.4
7.2.4 Qualification Qualification of of welding welding procedures procedures for for all all shop shop fabrication fabrication in in SaudiSaudi Arabia and field erection work shall be
Arabia and field erection work shall be performed In-Kingdom.performed In-Kingdom. Approval for use of previously qualified welding procedures or Out Approval for use of previously qualified welding procedures or Out -of- -of-Kingdom testing sites shall be obtained through the
Kingdom testing sites shall be obtained through the welding procedurewelding procedure review process.
review process. Out-of-Kingdom testing Out-of-Kingdom testing will be consiwill be considered for thedered for the following applications:
following applications: a)
a) If If special special tests tests such such as as Crack Crack Tip Tip Opening Opening Displacement Displacement (CTOD)(CTOD) tests are required and need to be conducted by Out-of-Kingdom tests are required and need to be conducted by Out-of-Kingdom laboratories.
laboratories. b)
b) For offshore lay barges, if the qualification is perforFor offshore lay barges, if the qualification is performed in themed in the Gulf region and is witnessed by either Saudi Aramco
Gulf region and is witnessed by either Saudi Aramco InspectionInspection or an approved independent third party inspection agency.
or an approved independent third party inspection agency. 7.2.5
7.2.5 For For In-Kingdom In-Kingdom qualifications:qualifications: a)
a) The The welding welding of of all all qualification qualification test test coupons coupons shall shall be be monitoredmonitored by either an approved independent test laboratory, an
by either an approved independent test laboratory, an
independent third party approved by Saudi Aramco, or Saudi independent third party approved by Saudi Aramco, or Saudi Aramco Inspection.
Aramco Inspection. The monitoring shall The monitoring shall include verification include verification of of the accuracy of the recorded parameters.
the accuracy of the recorded parameters. b)
b) All procedure qualification mechanical tests and examinationsAll procedure qualification mechanical tests and examinations shall be performed by an approved independent test laboratory shall be performed by an approved independent test laboratory unless the fabricator is specifically approved by Saudi Aramco unless the fabricator is specifically approved by Saudi Aramco Inspection to perform their own tests.
Inspection to perform their own tests. 7.2.6
7.2.6 For For all all automatic automatic welding welding and and any any process process with with pulsing, pulsing, the the weldingwelding procedure shall include all applicable equipment and controller procedure shall include all applicable equipment and controller parameter settings.
parameter settings. 7.3
7.3 Special Special qualification qualification tests, tests, such such as as stress stress corrosion corrosion cracking, cracking, may may be be specifiedspecified by CSD for special materials not covered by
by CSD for special materials not covered by ASME B31.4ASME B31.4 or or ASME B31.8ASME B31.8 or or for special applications (as determined by CSD), such as b
for special applications (as determined by CSD), such as b ut not limited tout not limited to severe corrosion service.
severe corrosion service.
API Grades X70 and higher are n
API Grades X70 and higher are not normally permitted in sour service andot normally permitted in sour service and require special stress corrosion cracking tests for sour service applications. require special stress corrosion cracking tests for sour service applications. These tests shall be specified by CSD.
These tests shall be specified by CSD. 7.4
7.4 Procedure Procedure VariablesVariables
The following additional restrictions shall be considered essential variables for The following additional restrictions shall be considered essential variables for procedure qualification:
7.4.1
7.4.1 The The material material groupings groupings and and restrictions restrictions listed listed inin API STD 1104API STD 1104 shallshall be also be used for qualifications to
be also be used for qualifications to ASME SEC IX.ASME SEC IX. The followingThe following exceptions to
exceptions to API STD 1104API STD 1104 shall apply:shall apply: i)
i) Procedures Procedures for for Grade Grade B B throughthrough API SPEC 5LAPI SPEC 5L X52 carbon steelX52 carbon steel pipe may be qualified on any grade in this range and for
pipe may be qualified on any grade in this range and for ASME SEC IX
ASME SEC IX qualifications shall be considered as P-No. 1,qualifications shall be considered as P-No. 1, Gr. 1 material.
Gr. 1 material. ii)
ii) Procedures Procedures for for API SPEC 5LAPI SPEC 5L Grade X60 and higher shall beGrade X60 and higher shall be qualified for
qualified for each specific material each specific material grade. grade. Qualifications usingQualifications using API SPEC 5L
API SPEC 5L Grade X60 may qualify all lower strength APGrade X60 may qualify all lower strength APII grades (including Grade B).
grades (including Grade B). 7.4.2
7.4.2 The The following following materials materials shall shall be be considered considered as as P-No. P-No. 1 1 in in accordanceaccordance with
with ASME SEC IXASME SEC IX and do not require separate qand do not require separate qualifications asualifications as "unlisted" materials: "unlisted" materials: A707 L3 A707 L3 A707 L5 A707 L5 A350 LF6 A350 LF6 A350 LF787 A350 LF787 MSS-SP-75
MSS-SP-75 (with grades classified the same as pipe)(with grades classified the same as pipe)
Note:
Note: ASTM A707 L5 flanges require a higher preheat refer to the notes in ASTM A707 L5 flanges require a higher preheat refer to the notes in
Tables 3A/B and 4A/B. Tables 3A/B and 4A/B.
7.4.3
7.4.3 For For ASME ASME P-No. P-No. 1 1 materials, materials, all all Group Group 3 3 or or 4 4 materials materials shall shall bebe qualified separately for each specific material, unless it is bein
qualified separately for each specific material, unless it is bein g used ing used in combination with a Group 1 or 2 material and the Group 1 or 2
combination with a Group 1 or 2 material and the Group 1 or 2 material strength requirements govern.
material strength requirements govern. 7.4.4
7.4.4 Any Any GMAW GMAW electrode electrode to to be be used used for for procedures procedures with with impactimpact
toughness requirements and any SAW flux or FCAW electrode shall toughness requirements and any SAW flux or FCAW electrode shall be restricted to the specific brand, type, and maximum size as used for be restricted to the specific brand, type, and maximum size as used for
the PQR.
the PQR. If so reIf so restricted, the brand name and type of stricted, the brand name and type of flux or electrodeflux or electrode shall be specified on both the WPS and PQR.
shall be specified on both the WPS and PQR. 7.4.5
7.4.5 A A change change in in filler filler metal metal or or deposit deposit chemistry chemistry from from A-number A-number 1 1 (based(based on
on ASME SEC IX)ASME SEC IX) to A-number 2 and vice-versa to A-number 2 and vice-versa is not permittedis not permitted without approval.
without approval. The approval shall The approval shall be obtained through be obtained through the weldingthe welding procedure review process.
procedure review process. A change from A-no. 1 to A-no. 2 is notA change from A-no. 1 to A-no. 2 is not permitted for sour service applications without requalifi
permitted for sour service applications without requalification.cation. 7.4.6
7.4.6 Any Any change change in in the the type type of of current current or or polarity polarity shall shall be be considered considered anan essential variable.
7.4.7
7.4.7 Aluminum Aluminum flake flake weldable weldable primers primers (e.g., (e.g., "Bloxide", "Bloxide", "Deoxaluminite","Deoxaluminite", or other brand approved by CSD) may be used without requalification or other brand approved by CSD) may be used without requalification of the procedure.
of the procedure. The welding procedure specifiThe welding procedure specification shall indicatecation shall indicate the use of
the use of the type and brand the type and brand of weldable primof weldable primer. er. The maximumThe maximum coating thickness shall
coating thickness shall not exceed 0.050 mm. not exceed 0.050 mm. The use of The use of other other weldable primers or coatings is not permitted unless specifically weldable primers or coatings is not permitted unless specifically approved by CSD.
approved by CSD. Additional procedure Additional procedure qualification and/or qualification and/or weldability tests may be required by CSD.
weldability tests may be required by CSD. 7.4.8 Position
7.4.8 Position 7.4.8.1
7.4.8.1 The The direction direction of of welding welding for for the the vertical vertical position position shall shall be be anan essential variable (i.e., a change from vertical-up t
essential variable (i.e., a change from vertical-up to vertical-o vertical-down or vice-versa shall be considered an essential
down or vice-versa shall be considered an essential variable).
variable). If the If the procedure was not procedure was not qualified in the qualified in the verticalvertical position, then the direction of welding shall be vertical-up. position, then the direction of welding shall be vertical-up. 7.4.8.2
7.4.8.2 For For automatic, automatic, semi-automatic, semi-automatic, or or mechanized mechanized welding, welding, thethe position limitations list
position limitations listed ined in ASME SEC IX,ASME SEC IX, QW-461.9 shallQW-461.9 shall be considered as an essential variable for procedure
be considered as an essential variable for procedure qualification.
qualification. 7.4.9
7.4.9 Procedures Procedures using using any any consumable consumable with with a a "G" "G" or or unlisted unlisted designationdesignation (ASME SEC II-C)
(ASME SEC II-C) shall be restricted to the brand and shall be restricted to the brand and type of electrodetype of electrode used for the PQR.
used for the PQR. The nominal chemistry of The nominal chemistry of the specific brand andthe specific brand and type of electrode shall be identified on the WPS.
type of electrode shall be identified on the WPS. 7.4.10
7.4.10 Deletion Deletion of of a a backing sbacking strip trip in in a a single-sided single-sided groove groove weld weld shall shall bebe considered an essential variable and shall require requ
considered an essential variable and shall require requ alification.alification. 7.4.11
7.4.11 For For single-sided single-sided groove groove welds welds without without backing, backing, the the process process andand electrode type used for the root pass shall
electrode type used for the root pass shall be considered an essentialbe considered an essential variable.
variable. The PQR shall The PQR shall be performed as be performed as a single-sided gra single-sided groove weldoove weld without backing.
without backing. 7.4.12
7.4.12 For For full full penetration, penetration, double-sided double-sided joints, joints, the the WPS WPS shall shall requirerequire backgouging (see 10.3.4) for all processes except for the following: backgouging (see 10.3.4) for all processes except for the following:
a)
a) For For automatic automatic or or mechanized mechanized welding welding processes processes if if additionaladditional PQR testing is conducted, the PQR shall include supplementary PQR testing is conducted, the PQR shall include supplementary coupons using the
coupons using the production equipment and joint production equipment and joint geometry. geometry. TheThe supplementary coupons shall be examined by UT or RT, as
supplementary coupons shall be examined by UT or RT, as appropriate for the joint geometry, and shall be s
appropriate for the joint geometry, and shall be s ectioned for ectioned for examination in at
cross-sections shall show complete fusion, complete penetration, and sections shall show complete fusion, complete penetration, and freedom from cracks.
freedom from cracks. b)
b) For other special processes on butt joints where the productionFor other special processes on butt joints where the production welds will be radiographed, the applications shall be approved by welds will be radiographed, the applications shall be approved by CSD.
CSD. 7.4.13
7.4.13 Deletion Deletion of of a a backing gas backing gas purge purge or or a a change change in in the the backing backing gasgas composition for a joint welded or brazed
composition for a joint welded or brazed from one side withoutfrom one side without backing material shall require requalification.
backing material shall require requalification. 7.4.14
7.4.14 Any Any supplementary supplementary qualification qualification tests tests required required by by this this or or any any other other standard or specification (e.g., hardness tests) shall comply with all of standard or specification (e.g., hardness tests) shall comply with all of the essential and, where applicable, supplementary essential va
the essential and, where applicable, supplementary essential va riablesriables of the this standard and either
of the this standard and either ASME SEC IXASME SEC IX or or API STD 1104.API STD 1104. 7.4.15
7.4.15 Repair Repair may may be be conducted conducted using using a a welding welding procedure procedure different different than than thethe original welding procedure used to weld the
original welding procedure used to weld the joint with the conditions:joint with the conditions: a)
a) Repair Repair procedures procedures shall shall be be qualified qualified for for each each base base metalmetal thickness range as listed in
thickness range as listed in API STD 1104.API STD 1104. b)
b) The weld deposit thickness used for the procedure qualificationThe weld deposit thickness used for the procedure qualification shall be the maximum qualified deposit thickness unless a shall be the maximum qualified deposit thickness unless a fullfull thickness procedure qualification is conducted.
thickness procedure qualification is conducted. 7.4.16
7.4.16 For For procedures procedures qualified qualified toto API STD 1104,API STD 1104, the tensile test results shallthe tensile test results shall be considered acceptable if the specimen breaks in the base metal be considered acceptable if the specimen breaks in the base metal
outside of the weld or fusion line,
outside of the weld or fusion line, provided the strength is not moreprovided the strength is not more than 5% below the specified minimum
than 5% below the specified minimum tensile strength of the basetensile strength of the base metal.
metal. 7.4.17
7.4.17 The The following following are are the the maximum maximum tolerance tolerance limits limits for for proceduresprocedures qualified in accordance with Section
qualified in accordance with Section12 Mechanized Welding with12 Mechanized Welding with Filler Metal
Filler Metal of of API STD 1104.API STD 1104.
Travel speed: ±20% of the actual PQR Travel speed: ±20% of the actual PQR valuevalue Voltage range: ±10% of the actual PQR value Voltage range: ±10% of the actual PQR value Current range: ±15% of the actual PQR value Current range: ±15% of the actual PQR value 7.4.18
7.4.18 Special Special requirements requirements for for impact impact testing testing of of welding welding proceduresprocedures 7.4.18.1
7.4.18.1 All All welding welding procedures procedures for for gas, gas, LPG LPG and and offshore offshore pipelinespipelines shall be impact
shall be impact tested. tested. The impact testing The impact testing shall be conductedshall be conducted at the design metal temperature or 0°C whicheve
7.4.18.2
7.4.18.2 Charpy Charpy impact tesimpact testing ting of P-No. of P-No. 1 Gr.1 1 Gr.1 and 2 and 2 materialsmaterials (including API grades through X70) shall have a
(including API grades through X70) shall have a minimumminimum absorbed energy of 34/27 J (25/20 ft-lb) for full size
absorbed energy of 34/27 J (25/20 ft-lb) for full size
(10 x 10 mm) specimens for both the weld and heat-affected (10 x 10 mm) specimens for both the weld and heat-affected zone.
zone. For other For other Group Numbers, Group Numbers, P-Numbers, and P-Numbers, and other other materials, the impact test criteria shall be established by materials, the impact test criteria shall be established by CSD.
CSD. 7.4.18.3
7.4.18.3 If If Charpy impact Charpy impact testing testing of the of the girth girth welding prwelding procedure isocedure is required for procedures qualified to
required for procedures qualified to API STD 1104,API STD 1104, then thethen the essential variables listed in
essential variables listed in API STD 1104API STD 1104 Appendix A,Appendix A, Section A3.0 shall be mandatory (even when Appendix A in Section A3.0 shall be mandatory (even when Appendix A in its entirety is not specified
its entirety is not specified or permitted).or permitted). 7.4.18.4
7.4.18.4 If If Charpy impact Charpy impact testing testing is ris required fequired for procedures, or procedures, thethe requirements for impact test temperature reduction due to requirements for impact test temperature reduction due to sub-size specimens (less than 10 x 10
sub-size specimens (less than 10 x 10 mm) shall complymm) shall comply with
with ASME B31.3,ASME B31.3, Table 323.3.4. Table 323.3.4. Note that Note that the temperaturethe temperature penalty for subsized samples only occurs if the impact size is penalty for subsized samples only occurs if the impact size is
less than 80% of the actual
less than 80% of the actual wall thickness.wall thickness. 7.4.18.5
7.4.18.5 The heat The heat input to input to be recorded be recorded on the on the PQR and PQR and used as used as thethe limiting value for the WPS shall be based on the welding limiting value for the WPS shall be based on the welding parameters used at the location where the impact specimens parameters used at the location where the impact specimens
are removed.
are removed. If the PQR heat If the PQR heat input varies by pass or input varies by pass or layer,layer, then additional impact specimens, in addition to those then additional impact specimens, in addition to those locations specified by the relevant Code, ma
locations specified by the relevant Code, may be required iny be required in order to utilize the full range of heat inputs
order to utilize the full range of heat inputs used in the PQR.used in the PQR. 7.4.18.6
7.4.18.6 If If multiple multiple processes processes or or consumables consumables are are used, sused, separateeparate impact test specimens shall be conducted for each
impact test specimens shall be conducted for each process or process or consumable.
consumable. If the impact If the impact test specimen size is test specimen size is larger thanlarger than the deposit thickness of a specific process or con
the deposit thickness of a specific process or con sumable,sumable, then the impact test specimen shall contain the maximum then the impact test specimen shall contain the maximum possible amount of the deposit for that process or
possible amount of the deposit for that process or
consumable (a separate set of specimens is still required for consumable (a separate set of specimens is still required for the other process or consumable).
the other process or consumable). 7.5
7.5 Welding Welding Procedure Procedure Qualification Qualification Hardness Hardness TestingTesting 7.5.1
7.5.1 Hardness Hardness testing testing of of the the welding welding procedure procedure qualification qualification is is required required for for sour service applications and for girth welds of all offshore pipelines. sour service applications and for girth welds of all offshore pipelines. The maximum allowable hardness for
The maximum allowable hardness for sour service is VHN sour service is VHN 250. 250. For For offshore pipelines in non-sour service, the maximum allowable
if it is to be used on
if it is to be used on external structural attachments only, and the pipeexternal structural attachments only, and the pipe wall at the attachment point is at
wall at the attachment point is at least 25 mm thick.least 25 mm thick. 7.5.2
7.5.2 For For applications applications where where hardness hardness testing testing is is specified specified (see (see 7.5.1), 7.5.1), thethe hardness testing shall be in accordance with Standard Drawing hardness testing shall be in accordance with Standard Drawing AB-036386,
AB-036386, Hardness Testing for Welding Procedure Qualifications.Hardness Testing for Welding Procedure Qualifications. Prior hardness test results may be accepted as equ
Prior hardness test results may be accepted as equ ivalent to theivalent to the Standard Drawing only with the approval of
Standard Drawing only with the approval of CSD and with theCSD and with the following conditions:
following conditions: a)
a) Only Only the the Vickers Vickers method method is is acceptable, acceptable, with with a a test test load load of of 5 5 kg kg or or 10 kg.
10 kg. b)
b) The location of the HAZ indents nearest the fusion line can beThe location of the HAZ indents nearest the fusion line can be demonstrated (by specification or actual measurement) to be demonstrated (by specification or actual measurement) to be within 0.2 mm of the fusion line.
within 0.2 mm of the fusion line.
Note the additional PQR requirements listed in 12.6 for PWHT for Note the additional PQR requirements listed in 12.6 for PWHT for
applications requiring hardness testing. applications requiring hardness testing. 7.6
7.6 Preparation Preparation of of Test Test CouponsCoupons
For new procedures or procedures that are to
For new procedures or procedures that are to be re-qualified (i.e., existing PQRsbe re-qualified (i.e., existing PQRs that are acceptable without any supplementar
that are acceptable without any supplementary tests are exempt), the followingy tests are exempt), the following additional requirements shall apply:
additional requirements shall apply: 7.6.1
7.6.1 The The tests tests shall shall be be made made using using butt-welded butt-welded pipe pipe samples samples in in either either thethe 5G or 6G position or the position to be used in production.
5G or 6G position or the position to be used in production. 7.6.2
7.6.2 The The qualification qualification test test shall shall include include all all of of the the required required tests tests on on the the samesame coupon unless size limitations restrict the number and type of
coupon unless size limitations restrict the number and type of specimens that can
specimens that can be reasonably removed from be reasonably removed from a single coupon. a single coupon. If If multiple coupons are required and approved by CSD, each of the multiple coupons are required and approved by CSD, each of the coupons shall be of the same
coupons shall be of the same material and size and shall be weldedmaterial and size and shall be welded with identical parameters.
with identical parameters. 7.6.3
7.6.3 For For groove groove weld weld qualifications, qualifications, the the test test coupons coupons shall shall be be radiographedradiographed and shall meet the acceptance criteria of
and shall meet the acceptance criteria of API STD 1104API STD 1104 or or ASME SEC IX
ASME SEC IX depending on the code being used for the qualification.depending on the code being used for the qualification. If any special NDT is required of production
If any special NDT is required of production welds (e.g., automaticwelds (e.g., automatic UT), then the PQR shall be examined by the same method and shall UT), then the PQR shall be examined by the same method and shall meet the same acceptance criteria.
meet the same acceptance criteria. 7.6.4
7.6.4 The The procedure procedure qualification qualification test test weld weld shall shall meet meet all all the the requirementsrequirements imposed on production welds.
8
8 Welder Welder and and Welding Welding Operator Operator QualificationQualification 8.1
8.1 All All welders, welders, welding welding operators, operators, brazers, brazers, and and brazing brazing operators operators shall shall be be qualifiedqualified in accordance with either
in accordance with either ASME SEC IXASME SEC IX or or API STD 1104API STD 1104 andand SAEP-321,SAEP-321, SAEP-323,
SAEP-323, andand SAEP-324,SAEP-324, as applicable, for all welding, including tack,as applicable, for all welding, including tack, temporary, and repair welds.
temporary, and repair welds. 8.2
8.2 Current Current production production repair repair rates rates of of each each welder welder shall shall be be made made available available to to SaudiSaudi Aramco Inspection
Aramco Inspection upon request. upon request. The repair ratThe repair rates shall be es shall be calculated andcalculated and reported weekly on
reported weekly on both a linear both a linear and joint basis. and joint basis. The individual welder'sThe individual welder's performance must meet the following values.
performance must meet the following values.
Less than or equal to 5% Joint Repair Rate weeklyLess than or equal to 5% Joint Repair Rate weekly
Less than or equal to 0.25% Linear Repair Rate weeklyLess than or equal to 0.25% Linear Repair Rate weekly
Individual welders exceeding the joint and
Individual welders exceeding the joint and linear welder performance guidelineslinear welder performance guidelines are subject to revocation of
are subject to revocation of their JCCs. their JCCs. One retraining attOne retraining attempt is allowed at theempt is allowed at the discretion of the Saudi Aramco Authorized Welding
discretion of the Saudi Aramco Authorized Welding Inspector.Inspector. 8.3
8.3 Performance Performance qualification qualification tests tests shall shall not not be be performed performed on on production production joints joints onon Saudi Aramco work.
Saudi Aramco work. 9
9 Joint Joint DetailsDetails 9.1
9.1 All All pressure pressure containing containing welds, welds, except except for for socket socket welds, welds, shall shall be be made made with with fullfull penetration groove welds only.
penetration groove welds only. 9.2
9.2 All All pressure pressure containing containing welds, welds, including including socket socket welds, welds, shall shall be be made made withwith multiple passes.
multiple passes. 9.3
9.3 Permanent Permanent backing backing rings rings or or strips strips shall shall not not be be used used except except for for the the backing backing stripsstrips on sleeve longitudinal welds.
on sleeve longitudinal welds. 9.4
9.4 Temporary Temporary backup backup strips strips in in weld weld joints joints may may be be used used if if the the backing backing material material is is of of a composition similar
a composition similar to the base metal to the base metal or weld metal. or weld metal. Under no circumstancesUnder no circumstances shall rebar
shall rebar or galvanized steel or galvanized steel be used. be used. Temporary backup shoes Temporary backup shoes made of non-made of non-metallic, non-fusing material may be used.
metallic, non-fusing material may be used. 9.5
9.5 Consumable Consumable inserts inserts may may be be used used for for all all applications applications providing providing the the compositioncomposition matches the weld metal composition.
matches the weld metal composition. 9.6
9.6 Full Full penetration penetration groove groove joints joints with with included included angles angles less less than than 30 30 degrees degrees (except(except for portions of
for portions of compound bevels) shall not be used witcompound bevels) shall not be used without approval. hout approval. TheThe approval shall be obtained through the welding procedure review process. approval shall be obtained through the welding procedure review process.
