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SAEP-321 Performance Qualification Testing and

Certification of Saudi Aramco Welders

沙特阿美规范

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Engineering Procedure

Qualification Testing and Certification of Saudi Aramco Welders

Responsibility: Inspection Department

July 2008
Aramco DeskTop Standards

of Contents

Scope............................................................. 2

Conflicts and Deviations................................ 2

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Applicable Documents................................... 2

Definitions and Acronyms.............................. 4

Responsibilities.............................................. 8

Instructions................................................... 10

1 – Flow Chart for Testing

Certifying Welders......................... 23
2 – Flow Chart for Maintaining
Certification.............................. 24
3 – List of Apprhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmloved
Welding
Supplements................................. 25
4 – Performance Qualification
Prerequisites............................ 26
5 – Minimum Retraining Times
Welders Taking the Performance
Retest.............................. 27
6 – Welder Experience Record.......... 28

Issue: 30 June 2003 Next Planned Update: 1 July 2013

contact: Supervisor, IEU on 874-6604

1 of 28
Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders
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Scope

.1 This Engineering Procedure specifies the minimum requirements for the testing,
and registration of Saudi Aramco welders working for
. For the purpose of this Engineering Procedure Maintenance shall
include to mean other proponent
orhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlganizations
performing fabrication and
welding activities such as Operations Field Services, Pump Shops,
& Workover, etc.
specifically noted otherwise the term welder shall also mean welding
. 1.2

Conflicts and Deviations

between this Engineering Procedure and any other Saudi Aramco Standard
be resolved by the Operations Inspection Division of the Inspection Department in
.

Applicable Documents
stated otherwise, all codes and standards referenced shall be the latest issue

(including Revisions and Addenda). Sections of industry codes and standards

herein shall be considered as part of this standard.

.1 Saudi Aramco References

Aramco Engineering Procedures

Supplement S01 for Welder Performance Qualification Test

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Supplemenhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlt S02 for
Welder Performance Qualification Test Supplement S03 for Welder Performance
Qualification Test Supplement S04 for Welder Performance Qualification Test
Supplement S05 for Welder Performance Qualification Test Supplement S06 for Welder
Performance

Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders

Aramco Forms
3331-ENG
4758-ENG Test Supplement S07 for Welder Performance Qualification Test Supplement
S08 for Welder Performance Qualification Test Supplement S09 for Welder Performance
Qualification Test Supplement S10 for Welder Performance Qualification Test
Supplement S11 for Welder Performance Qualification Test Supplement S12 for Welder
Performance Qualification Test Supplement S13 for Welder Performance Qualification
Test Supplement S14 for Welder Performance Qualification Test Supplement S15 for
Welder Performance
Qualifichttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlation Test
Supplement S16 for Welder Performance Qualification Test Supplement S17 for Welder
Performance Qualification Welder Qualification Record Welder Qualification Card Job
Clearance Card Radiography Request/Performance/Interpretation

.2 Industry Codes and Standards

Society of Mechanical Engineers/Boiler & Pressure Vessel Code
SEC IIC
SEC V
SEC IX
Rods, Electrodes and Filler Metals Nondestructive Examination Welding and Brazing
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Qualifications
Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders ASME B31.3

Definitions and Acronyms Process Piping

Test: An ad hoc test used to determine if a welder has the ability to produce
in accordance with a valid certification. The Ability Test shall be performed on
a production weld or test coupon that falls
withihttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmln the limits of
the certification.
be valid the test shall be witnessed and documented by the OIU inspector.
is based on visual inspection and radiographic examination.
: Aluminum.
Recertification: The mandatory retesting of all welders every three (3)
on the anniversary date of the issue of their first performance qualification
(all welding certifications become invalid on that date). Welders shall
to each Supplement in the month prior to the anniversary date if welding to
Supplement is to be permitted after that date. Anniversary recertification testing
is
by the WTC in accordance with approved Test Supplements.
Strike: A discontinuity resulting from an arc caused by the inadvertent striking
of
welding electrode against the surface of a metal.
: Anniversaryhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.html
Recertification Date.
B&PVC: American Society of Mechanical Engineers, Boiler and Pressure
Code.
Gouging: The removal of weld metal and base metal from the other side of a
welded joint to assure complete penetration upon subsequent welding from that
.
Ring or Strip: A material (either pipe, flat plate, or rolled plate) placed at the
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side of a single groove weld joint to support molten weld metal.
Weld: A weld deposited on the backside of a single groove weld.
: See preferred term Welder Certification.
Welder: A welder that has a valid welding certification. A certified welder
only qualified to weld with those welding processes, and within the essential
, of the valid certification(s).
(SMAW) Ability Performance Test: An ad hoc
corrosionhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.html resistant
weld
overlay performance test given to welders to determine if they have the ability to
work in accordance with specific job requirements. Testing is conducted by
OIU in accordance with a specific project WPS. The test qualifies the welder for
a
Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders specific
project only (Job Clearance Card is issued by the OIU) and is valid as long as
welder maintains a valid SMAW certification.
: Carbon Steel.
Cored Arc Welding (FCAW): An arc welding process which produces
of metals by heating them with an arc between a continuous filler metal

(tubular) electrode and the work. Shielding is provided by a flux contained in the
filler metal. Additional shielding can be obtained from an externally supplied
or gas mixture.
://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmllobular Transfer: In arc
welding, a type of metal transfer in which molten filler
is transferred across the welding arc in large droplets (applicable to the GMAW
FCAW welding processes).
Metal Arc Welding (GMAW): An arc welding process which produces
of metals by heating them with an arc between a continuous filler metal
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(consumable) electrode and the work. Shielding is obtained entirely from an
externally
gas or gas mixture. Sometimes this process is referred to as MIG or CO2
(nonpreferred terms).
Tungsten Arc Welding (GTAW): An arc welding process which produces
of metals by heating them with an arc between a nonconsumable tungsten
and the work. Filler metal is added manually. Shielding is obtained from a
or gas mixture. It is sometimes referred to as TIG welding (a
nonhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlpreferred term).
: Inspection Department.
Field Testing: Examination of the first production work produced by a welder
after WTC certification testing and OIU registration.
: Job Clearance Card (Form SA 4758-ENG).
Clearance Card (Form SA 4758-ENG): An identification card issued by OIU to
welder passing a CRWMO SMAW Ability Test. The JCC lists the welders name,
symbol and qualification limits of the major essential variables.
: Low Alloy Steel.
: Nickel.
: Operations Inspection Division.
: Operations Inspection Unit.
: Process Expiry Date.
Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders PT: Penetrant
Test.
: See preferred terms Welder Performance Qualification.
Card (Form SA 3331-ENG): A photo
identhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlity card issued
by the WTC
a welder that lists all welding certifications held by the welder. Qualification
Cards
be carried at all times by the welder, and must be presented for review upon
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.
Record (Form ): See preferred term welder certification.
Welder: See preferred term Certified Welder.
Test: The performance qualification test conducted by the WTC to
a revoked certification.
Welder: A welder whose certification has been reviewed, found to be
, and is on file with the Operations Inspection Unit.
: The act of registering a welder certification, or a photostatic copy
. Registration is performed by the responsible Inspection Authority.
: The repeat test that is permitted to be taken when a welder fails the initial
://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlrtification test to a Test
Supplement, or recertification test to reinstate a revoked
. Only one retest is permitted.
Polarity (DCEP, DCRP, DC or E ): The arrangement of direct current arc
leads with the work as the negative pole and the electrode as the positive pole
the welding arc.
Welder Certification: A certification that is no longer valid as a result of a
not welding with a welding process for six or more consecutive months or not
an Ability Test (does not include the Corrosion Resistant Overlay Welding
Test). When a certification with a process is revoked all certifications with that
are revoked (this does not apply to an Ability Test). Welders whose
with a process are revoked must pass a recertification test for each
Test Supplement (conducted
http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlby the WTC) prior to
resuming production
with those Test Supplements.
Face (land): That portion of the groove face adjacent to the root of the joint.
Opening (gap): The separation between members to be joined at the root of the
.
Penetration (pipe): The distance a weld extends past the inside surface of the pipe
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in a pipe groove weld.
Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders RT:
Radiographic Testing.
Gas: Protective gas used to prevent atmospheric contamination of the
weld metal in the vicinity of the welding arc.
Polarity (DCEN, DCSP, DC- or E-): The arrangement of direct current arc
leads in which the work is the positive pole and the electrode the negative pole
the welding arc.
Metal Arc Welding (SMAW): An arc welding process
thttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlhat produces
of metals by heating them with an arc between a covered metal electrode
the work. Shielding is obtained from the decomposition of the electrode covering.
Transfer: A type of metal transfer in which molten filler metal is propelled
across the arc in small droplets (applicable to the GMAW and FCAW welding
).
: Stainless Steel.
Arc Welding (SAW): An arc welding process which produces
of metals by heating them with an arc between a bare metal electrode or
and the work. The arc is shielded by a blanket of granular, fusible material

(flux) on the work.

Supplement: Contains the performance qualification test requirements needed to
a welding certification test, and the limitations of that certification.
: A groove melted in the
basehttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.html metal adjacent
to the toe or root of a weld and
unfilled by weld metal.
: A depression on the face of the weld or root surface extending below the
base metal.
Welder: A welder that does not have a valid welding certification.
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Welder: See preferred term Uncertified Welder.
Reinforcement: Weld metal in excess of the quantity required to fill a joint.
: One who performs a manual or semiautomatic welding operation (this term is
erroneously used to denote a welding machine).
Certification: Certification in writing (i.e., Form 2318-ENG) that a welder has
produced a test weld meeting a defined standard.
Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders Welder
Performance Qualification: The demonstration of a welders ability to
a test weld meethttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmling a
defined standard.
Operator: One who operates machine or automatic welding equipment.
: Welding Procedure Specification.
: Welder Test Center.
: Welder Tracking System.

Responsibilities

.1 Inspection Department

.1.1 The Operations Inspection Division (OID) is responsible for:

)
)
) preparing revisions to this Engineering Procedure; auditing records of the NDE &
Welder Testing Unit; auditing records of the Operations Inspection Units.

.1.2 The NDE & Welder Testing Unit of the Operations Inspection Division
responsible for:
)
) administering all welder performance qualification tests; keeping track of the
status of all Saudi Aramco welders.
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.1.3 The Welder Test Center (WTC) of the NDE & Welder Testing Unit is
for:
) conducting performance
qualificahttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmltion
testing of welders in
with approved Test Supplements;
) conducting recertification testing of welders with revoked
;
)
)
)
) preparing certifications (Form ) for welders that pass performance qualification
or recertification tests; inputting certification results (Form ) in the WTS for
welders that take performance qualification or recertification; obtaining welder
symbols (assigned automatically) from WTS for all welders who take the performance
qualification tests; preparing new or updating old Qualification Cards for welders
passing certification tests;
Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders g) conducting
Anniversary Recertification testing of welders every
years;
)
) sending welder certification information to the WTS Administrator; generating new
or updating welder
rehttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlcords/data in WTS.

.1.4 The WTC Welding Inspector is responsible for:

) witnessing and evaluating welder performance qualification tests;
) witnessing and evaluating recertification tests of welders with
certifications.

.1.5 The WTS Administrator is responsible for:

) maintaining the WTS database on the mainframe computer current
inputting performance qualification and recertification test
(Form ) into the WTS database;
the WTS database on the mainframe computer current
terminating revoked welder or brazer certification information
the WTS database;
WTS access to new users and updating their access
; b) c)
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) creating/updating proponent Maintenance Organization or
Inspection Unit in WTS.

.2 Business Line Maintenance Organizations

://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.html5.2.1 The Maintenance
Superintendent/Foreman is responsible for:
)
)
)
)
)
)
)
all welders are properly certified prior to the start of work; ensuring all welders
maintain valid certifications for every process certified through continuous welding;
ensuring all welders undergo the additional training prior to taking a retest;
maintaining a log of welders working in the Organization; ensuring all welders take
the Anniversary Recertification Test Thirty (30) days prior to the ARD; ensuring all
welders working in the Maintenance Organization are available and tracked by WTS;
and notifying the OIU, in advance, through a written correspondence about their
welders availability and movement/transfer status.
Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders 5.3 Business
Line Engineering Organizations

.3.1 The Operations

Inshttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlpection Unit (OIU)
is responsible for:
) ensuring all welder performance certifications are current and up to
through WTS and documentation of welder activity;
) ensuring all newly certified welders are capable of making sound
by conducting Initial Field Testing as per Section 6.3.1 of
procedure;
Ability Testing of welders whose skills may be in
; c)
) conducting SMAW Corrosion Resistant Overlay Welding Ability
;
)
)
) registering properly certified Maintenance welders as per Section 6.2.2 of this
procedure; issuing Job Clearance Cards to welders that pass the CRWMO SMAW Ability
Test inputting welder's performance records (Visual and RT inspection
) in WTS in a timely manner within the duration of a process
date (PED).

.3.2 The Operations Inspection Unit Inspector

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http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlis responsible for:
)
)
) witnessing and evaluating Initial Field Tests and Ability Tests; witnessing
Corrosion Resistant Overlay Welding Ability Testing; reporting all field welding
inspection results in order to be entered
WTS in a timely manner.

Instructions

.1 Welder Performance Qualification Test

.1.1 General Information

.1.1.1 Performance qualification testing shall be conducted at a

Test Center (WTC) and be witnessed by a WTC
inspector. SAW and FCAW testing may be performed
a proponent's facility if appropriate equipment is unavailable
the WTC. A flow chart showing the steps involved in
and certifying welders is shown in Appendix 1.
Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders 6.1.1.2 When
it is impractical to bring welders from remote locations
://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlrto take a test at the WTC,
the Inspection Department shall
the testing to a local inspection organization.

.1.1.3 Performance qualification testing shall be conducted in

with an approved Saudi Aramco Engineering
Test Supplement. A list and description of all of the
Test Supplements is given in Appendix 3.

.1.1.4 Prior to testing the WTC shall verify the performance

prerequisites required by each Test Supplement
have been met (refer to Appendix 4).

.1.1.5 If at any time it becomes apparent to the WTC welding

that a welder does not have the necessary skill to
the performance qualification test, the test shall be
and the welder sent back to the proponent
for retraining and/or reassignment.

.1.2 Coupon Fit Up and Welding

http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.html.1.2.1 The welder

shall fit up the test coupon as per the Test
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. The welder's name and welder's symbol (if
) shall be hard stamped on both ends of the fit up test
. The WTC welding inspector shall inspect the fit up
hard stamping prior to the start of welding.

.1.2.2 The test coupon shall be secured in the test position at a height
eighteen (18") inches above the floor of the test booth. The
shall not begin until the WTC welding inspector has
the test position. The welder shall not move the test
until told to do so by the WTC welding inspector at the
of the test.

.1.2.3 The WTC welding inspector shall inspect the completed root
of all SMAW and GTAW pipe test coupons prior to the
of the hot pass. If grinding of the groove side of the test
://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.html is required (i.e., root
passes welded with E6010
) the WTC welding inspector shall also inspect the
grinding. If the root pass work is acceptable the
shall be permitted to weld the fill and cap. If the root
work is unacceptable it shall be cause for rejection of the
(test failure).

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders 6.1.2.4
Grinding, back gouging, welding or any other alteration
shall not be performed on the backside of a root pass
specifically required as part of the performance
test. When back gouging or grinding is required
the performance qualification test, the backside of the
groove shall be inspected by the WTC welding
. If the work is acceptable the welder shall be given
to start weldhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmling the
second side. Excessive or
back gouging, grinding, welding or any other
dressing is considered unacceptable and shall be
for rejection of the coupon (test failure).

.1.2.5 Grinding may be used in between passes to remove slag and

strikes, however, excessive grinding is not permitted and
be cause for rejection of the coupon (test failure).

.1.2.6 Grinding, filing, or mechanical dressing of the cap pass is not

. Any evidence of such shall be cause for rejection of
coupon (test failure).
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.1.3 Visual Examination of the Test Coupon

.1.3.1 After completion of welding the WTC welding inspector shall

a visual examination of the test coupon. Coupons that
not meet the following acceptance criteria shall be
unacceptable (test failure).

.1.3.2 Welhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmld
reinforcement and root penetration shall not exceed the
as shown in Table 1.

Coupon
Thickness

¼" and under

than ¼" up to ½"
than ½" up to 1"
than 1"
Weld Reinforcement or Excess Root penetration 1/16" 1/8" 5/32"
3/16"

.1.3.3 Undercut not exceeding 1/32" in depth shall be permitted for a

length of 2" maximum. Undercut exceeding 1/32" in
is not permitted.

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders 6.1.3.4
Underfill not exceeding 1/16" in depth shall be permitted for a
length of 2" maximum. Underfill exceeding 1/16" in
is not be permitted

.1.3.5 Lack of root penetration is

unacceptablhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmle.

.1.3.6 Incomplete fusion is unacceptable.

.1.3.7 Unremoved Arc strikes on the base metal are unacceptable.

.1.4 Radiographic Examination of the Test Coupon

.1.4.1 Test coupons that meet the visual acceptance criteria of Section
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.1.3 shall be radiographically examined.

.1.4.2 Radiography shall be performed in accordance with the

of the ASME SEC V B&PV code.

.1.4.3 Radiographic acceptance criteria shall be as specified in

QW-191 of the ASME SEC IX B&PV code.

.1.5 Guided Bend Testing

.1.5.1 Guided bend testing, when required, shall be conducted by the

Welding Inspector in accordance with the following
(see paragraph 6.5.2.5 for special requirements
CRWMO SAW test coupons).

.1.5.2 Four guided bend specimens shall be prepared and tested for
posithttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlion tested as
per Table 2.

Coupon Thickness
than 3/8"
3/8" but less than 3/4"
or greater than 3/4"
and Type 2F and 2R 2F and 2R, or 4S 4S

.1.5.3 Guided bend specimens shall be either mechanically or flame

and shall be taken from the locations shown in QW-463 of
ASME SEC IX B&PV Code. If flame cutting is employed,

/8" shall be removed from each flame cut edge by grinding.

grinding, care shall be taken to ensure that the
is not overheated. Excessive grinding of guided bend
is not permitted.

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders 6.1.5.4
Testing shall be performed in accordance with requirements of
QW-162, of the ASME SEC IX B&PV Code.

.1.5.5 Test
http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlacceptance criteria
shall be as specified in paragraph
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of the ASME SEC IX B&PV Code.

.1.6 Retest

.1.6.1 Welders are permitted to take one (1) retest per Test
provided they receive the minimum training
in Appendix 5 prior to the retest.

.1.6.2 Welders that fail the initial performance qualification test for
causes shall undergo a total minimum retraining time
to the sum of the minimum retraining times for each of
causes given in Appendix 5 prior to the retest.

.1.6.3 Prior to taking the retest the Maintenance Superintendent shall

in writing that the welder has undergone the required
training and is fully prepared to take the retest. A
shall be attached to the request for retest submitted by the
to the WTC.

.1.6.4 All retests shall be

conducthttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmled at the WTC
(or the proponents
if necessary) and witnessed by the WTC Welding
.

.1.6.5 Welders that fail the retest shall not be permitted to take a
retest and shall be prohibited from retaking that
performance qualification test sooner than three (3)
from the date of the failed retest. During the waiting
the welder shall be given additional training by the
Organization. If the Maintenance Organization
the welder to retake the test at the end of three (3)
the Maintenance Superintendent shall certify in writing
the welder has received sufficient training and is fully
to take the Supplement Test (the letter shall be
to the request for test submitted by the OIU to the
).

.2 Certification and Registration of Welders

.2.1 http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlUpon successful

completion of the performance qualification test, the
shall certify the test result by:

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders a)
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verifying whether newly tested welder is available in the WTS or
. If yes, WTC is only to update the welder's certification
on the WTS, by selecting "New Cert" icon. If the welder is
found in the WTS, WTC is to select the "New Welder" icon
the certification screen of the WTS;
the welder's performance qualification test records in the
(applies to all welders) and obtaining the welder symbol from
, which is assigned automatically for all welders. The welder
is unique and is not transferable. When a welder leaves the
of the company or his job title is permanently changed to
job dehttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlscription, that
welder's symbol shall be retired and
from WTS database through a written request submitted
Maintenance Organization and sent to both WTC and the WTS
, and a copy should also be sent to the OIU;
Welder and Welding Operator Qualification Record
. The original shall be kept on file with the
. Copies shall be sent to the WTS Administrator and the OIU;

a Welders Qualification Card (Form SA 3331-ENG). The

Card shall list all valid certifications, including the
Date, held by the welder. It shall also include a recent
of the welder and be carried by the welder at all times.
copy of the card shall be kept on file at the WTC, and also be
to the OIU and the WTS Administrator. For new welders, one
recent photoghttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlraph
shall be sent to the WTS
. b) c) d)

.2.2 Immediately after the successful completion of the performance

test, the newly certified welder shall report to the OIU to be
. Welders shall not be permitted to start production welding
first being registered by the OIU.

.3 Maintaining Welder Certifications

.3.1 Initial Field Testing

.3.1.1 The first three (3) production pressure retaining butt welds
by each newly certified welder, employing each newly
certification, shall be 100% radiographed. The OIU
shall witness the welding of at least one of these
. Radiographic acceptance shall be as specified by the
design code governing the work.
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Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders 6.3.1.2
If the radiographs
http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlare all acceptable
the welder shall be
to continue production welding. Subsequent
welding shall be radiographed at normal job
levels. All RT inspection results shall be entered
OIU in the WTS utilizing the radiography request form .

.3.1.3 If radiography shows that one or two of the first three (3) welds
unacceptable, the OIU inspector shall visually examine all
welds and their corresponding radiographs. If the weld
is poor, that particular certification shall be revoked. If
weld quality is borderline, the welder may be permitted to
production welding provided all subsequent welding
is 100% radiographed. If the weld quality improves, the
shall be reduced to normal job monitoring levels.
the weld quality does not improve, the newly qualified
://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlrcertification shall be
revoked.

.3.1.4 If radiography shows that all three welds are unacceptable the
qualified certification shall be revoked.

.3.1.5 When a new certification is revoked as a result of the Initial

Test the, OIU shall send that welders Qualification Card
a letter of notification to the WTC. The WTC shall delete
revoked certification from the Qualification Card and return
to the welder through the OIU. A copy of the revised
Card and a letter of notification shall be sent to
WTS Administrator.

.3.1.6 Welders that have a certification revoked during the Initial

Test shall not be allowed to retake that certification test
at least three (3) months. During that time the welder shall
given additional training. When the welder is ready to
the Supplement Thttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlest
the Maintenance Superintendent
certify in writing that the welder has been given the
additional training and is fully prepared to take the
. The test shall be scheduled in writing by the OIU with the
.

.3.1.7 Initial Field Test radiographs shall be kept on file by the OIU
at least one (1) year.
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.3.2 General Requirements

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders 6.3.2.1
A flow chart showing the steps involved in maintaining welder
is shown in Appendix 2.

.3.2.2 If a welder does not weld with a process (i.e., SMAW or

) or specialized welding equipment for a period
six (6) consecutive months, all certifications with
process or equipment shall immediately become revoked.
, if OIU is not entering the required welder performance
ihttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmln
WTS within the PED, the welder will automatically
"Inactive" on WTS which requires re-certification of
affected process certifications. The welder shall be re-
by WTC.

.3.2.3 All pressure containing welds made by a welder after a

is revoked shall be cut out.

.3.2.4 If there is a specific reason to question a welders ability to

sound welds, the inspector shall request the welder to
an Ability Test. After completion of the test the weld
be visually examined and radiographed. If the NDE
criteria of Sections 6.1.3 and 6.1.4 are not met, the
in question shall be revoked.

.3.2.5 Welders whose certification with a process has been revoked

not be permitted to weld with that process on production
until they have passed a
Rhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlecertification Test
to the
Test Supplement(s).

.3.2.6 When a welder's certification is revoked, the OIU shall send

welders Qualification Card and a letter of notification to the
. The WTC shall delete the revoked certification from the
Card and return it to the welder through the OIU.
copy of the revised Qualification Card and the letter shall be
to the WTS Administrator.

.3.2.7 A welder certifications shall expire (cease to be valid) every

(3) years on the anniversary date of the issue of the
first performance certification. During the month prior
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the anniversary date welders shall be recertified to every
Supplement previously held and/or required. This shall be
the Anniversary Recertification Test. Those
obtained in the year prior to the
anhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlniversary date
exempt from testing until the following anniversary date.
Anniversary Recertification shall be conducted by the
. The soon to be expired, Qualification Card shall be

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders
surrendered to the WTC at the time of testing. An updated
Card shall be issued by the WTC after
of testing.
Note:
welder will be placed in the Inactive welders list if he did not
for Anniversary Exam (ARD) within 90 days. The
will be in the Separated welders list if he did not appear
ARD after the 90 days period; subsequently to reinstate him
the WTS, a letter from his perspective Maintenance Division
explaining the welder's case shall be sent to the
Inspection Division head of the
Inspecthttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlion
.

.3.2.8 The OIU shall maintain Welder Experience Records to verify

welding activity of each certified welder. Verification of
shall be by reference to an inspection or
report, weld number or similar documentation. A
Welder Experience Record is given in Appendix 6.

.3.2.9 The OIU shall also maintain a record of the groove welds made
each welder with each process or combination thereof.
and yearly repair rates shall be calculated on a butt
and/or lineal inch basis. The method for calculating
rate limits shall be as defined in the Saudi Aramco
Welding Standards. Welders with high repair
shall have their certifications with the applicable welding
or processes revoked.

.3.2.10 The Maintenance Foreman shall maintain an up

http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlto date log of
working in the Unit. This welders log shall include a
of the welders valid certifications, welding activity,
Recertification date and other vital information.
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.4 Recertification of Welders with Revoked Certifications

.4.1 Welders whose certification with a process becomes revoked shall not be
to weld on production work with the process until they have
and passed the required Recertification Test(s). The
Test(s) shall be conducted by the WTC in accordance
the requirements of Section 6.1 of this Engineering Procedure.

.4.2 The welder Recertification Test shall be scheduled by the OIU with the
in writing. It shall not be scheduled sooner than three (3) months
the date the certification was revoked. When the welder is ready to
the Recertificahttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmltion
Test the Maintenance Superintendent shall

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders certify
in writing that the welder has been given the required training and
fully capable of passing the Recertification Test.

.4.3 Welders that fail the initial Recertification Test shall be permitted to take
retest.

.4.4 Welders that pass the Recertification Test or retest shall be certified and
in accordance with the requirements of Section 6.2 of this
Procedure. Subsequent production work shall meet the
of Section 6.3.1 (Initial Field Testing).

.4.5 Welders that fail the retest shall have all of their certifications with the
(es) tested revoked if the certifications were originally revoked as
result of welding inactivity. If the certification was originally
revoked://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmla result of a
failed Ability Test, only the particular certification tested
be revoked.

.4.6 Welders that fail the retest shall not be permitted to retake the
Test for a period of at least three (3) months. The WTC
inform the OIU and WTS Administrator of the test results in
.

.5 Corrosion Resistant Weld Metal Overlay (CRWMO)

.5.1 CRWMO SMAW Ability Performance Test

.5.1.1 Welders with an S03, S04 or S05 certification shall be allowed

perform CRWMO welding within the limits of an approved
WPS provided the welder passes a CRWMO SMAW
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Performance Test.

.5.1.2 The CRWMO SMAW Ability Performance Test shall be

by the OIU (witnessed by the OIU inspector) in
with an approved project WPS.

.5.1.3 The CRWMO SMAW Ability Performance Test shall

consist://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlra welding coupon
(plate or pipe) for each welding position
to be used on the job (the 6G all position test shall not
used). Base metal thickness of the coupon shall not be
an essential variable.

.5.1.4 The finished length/width of the weld metal overlay deposited

the test coupon for each position shall be at least four inches

(4") by one inch (1"). The thickness of the overlay and number
layers shall be as specified in the WPS.

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders 6.5.1.5
The filler metals (size and type), preheat (if required), and
(stringer or weave) specified in the approved project
shall be used in the test.

.5.1.6 After the completion of welding, the OIU inspector shall

a visual examination of the test coupon. Welds that
://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlarmeet the dimensional
requirements specified in the approved
(bead size, number of layers, bead width, overlay
, bead overlap, etc.) shall be considered acceptable.
arc strikes are unacceptable and shall be cause for
of the test coupon (failure).

.5.1.7 If the visual examination of the test coupon is acceptable, the

inspector shall perform a PT (liquid penetrant)
in accordance with Article 6 of the ASME SEC V
&PV Code. Acceptance criteria shall be as specified in
QW-195, of the ASME SEC IX B&PV Code.

.5.1.8 Welders that pass the CRWMO SMAW Ability Performance

shall be issued a JCC and only be permitted to perform
welding for the particular project in accordance with
approved project WPS used.

.5.2 CRWMO SAW Welding Operator Performance

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Qualifhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlication Test

.5.2.1 The CRWMO SAW Welding Operator Performance

Test shall be conducted by the WTC and
by the WTC welding inspector.

.5.2.2 Performance qualification testing shall be conducted in

with an approved Test Supplement.

.5.2.3 Upon completion of the test, the WTC welding inspector shall
examine the test coupon. The surface of the weld shall
smooth and even, and the bead spacing uniform.

.5.2.4 Coupons that pass the visual examination shall be examined

the PT method in accordance with Article 6 of the ASME
V B&PV Code. The acceptance criteria shall be as
in paragraph QW-195 of the ASME SEC IX B&PV
. The testing shall be conducted by the WTC welding
.

.5.2.5 Following the PT examination, four side bend test specimens

://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlarshall be cut
(perpendicular to the direction of welding) from the

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders test
coupon and tested by the WTC welding inspector. The
criteria shall be as specified in paragraph QW-163 of
ASME SEC IX B&PV Code.

.5.2.6 Welding operators that fail the CRWMO SAW Welding

Performance Qualification Test shall be permitted to
one retest no sooner than seven (7) days after the initial
failure.

.5.2.7 Welding operators that pass the CRWMO SAW Welding

Performance Qualification Test shall be certified in
with the requirements of Chapter 6.2.

.5.2.8 The Anniversary Recertification testing requirements of

6.3.2.7 shall not apply to the CRWMO SAW Test.

.5.3 Job Clearance Card (JCC)

.5.3.1 Welders that

pahttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlss CRWMO SMAW
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Ability Performance
Test shall be registered and issued a JCC for the
by the OIU.

.5.3.2 The JCC shall remain valid for the duration of the project
the welders certification with the SMAW process
not become either EXPIRED or REVOKED.

.5.3.3 After completion of the project the JCC shall be returned to the
.

.6 Corrosion Resistant Strip Lining

.6.1 Welders installing corrosion resistant strip shall be certified to an

Test Supplement prior to the start of welding. Only those
that have the required prerequisites (refer to Appendix 4) shall
permitted to take the performance qualification test.

.6.2 The corrosion resistant strip lining test shall be conducted by the WTC
witnessed by the WTC welding inspector.

.6.3 The welder shall remove all mill

http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlscale and rust from
the test coupon
to fit up. Failure to do so shall be cause for rejection of the test
(test failure).

.6.4 The welder shall fit up the test assembly as instructed by the WTC
inspector, who shall check and approve the fit up. The gap

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders between
the strip lining and base material shall not exceed one sixteenth
(1/16").

.6.5 The welder shall secure the test assembly in the test booth and shall not
welding until instructed by the WTC welding inspector. The
inspector shall observe the welding of the entire test assembly.
welder shall remove the slag from each weld bead. The end of each
bead shall be brushed clean prior to the start of welding with the
electrode. Grinding of stop/starts and
arehttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlas of tightly
adhering slag
permitted and should be encouraged. Beads shall not start or end at
. After completion of the welding the welder shall brush clean
entire assembly. All arc strikes shall be removed by grinding. Failure
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a welder to adequately perform these tasks shall be cause for rejection

(test failure).

.6.6 After completion of the welding the WTC welding inspector shall
inspect the test assembly. The surface of the weld beads shall be
in appearance. Undercut and underfill in excess of that permitted
Section 6.1.3 is not permitted. Welds that do not meet these criteria
be rejected (test failure).

.6.7 Test assemblies that pass the visual inspection shall be leak tested by the
welding inspector and the welder. A small hand pump (or bulb)
be used to apply five (5)
pshttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlig pressure through
the 1/4" leak test
in the strip lining while leak detection solution is applied over the
. Leaks are not permitted (test failure).

.6.8 Leaks shall be repaired by the welder under the supervision of the WTC
inspector. After repairs are complete the welder shall be
to take one retest. The retest may be rescheduled immediately.

.6.9 Welders that fail the retest shall not be permitted to retake the
Test for a period of at least one (1) month.

.6.10 Welders that pass the initial test or the immediate retest shall be certified
accordance with the requirements of Chapter 6.2 of this Engineering
.

Summary

July 2008 Revised the "Next Planned Update". Reaffirmed the contents of
the document, and reissued
no other changes.

http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlNext Planned Update:

1 July 2013 and Certification of Saudi Aramco Welders
1 – Flow Chart for Testing and Certifying Welders

[此处图片未下载成功]

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders
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2 – Flow Chart for Maintaining Welder Certification

[此处图片未下载成功]

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders
3 – List of Approved Welding Test Supplements

Num Type Proc Base Mat'l Filler Metal Limitations

S01 Pipe SMAW CS EXX10/EXX18 Vertical up

S02 Pipe SMAW CS EXX10 Vertical down

S03 Pipe SMAW SS EXXX-15/16 Fill/cap only

S04 Pipe SMAW SS EXXX-15/16 Fill/cap only

-- ---- ---- Ni Alloys EXXXXX-X Fill/cap only

S05 Pipe SMAW Ni Alloys EXXXXX-X Fill/cap only

S06 Pipe GTAW Al Alloys

ERXXXhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlX Structural
only

S07 Pipe GTAW CS/LAS/SS ERXXS-X ----------------

-- ---- ---- LAS ERXXS-XX ----------------

-- ---- ---- SS ERXXX ----------------

S08 Pipe GTAW Ni alloys ERXXX-X ----------------

S09 Pipe GTAW Al alloys ERXXXX ----------------

S10 Pipe SAW CS/LAS FXX-EXXX ----------------

S11 Pipe SAW CS/LAS SS & Ni Alloy CRWMO

S12 Pipe SMAW Small Dia CS EXX10/EXX18 Cat-"D" service

S13 Pipe FCAW SS EXXT-X Spray/globular

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S14 Plate SMAW CS EXX10/E7018 Vertical up

S15 Lap SMAW SS to CS EXXX-15/16 Vertical down

S16 Lap SMAW Ni to CS EXXXXX-X Vertical down

S17 Fillet SMAW CS BROSCO Wet Welding

============RESERVED FOR FUTURE TEST SUPPLEMENTS=============

============RESERVED FOR FUTURE TEST SUPPLEMENTS=============

==========http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.html==RESERVED
FOR FUTURE TEST SUPPLEMENTS=============

============RESERVED FOR FUTURE TEST SUPPLEMENTS=============

============RESERVED FOR FUTURE TEST SUPPLEMENTS=============

============RESERVED FOR FUTURE TEST SUPPLEMENTS=============

============RESERVED FOR FUTURE TEST SUPPLEMENTS=============

X's in the filler metal classifications indicate that multiple ASME SEC IIC Filler
Metal Specifications are applicable. For example, EXX18 represents E7018, E8018-B1,
E8018-C2, E9018, etc. Al = Aluminum Cat-"D" = Category "D"
Service as defined in ASME B31.3 CS = Carbon steel Cu = Copper LAS = Low alloy steel
Ni = Nickel SS = Stainless steel

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders
4 – Performance Qualification Testing Prerequisites

___ ___ ___ _http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.html__ ___

___ ___ ___ ___ ___

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P
L
S06 ___ ___ ___ ___ ___

E
S10 ___ ___ ___ ___ ___

S11 ___ ___ ___ ___ ___

E
T
S14 ___ ___ ___ ___ ___

___ ___ ___ ___ ___

(A) (B) Prior certification to this Supplement is required. Prior certification to

one of two Supplements listed is required.

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders
5 – Minimum Retraining Times for
Taking the Performance Qualification Retest

: Cause of Test Failure Unacceptable root (6.1.2.3/4) Excessive grinding (6.1.2.4/6)

Excessive backgouging (6.1.2.4) Final visual (6.1.3.2/3/4/5/6/7) Rejection of x-ray
(6.1.4.3) Bend test failure (6.1.5.5) Rejection for cause (6.1.1.5)
Mhttp://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.htmlinimum Retraining
Time 14 days 7 days 7 days 7 days 7 days 7 days 30 days Prior to taking
the retest the Maintenance Superintendent shall certify in writing that the welder
has undergone
training and is fully prepared to take the retest. Welders that fail the retest shall
not be permitted to take a
retest, and are also prohibited from taking that welding performance qualification
test sooner than three (3)
from that date.

Next Planned Update: 1 July 2013 and Certification of Saudi Aramco Welders
6 – Welder Experience Record
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____________________ Employee Number __________ Welder Symbol ___________

Code ____________
Recertification Date _____________

Number Qualified To _____ _____ _____ _____ _____

_____ _____ _____ _____ _____

_____ _____ _____

__http://www.wenkuxiazai.com/doc/1f83479f581b6bd97e19ea05.html___ _____

_____ _____ _____ _____ _____

_____ _____ _____ _____ _____

_____ _____ _____ _____ _____

_____ _____ _____ _____ _____

_____ _____ _____ _____ _____

_____ _____ _____ _____ _____

_____ _____ _____ _____ _____

_____ _____ _____ _____ _____

_____ _____ _____ _____ _____

_____ _____ _____ _____ _____ Month _____ 1 _____ _____ _____ _____ _____ _____
_____ _____ _____ _____ _____ _____

(A) 2 3 4 5 6 7 8 9 10 11 12

inspection report, RT report, weld/braze number, etc.

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