Engineering Procedure

SAEP-321
Saudi Aramco Welders Performance
Qualification and Tracking Requirements
Document Responsibility: Inspection Engineering Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations................................ 2
3 Applicable Documents................................... 2
4 Definitions and Acronyms.............................. 4
5 Responsibilities.............................................. 8
6 Instructions................................................... 11

Appendix 1 - Flow Chart for Testing

and Certifying Welders......................... 24
Appendix 2 - Flow Chart for Maintaining
Welder Certification.............................. 25
Appendix 3 - List of Approved Welding
Test Supplements................................. 26
Appendix 4 - Performance Qualification
Testing Prerequisites............................ 27
Appendix 5 - Minimum Retraining Times
for Welders Taking the Performance
Qualification Retest............................... 28
Appendix 6 - Welder Experience Record........... 29
Appendix 7- Welding Shop Audit Checklist.…… 30
1 Scope

1.1 This Engineering Procedure specifies the minimum requirements for the testing,
certification, registration and tracking of Saudi Aramco Welders working for
Maintenance.

1.2 This SAEP applies to all proponent Maintenance groups including those
proponent organizations performing fabrication and maintenance welding
activities such as Operations Field Services, Pump Shops, Drilling & Workover,
etc.

1.3 The term Welder in this SAEP shall also mean welding operator unless
specifically noted otherwise.

2 Conflicts and Deviations

2.1 Conflicts

Any conflicts between this SAEP and other applicable Mandatory Saudi Aramco
Engineering Requirement (MSAER) shall be resolved in writing by the Company
through the Chairman, Inspection Engineering Standards Committee.

2.2 Deviations and Waivers

Direct and process all requests to deviate or waive the requirements of this
SAEP according to the internal company procedure SAEP-302, Instructions for
Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement.

3 Applicable Documents

Unless stated otherwise, all codes and standards referenced shall be the latest issue
(including Revisions and Addenda). Sections of industry codes and standards
referenced herein shall be considered as part of this standard.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement
SAEP-323 Contract Welders and Brazers Performance
Qualification Testing and Tracking Requirements
SAEP-1101 Test Supplement S01 for Welder Performance
Qualification
 SAEP-1102 Test Supplement S02 for Welder Performance
Qualification
SAEP-1103 Test Supplement S03 for Welder Performance
Qualification
SAEP-1104 Test Supplement S04 for Welder Performance
Qualification
SAEP-1105 Test Supplement S05 for Welder Performance
Qualification
SAEP-1106 Test Supplement S06 for Welder Performance
Qualification
SAEP-1107 Test Supplement S07 for Welder Performance
Qualification
SAEP-1108 Test Supplement S08 for Welder Performance
Qualification
SAEP-1109 Test Supplement S09 for Welder Performance
Qualification
SAEP-1110 Test Supplement S10 for Welder Performance
Qualification
SAEP-1111 Test Supplement S11 for Welder Performance
Qualification
SAEP-1112 Test Supplement S12 for Welder Performance
Qualification
SAEP-1113 Test Supplement S13 for Welder Performance
Qualification
SAEP-1114 Test Supplement S14 for Welder Performance
Qualification
SAEP-1115 Test Supplement S15 for Welder Performance
Qualification
SAEP-1116 Test Supplement S16 for Welder Performance
Qualification
SAEP-1117 Test Supplement S17 for Welder Performance
Qualification

Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-A-206 Positive Material Identification
 SAES-W-011 Welding Requirements for On-Plot Piping

Saudi Aramco Inspection Procedure

00-SAIP-07 Positive Material Identification Requirements

Saudi Aramco Forms

SA-2318-ENG Welder Qualification Record
SA-3331-ENG Welder Qualification Card
SA-4758-ENG Job Clearance Card
SA-4719-A-ENG Radiography Request/Performance/Interpretation
Report

3.2 Industry Codes and Standards

American Society of Mechanical Engineers/Boiler & Pressure Vessel Code

ASME SEC IIC Welding Rods, Electrodes and Filler Metals
ASME SEC V Nondestructive Examination
ASME SEC IX Welding and Brazing Qualifications
ASME B31.3 Process Piping

4 Definitions and Acronyms

Ability Test: An ad hoc test used to determine if a welder has the ability to produce
work in accordance with a valid certification. The Ability Test shall be performed on
either a production weld or test coupon that falls within the limits of the certification.
To be valid the test shall be witnessed and documented by the OIU inspector.
Acceptance is based on visual inspection and radiographic examination.

Al: Aluminum.

Anniversary Recertification: The mandatory retesting of all welders every three (3)
years on the anniversary date of the issue of their first performance qualification
certification (all welding certifications become invalid on that date). Welders shall
recertify to each Supplement in the month prior to the anniversary date if welding to
that Supplement is to be permitted after that date. Anniversary recertification testing is
conducted by the WTC in accordance with approved Test Supplements.

Arc Strike: A discontinuity resulting from an arc caused by the inadvertent striking of
a welding electrode against the surface of a metal.

ARD: Anniversary Recertification Date.

ASME B&PVC: American Society of Mechanical Engineers, Boiler and Pressure
Vessel Code.

Back Gouging: The removal of weld metal and base metal from the other side of a
partially welded joint to assure complete penetration upon subsequent welding from that
side.

Backing Ring or Strip: A material (either pipe, flat plate, or rolled plate) placed at the
back side of a single groove weld joint to support molten weld metal.

Back Weld: A weld deposited on the backside of a single groove weld.

Certification: See preferred term Welder Certification.

Certified Welder: A welder that has a valid welding certification. A certified welder
is only qualified to weld with those welding processes, and within the essential
variables, of the valid certification(s).

CRWMO (SMAW) Ability Performance Test: An ad hoc corrosion resistant weld

metal overlay performance test given to welders to determine if they have the ability to
produce work in accordance with specific job requirements. Testing is conducted by
the OIU in accordance with a specific project WPS. The test qualifies the welder for a
specific project only (Job Clearance Card is issued by the OIU) and is valid as long as
the welder maintains a valid SMAW certification.

CS: Carbon Steel.

Flux Cored Arc Welding (FCAW): An arc welding process which produces
coalescence 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
tubular filler metal. Additional shielding can be obtained from an externally supplied
gas or gas mixture.

Globular Transfer: In arc welding, a type of metal transfer in which molten filler
metal is transferred across the welding arc in large droplets (applicable to the GMAW
and FCAW welding processes).

Gas Metal Arc Welding (GMAW): An arc welding process which produces
coalescence of metals by heating them with an arc between a continuous filler metal
(consumable) electrode and the work. Shielding is obtained entirely from an externally
supplied gas or gas mixture. Sometimes this process is referred to as MIG or CO2
welding (non-preferred terms).

Gas Tungsten Arc Welding (GTAW): An arc welding process which produces
coalescence of metals by heating them with an arc between a non-consumable tungsten
electrode and the work. Filler metal is added manually. Shielding is obtained from a
gas or gas mixture. It is sometimes referred to as TIG welding (a non-preferred term).

ID: Inspection Department.

Initial Field Testing: Examination of the first production work produced by a welder
immediately after WTC certification testing and OIU registration.

JCC: Job Clearance Card (Form SA-4758-ENG).

Job Clearance Card: an identification card issued by OIU to a welder passing a

CRWMO SMAW Ability Test. The JCC lists the welders name, identification symbol
and qualification limits of the major essential variables.

LAS: Low Alloy Steel.

Ni: Nickel.

OID: Operations Inspection Division.

OIU: Operations Inspection Unit.

PED: Process Expiry Date.

PT: Penetrant Test.

Qualification: See preferred terms Welder Performance Qualification.

Qualification Card (Form SA 3331-ENG): A photo identity card issued by the WTC
to a welder that lists all welding certifications held by the welder. Qualification Cards
shall be carried at all times by the welder, and must be presented for review upon
request.

Qualification Record (Form SA-2318-ENG): See preferred term welder certification.

Qualified Welder: See preferred term Certified Welder.

Recertification Test: The performance qualification test conducted by the WTC to

reinstate a revoked certification.

Registered Welder: A welder whose certification has been reviewed, found to be

acceptable, and is on file with the Operations Inspection Unit.

Registration: The act of registering a welder certification, or a photostatic copy

thereof. Registration is performed by the responsible Inspection Authority.
Retest: The repeat test that is permitted to be taken when a welder fails the initial
certification test to a Test Supplement, or recertification test to reinstate a revoked
certification. Only one retest is permitted.

Reverse Polarity (DCEP, DCRP, DC+ or E+): The arrangement of direct current arc
welding leads with the work as the negative pole and the electrode as the positive pole
of the welding arc.

Revoked Welder Certification: A certification that is no longer valid as a result of a

welder not welding with a welding process for six or more consecutive months or not
passing an Ability Test (does not include the Corrosion Resistant Overlay Welding
Ability Test). When a certification with a process is revoked all certifications with that
process are revoked (this does not apply to an Ability Test). Welders whose
certifications with a process are revoked must pass a recertification test for each
required Test Supplement (conducted by the WTC) prior to resuming production
welding with those Test Supplements.

Root Face (land): That portion of the groove face adjacent to the root of the joint.

Root Opening (gap): The separation between members to be joined at the root of the
joint.

Root Penetration (pipe): The distance a weld extends past the inside surface of the
pipe in a pipe groove weld.

RT: Radiographic Testing.

Shielding Gas: Protective gas used to prevent atmospheric contamination of the

molten weld metal in the vicinity of the welding arc.

Straight Polarity (DCEN, DCSP, DC- or E-): The arrangement of direct current arc
welding leads in which the work is the positive pole and the electrode the negative pole
of the welding arc.

Shielded Metal Arc Welding (SMAW): An arc welding process that produces
coalescence of metals by heating them with an arc between a covered metal electrode
and the work. Shielding is obtained from the decomposition of the electrode covering.

Spray Transfer: A type of metal transfer in which molten filler metal is propelled
axially across the arc in small droplets (applicable to the GMAW and FCAW welding
processes).

SS: Stainless Steel.

Submerged Arc Welding (SAW): An arc welding process which produces

coalescence of metals by heating them with an arc between a bare metal electrode or
 electrodes and the work. The arc is shielded by a blanket of granular, fusible material
(flux) on the work.

Test Supplement: Contains the performance qualification test requirements needed to

perform a welding certification test, and the limitations of that certification.

Undercut: A groove melted in the base metal adjacent to the toe or root of a weld and
left unfilled by weld metal.

Underfill: A depression on the face of the weld or root surface extending below the
adjacent base metal.

Uncertified Welder: A welder that does not have a valid welding certification.

Unqualified Welder: See preferred term Uncertified Welder.

Weld Reinforcement: Weld metal in excess of the quantity required to fill a joint.

Welder: One who performs a manual or semiautomatic welding operation (this term is
sometimes erroneously used to denote a welding machine).

Welder Certification: Certification in writing (i.e., Form SA-2318-ENG) that a welder

has produced a test weld meeting a defined standard.

Welder Performance Qualification: The demonstration of a welders ability to

produce a test weld meeting a defined standard.

Welding Operator: One who operates machine or automatic welding equipment.

WPS: Welding Procedure Specification.

WTC: Welder Test Center.

WTS: Welder Tracking System.

5 Responsibilities

5.1 Inspection Department

5.1.1 Operations Inspection Division (OID)

a) audits records of the NDE & Welder Testing Unit
c) audits records of the Operations Inspection Units

5.1.2 NDE & Welder Testing Unit of the Operations Inspection Division
a) administers all welder performance qualification tests
 b) keeps track of the status of all Saudi Aramco welders

5.1.3 Welder Test Center (WTC) of the NDE & Welder Testing Unit
a) conducts performance qualification testing of welders in
accordance with approved Test Supplements
b) conducts recertification testing of welders with revoked
certifications
c) prepares certification (Form SA-2318-ENG) for welders that pass
performance qualification or recertification tests
d) inputs certification results (Form SA-2318-ENG) in the WTS for
welders that take performance qualification or recertification
e) obtains welder symbols (assigned automatically) from WTS for all
welders who take the performance qualification tests
f) prepares new or updating old Qualification Cards for welders
passing certification tests
g) conducts Anniversary Recertification testing of welders every three
years
h) ensures welder certification information are sent to the WTS
Administrator
i) generates new or updates welder records/data in WTS as necessary

5.1.4 WTC Welding Inspector

a) Witness and evaluates welder performance qualification tests
b) witness and evaluates recertification tests of welders with revoked
certifications

5.1.5 WTS Administrator

a) maintains the WTS database on the mainframe computer current by
inputting performance qualification and recertification test
information (Form SA-2318-ENG) into the WTS database
b) maintains the WTS database in SAIF current by terminating
revoked welder or brazer certification information from the WTS
database
c) assigns WTS access to new users and updating their access
information
d) creates/updates proponent Maintenance Organization or Operations
Inspection Unit in WTS.
5.2 Business Line Maintenance Organizations

Maintenance Superintendent/Foreman
a) ensures all welders are properly certified prior to the start of work
b) ensures all welders maintain valid certifications for every process
certified through continuous welding
c) ensures all welders undergo the additional training prior to taking a
retest
d) maintains a log of welders working in the Organization
e) ensures all welders take the Anniversary Recertification Test Thirty
(30) days prior to the ARD
f) ensures all welders working in the Maintenance Organization are
available and tracked by WTS
g) notifies the OIU/WTS coordinator, in advance, through a written
correspondence about their welders’ availability and
movement/transfer status

5.3 Business Line Engineering Organizations

5.3.1 Operations Inspection Unit (OIU) Supervisor

a) Assigns a WTS Coordinator(s) for areas covered

b) Ensures an experienced inspection personnel is assigned to
conduct an annual audit on the welding shops and welders in area
of responsibility under his department
c) Ensures timely completion, documentation of findings and follow
up on corrective actions resulting from the annual audit on the
welding shops and welders

5.3.2 Operations Inspection Unit (OIU) Inspector:

a) ensures all welder performance certifications are current and up to
date through WTS and documentation of welder activity; ensuring
all newly certified welders are capable of making sound welds by
conducting Initial Field Testing as per Section 6.3.1 of this
procedure
b) conducts Ability Testing of welders whose skills may be in doubt
c) conducts SMAW Corrosion Resistant Overlay Welding Ability
Testing
 d) registers properly certified Maintenance welders as per this
procedure
e) issues Job Clearance Cards to welders that pass the CRWMO
SMAW Ability Test
f) reports the welders’ field NDT results including VT, RT, PT ant
MT to WTS coordinator upon inspection/ interpretation to the
WTS coordinator in order to be entered in WTS in a timely or
manner or entering them with 1 week of the job completion.
g) ensures all welders are holding active and valid certificates prior to
start any welding job
h) witness and evaluating Initial Field Tests and Ability Tests
i) witness Corrosion Resistant Overlay Welding Ability Testing

5.3.3 WTS Coordinator

a) enters welding inspection results (Visual and RT inspection results)
in WTS in a timely manner and within 1 week from receiving the
NDT results.
b) notifies WTS Administrator about welders’ movement in his
organization.
c) notifies Welding Shop Foremen about the welders ARD, two
months in advance.
d) notifies Welding Shop Foremen two months in advance prior a
welder becomes inactive.
e) participates in annual audit of the welding shops and welders.
f) issues bi-monthly welders performance report containing welders’
performance, rejection rate, PED and ARD.
g) ensures all welders working for his Maintenance Organization are
available and tracked by WTS.
h) requests WTS Administrator to transfer the Saudi Aramco welders
to his maintenance organization in the WTS after getting the
approval from the releasing department WTS Coordinator.

6 Instructions

6.1 Welder Performance Qualification Test

6.1.1 General Information

 6.1.1.1 Performance qualification testing shall be conducted at a
Welder Test Center (WTC) and be witnessed by a WTC
welding inspector. SAW and FCAW testing may be performed
at a proponent's facility if appropriate equipment is unavailable
at the WTC. A flow chart showing the steps involved in
testing and certifying welders is shown in Appendix 1.

6.1.1.2 When it is impractical to bring welders from remote locations

to take a test at the WTC, the Inspection Department shall
assign the testing to a local inspection organization.

6.1.1.3 Performance qualification testing shall be conducted in

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

6.1.1.4 Prior to testing the WTC shall verify the performance

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

6.1.1.5 If at any time it becomes apparent to the WTC welding

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

6.1.2 Coupon Fit Up and Welding

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

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

6.1.2.3 The WTC welding inspector shall inspect the completed root
pass of all SMAW and GTAW pipe test coupons prior to the
start of the hot pass. If grinding of the groove side of the test
coupon is required (i.e., root passes welded with E6010
 electrodes) the WTC welding inspector shall also inspect the
completed grinding. If the root pass work is acceptable the
welder shall be permitted to weld the fill and cap. If the root
pass work is unacceptable it shall be cause for rejection of the
coupon (test failure).

6.1.2.4 Grinding, back gouging, welding or any other alteration

dressing shall not be performed on the backside of a root pass
unless specifically required as part of the performance
qualification test. When back gouging or grinding is required
by the performance qualification test, the backside of the
welding groove shall be inspected by the WTC welding
inspector. If the work is acceptable the welder shall be given
permission to start welding the second side. Excessive or
unauthorized back gouging, grinding, welding or any other
alteration dressing is considered unacceptable and shall be
cause for rejection of the coupon (test failure).

6.1.2.5 Grinding may be used in between passes to remove slag and

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

6.1.3 Visual Examination of the Test Coupon

6.1.3.1 After completion of welding the WTC welding inspector shall

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

6.1.3.2 Weld reinforcement and root penetration shall not exceed the
values as shown in Table 1.

Table 1
Test Coupon Maximum Weld Reinforcement
Wall Thickness or Excess Root penetration

¼” and under 1/16”

greater than ¼” up to ½” 1/8”
greater than ½” up to 1” 5/32”
greater than 1” 3/16”

6.1.3.3 Undercut not exceeding 1/32” in depth shall be permitted for a

total length of 2” maximum. Undercut exceeding 1/32” in
depth is not permitted.
 6.1.3.4 Underfill not exceeding 1/16” in depth shall be permitted for a
total length of 2” maximum. Underfill exceeding 1/16” in
depth is not be permitted

6.1.3.5 Lack of root penetration is unacceptable.

6.1.3.6 Incomplete fusion is unacceptable.

6.1.3.7 Unremoved Arc strikes on the base metal are unacceptable.

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

permitted. Any evidence of such shall be cause for rejection of
the coupon (test failure).

6.1.4 Radiographic Examination of the Test Coupon

6.1.4.1 Test coupons that meet the visual acceptance criteria of Section
6.1.3 shall be radiographically examined.

6.1.4.2 Radiography shall be performed in accordance with the

requirements of the ASME SEC V B&PV code.

6.1.4.3 Radiographic acceptance criteria shall be as specified in

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

6.1.4.4 Use of Ultrasonic Testing (UT) for Test Coupon examination

in-Lieu of radiography is acceptable provided prior approval of
process is obtained in writing from Supervisor, Advanced NDT
Services Unit, OID/ID, Dhahran.

6.1.5 Guided Bend Testing

6.1.5.1 Guided bend testing, when required, shall be conducted by the

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

6.1.5.2 Four guided bend specimens shall be prepared and tested for
each position tested as per Table 2.

Table 2
Test Coupon Thickness Number and Type

Less than 3/8” 2F and 2R

Over 3/8” but less than 3/4” 2F and 2R, or 4S
Equal or greater than 3/4” 4S
 6.1.5.3 Guided bend specimens shall be either mechanically or flame
cut and shall be taken from the locations shown in QW-463 of
the ASME SEC IX B&PV Code. If flame cutting is employed,
1/8” shall be removed from each flame cut edge by grinding.
During grinding, care shall be taken to ensure that the
specimen is not overheated. Excessive grinding of guided bend
specimens is not permitted.

6.1.5.4 Testing shall be performed in accordance with requirements of

paragraph QW-162, of the ASME SEC IX B&PV Code.

6.1.5.5 Test acceptance criteria shall be as specified in paragraph

QW-163 of the ASME SEC IX B&PV Code.

6.1.6 Retest

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

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

6.1.6.3 Prior to taking the retest the Maintenance Superintendent shall

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

6.1.6.4 All retests shall be conducted at the WTC (or the proponents shop
if necessary) and witnessed by the WTC Welding Inspector.

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

6.2 Certification and Registration of Welders

6.2.1 Upon successful completion of the performance qualification test, the

WTC shall certify the test result by:

a) verifying whether newly tested welder is available in the WTS or

not. If yes, WTC is only to update the welder's certification
records on the WTS, by selecting “New Cert” icon. If the welder is
not found in the WTS, WTC is to select the “New Welder” icon
from the certification screen of the WTS;

b) inputting the welder's performance qualification test records in the

WTS (applies to all welders) and obtaining the welder symbol from
WTS, which is assigned automatically for all welders. The welder
symbol is unique and is not transferable. When a welder leaves the
employ of the company or his job title is permanently changed to
another job description, that welder's symbol shall be retired and
terminated from WTS database through a written request submitted
by Maintenance Organization and sent to both WTC and the WTS
Administrator, and a copy should also be sent to the OIU;

c) completing Welder and Welding Operator Qualification Record

Form SA-2318-ENG. The original shall be kept on file with the
WTC. Copies shall be sent to the WTS Administrator and the OIU;
and

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

The Qualification Card shall list all valid certifications, including the
Anniversary Date, held by the welder. It shall also include a recent
photograph of the welder and be carried by the welder at all times.
A copy of the card shall be kept on file at the WTC, and also be sent
to the OIU and the WTS Administrator. For new welders, one
additional recent photograph shall be sent to the WTS Administrator.

6.2.2 Immediately after the successful completion of the performance

qualification test, the newly certified welder shall report to the OIU to be
registered. Welders shall not be permitted to start production welding
without first being registered by the OIU.

6.3 Maintaining Welder Certifications

6.3.1 Initial Field Testing

6.3.1.1 The first three (3) production pressure retaining butt welds
welded by each newly certified welder, employing each newly
qualified certification, shall be 100% radiographed. The OIU
inspector shall witness the welding of at least one of these
welds. Radiographic acceptance shall be as specified by the
applicable design code governing the work.

6.3.1.2 If the radiographs are all acceptable the welder shall be permitted
to continue production welding. Subsequent production welding
shall be radiographed at normal job monitoring levels. All RT
inspection results shall be entered by OIU in the WTS utilizing
the radiography request form SA-4719-A-ENG.

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

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

6.3.1.5 When a new certification is revoked as a result of the Initial

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

6.3.1.6 Welders that have a certification revoked during the Initial

Field Test shall not be allowed to retake that certification test
for at least three (3) months. During that time the welder shall
be given additional training. When the welder is ready to
retake the Supplement Test the Maintenance Superintendent
shall certify in writing that the welder has been given the
required additional training and is fully prepared to take the
test. The test shall be scheduled in writing by the OIU with the
WTC.
 6.3.1.7 Initial Field Test radiographs shall be kept on file by the OIU
for at least one (1) year.

6.3.2 General Requirements

6.3.2.1 A flow chart showing the steps involved in maintaining welder

certifications is shown in Appendix 2.

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

GTAW) or specialized welding equipment for a period
exceeding six (6) consecutive months, all certifications with
that process or equipment shall immediately become revoked.
Also, if OIU is not entering the required welder performance in
the WTS within the PED, the welder will automatically
become “Inactive” on WTS which requires re-certification of
all affected process certifications. The welder shall be re-
certified by WTC.

6.3.2.3 All pressure containing welds made by a welder after a

certification is revoked shall be cut out.

6.3.2.4 If there is a specific reason to question a welder’s ability to

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

6.3.2.5 Welders whose certification with a process has been revoked

shall not be permitted to weld with that process on production
work until they have passed a Recertification Test to the
appropriate Test Supplement(s).

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

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

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

three (3) years on the anniversary date of the issue of the
welders first performance certification. During the month prior
to the anniversary date welders shall be recertified to every
Test Supplement previously held and/or required. This shall be
 called the Anniversary Recertification Test.
Those certifications obtained in the year prior to the
anniversary date are exempt from testing until the following
anniversary date. The Anniversary Recertification shall be
conducted by the WTC. The soon to be expired, Qualification
Card shall be surrendered to the WTC at the time of testing.
An updated Qualification Card shall be issued by the WTC
after completion of testing.
Commentary Note:

A welder will be placed in the Inactive welders list if he did not

appear for Anniversary Exam (ARD) within 90 days. The welder
will be in the Separated welders list if he did not appear for ARD
after the 90 days period; subsequently to reinstate him in the
WTS, a letter from his perspective Maintenance Division head
explaining the welder's case shall be sent to the Operations
Inspection Division head of the Inspection Department.

6.3.2.8 The OIU shall maintain Welder Experience Records to verify

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

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

6.3.2.10 The Maintenance Foreman shall maintain an up to date log of

welders working in the Unit. This welders log shall include a
listing of the welders valid certifications, welding activity,
Anniversary Recertification date and other vital information.

6.4 Recertification of Welders with Revoked Certifications

6.4.1 Welders whose certification with a process becomes revoked shall not be
permitted to weld on production work with the process until they have
taken and passed the required Recertification Test(s). The Recertification
Test(s) shall be conducted by the WTC in accordance with the
requirements of Section 6.1 of this Engineering Procedure.
 6.4.2 The welder Recertification Test shall be scheduled by the OIU with the
WTC in writing. It shall not be scheduled sooner than three (3) months
from the date the certification was revoked. When the welder is ready to
take the Recertification Test the Maintenance Superintendent shall
certify in writing that the welder has been given the required training and
is fully capable of passing the Recertification Test.

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

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

6.4.5 Welders that fail the retest shall have all of their certifications with the
process(es) tested revoked if the certifications were originally revoked as
a result of welding inactivity. If the certification was originally revoked
as a result of a failed Ability Test, only the particular certification tested
shall be revoked.

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

6.5 Corrosion Resistant Weld Metal Overlay (CRWMO)

6.5.1 CRWMO SMAW Ability Performance Test

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

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

6.5.1.2 The CRWMO SMAW Ability Performance Test shall be

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

6.5.1.3 The CRWMO SMAW Ability Performance Test shall consist

of a welding coupon (plate or pipe) for each welding position
required to be used on the job (the 6G all position test shall not
be used). Base metal thickness of the coupon shall not be
considered an essential variable.

6.5.1.4 The finished length/width of the weld metal overlay deposited

on the test coupon for each position shall be at least four inches
 (4”) by one inch (1”). The thickness of the overlay and number
of layers shall be as specified in the WPS.

6.5.1.5 The filler metals (size and type), preheat (if required), and
technique (stringer or weave) specified in the approved project
WPS shall be used in the test.

6.5.1.6 After the completion of welding, the OIU inspector shall

conduct a visual examination of the test coupon. Welds that
meet the dimensional requirements specified in the approved
WPS (bead size, number of layers, bead width, overlay
thickness, bead overlap, etc.) shall be considered acceptable.
Unremoved arc strikes are unacceptable and shall be cause for
rejection of the test coupon (failure).

6.5.1.7 If the visual examination of the test coupon is acceptable, the

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

6.5.1.8 Welders that pass the CRWMO SMAW Ability Performance

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

6.5.2 CRWMO SAW Welding Operator Performance Qualification Test

6.5.2.1 The CRWMO SAW Welding Operator Performance

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

6.5.2.2 Performance qualification testing shall be conducted in

accordance with an approved Test Supplement.

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

6.5.2.4 Coupons that pass the visual examination shall be examined using
the PT method in accordance with Article 6 of the ASME SEC V
B&PV Code. The acceptance criteria shall be as specified in
paragraph QW-195 of the ASME SEC IX B&PV Code.
The testing shall be conducted by the WTC welding inspector.
 6.5.2.5 Following the PT examination, four side bend test specimens
shall be cut (perpendicular to the direction of welding) from
the test coupon and tested by the WTC welding inspector.
The acceptance criteria shall be as specified in paragraph QW-
163 of the ASME SEC IX B&PV Code.

6.5.2.6 Welding operators that fail the CRWMO SAW Welding

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

6.5.2.7 Welding operators that pass the CRWMO SAW Welding

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

6.5.2.8 The Anniversary Recertification testing requirements of

paragraph 6.3.2.7 shall not apply to the CRWMO SAW Test.

6.5.3 Job Clearance Card (JCC)

6.5.3.1 Welders that pass CRWMO SMAW Ability Performance

Qualification Test shall be registered and issued a JCC for the
project by the OIU.

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

6.5.3.3 After completion of the project the JCC shall be returned to the
OIU.

6.6 Corrosion Resistant Strip Lining

6.6.1 Welders installing corrosion resistant strip shall be certified to an

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

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

6.6.3 The welder shall remove all mill scale and rust from the test coupon
prior to fit up. Failure to do so shall be cause for rejection of the test
coupon (test failure).
 6.6.4 The welder shall fit up the test assembly as instructed by the WTC
welding inspector, who shall check and approve the fit up. The gap
between the strip lining and base material shall not exceed one sixteenth
inch (1/16”).

6.6.5 The welder shall secure the test assembly in the test booth and shall not
start welding until instructed by the WTC welding inspector.
The welding inspector shall observe the welding of the entire test
assembly. The welder shall remove the slag from each weld bead.
The end of each weld bead shall be brushed clean prior to the start of
welding with the next electrode. Grinding of stop/starts and areas of
tightly adhering slag is permitted and should be encouraged. Beads shall
not start or end at corners. After completion of the welding the welder
shall brush clean the entire assembly. All arc strikes shall be removed by
grinding. Failure of a welder to adequately perform these tasks shall be
cause for rejection (test failure).

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

6.6.7 Test assemblies that pass the visual inspection shall be leak tested by the
WTC welding inspector and the welder. A small hand pump (or bulb)
shall be used to apply five (5) psig pressure through the 1/4” leak test
hole in the strip lining while leak detection solution is applied over the
welds. Leaks are not permitted (test failure).

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

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

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

Revision Summary
30 June 2014 Revised the Next Planned Update, reaffirmed the content of the document, and reissued as
major revision.
Appendix 1 – Flow Chart for Testing and Certifying Welders
Appendix 2 – Flow Chart for Maintaining Welder Certification
Appendix 3 – List of Approved Welding Test Supplements

SAEP Num Type Proc Base Mat'l Filler Metal Limitations

1101 S01 Pipe SMAW CS EXX10/EXX18 Vertical up
1102 S02 Pipe SMAW CS EXX10 Vertical down
1103 S03 Pipe SMAW SS EXXX-15/16 Fill/cap only
1104 S04 Pipe SMAW SS EXXX-15/16 Fill/cap only
--- ---- ---- Ni Alloys EXXXXX-X Fill/cap only
1105 S05 Pipe SMAW Ni Alloys EXXXXX-X Fill/cap only
1106 S06 Pipe GTAW Al Alloys ERXXXX Structural only
1107 S07 Pipe GTAW CS/LAS/SS ERXXS-X ----------------
--- ---- ---- LAS ERXXS-XX ----------------
--- ---- ---- SS ERXXX ----------------
1108 S08 Pipe GTAW Ni alloys ERXXX-X ----------------
1109 S09 Pipe GTAW Al alloys ERXXXX ----------------
1110 S10 Pipe SAW CS/LAS FXX-EXXX ----------------
1111 S11 Pipe SAW CS/LAS SS & Ni Alloy CRWMO
1112 S12 Pipe SMAW Small Dia CS EXX10/EXX18 Cat-”D” service
1113 S13 Pipe FCAW SS EXXT-X Spray/globular
1114 S14 Plate SMAW CS EXX10/E7018 Vertical up
1115 S15 Lap SMAW SS to CS EXXX-15/16 Vertical down
1116 S16 Lap SMAW Ni to CS EXXXXX-X Vertical down
1117 S17 Fillet SMAW CS BROSCO Wet Welding
1118 ============RESERVED FOR FUTURE TEST SUPPLEMENTS=============
1119 ============RESERVED FOR FUTURE TEST SUPPLEMENTS=============
1120 ============RESERVED FOR FUTURE TEST SUPPLEMENTS=============
1121 ============RESERVED FOR FUTURE TEST SUPPLEMENTS=============
1122 ============RESERVED FOR FUTURE TEST SUPPLEMENTS=============
1123 ============RESERVED FOR FUTURE TEST SUPPLEMENTS=============
1124 ============RESERVED FOR FUTURE TEST SUPPLEMENTS=============

NOTE: The 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
Appendix 4 – Performance Qualification Testing Prerequisites

S01 S03 S04 S05 S07

S01 ___ ___ ___ ___ ___

S02 ___ ___ ___ ___ ___

S03 _A_ ___ ___ ___ ___

S
U S04 _A_ ___ ___ ___ ___
P
P S05 _A_ ___ ___ ___ ___
L
E S06 ___ ___ ___ ___ ___
M
E S07 _A_ _B_ _B_ ___ ___
N
T S08 _A_ ___ _B_ _B_ _A_

B S09 _A_ ___ ___ ___ ___

E
I S10 ___ ___ ___ ___ ___
N
G S11 ___ ___ ___ ___ ___

T S12 _A_ ___ ___ ___ ___

E
S S13 _A_ ___ ___ ___ ___
T
E S14 ___ ___ ___ ___ ___
D
S15 _A_ _B_ _B_ ___ ___

S16 _A_ ___ _B_ _B_ ___

S17 ___ ___ ___ ___ ___

(A) Prior certification to this Supplement is required.

(B) Prior certification to one of two Supplements listed is required.
 Appendix 5 – Minimum Retraining Times for
Welders Taking the Performance Qualification Retest

Cause of Test Failure Minimum Retraining Time

Unacceptable root (6.1.2.3/4) 14 days
Excessive grinding (6.1.2.4/6) 7 days
Excessive backgouging (6.1.2.4) 7 days
Final visual (6.1.3.2/3/4/5/6/7) 7 days
Rejection of x-ray (6.1.4.3) 7 days
Bend test failure (6.1.5.5) 7 days
Rejection for cause (6.1.1.5) 30 days

NOTE: Prior to taking the retest the Maintenance Superintendent shall certify in writing that the welder has undergone
additional training and is fully prepared to take the retest. Welders that fail the retest shall not be permitted to take a
second retest, and are also prohibited from taking that welding performance qualification test sooner than three (3)
months from that date.
 Appendix 6 – Welder Experience Record

Name ____________________ Employee Number __________ Welder Symbol ___________

Org Code ____________ Anniversary Recertification Date _____________

Supplement Number Qualified To

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

2 _____ _____ _____ _____ _____ _____

3 _____ _____ _____ _____ _____ _____

4 _____ _____ _____ _____ _____ _____

5 _____ _____ _____ _____ _____ _____

6 _____ _____ _____ _____ _____ _____

7 _____ _____ _____ _____ _____ _____

8 _____ _____ _____ _____ _____ _____

9 _____ _____ _____ _____ _____ _____

10 _____ _____ _____ _____ _____ _____

11 _____ _____ _____ _____ _____ _____

12 _____ _____ _____ _____ _____ _____

(A) Reference inspection report, RT report, weld/braze number, etc.

 Appendix 7 – Welding Shop Audit Checklist

Welding Shop Assessment Checklist

Item Status
NDT Requirements Implementations Remarks
No. Yes No NA
1 Visual Inspection is performed at all production welds and documented
2 Hardness test is carried out on 10% of welds in sour service as per SAES-W-011
3 The requirements of hydrotest are specify on layout drawings as per SAES-A-004
4 Type of NDT and their requirements and extent are specified on layout drawings
5 Welder symbol and WPS No. are put on each weld joint or repair as per SAES-W-011
6 Radiographic Tests performed are meeting SAES-W-Series requirement
7 PMI is performed as per 00-SAIP-07 and SAES-A-206 requirements and on SS joints
8 PT & MT are performed on fillet welds as per the requirements of SAES-W-011, 17.5.3

Item Status
Electrodes Storage and Handling Remarks
No. Yes No NA
Different types of electrodes and other welding consumables are stored and kept segregated
1
and not mixed and grinding disc for CS and SS shall be color coded and segregation
There is a copy of the electrodes handling and storage requirements stated in SAES-W-011
2 Attachment I posted near the ovens and consumables storage areas to remind welders of the
those requirements
All opened low hydrogen, SS & non-ferrous electrodes are stored in ovens as per
3
SAEP-W-011 Attachment I requirements
The storage temperature of the ovens is correct and maintained at the required temperature of
4
120oC for storing low-hydrogen electrodes.
5 The used portable electrode storage ovens are plugged in
6 The temperature of the portable oven is checked and maintained while it is in service
 Other types of electrodes (i.e., non-low hydrogen electrodes, e.g., 6010) that have been
7
opened are stored in a dry environment
8 All electrodes with visible rusting, broken or loose fluxes are discarded and not used

Item Status
Welders Performance and Tracking Remarks
No. Yes No NA
1 Visual Inspection is performed on all welds and results entered in WTS for each welder
Job Clearance Card (JCC) is issued for any contract welder prior to beginning any welding
3
activity as required by SAEP-323, Paragraph 6.1.5?
The first three butt welds of any Saudi Aramco and Contractors welders are radiographed as
4
required by SAEP-323 and entered in WTS
5 Radiography test is applied as per the requirements of SAES-W-011, Paragraph 17.5
6 RT results are entered in WTS

Item Status
Documentation, Filing and Reporting Remarks
No. Yes No NA
The Shop Forman receives a report of all welders certification due for expiration in the next
1
60 days welders’ acceptance/ rejection rate from inspection regularly
2 A copy of SA approved WTS is available for welders in the shop and the filed
The radiographs records of first three butt welds are kept on file by the OIU for at least
3
1 year as per SAEP-321 Paragraph 6.3.1 and SAEP-323 requirements
There is a file for all welders containing copy of their certification card, photo, RT films of
4
their first three radiographs, copy of the issued JCC, NDT testing results from the WTC
5 NDT (PT,MT,RT, PMI) records are maintained for the new welds and repairs
There is a file and log for all welding activities performed at the workshop which is
6 containing referenced Worksheet/Engineering package, approved WPS used, type of
materials, welder symbol welding inspection performed and their results
Item Status
Welding Shop Equipment Remarks
No. Yes No NA
1 Electrodes storage ovens are equipped with temperature gauges
2 Temperature gauges are calibrated and have valid calibration stickers
3 Welding machines) are in good and safe condition (including cables condition)
4 Fume extractors are available and being utilized effectively
5 Quiver – portable oven are available
6 Local PWHT equipment is available and in good condition
7 PPE are supplied for each workers and used effectively
8 General Housekeeping of shop is acceptable
9 The contractors welding yards are inspected regularly

Item Status
Workmanship Remarks
No. Yes No NA
1 There are at least two welders certified to the SMAW Process
There is at least one welder certified to the GTAW Process to perform root pass weld
2
as per SAEP-W-011, Paragraph 5.2 Requirements. (i.e., Supplement 07)
3 There are certified welders to weld on SS materials (e.g., Supplement 03)
4 There are certified welders to weld on 1” diameter pipe (S 12)
5 A dedicated welding inspector is available at the weld shops
6 The weld shop inspector is certified as RTFI Level II
7 The weld shop inspector is CSWIP certified inspector or AWS
8 There is an assigned WTS coordinator and all mechanical inspection have access to the WTS
9 There is a need for more welders with different qualification