SAEP-1160 (NDT- TRACKING AND REPORTING OF WELDING, NDT AND PRESSURE TESTING FOR CAPITAL PROJECTS

Engineering Procedure SAEP-1160 Tracking and Reporting of Welding, NDT and Pressure Testing for Capital Projects Inspection Engineering Standards Committee Members

2 August 2009

Kakpovbia, Anthony Eyankwiere, Chairman Rajeh, Saleh Rashid, Vice Chairman Albarillo, Rodolfo Celino Anazy, Khalid Juma Boult, David Carrera, R L Ghamdi, Khalid Salem Ingram, James Young Keen, Peter David Khunaizi, Mohammad Redhi Langla, Edward Charles Mc Ghee, Patrick Timothy Mohsen, Hassan Abdallah Seyed Mohamed, Abdul Cader Shammary, Hamed Abdulwahab Stockenberger, Hans J Suwaidan, Khalid Ali

Saudi Aramco DeskTop Standards Table of Contents 1 2 3 4 5 6 7 8 9

Scope............................................................. 2 Conflicts and Deviations................................ 2 Applicable Documents................................... 2 Abbreviations................................................. 3 General Requirements................................... 4 Production Welding........................................ 6 Tracking and Reporting Welder Performance.................................... 10 Pressure Test Verification............................ 11 Guidelines for the Use SATIPS and SAICS.............................. 11

Previous Issue: 17 July 2006 Next Planned Update: 7 June 2011 Revised paragraphs are indicated in the right margin Primary contact: Mohsen, Hassan Abdallah on 966-3-8745017 Copyright©Saudi Aramco 2009. All rights reserved.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1160 Issue Date: 2 August 2009 Tracking and Reporting of Welding, Next Planned Update: 7 June 2011 NDT and Pressure Testing for Capital Projects

1

Scope This document establishes minimum requirements and responsibilities for the tracking and reporting of production welding (full penetration grove welds), welder performance, NDE tracking and pressure test verification associated with In-Kingdom construction activities at Saudi Aramco facilities.

2

3

Conflicts and Deviations 2.1

Any conflicts between this Procedure and other applicable Saudi Aramco Engineering Standards (SAES), Saudi Aramco Materials System Specifications (SAMSS), Saudi Aramco Engineering Procedures (SAEP), Saudi Aramco Standard Drawings (SASD), or industry standards, codes, and forms shall be resolved in writing through the Manager, Inspection Department of Saudi Aramco, Dhahran.

2.2

Direct all requests for deviations from this Procedure in writing and forward such requests to the Manager, Inspection Department of Saudi Aramco, Dhahran.

Applicable Documents Except as modified by this SAEP or other contract documents, applicable requirements in the latest issues of the following industry Codes, Standards, and Practices shall be considered an integral part of this procedure. 3.1

Saudi Aramco References Saudi Aramco Engineering Standards SAES-A-004

General Requirements for Pressure Testing

SAES-A-007

Pressure Testing Fluids and Lay-up Procedures

SAES-L-150

Pressure Testing of Plant Piping and Pipelines

SAES-L-350

Construction of Plant Piping

SAES-L-450

Construction of On-Land and Near Shore Pipelines

SAES-W-010

Welding Requirements for Pressure Vessels

SAES-W-011

Welding Requirements for On-Plot Piping

SAES-W-012

Welding Requirements for Pipelines

SAES-W-017

Welding Requirements for API Tanks Page 2 of 12

Document Responsibility: Inspection Engineering Standards Committee SAEP-1160 Issue Date: 2 August 2009 Tracking and Reporting of Welding, Next Planned Update: 7 June 2011 NDT and Pressure Testing for Capital Projects

Saudi Aramco General Instructions GI-0002.102 3.2

Pressure Testing Safely

Industry Codes and Standards American Society of Mechanical Engineers ASME B31.1

Power Piping

ASME B31.3

Process Piping

ASME B31.4

Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids

ASME B31.5

Refrigeration Piping

ASME B31.8

Gas Transmission and Distribution Piping Systems

ASME B31.9

Building Services Piping

ASME BPV

Boiler and Pressure Vessel Code

American Petroleum Institute API STD 620

Design and Construction of Large, Welded, LowPressure Storage Tanks

API STD 650

Welded Steel Tanks for Oil Storage

API STD 653

Tank Inspection, Repair, Alteration, and Reconstruction

API STD 1104

Welding of Pipelines and Related Facilities

American Water Works Association AWWA D100 4

Construction of Water Tanks

Abbreviations API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

HT

Hardness Testing

IR

Inspection Request (formerly RFI, Request for Inspection)

QMIS

Quality Management Information System (Electronic Logbook of Inspection Results)

MSAER Mandatory Saudi Aramco Engineering Requirements

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1160 Issue Date: 2 August 2009 Tracking and Reporting of Welding, Next Planned Update: 7 June 2011 NDT and Pressure Testing for Capital Projects

5

MT

Magnetic Particle Testing

NDT

Nondestructive Testing

PID

Projects Inspection Division

PMI

Positive Material Identification

PQM

Saudi Aramco Project Quality Manager

PT

Penetrant Testing

PWHT

Post-Weld Heat Treatment

RT

Radiographic Testing

SAIC

Saudi Aramco Inspection Checklist

SATIP

Saudi Aramco Typical Inspection Plan

SATR

Saudi Aramco Test Report

SPC

Single Point Contact

UT

Ultrasonic Testing

VT

Visual Testing

WPS

Weld Procedure Specification

General Requirements 5.1

Production Welding, Welder Performance, Reporting, NDE Tracking, and Pressure Test Verification This information shall be gathered, correlated, linked, reported, and stored in an electronic format (Excel, Access, PDF or similar) acceptable to Saudi Aramco. The contractor's data management and tracking system must be approved by Saudi Aramco prior to the start of work. The data tracking system must meet the minimum requirements of 6.1 and 6.3 below. Note: For limited scope project work, fewer than 500 groove/butt weld joints, contractor may elect to use hardcopy tracking system with the approval of the Saudi Aramco Inspection Department. Reporting for these projects shall use the applicable SATR such as; SATR weld/welder reports: SATR-W-2013 Weekly Welders Reject Rate.xls, SATR-W-2018 Weekly Welder Repair & Tracer-RLCf.xls, SATR-W-2019 Weekly Weld Status Report-RLC-f.xls, SATR-W-2008 Weld Summary Report.xls

5.2

Data Availability The data tracking system(s) shall be maintained and kept current and available for Saudi Aramco's review at all times. The data shall be available on a daily

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1160 Issue Date: 2 August 2009 Tracking and Reporting of Welding, Next Planned Update: 7 June 2011 NDT and Pressure Testing for Capital Projects

basis for both current data and cumulative data. Data shall be retrievable by date for any given day from commencement of the work through project completion. At the end of the project the archived records shall be submitted in accordance with contract requirements. 5.3

Data Reporting The Contractor shall track welding activities on a daily basis and submit to Saudi Aramco each week a weld tracking and welder performance report for that week's work. Cut-off date for submitting weekly performance report shall be agreed to by Contractor and Saudi Aramco PQM.

5.4

6

Output for cumulative weld data and welder data required by this document is to be reported weekly in the weld tracking and welder performance report. Shop and field weld and welder data may be included on the same report.

Production Welding 6.1

Minimum Data Requirements The following minimum data items associated with full penetration groove and butt welds and associated special processes for pressure piping or field-erected pressure vessels and API storage tanks are required to be collected, linked, and maintained for each weld to the extent it is applicable. The acceptance or rejection of groove and butt weld special processes shall be indicated as applicable. When UT is used in lieu of RT the tracking and reporting requirements shall remain the same. Contractor shall record and track production, inspection and testing of socket and fillet welds in a separate database and submit to Saudi Aramco on a weekly basis. DATA ITEM

COMMENTS AND CLARIFICATION

Weld Identification – Basic Information Isometric Drawing Number

Design Information

Weld Joint Number

Assigned by Contractor

Line Number

Design Information

Line Class

Design Information

Pipe Diameter

Design Information

Spool Number

Design Information

Wall Thickness

Design Information

Material Class/Grade

Design Information Page 5 of 12

Document Responsibility: Inspection Engineering Standards Committee SAEP-1160 Issue Date: 2 August 2009 Tracking and Reporting of Welding, Next Planned Update: 7 June 2011 NDT and Pressure Testing for Capital Projects DATA ITEM

COMMENTS AND CLARIFICATION

Type of Joint

Design Information - groove or butt

NDT Required

Design Information – Indicate method (s) and extent

PMI Required

Yes/No

PWHT Required

Yes/No - Regardless of reason for requirement

Post-PWHT NDT

Yes/No - Required for final acceptance of all PWHT welds

HT

Sampling required for specific production and PWHT welds

Design information must reflect actual data should changes occur during evolution of the project. Weld Fit-up Inspection Date of Inspection SATR Number In-Process Weld Inspection Welder Identification

Indicate approved welder or welders by identification symbol(s) who are welding the joint.

WPS Identification

Indicate the approved WPS(s) used to weld the joint.

WPS Parameters

Verified - Yes/No, reference SAIC number

Completed Weld Visual Inspection Visual Inspection

Indicate accept or reject per specified acceptance criteria

SAIC/SATR Number

This number may be the same as IR number or Quality Record number.

Weld Selection for NDT Selected for NDT

Indicate Yes/No – If "No" record the weld as completed and visually accepted.

Criteria for selection for NDT are listed in the applicable SATIP-W-XXXX. Note: NDT of PWHT welds for P-Nos 3, 4 & 5 materials prior to PWHT should be considered for information only and not final acceptance. The intent is to evaluate the weld quality prior to PWHT so any unacceptable discontinuities can be repaired prior to PWHT. Weld Selection for HT Selected for HT

Indicate Yes/No

Criteria for selection of HT are listed in SAES-W-011. (Ref. SATIP-W-011-01 and SAIC-W-2012) Page 6 of 12

Document Responsibility: Inspection Engineering Standards Committee SAEP-1160 Issue Date: 2 August 2009 Tracking and Reporting of Welding, Next Planned Update: 7 June 2011 NDT and Pressure Testing for Capital Projects DATA ITEM

COMMENTS AND CLARIFICATION

NDT Control and Identification Date of NDT Request

Indicate the date the NDT Request was generated

NDT Report Number

This number, once assigned to a weld, shall remain with weld until final acceptance. Repeated NDT on a weld shall be indicated by adding or modifying the NDT Report Number suffix similar to that used for weld repair as stated below.

Date NDT Completed Date of NDT Results

Date of initial NDT acceptance or rejection

Selection of Tracer Welds

Selection of Tracer Welds

Two tracer welds must be selected for each rejected weld in a 10% RT system. The two welds must have been welded by the same welder using the same welding process and use the NDT method as the initial weld for evaluation.

Identify Original Rejected Weld Date of NDT Result

Date of acceptance or rejection

Progressive sampling of welds (tracer welds) shall follow the progressive sampling method as stated in governing SAES. Tracer welds are not to be counted in the 10% sampling process. Results of RT Film Evaluation by Saudi Aramco

Film Quality

Indicate the acceptance or rejection of film quality. Rejection will require the reshoot of rejected film(s). The weld identification number will have a suffix added as described 6.2 below.

Weld Quality

Indicate the acceptance or rejection of weld quality. Rejection will require weld repair(s) and the reshoot of rejected weld or weld areas.

Welds rejected for weld quality requiring repairs shall require modification of their original weld identification numbers as stated in 6.2 below. (Ref. SATR-W-2018) Evaluation of other completed Special Processes PWHT Process PMI Process

Indicate the date of acceptance or rejection of the completed and recorded PWHT. Indicate the date of acceptance or rejection of the completed and recorded PMI for the weld.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1160 Issue Date: 2 August 2009 Tracking and Reporting of Welding, Next Planned Update: 7 June 2011 NDT and Pressure Testing for Capital Projects DATA ITEM HT Process

COMMENTS AND CLARIFICATION Indicate the date of acceptance or rejection of the completed and recorded HT.

Rejected CSP welds shall require modification of their original weld identification numbers as stated below. Rejection will also require progressive sampling. Retests for HT Status of HT-rejected test

6.2

If any reading exceeds the specified limit by no more than 10 BHN, then a minimum of three (3) additional indentations shall be made near the original high reading

Progressive confirmation testing

Indicate acceptance or rejection of the required 3 additional HT test on the same weld. If all three (3) retests are below the specified limits, then the joint is acceptable. If any of the retest readings are found to exceed the specified limits, then the weld shall be considered unacceptable.

Selection of Tracer Welds

If any welds are found to be unacceptable, then two additional welds from the same lot shall be tested. If more than one weld in a lot is found to be unacceptable, then all welds in that lot shall be tested.

Date of NDT Result

Date of acceptance or rejection

Weld Identification Numbering System The following weld identification numbering system shall be used to identify and track piping groove and butt welds as a minimum. Weld numbering shall be consecutive in the direction of flow per line. Each weld shall be identified by joint number, line number, and spool number. Physical marking of welds shall comply with the applicable SAES-W specification. In addition to the spool number and line number identification, each weld shall be identified as follows. The example of a first weld is used. W-01

This number has been given to a weld prior to production welding. If required examinations are accepted no change is required.

W-01R1

The W-01 weld has been completed and examination has revealed an unacceptable discontinuity that was repaired. If subsequent examinations are accepted no change is required.

W-01R2

The W-01R1 weld repair has been completed and examination has revealed an unacceptable discontinuity. If subsequent examinations are accepted no change is required. No further

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1160 Issue Date: 2 August 2009 Tracking and Reporting of Welding, Next Planned Update: 7 June 2011 NDT and Pressure Testing for Capital Projects

repairs are permitted without express approval of Saudi Aramco. If permitted the suffix R3 shall be used. W-01RW

The unaccepted weld W-01R2 has been cut out and the joint has been rewelded. The identification methodology above is to be applied should further weld repairs be necessary.

W-01T1

The W-01 weld has been completed and examination has revealed

W-01T2

an unacceptable weld discontinuity or HT tests have been rejected. Progressive sampling is required in both cases and the "tracer" welds will be identified. If subsequent tests are accepted no change is required. Repairs on tracer welds will require further sampling in which case the suffix numbering system shall progress accordingly.

Welds fabricated in the field shall be prefixed with the letter 'F' and welds fabricated in a weld shop with the letter 'S'. The above numbering system shall be applied as a minimum for all types of tests and inspections of pipe welds.

6.3

6.2.1

The weld numbering identification system for pressure vessels, tanks, and other pressure-retaining non-pipe welds shall be approved by the Inspection Department Representative prior to the start of work.

6.2.2

Contractors/fabricators may propose alternative numbering systems for approval by PQM. The identification system shall be used to identify all examinations, surveys, inspections, etc.

Pipe welds are to be tracked and reported by line class as follows. Pressure welds other than piping shall be tracked and reported by equipment number as follows. 1)

Number of welds completed

2)

Number of welds subjected to NDT (excluding tracer welds)

3)

Number of welds rejected by each NDT method applied

4)

Number of welds subjected to PMI

5)

Number of welds subjected to PWHT

6)

Number of welds subjected to HT

7)

Number of welds repaired and rejected

8)

Number of repairs outstanding

9)

Report actual backlogs: Page 9 of 12

Document Responsibility: Inspection Engineering Standards Committee SAEP-1160 Issue Date: 2 August 2009 Tracking and Reporting of Welding, Next Planned Update: 7 June 2011 NDT and Pressure Testing for Capital Projects

a)

PMI Backlog

b)

PWHT Welds - Outstanding PWHT

c)

Completed Welds - Outstanding (backlog) NDT (by NDT method)

d)

HT Backlog

e)

Tracer Welds - Outstanding NDT

f)

Tracer Welds - Outstanding HT

g)

Weld rejection rate by line class and NDT method (joint and linear basis)

h)

Tracer weld reject rate percentage

i)

Overall production weld rejection percentage

j)

SA RTFI results – to be reported by number of weld films reviewed, separate film quality and weld quality results, and percentage disagreement with initial film interpreter.

Note: A backlog exists when Special Process results are not received and recorded within a project-specific time, usually 7 days, after the welds have been visually accepted.

7

Tracking and Reporting Welder Performance 7.1

Welder performance data shall be tracked and recorded on a daily basis and reported to Saudi Aramco weekly during the Weekly Meeting. Welder performance percentage rejection rate shall be calculated and reported on a per joint and linear basis.

7.2

The contractor shall track and report the following welder performance data:

7.3

1.

Total number of pressure welds made per weld type (e.g., fillet, groove, butt)

2.

Total number of pressure welds made per weld process

3.

Total number of pressure welds rejected by NDT method

Reporting – Minimum Requirements 7.3.1

Reporting format shall follow the weld identification scheme as stated in paragraph 6.2.

7.3.2

Paragraph 6.3 lists the minimum requirements that shall be included in the weld tracking and welder performance report submitted to Saudi Aramco each week.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1160 Issue Date: 2 August 2009 Tracking and Reporting of Welding, Next Planned Update: 7 June 2011 NDT and Pressure Testing for Capital Projects

8

Pressure Test Verification For each pressure test, the Contractor shall demonstrate to the satisfaction of the Inspection Department Representative the following, as a minimum, prior to pressure testing:  Submittal to SAUDI ARAMCO of a Pressure Test Package containing the following:

9



Reference the "Approved" Pressure Test Procedure



Pressure Test Diagram which shall include the limits of piping (including test manifold) and equipment included in each pressure test, high points and low points (drain), locations of pressure gauges, test pressures, test temperature, test fluid, line flushing requirements, and safety precautions



Relief valve capacity, testing and installation



Pressure gages and recorders calibration records



COMPANY Safety Instruction Sheet (for critical piping) and Pressure Test Report Form



Copies of P&ID and isometric drawings of the piping system to be pressure tested



Piping spools control sheet with NDT extent and results.



Pre-pressure test check List



Re-instatement procedure and Check List



Flange set completion documentation for permanent installations



Identification of pressure testing SPC from contractor



Lay-up method to be applied



Verification of chemical dosing calculations when applicable



Test manifold hydro test verification

Guidelines for the Use SATIPS and SAICS 9.1

Project-specific SATIP witness and hold points may be modified from initial approved requirements as the project progresses. Requests for SATIP modifications must be requested and shall have the concurrence of the Saudi Aramco Inspection Department and should be directed to the appropriate Saudi Aramco Project Quality Manager.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1160 Issue Date: 2 August 2009 Tracking and Reporting of Welding, Next Planned Update: 7 June 2011 NDT and Pressure Testing for Capital Projects

9.2

7 June 2006 17 July 2006 2 August 2009

Use of Welding and NDT SAICS 9.2.1

One SAIC per day per activity is required for production welding on a daily or continual basis, e.g., fit-up, in-process, and final inspection. Applicable weld numbers must be entered in the Remarks Box on the appropriate SAIC.

9.2.2

Special welding activities such as branch connections, tie-ins, sleeve installation, hot-tap welding, and temperature tie-ins will require a separate IR per weld per activity in accordance with the applicable SATIP.

9.2.3

NDT subcontractors must complete NDT Checklists on a daily basis per above but not as an IR with the exception of the start of NDT activities.

Revision Summary New Saudi Aramco Engineering Procedure. Revise document title to reflect the document scope clearly. Editorial revision to change document responsibility.

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