Engineering Procedure

SAEP-1160 18 August 2019

Tracking and Reporting of Welding,
NDT, and Pressure Testing for Capital Projects
Document Responsibility: Project Quality Standards Committee

Contents
1 Scope ..................................................................... 2
2 Conflicts and Deviations ......................................... 2
3 References ............................................................. 2
4 Definitions and Acronyms ....................................... 4
5 General Requirements ........................................... 6
6 Data Management and Tracking System ............... 7
7 Tracking and Reporting Welder Performance ...... 16
8 Guidelines for the Use SATIPS and SAICS ......... 17
Revision Summary ...................................................... 18

Appendix A - Contents of Pressure Test Packages .... 22

Previous Issue: 2 August 2016 Next Planned Update: 18 August 2024

Page 1 of 24
Contact: Megren, Abdulaziz A (megraa0a) on phone +966-13-574-4220

©Saudi Aramco 2019. All rights reserved.

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

1 Scope

1.1 This Engineering Procedure specifies the minimum requirements and

responsibilities for the tracking and reporting of production welding, welder
performance, NDE tracking, and pressure test verification associated with
in-Kingdom or Out-of-Kingdom construction project sites and fabrication
Shops/Yards.

1.2 This engineering procedure does not apply to Manufacturer Fabrication

Facilities as defined in Section 4.

1.3 This engineering procedure does not apply to Maintenance Projects as defined in
Section 4.

2 Conflicts and Deviations

2.1 Any conflicts between this document and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) shall be addressed to the
EK&RD Coordinator.

2.2 Any deviation from the requirements herein shall follow internal company
procedure SAEP-302.

3 References

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 Procedures

SAEP 122 Project Records
SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering
Requirement
SAEP-323 Contractor Welders and Brazers Performance
Qualification Testing and Tracking Requirements
SAEP-324 Certification Review and Registration of Project
Welders

©Saudi Aramco 2019. All rights reserved. Page 2 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-A-007 Pressure Testing Fluids and Lay-up Procedures
SAES-L-110 Limitations on Pipe Joints and Components
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-L-850 Design of Submarine Pipelines and Risers
SAES-M-005 Design and Construction of Fixed Offshore Platforms
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-013 Welding Requirements for Offshore Structures
SAES-W-016 Welding of Special Corrosion-resistant Materials
SAES-W-017 Welding Requirements for API Tanks

Saudi Aramco Materials System Specifications

12-SAMSS-007 Fabrication of Structural and Miscellaneous Steel
12-SAMSS-018 Structural Plates, Rolled Shapes, and Tubulars
Specification for Fixed Offshore Platforms
32-SAMSS-005 Manufacturing of Atmospheric Tanks
32-SAMSS-006 Manufacturing of Low Pressure Tanks

Saudi Aramco General Instructions

GI-0002.102 Pressure Testing Safely
GI-002.710 Mechanical Completion and Performance
Acceptance of Facilities

3.2 Industry Codes and Standards

American Petroleum Institute

API STD 620 Design and Construction of Large, Welded, Low-
Pressure Storage Tanks
API STD 650 Welded Steel Tanks for Oil Storage

©Saudi Aramco 2019. All rights reserved. Page 3 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

API STD 653 Tank Inspection, Repair, Alteration, and

Reconstruction
API STD 1104 Welding of Pipelines and Related Facilities
API RP 2A WSD Planning, Designing, and Constructing Fixed
Offshore Platforms—Working Stress Design

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 Water Works Association

AWWA D100 Construction of Water Tanks

American Welding Society

AWS D1.1 Structural Welding Code - Steel

4 Definitions and Acronyms

4.1 Definitions

Fabrication Shop: A facility with a controlled environment used for the

fabrication and/or assembly of equipment and structures such as pipe spools,
pressure vessel, etc. Controlled environment refers to atmospheric weather
condition, established quality system, and welder’s accessibility to welds joints.

Fabrication Yard: A large open outdoor area used for the fabrication and/or
assembly of very large structures such as offshore platforms, etc.

Manufacturer’s Fabrication Facility: A facility engaged in fabrication of

assembled or sub-assembled products under a Purchase Order and monitored by
Vendor Inspection.

Maintenance Project: A project to perform maintenance work under a short

form contract with the maintenance department as the proponent.

©Saudi Aramco 2019. All rights reserved. Page 4 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

4.2 Acronyms
API American Petroleum Institute
ASR After Stress Relieving
AUT Automatic Ultrasonic Testing
ASME American Society of Mechanical Engineers
BSR Before Stress Relieving
EPM Enterprise Project Management
GI General Instruction
HT Hardness Testing
QMIS Quality Management Information System (Electronic Logbook of
Inspection Results)
MSAER Mandatory Saudi Aramco Engineering Requirements
MT Magnetic Particle Testing
MUT Manual Ultrasonic Testing
NDE Nondestructive Examination
NDT Nondestructive Testing
PID Projects Inspection Division
PMI Positive Material Identification
PQM Saudi Aramco Project Quality Manager
PAUT Phased Array Ultrasonic Testing
PT Penetrant Testing
PWHT Post-Weld Heat Treatment
RFI Request for Inspection
RT Radiographic Testing
RTFI Radiographic Test Film Interpretation
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

©Saudi Aramco 2019. All rights reserved. Page 5 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

WPS Welding Procedure Specification

WRR Weld Rejection Rate/ Weld Repair Rate

5 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 acceptable to Saudi Aramco. The contractor's data
management and tracking system must be approved by Saudi Aramco Project
Inspection Supervisor prior to the start of any welding activities. The data
tracking system must meet the minimum requirements of Section 6.
Note: For limited scope project work, fewer than 500 groove/butt weld joints,
contractor may elect to use tracking system with the approval of the Saudi
Aramco Inspection Department. Reporting for these projects shall use the
format of applicable SATR such as; SATR-W-2013 (Weekly Welders Reject
Rate), SATR-W-2018 (Weekly Welder Repair and Tracer), SATR-W-2019
(Weekly Weld Status Report) - SATR-W-2008 (Weld Summary Report), etc.

Contractor shall provide required demonstration and training to the selected PID
personnel about their data management and tracking system.

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. Contractor shall provide an electronic copy of
production weld data in a native file format which data can be filtered by different
values such as Welder ID, date, weld type, NDE, etc. The data shall be
available on a daily 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 by Contractor and Saudi Aramco PQM.
Note: Contractor shall provide hardcopy and electronic copies of production weld data
in native file format which data can be filtered by different values such as
welder ID, date, weld type, NDE, etc.

©Saudi Aramco 2019. All rights reserved. Page 6 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

5.4 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.

5.5 Designer shall prepare the NDT matrix to establish the different NDT
requirements based on the design consideration and approved piping material
specification in line with applicable standards. This shall be reviewed and
approved by the area Project Inspection prior to start fabrication. The NDT
matrix shall contain as a minimum but not limited to; Piping class, material
specification, thickness range, diameter range, MDT, fluid description, fluid
code, fluid category (as per ASME B31.3, i.e., Normal, Category D, PWHT,
different NDE requirements including Hardness, PMI, Ferrite Element tests, etc.

5.6 Prior to start welding activities, contractor shall sign an agreement with
Approved NDT Company to conduct required NDE during project construction
in order to avoid NDT backlog. The NDT Procedures and Technicians resumes
shall be submitted to for Company approval according to Schedule Q.

5.7 For Offshore Structures, Designer shall prepare the Structural NDT Matrix/Map
to establish the different NDT requirements based on the design consideration
and Component Categories established in applicable SAES, which shall be
reviewed and approved by the area Project Inspection prior to start of work.

6 Data Management and Tracking System

The following minimum data associated with the project shall be collected, linked, and
maintained.

6.1 Material Receiving

Contractor shall track and maintain the material receiving data of pipes, flanges
and fittings procured from manufacturer and stockiest. The following minimum
data associated with received materials shall be collected, linked and
maintained:

DATA ITEM COMMENTS AND CLARIFICATION

Piping Materials Received
Heat Number of the pipes, flanges, and
6.1.1 Heat Number
fittings
Detailed Description of the material
6.1.2 Material description including but not limited to Dia., Schedule
/ Thickness, ASTM Classification, etc.
6.1.3 Quantity In Number and Length
6.1.4 Material Receiving Inspection RFI The RFI number from QMIS/EPM

©Saudi Aramco 2019. All rights reserved. Page 7 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

6.2 Piping and Pipeline Welding

Production welding includes full penetration grove welds, fillets welds, socket
welds, pressure containing welds, and all attachment welds direct to pressure
boundary including seal welds after pressure testing. 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 or same database with
suitable legends and submit to Saudi Aramco on a weekly basis.

DATA ITEM COMMENTS AND CLARIFICATION

6.2.1 Weld Identification – Basic Information

6.2.1.1 Isometric Drawing Number Design Information
6.2.1.2 Weld Joint Number Assigned by Contractor
6.2.1.3 Line Number Design Information
6.2.1.4 Line Class Design Information
6.2.1.5 Pipe Diameter Design Information
6.2.1.6 Spool Number Design Information
6.2.1.7 Wall Thickness Design Information
6.2.1.8 Material Class/Grade Design Information
Welding consumable
6.2.1.9 Design Information
batch/ lot no.
6.2.1.10 Type of Joint Design Information - groove or butt
Design Information – Indicate method (s) and
6.2.1.11 NDT Required
extent
6.2.1.12 PMI Required Yes/No
Yes/No - Regardless of reason for
6.2.1.13 PWHT Required
requirement
Yes/No - Required for final acceptance of all
6.2.1.14 Post-PWHT NDT
PWHT welds
Sampling required for specific production and
6.2.1.15 HT
PWHT welds
Design information must reflect actual data should changes occur during
6.2.1.16
evolution of the project.
6.2.2 Weld Fit-up Inspection
6.2.2.1 Date of Inspection Fit up inspection date
6.2.2.2 SATR Number Report number

©Saudi Aramco 2019. All rights reserved. Page 8 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

DATA ITEM COMMENTS AND CLARIFICATION

6.2.2.3 Component heat no. Heat number of piping components
6.2.3 In-process Weld Inspection
Indicate approved welder or welders by
6.2.3.1 Welder Identification identification symbol(s) who are welding the
joint.
Welding consumable Indicate the welding consumables utilized
6.2.3.2
batch/ lot no. during welding in each passes.
Indicate the approved WPS(s) used to weld
6.2.3.3 WPS Identification
the joint.
6.2.3.4 WPS Parameters Verified - Yes/No, reference SAIC number
6.2.3.3 Completed Weld Visual Inspection
Indicate accept or reject per specified
6.2.4.1 Visual Inspection
acceptance criteria
This number may be the same as IR number
6.2.4.2 SAIC/SATR Number
or Quality Record number.
6.2.5 Weld Selection for NDT
Selected for NDT (RT, Indicate Yes/No – If “No” record the weld as
6.2.5.1
AUT, PT, MT, MUT, etc.) completed and visually accepted.
Notes:
1. Criteria for selection for NDT are listed in the applicable
SATIP-W-XXXX.
2. NDT of PWHT welds for P-Nos. 3, 4, and 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.
Any repairs identified from such NDT shall be included in the calculation
of Project Welding Rejection Rate as well as in the welder performance.
3. Time of NDT of welds for the PWHT’s joint shall follow respective
SAES-W-series.
4. The NDT reports and RT Film (in case of RT) shall be clearly identified
with BSR or ASR based on the NDT performed before or after PWHT.
5. NDT performed for the bevel and the final joints shall be recorded
separately and shall be tracked.

6.2.6 Weld Selection for HT

6.2.6.1 Selected for HT Indicate Yes/No
Criteria for selection of HT shall be done as per applicable SAES-W-series.
6.2.7 NDT Control and Identification
Indicate the date the NDT Request was
6.2.7.1 Date of NDT Request
generated.

6.2.7.2 NDT Report Number This number, once assigned to a weld, shall
remain with weld until final acceptance.

©Saudi Aramco 2019. All rights reserved. Page 9 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

DATA ITEM COMMENTS AND CLARIFICATION

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 in paragraph 6.4 of this SAEP.
6.2.7.3 Date of NDT Completed Date of NDT Completed
Result of initial NDT Accept, Reject, or
6.2.7.4 Result of NDT
Reshoot.

6.2.8 Selection of Tracer Welds

Two tracer welds must be selected for each
rejected weld in a 10% RT system. The two
welds must have selected from the same lot
6.2.8.1 Selection of Tracer Welds defined in applicable SAES-W-series and
international standards. Selection of tracer
weld shall be done jointly by contractor QC
and PID.
Identify Original Rejected Identify the joint rejected which required
6.2.8.2
Weld tracer
Date and report number Date and report number of acceptance or
6.2.8.3
of NDT Result rejection
Note:
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. The result of tracer welds shall be
included in the calculation of Project Welding Rejection Rate as well as in the
welder performance.

6.2.9 Results of RT Film Evaluation by Saudi Aramco

RT Assessment Report
6.2.9.1 Number and date of Date and RT Assessment Report Number
assessment
Indicate the acceptance or rejection of film
quality. Rejection will require the reshoot of
6.2.9.2 Film Quality rejected film(s).
The weld identification number will have a
suffix added as described in 6.4 below.
Indicate the acceptance or rejection of weld
quality. Rejection will require weld repair(s)
and the reshoot of rejected weld or weld
6.2.9.3 Weld Quality
areas. The weld identification number will
have a suffix added as described 6.4 below
(Ref. SATR-W-2018).
6.2.10 Evaluation of other Completed Special Processes (CSP)
6.2.10.1 PWHT Process Indicate the date and report number of

©Saudi Aramco 2019. All rights reserved. Page 10 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

DATA ITEM COMMENTS AND CLARIFICATION

acceptance or rejection of the completed and
recorded PWHT.
Indicate the date and report number of
6.2.10.2 PMI Process acceptance or rejection of the completed and
recorded PMI for the weld.
Indicate the date and report number of
6.2.10.3 HT Process acceptance or rejection of the completed and
recorded HT.
Note:
Rejected CSP welds shall require modification of their original weld
identification numbers as stated in paragraph 6.4 of this SAEP.
Rejection will also require progressive sampling.

6.2.11 Retests for HT

If any reading exceeds the specified limit by
no more than 10 BHN; then, a minimum of
6.2.11.1 Status of HT-rejected test
three (3) additional indentations shall be
made near the original high reading.
Indicate acceptance or rejection of the
required 3 additional HT test on the same
weld. If all three (3) retests are below the
Progressive confirmation
6.2.11.2 specified limits; then, the joint is acceptable.
testing
If any of the retest readings are found to
exceed the specified limits; then, the weld
shall be considered unacceptable.
If any welds are found to be unacceptable;
then, two additional welds from the same lot
shall be tested.
6.2.11.3 Selection of Tracer Welds
If more than one weld in a lot is found to be
unacceptable; then, all welds in that lot shall
be tested.
Date and report number Date and report number of acceptance or
6.2.11.4
of NDT Result rejection

6.3 Offshore Structures Welding

The intent of this section is to identify the data tracking and reporting of Fixed
Offshore Platforms Production Welding, Welder Performance, NDE Tracking,
PWHT, and Hardness requirements in addition to other sections defined in this
procedure.

Contractor shall have a dedicated Electronic Data management system procedure

which explains the entire sequence of data reporting and tracking with defined roles
and responsibilities. Data management system procedure shall be submitted for
project inspection review and approval prior to start welding activities.

©Saudi Aramco 2019. All rights reserved. Page 11 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

Production welding of structural joints detail shall be properly gathered,

correlated, linked, reported, and stored in the database and Welding summary
sheet based on the Table-1 and Table-2 of SAES-W-013.

The following minimum data requirements of all structural welds for offshore
facilities fabrication or field-installation are required to be collected, linked, and
maintained for each weld. The acceptance or rejection of welds shall be
indicated as applicable. When different NDT technique is used in lieu of those
defined in weld inspection requirements, the tracking and reporting requirements
shall remain the same.

DATA ITEM COMMENTS AND CLARIFICATION

6.3.1 Design Drawing Number Design Information

6.3.2 Shop Drawing Number Contractor Design
6.3.3 Weld Joint Number Assign by Contractor
6.3.4 Component Category Design Information
6.3.5 Type of Joint Design Information
6.3.6 Bevel Type Design Information
6.3.7 Diameter or Size of Material Design Information
6.3.8 Wall Thickness Design Information
6.3.9 Material Class/Grade Design Information
Component Heat no. /
6.3.10 Plate no. / Pipe no. as Material Test Certificate (MTC’s)
applicable
Carbon Equivalent and
Material Test Certificate for Component
6.3.11 Material supply / Heat
Categories A-A and A-B
treatment conditions
Design Information – Indicate method (s) and
6.3.12 NDT Required
extent
Two tracer welds must be selected for each
rejected weld in a 10% RT/UT system.
The two welds must have been welded by the
same welder using the same welding process
from the same day production in which joint
was rejected, in case if there are no such
6.3.13 Tracer weld
welds; then, selection may extend to weekly
completed welds or from welds completed
after the last accepted weldment by the same
welder. Use the same NDT method as the
initial weld for evaluation. Selection of tracer
weld shall be done by Company Inspector.

©Saudi Aramco 2019. All rights reserved. Page 12 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

6.3.14 PWHT Required Yes/No

6.3.15 HT Yes/No
6.3.16 Weld Fit-up Inspection date Indicate date of inspection
Indicate approved welder or welders by
6.3.17 Welder Identification identification symbol(s) who are welding the
joint.
Indicate the approved WPS(s) used to weld
6.3.18 WPS Identification
the joint.
Indicate accept or reject per specified
6.3.19 Visual Inspection
acceptance criteria
6.3.20 Date of NDT Request Indicate the date of NDT Request.
This number, once assigned to a weld, shall
remain with weld until final acceptance.
Repeated NDT on a weld shall be indicated
6.3.21 NDT Report Number
by adding or modifying the NDT Report
Number suffix similar to that used for weld
repair as stated below.
6.3.22 Date of NDT Completed Indicate date of NDT
Result of initial NDT Accept, Reject, or
6.3.23 Result of NDT
Reshoot.
Date and report number of Date and report number of acceptance or
6.3.24
NDT Result rejection
Indicate the acceptance or rejection of film
quality. Rejection will require the reshoot of
rejected film(s). The weld identification
number shall have a suffix followed by weld
6.3.25 Film Quality number as defined below.
RS – Reshoot,
GRS – Grind and Reshoot,
CRS – Clean and Reshoot,
RSC – Confirmation Reshoot
Indicate the acceptance or rejection of weld
quality. Rejection will require weld repair(s)
6.3.26 Weld Quality
and the reshoot of rejected weld or weld
areas.
Notes:

1) Weld identification system shall be follow as per paragraph 6.2 of this procedure.
2) UT lamination check is mandatory to be performed before connecting incoming
member, manufacturer test cannot be considered as substitute for field lamination
check required by this procedure and it shall be reported in the data system.

6.4 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

©Saudi Aramco 2019. All rights reserved. Page 13 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

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.
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 requires repair.
W-01R2 Designation assigned to the weld joint that was rejected and
repaired for the second time. This refers to the second time that
the joint was repaired. No further 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 re-welded. The identification methodology above is to be
applied if further weld repairs are necessary.
W-01T1 Designation assigned to a previously welded joint that was
selected as the first Tracer Weld of the production weld rejected
by NDE. The tracers shall be selected accordance with the
applicable SAES-W-series.
W-01T2 Designation assigned to a previously welded joint that was
selected as the second Tracer Weld of the production weld
rejected by NDE. The tracers shall be selected accordance with
the applicable SAES-W-series.
Commentary Note:

Repairs on tracer welds will require further sampling in case any

tracer weld rejected. In that case, the progressive suffix
numbering shall be used.

W-01RS1 Designation assigned to a previously welded joint that was

selected for RT and was rejected due to Film Quality. The suffix
numbering system shall progress sequentially (e.g., RS1, RS2, etc.)
in case the same joint rejected due to film quality multiple times.
W-01CRS1 Designation assigned to a previously welded joint that was
selected for RT and was rejected due to presence of debris which
is covering the interested area and may require the joint to be
cleaned and re-shoot. The suffix numbering system shall
progress sequentially (e.g., CRS1, CRS2, etc.) in case the same
joint rejected due the same reason.

©Saudi Aramco 2019. All rights reserved. Page 14 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

W-01GRS1 Designation assigned to a previously welded joint that was selected

for RT and was rejected due to debris which are stuck to the area of
interest which may require grind and re-shoot. The suffix
numbering system shall progress sequentially (e.g., GRS1, GRS2,
etc.) in case the same joint rejected due the same reason.

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

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

6.4.2 Contractors/fabricators may propose alternative numbering systems for

approval by PQM. The identification system shall be used to identify all
examinations, surveys, inspections, etc.

6.5 Pipe welds are to be tracked and reported weekly 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 and initial
production joints of welders)
3) Number of welds rejected by each NDT method applied:
a) Number of repair joints repaired and accepted
b) Number of tracer welds selected and completed regardless of
acceptance or rejection.
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) Weld rejection rate by week for each NDT method (joint and linear basis)
for the weekly production.
9) Tracer weld reject rate percentage
10) Overall production weld rejection percentage

©Saudi Aramco 2019. All rights reserved. Page 15 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

11) 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.
12) Report actual backlogs:
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) Number of repairs outstanding
h) Initial production weld outstanding.
Note: A backlog exists when Special Process results are not received and
recorded within a project-specific time, usually seven (7) days for RT and
other conventional NDT methods after the welds have been visually
accepted. The backlog shall be calculated based on the weld date and
not NDT request date. Also, RT reshoot shall be considered part of the
RT backlog since the results are still unknown. For pipeline, the AUT
backlog shall be in accordance with SAES-W-012.

6.6 RT backlog shall be tracked by the contractor on a daily basis and reported to
Saudi Aramco on a weekly basis. Contractor shall consider all RT’D joints not
reviewed and or evaluated by both Contractors and Saudi Aramco RTFI as a RTFI
evaluation backlog. RTFI evaluation backlog shall be tracked by the contractor
separately from RT backlog and reported to Saudi Aramco on a weekly basis.
Contractor shall not consider RTFI backlog in their weekly WRR reporting.

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
rejection rate shall be calculated and reported on as per joint and linear basis.

7.2 The contractor shall track and report the following welder performance data:
1) Total number of pressure welds made per weld type (e.g., fillet, groove,
butt, socket, etc.)
2) Total number of pressure welds made per weld process (e.g., GTAW,
SMAW, SAW, etc.)
3) Total number of pressure welds rejected by NDT method
4) Total number of Rejections per type of repairs.

©Saudi Aramco 2019. All rights reserved. Page 16 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

5) Category of the welders in line with SAEP-324

6) The revoked welders
7) In addition to above, for Offshore Structures:
a) Total number of Structural welds made per each weld type
(e.g., Fillet, Groove, Butt, TKY, etc.)
b) Total number of Structural welds rejected by NDT method
c) Total number of Structural welds made by each welding process

7.3 Reporting – Minimum Requirements

7.3.1 Reporting format shall follow the weld identification scheme as stated in
paragraph 6.4.

7.3.2 Paragraph 6.5 lists the minimum requirements that shall be included in
the weld tracking and welder performance report submitted to Saudi
Aramco each week.

7.4 Determining welder performance shall be done in accordance with SAEP-324.

8 Guidelines for the Use SATIPS and SAICS

8.1 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.

8.2 Use of Welding and NDT SAICS

8.2.1 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.

8.2.2 Special welding activities such as branch connections, tie-ins, sleeve

installation, hot-tap welding, and temperature tie-ins will require a
separate RFI per weld per activity in accordance with the applicable
SATIP.

8.2.3 NDT subcontractors through its contractor must complete NDT

Checklists on a daily basis per above but not as an RFI with the
exception of the start of NDT activities.

©Saudi Aramco 2019. All rights reserved. Page 17 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

Revision Summary
2 August 2016 Revised the “Next Planned Update.” Reaffirmed the contents of the document,
and reissued with editorial revision to transfer this document from Inspection
Engineering to Project Quality Standards Committee (PQSC) with the following
justifications: (1) This document falls under the charter of PQSC; (2) The
transfer was agreed between IESC and PQSC; and (3) IESC has no
interaction with the review of this document.
18 August 2019 Major revision. Introduced a systematic approach to collect, link and maintain
the minimum welding data associated with in-Kingdom or Out-of-Kingdom
construction project sites and fabrication Shops/Yards. Also, Introduced data
collection and evaluation for the received loose materials to the project and
offshore structural fabrication and installation. The detailed changes are
shown below:

Summary of Change Form (rev. 18 August 2019)

Paragraph Change Type
No. Technical Change(s)
Number (New, Modification,..)
1 1 Modification Scope modified to include both in-Kingdom and Out-
of-Kingdom construction project sites and fabrication
Shops/Yards.
2 3 Modification Added standards applicable for offshore platform
fabrication and welding such as SAES-W-013,
SAES-W-016, SAES-M-005, SAES-L-850,
12-SAMSS-018, 12-SAMSS-007 API RP 2A WSD,
and AWS D1.1. Additionally, SAEP-122,
32-SAMSS-005, 32-SAMSS-018, and GI-0002.710.
3 4 Modification Title changed from Abbreviations to Definitions and
Acronyms
4 4 New Below definitions introduced to support the modified
scope:
Fabrication Shop: A facility with a controlled
environment used for the fabrication and/or assembly
of equipment and structures such as pipe spools,
pressure vessel, etc. Controlled environment refers to
atmospheric weather condition, established quality
system, and welder’s accessibility to welds joints.
Fabrication Yard: A large open outdoor area used
for the fabrication and/or assembly of very large
structures such as offshore platforms, etc.
Manufacturer’s Fabrication Facility: A facility
engaged in fabrication of assembled or sub-assembled
products under a Purchase Order and monitored by
Vendor Inspection.

©Saudi Aramco 2019. All rights reserved. Page 18 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

Summary of Change Form (rev. 18 August 2019)

Paragraph Change Type
No. Technical Change(s)
Number (New, Modification,..)
Maintenance Project: A project to perform
maintenance work under a short form contract with the
maintenance department as the proponent.
5 4 New Added Acronyms for ASR, BSR, AUT, EPM, MUT,
PAUT, RFI, RTFI, WRR.
6 5.1 Modification The contractor's data management and tracking system
must be approved by Saudi Aramco Project Inspection
Supervisor prior to the start of any welding activities.
7 5.1.1 New Contractor shall provide required demonstration and
training to the selected PID personnel about their data
management and tracking system.
8 5.5 & 5.7 New Added the requirement of NDT to establish in the
project and offshore structures by Designer and
approved by Area Project Inspection
9 5.6 Modification Three months prior starting welding activities,
contractor shall sign an agreement with NDT company
to conduct required NDE during project construction
in order to avoid NDT backlog. The NDT Procedures
and Technicians resumes shall be submitted to for
Company approval according to Schedule Q.
10 6 Modification Title changed from “Production Welding” to “Data
Management and Tracking System”.
11 6 Modification Added numbering for each data to be collected.
12 6.1 New Contractor shall track and maintain the material
receiving data of fabrication materials like pipes,
flanges, fittings, etc., procured from manufacturer and
stockiest.
13 6.2 Modification Paragraph 6.1 in the previous version:
No major changes. Re-arranged the list of data to be
collected based on the sequence of activities during
fabrication.
• Few notes added for better clarifications
14 6.3 New Introduced, minimum data requirements required to be
collected, linked, and maintained for all structural
welds for offshore facilities fabrication or field-
installation for each weld.
15 6.4 Modification Paragraph 6.2 in previous version:
W-01T1 Designation assigned to a previously welded
joint that was selected as the first Tracer Weld of the
production weld rejected by NDE. Generally, the first
tracer Weld shall be the weld joint completed by the

©Saudi Aramco 2019. All rights reserved. Page 19 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

Summary of Change Form (rev. 18 August 2019)

Paragraph Change Type
No. Technical Change(s)
Number (New, Modification,..)
welder before the rejected weld joint. The tracers shall
be selected accordance with the applicable SAES-W-
series.
W-01T2 Designation assigned to a previously welded
joint that was selected as the second Tracer Weld of
the production weld rejected by NDE. Generally, the
second tracer Weld shall be the weld joint completed
by the welder immediately after the rejected weld
joint. The tracers shall be selected accordance with the
applicable SAES-W-series.
Commentary Note:
Repairs on tracer welds will require further sampling in
case any tracer weld rejected. In that case the suffix
numbering system shall progress accordingly.
16 6.4 New W-01RS1 Designation assigned to a previously
welded joint that was selected for RT and was rejected
due to Film Quality. The suffix numbering system
shall progress sequentially (e.g., RS1, RS2, etc.) in
case the same joint rejected due to film Quality
multiple times.
W-01CRS1 Designation assigned to a previously
welded joint that was selected for RT and was rejected
due to presence of debris which is covering the
interested area and may require the joint to be cleaned
and re-shoot. The suffix numbering system shall
progress sequentially (e.g., CRS1, CRS2, etc.) in case
the same joint rejected due the same reason.
W-01GRS1 Designation assigned to a previously
welded joint that was selected for RT and was rejected
due to debris which are stuck to the area of interest
which may require grind and re-shoot. The suffix
numbering system shall progress sequentially (e.g.,
GRS1, GRS2, etc.) in case the same joint rejected due
the same reason.
17 6.5 Modification Paragraph 6.2 in previous version:
The note for the clarification of the backlog is
modified as below:
A backlog exists when Special Process results are not
received and recorded within a project-specific time,

©Saudi Aramco 2019. All rights reserved. Page 20 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

Summary of Change Form (rev. 18 August 2019)

Paragraph Change Type
No. Technical Change(s)
Number (New, Modification,..)
usually seven (7) days for RT and other conventional
NDT methods after the welds have been visually
accepted. The backlog shall be calculated based on the
weld date and not NDT request date. Also, RT reshoot
shall be considered part of the RT backlog since the
results are still unknown. For pipeline, the AUT
backlog shall be in accordance with SAES-W-012.
18 7.2 Modification The contractor shall track and report the following
welder performance data:
1. Total number of pressure welds made per weld
type (e.g., fillet, groove, butt, socket, etc.)
2. Total number of pressure welds made per weld
process (e.g., GTAW, SMAW, SAW, etc.)
3. Total number of pressure welds rejected by NDT
method
4. Total number of Rejections per type of repairs.
5. Category of the welders in line with SAEP-324
6. The revoked welders
7. For Offshore Structures:
a) Total number of Structural welds made per
each weld type (e.g., Fillet, Groove, Butt,
TKY, etc.)
b) Total number of Structural welds rejected by
NDT method
c) Total number of Structural welds made by
each welding process
19 7.4 Modification Editorial change:
Determining welder performance shall be done in
accordance with SAEP-324.
20 Appendix A New / Modification Paragraph 6.3 in previous version: Contents of Hydro
Test packages:
• Introduced New Appendix with minimum required
documentations to be included in the Pressure test
package. The list is consolidated from different
Company standards and GI’s (SAES-A-004,
SAEP-1160, and GI-0002.102).
• Also, added minimum information to be included
in the Weld Summary Sheet which is one of the
document to be included in the pressure test
package.

©Saudi Aramco 2019. All rights reserved. Page 21 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

Appendix A - Contents of Pressure test packages

A.1 For each pressure test, the Contractor shall submit a Pressure Test Package to Saudi
Aramco containing minimum but not limited to the following:
1) Reference the “Approved” Pressure Test Procedure
2) Cover page with essential information’s about the test package such as; System
and/or Sub-System, Fluid Description, Test Package No., Service, Test Type
(Hydrostatic, Pneumatic, Visual), Test Medium, Test Pressure, Line Class, method
of Internal Lining, Lay-up Method, etc.
3) Test Package Flow Chart with signature blocks (SAIC-A-2003 Attachment 2).
4) Pressure Test Diagram which shall include the limits of piping (including test
manifold) and equipment included in each pressure test, high points (vents), low
points (drains), locations of pressure gauges, test pressures, test temperature, test
fluid, and position of in-line valve.
5) Relief valve capacity, testing, and installation
6) Pressure gauges and recorders calibration records
7) COMPANY Safety Instruction Sheet (for critical piping and pressure vessels) and
Pressure Test Report Form
8) Test diagram legend sheet
9) Copies of marked up P&ID and isometric drawings showing test limits of the
piping system to be pressure tested with identified components to be removed
during pressure testing.
10) Plot Plan showing testing location.
11) Applicable piping support drawings.
12) Weld map and Weld Summary Sheet containing information as per paragraph 8.2
of this SAEP for the system to be pressure tested.
13) Visual and NDT inspection reports for the orifice flange (root penetration) report if
applicable.
14) Field valve test report (if applicable).
15) Pre-pressure test check List
16) Re-instatement procedure and Check List
17) Flange Joint, Gasket Verification inspection and bolt torque reports for permanent
installations of flange joints.
18) Identification of pressure testing SPC from contractor

©Saudi Aramco 2019. All rights reserved. Page 22 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

19) Lay-up method to be applied

20) Verification of chemical dosing calculations when applicable
21) Test manifold hydro test verification
22) Internal cleaning requirements and report
23) Punch list (remaining works)
24) Certificate of test medium/water
25) For pneumatic testing:
a) Evidence of test procedure approval
b) Calculation for safe exclusion zone

A.2 Contractor shall maintain a tracking sheet to track the status of the test packs and shall
be submitted to Company on weekly basis. This tracking sheet content shall be agreed
with Project Inspection Supervisor, but shall contain following as minimum:
1) Pre-commissioning system/subsystem
2) Test pack number
3) Test pressure, test medium
4) Internal Cleaning Date and RFI number
5) Hydrotest Date and RFI number
6) Dewatering Date and RFI number
7) Lay-up Date and RFI number
8) Reinstatement Date and RFI number

A3. Weld Summary Sheet shall contain a minimum but not limited to following data:
1) The test pack number
2) Line Information such as Isometric number with its revision, size, thickness, Weld
Joint number, weld type (i.e., Butt weld, Fillet, etc.), weld cat (Shop, Field), Piping
Class
3) Type of materials used with Heat number of each component
4) Weld Joint history (the joint and the applied NDT shall be reflected even the joint
is repaired or cut and re-welded)
5) Report and date of Fit-up inspection
6) Report and date of Visual inspection
7) Welder number for each pass
8) WPS used
9) NDT request Number or status whether particular joint is requested for any NDT

©Saudi Aramco 2019. All rights reserved. Page 23 of 24

Saudi Aramco: Company General Use

 Document Responsibility: Project Quality Standards Committee SAEP-1160
Issue Date: 18 August 2019 Tracking and Reporting of Welding,
Next Planned Update: 18 August 2024 NDT, and Pressure Testing for Capital Projects

10) Report number, date of test and Result of all the NDT (RT/AUT, MPI/PT), PWHT,
Hardness test, PMI, and Ferrite Test performed.
Commentary Note:

Weld summary shall be generated automatically from Contractor’s system and shall
show pending NDT and activities in order to ensure the test pack got release for
testing without completing the requested NDTs.

©Saudi Aramco 2019. All rights reserved. Page 24 of 24

Saudi Aramco: Company General Use