Yanbu Export Refinery Project

PROJECT PROCEDURE MANUAL (PPM)

YERP-SAEP-324, Certification Review and Registration of Project Welders and Brazers
Document No.: 100-YER-PM-PPM-0550
Revision No.: 0 Issue Date: 31 July 2007

PREFACE

This procedure is a revision or an overlay to a Saudi Aramco Engineering Procedure,

SAEP for the scope of the Yanbu Export Refinery Project, YERP, unless specifically
defined as a New document. A YERP specification consists of a revision or an
overlay and the Saudi Aramco (SA) document with the same name. An overlay
establishes any required changes to the SA document and specifically defines the
changes. If the SA document is to be used without any changes the overlay will
state there are no changes required. If the document is a new YERP document, with
no reference to a SA standard, the overlay will state it.

The YERP Procedure Index identifies which YERP documents are new and the ones
that relate to SA documents that are unchanged, changed, or deleted.

All references to SA procedures, specifications and standards are to be defined as

references to YERP procedures, specifications and standards unless specifically
stated otherwise in the overlay.

All references to SA organizations are to be defined as the YERP Management

Team.

Interpret the following as specified:

• Revise – A specific revision to a SA or other Code paragraph or sentence as
noted in this specification
• Add – continuation of an SA or other Code paragraph with an overlay
requirement
• Substitute – replace the SA or other Code paragraph in entirety by the overlay
requirement
• New – New paragraph number in the overlay with no corresponding SA or other
Code paragraph
• Delete – SA or other Code paragraph is deleted by the overlay

REVISION
This overlay is a revision to Saudi Aramco Engineering Procedure, SAEP-324,
Certification Review and Registration of Project Welders and Brazers, 30 June,
2003.
The following sections and paragraph numbers match that of the SA document of the
same name unless noted as new.
ATTACHMENT
SAEP-324, dated 30 June, 2003.

General Business Confidential

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 Yanbu Export Refinery Project
PROJECT PROCEDURE MANUAL (PPM)
YERP-SAEP-324, Certification Review and Registration of Project Welders and Brazers
Document No.: 100-YER-PM-PPM-0550
Revision No.: 0 Issue Date: 31 July 2007

2 Conflicts and Deviations

(New) Direct all requests to deviate from this specification in writing to the
YERP PMT who shall follow internal project procedure YERP-SAEP-302.

3.1 (Revise) Delete reference “Saudi Aramco Forms, SA 4758-ENG, Job Clearance
Card”.

4 Definitions and Acronyms

(Revise) Delete (Form SA 4758-ENG) after JCC: Job Clearance Card

5.1 (Revise) The Project Inspector is responsible for:

5.2 (Delete)

5.3 (Substitute) The Contractor is responsible for tracking all withdrawn JCC’s for the
duration of their contract.

6.5.1 (Revise) Delete (Form SA 4758-ENG)

General Business Confidential

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Engineering Procedure
SAEP-324 30 June, 2003
Certification Review and Registration
of Project Welders and Brazers
Document Responsibility: Inspection Department

Saudi Aramco DeskTop Standards

Table of Contents

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

Previous Issue: 31 January, 2000 Next Planned Update: 1 July, 2008

Revised paragraphs are indicated in the right margin Page 1 of 8
Primary contact: Supervisor, IEU on 874-6604
Document Responsibility: Inspection Department SAEP-324
Issue Date: 30 June, 2003 Certification Review and Registration
Next Planned Update: 1 July, 2008 of Proj ec t W e lder s and Br a zer s

1 Scope

1.1 This Engineering Procedure specifies the minimum requirements for

certification review and registration of contractor welders and brazers working
on In-Kingdom construction, fabrication and Maintenance projects.

1.2 Unless specifically noted otherwise the term welder shall also mean welding
operator or brazer.

2 Conflicts and Deviations

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

3 Applicable Documents

Unless stated otherwise, all codes and standards referenced shall be the latest issue
(including Revisions and Addenda). When industry codes and standards, or Saudi
Aramco standards are required for use by project specification they shall become a part
of this Engineering Procedure.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-321 Performance Qualification Testing and
Certification of Saudi Aramco Welders
SAEP-322 Performance Qualification Testing and
Certification of Saudi Aramco Brazers

Saudi Aramco Engineering Standard

SAES-W-013 Welding Requirements for Offshore Structures

Saudi Aramco Forms

SA 4758-ENG Job Clearance Card

3.2 Industry Codes and Standards

American Petroleum Institute

API STD 1104 Welding of Pipelines & Related Facilities

American Society of Mechanical Engineers/Boiler & Pressure Vessels Code

ASME SEC IIC Welding Rods, Electrodes and Filler Metals

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Document Responsibility: Inspection Department SAEP-324
Issue Date: 30 June, 2003 Certification Review and Registration
Next Planned Update: 1 July, 2008 of Proj ec t W e lder s and Br a zer s

ASME SEC V Nondestructive Examination

ASME SEC IX Welding and Brazing Qualifications

American Welding Association

AWS D1.1 Structural Welding Code - Steel

4 Definitions and Acronyms

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

Contractor Welder: A welder working directly for, and under the supervision of, a
contractor.

Fabrication Shop: A building used for the fabrication and/or assembly of equipment
and structures such as pipe spools, pressure vessels, etc.

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

Field Fabrication Shop: A temporary fabrication shop set up in the field near a
construction project by a contractor to fabricate piping, fittings and/or structural
components.

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

Job Clearance Card (JCC): A identification card issued by Saudi Aramco Inspection
to contractor welders registered on field fabrication projects. The JCC lists
certifications held, description of the job, and the welders name and symbol.

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

contract with the Maintenance Department as the proponent.

OIU: Operations Inspection Unit.

Qualification: See preferred term Welder Performance Qualification.

Qualification Card: A photo identity card issued by a welder testing agency or

contractor to a welder passing a certification test that lists all the certifications held by
the welder. Qualification Cards must be carried at all times by the welder, and must be
presented for review upon request.

Qualified Welder: See preferred term Certified Welder.

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Document Responsibility: Inspection Department SAEP-324
Issue Date: 30 June, 2003 Certification Review and Registration
Next Planned Update: 1 July, 2008 of Proj ec t W e lder s and Br a zer s

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

acceptable, and is on file with the project inspector.

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

thereof. Registration is performed after certification review and approval. Current lists
of approved welders and/or Job Clearance Cards are examples of registration.

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

Unqualified Welder: See preferred term Uncertified Welder.

Welder Certification: Certification in writing 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.

WPS: Welding Procedure Specification.

WTC: Welder Test Center.

WTS: Welder Tracking System.

5 Responsibilities

5.1 The Project Inspector or is responsible for:

a) Reviewing contractor welder certifications prior to the start of welding;

b) Registering contractor welders with valid welder certifications;

c) Monitoring the initial production work of contract welders to determine

their ability to make sound welds.

d) Monitoring the contractors quality control program to ensure contractor

welder certifications are being maintained in accordance with the
governing codes and standards of the job or project.

e) Issuing and controlling Job Clearance Cards on the job.

Commentary Note:

If inspection of small, single job maintenance contracts or other non BI/JO

work is handled by OIU, OIU Inspector is responsible for the above.

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Document Responsibility: Inspection Department SAEP-324
Issue Date: 30 June, 2003 Certification Review and Registration
Next Planned Update: 1 July, 2008 of Proj ec t W e lder s and Br a zer s

5.2 The Welder Test Center is responsible for the testing of contractor welders when
there is insufficient time for the contractor to have welders tested by an
independent welder testing agency (only applies to Maintenance projects).

5.3 The Welder Tracking System Administrator is responsible for tracking all
withdrawn JCC's for a period of at least three years.

6 Instructions

6.1 General Requirements

6.1.1 Contractors, fabricators and vendors are responsible for the testing and
certification of welders working under their supervision in accordance
with the governing Codes, standards, and or specifications of each
project.

6.1.2 The project inspector shall have the right to require the removal or retest
of any welder at any time due to unsatisfactory work.

6.1.3 Performance qualification testing of welders strictly for tack welding is

prohibited.

6.1.4 For SMAW performance qualification testing welders shall be qualified

for all passes and the full thickness of the test coupon.

6.2 Field Fabrication Work

6.2.1 Contractor welders shall be tested in accordance with either ASME SEC
IX, AWS D1.1, or API STD 1104 as required, for all types of welding
(includes tack, repair and temporary).

6.2.2 Contractor welders working on In Kingdom field construction projects

(includes field fabrication shops also) shall be tested and certified by an
independent welder testing agency approved by the Saudi Aramco
Inspection Department prior to the start of work. Established contractors
and fabricators with extensive experience and a proven ability in welder
testing shall be permitted to test their own welders through written
approval of the Saudi Aramco Inspection Department.

6.2.3 Certifications of contractor welders shall be reviewed by the project

inspector prior to the start of work.

6.2.4 Contractor welders that have not been properly certified shall not be
permitted to weld.

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Document Responsibility: Inspection Department SAEP-324
Issue Date: 30 June, 2003 Certification Review and Registration
Next Planned Update: 1 July, 2008 of Proj ec t W e lder s and Br a zer s

6.2.5 All properly certified contractor welders shall be registered by the

project inspector and issued a Job Clearance Card (JCC) prior to the start
of work.

6.2.6 The initial production work of contractor welders shall be monitored by

the project inspector to determine their ability to make sound welds.

6.2.7 The project inspector shall monitor the contractors quality control
program to determine whether contractor welder certifications are being
maintained in accordance with the governing Codes and standards of the
job or project. Contractor welders that do not maintain valid
certifications shall have their JCC withdrawn. Once withdrawn, JCC's
will only be reinstated upon receipt of written proof of training, and the
successful completion of a recertification test. All withdrawn JCC's shall
be sent to the WTS Administrator for tracking, where they will be kept
on file for a period of at least three years.

6.2.8 For offshore pipelines and structures all welders welding primary joints
(refer to SAES-W-013, Table 4, Note 7) shall be requalified if the
original performance qualification test was not witnessed by a third party
inspection agency. Requalification testing shall be witnessed by a third
party inspection agency or the project inspector.

6.2.9 For offshore pipelines and structures all welders welding joints other
than primary joints shall be retested on a 10% random basis, as selected
by the project inspector unless the original performance qualification test
was witnessed by a third party welder testing agency. Requalification
testing shall be witnessed by a third party inspection agency or project
inspector. If the requalification failure rate exceeds 20%, all welders
shall be retested.

6.3 Fabrication Yard Work

6.3.1 The fabricator shall maintain a welder identification system acceptable to

the project inspector. Welders shall carry an identification card that
includes a photo, welders name, company identification number, and
welders symbol.

6.3.2 A list of all welders shall be submitted to the project inspector prior to
the start of work. This list shall be maintained up to date by the
fabricator. The list shall include the welders name, symbol, processes
qualified and all other important essential variables as well as
certification issue dates.

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Document Responsibility: Inspection Department SAEP-324
Issue Date: 30 June, 2003 Certification Review and Registration
Next Planned Update: 1 July, 2008 of Proj ec t W e lder s and Br a zer s

6.3.3 The project inspector shall audit welder certifications to ensure fabricator
compliance with the Codes, standards and approved Quality Plan.

6.4 Maintenance Projects

6.4.1 Contractor welders working on small single job Maintenance projects

(short form contracts) shall be properly certified by a Saudi Aramco
approved In-Kingdom independent welder testing agency prior to the
start of work.

6.4.2 Certifications shall be submitted to the project inspector prior to the start
of work for review. Contractor welders with acceptable certifications
shall be registered by the project inspector.

6.4.3 Welders that are not properly certified shall not be registered and shall
not be permitted to work.

6.4.4 For critical work, where time is of the essence, contractor welders may be
tested by the Welder Testing Center in accordance with either SAEP-321
(or SAEP-322 if required) in lieu of testing by an independent third party
welder testing agency(except that retests are not permitted). This is not
intended to be used as a substitute for proper planning by the proponent
organization and shall only be permitted when there are no other feasible
options. Upon completion of testing the WTC shall issue a letter to the
proponent inspection authority summarizing the results of the testing.

6.5 Job Clearance Cards (JCC)

6.5.1 Contractor welders working on field fabrication projects such as BI and

JO work, and who are properly certified, shall be registered and issued a
Job Clearance Card (Form SA 4758-ENG) by the project inspector prior
to the start of work.

6.5.2 The issuance of Job Clearance Cards to contractor welders on small,

single job maintenance contracts or other non BI/JO work, is optional
and shall be determined by the project inspector.

6.5.3 Job Clearance Cards are only valid for the job or project for which they
are issued.

6.5.4 Job Clearance Cards can be withdrawn by the project inspector at any
time for cause if the contractor welder is not producing work of
acceptable quality. Once withdrawn, JCC's will only be reinstated upon
receipt of written proof of training, and the successful completion of a
recertification test.

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Document Responsibility: Inspection Department SAEP-324
Issue Date: 30 June, 2003 Certification Review and Registration
Next Planned Update: 1 July, 2008 of Proj ec t W e lder s and Br a zer s

6.5.5 Job Clearance Cards shall be returned to the project inspector when the
contractor welder goes on home leave or is terminated from the project.
Contractor welders that return to work within three months from home
leave (to the same project) may be reinstated without retesting.

Revision Summary
30 June, 2003 Revised the "Next Planned Update. Reaffirmed the contents of the document, and reissued
with editorial changes.

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