Engineering Procedure

SAEP-1105 13 July 2014

Welding Test Supplement S05
for SMAW, Nickel, Single Sided
Document Responsibility: Inspection Engineering Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................ 2
2 Applicable Documents................................... 2
3 Instructions.................................................... 2

Previous Issue: 26 April 2009 Next Planned Update: 13 July 2019

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Primary contact: Kakpovbia, Anthony E. on 966-13-8801772

Copyright©Saudi Aramco 2014. All rights reserved.

Document Responsibility: Inspection Engineering Standards Committee SAEP-1105
Issue Date: 13 July 2014 Welding Test Supplement S05
Next Planned Update: 13 July 2019 for SMAW, Nickel, Single Sided

1 Scope

This welder performance qualification Test Supplement shall govern the testing of
welders with the Shielded Metal Arc Welding (SMAW) process, welding progression
vertical up, for welding nickel-based alloy pipe (limited application - refer to the
restrictions in paragraph 3.4).

2 Applicable Documents

The requirements contained in the following documents apply to the extent specified in
this procedure.

2.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-321 Performance Qualification Testing and
Certification of Saudi Aramco Welders
SAEP-1101 Welding Test Supplement S01 for SMAW, Carbon
and Low Alloy Steel Pipe, Uphill

2.2 Industry Code(s) and Standards(s)

American Society of Mechanical Engineers

ASME SEC IX Qualification Standard for Welding and Brazing
Procedures, Welders, Brazers, and Welding
and Brazing Operators

3 Instructions

Conduct the Performance qualification testing of welders following the requirements of

SAEP-321 as supplemented by the subsequent instructions.

3.1 Applications

Piping Yes *
Pipelines Yes *
Pressure Vessels Yes *
Tanks Yes *
Structural Yes *
Dissimilar Metals Yes *
CRWMO Yes *
* See restrictions in paragraph 3.9.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1105
Issue Date: 13 July 2014 Welding Test Supplement S05
Next Planned Update: 13 July 2019 for SMAW, Nickel, Single Sided

3.2 Testing and Inspection Requirements

Time Limit of Test Two (2) hours maximum

Radiography 100% (ASME QW-191)
Visual Inspection See paragraph 6.1.3 of SAEP-321

3.3 Qualification Limits

Material Form Plate or pipe

Joint Type Groove welds with backing and fillet welds

Base Material Nickel alloys (P4X) to themselves and to carbon

steels. Dissimilar metal welds include: Ni-based
alloys to carbon steels, low alloy steels, stainless
steels, nickel and monel alloys; monel alloys
joined to carbon steels; nickel joined to stainless
steels; stainless steels to carbon steels.

Process SMAW

Filler Metal Ni-based (A5.11)

Base Metal Thickness Unlimited

Diameter Range 2.5" NPS and greater

Positions All

Vertical Progression Uphill

3.4 Restrictions

A) Piping - root pass welding is only permitted:

1) when the backside of the root is accessible for back grinding and
back welding, or

2) when the piping to be welded is a gravity drain, or a vent operating at

atmospheric pressure.

B) Pipelines - nickel-based SMAW welding electrodes shall not be used for

root pass welding when welding stainless steel fittings (i.e., COSASCO
fittings) to pipelines (root pass welds must be made with the GTAW
process which requires a Test Supplement S08 certification).

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1105
Issue Date: 13 July 2014 Welding Test Supplement S05
Next Planned Update: 13 July 2019 for SMAW, Nickel, Single Sided

C) Pressure Vessels and Tanks - limited to single sided full penetration welds
with backing, double sided full penetration welds (second side back
gouged or back ground to sound metal prior to welding), fillet welds and
CRWMO welding [see (E) below].

D) Dissimilar Metal Welding (Piping, Pressure Vessels, Tanks, Pipelines) -

nickel-based electrodes shall be used to weld ferritic steels to austenitic
stainless steels, duplex stainless steels, and nickel based alloys.

E) Corrosion-Resistant Weld Metal Overlay - welders with valid

certifications can be allowed to perform corrosion-resistant overlay
welding provided a CRWMO Ability Performance Test is performed and
passed (refer to Section 6.5.1 of SAEP-321).

Revision Summary
13 July 2014 Major revision.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1105
Issue Date: 13 July 2014 Welding Test Supplement S05
Next Planned Update: 13 July 2019 for SMAW, Nickel, Single Sided

WPS S05
WELDING PROCEDURE Rev. 0
SPECIFICATION (WPS)
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Procedure Qualification Record (PQR): None Welding Process: SMAW, manual

Scope: For welder qualification only Prior Qualification Requirement: None

BASE MATERIAL (QW-403) POST WELD HEAT TREATMENT (QW-407)

Test coupon type: Pipe Temperature: None
Material Spec, type or Grade:Nickel based Alloy (P43)
Diameter of test coupon: 2" NPS and Greater Time:
Thickness of test coupon: Unlimited Other:
To Material spec. type or grade:Nickel based Alloy
(P43)
Tack Welds: Four (4) made by the welder and
incorporated into the root pass
FILLER METALS (QW-404) GAS (QW-408)
Weld Metal Analysis Number: NA Gas Composite Flow (CFH)
Filler Metal F No.: F 43 Shielding NONE
AWS specification: A 5.11 Backing NONE
AWS Classification: ENiCrFe-3
Trailing
POSITION (QW-405) TECHNIQUE
Position of Groove: 6G String or weave: Stringer or Weave
Weld Progression: Uphill Oscillation:No more than 3 times the electrode size.
PREHEAT (QW 406) Multiple or Single pass per side: Multiple
Preheat Temperature: 10°C Single or multiple electrode: Single
Interpass temperature: 177°C Other:
Other:

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1105
Issue Date: 13 July 2014 Welding Test Supplement S05
Next Planned Update: 13 July 2019 for SMAW, Nickel, Single Sided

WPS S05
WELDING PROCEDURE Rev. 0
SPECIFICATION (WPS)
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Joint Design: Single Vee

A = 30° ± 2.5°
B = 1.6 ± 0.8 mm
C = 3.2 ± 0.8 mm

FILLER METAL CURRENT

TRAVELSPEED
WELD LAYER PROCESS Dia. VOLTAGE
Class Polarity Amps. (cm/min)
(mm)
Root SMAW ENiCrFe-3 3.2/4.0 DCEP 80-140 19-25 3.8-8.9
Hot SMAW ENiCrFe-3 3.2/4.0 DCEP 70-100 19-25 3.8-10.2
Fill SMAW ENiCrFe-3 3.2/4.0 DCEP 90-160 22-28 3.8-14
Cap SMAW ENiCrFe-3 3.2/4.0 DCEP 90-160 22-28 5.0-15.2

Comments:

1. The welding parameters shall be monitored during performance welding to ensure full
compliance with above parameters.

2. When more than one filler metal F-Number is used to deposit weld metal in a coupon, the
thickness, t, of the weld metal in the coupon deposited by the welder of each filler metal F-
Number shall be determined and used individually to define the “Thickness of Weld Metal
Qualified.”

3. All qualification testing and qualified ranges of diameters and thickness shall be made in
accordance with ASME Sec IX requirements.

4. Fillet Welds are qualified when a welder/welding operator qualifies on a groove weld test.

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Document Responsibility: Inspection Engineering Standards Committee SAEP-1105
Issue Date: 13 July 2014 Welding Test Supplement S05
Next Planned Update: 13 July 2019 for SMAW, Nickel, Single Sided

5. Additional filler metal listing:

Base Metal Filler Metal

Avesta 254 SMO ENiCrMo-3
Monel ENiCu-7
Alloy 20 ENiCrMo-3
Hastelloy C22/C276 ENiCrMo-4
Hastelloy B2 ENiMo-1
Alloy 600 ENiCrFe-3

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