Inspect Hot Tap Installation: Saudi Aramco

Saudi Aramco
Inspection Department
Training & Contractor Workforce Saudization Group
INSPECT HOT TAP

INSTALLATION
PEW-403.02
The training materials contained in this module are the property of the Saudi Arabian Oil Company (Saudi Aramco) and
are intended for the exclusive use of Saudi Aramco employees enrolled in advanced inspection training courses. Any
material contained in this manual which is not already in the public domain, may not be copied, reproduced, sold, given or
disclosed to third parties or otherwise used, in whole or in part, for purposes other than for use in Saudi Aramco’s
Professional Engineering Development Unit courses without the prior written permission of the Chief Engineer of Saudi
Aramco.
PEW-403.02 PARTICIPANT REVISION
DATE REVISION DESCRIPTION PAGE(S) AFFECTED
12/06/04 COMPLETE REVISION ALL

S.U. BASHA, S. CAVE, M. AKKAD
i
PEW-403.02 PARTICIPANT OBJECTIVES
MODULE COMPONENT PAGE
OBJECTIVES 1
Terminal Objective 1
Enabling Objectives 1
INTRODUCTION 2
Scope 2
PERFORM PRE-INSPECTION DOCUMENT REVIEW 3
Review Job file 3
WPS/PQR/Weld Map 3
Welder Qualification Record 4
Safety Instruction Sheet (SIS) 4
S. A. Form 7627 (Hot-tap/Stopple & Reinforcement Calculation Request) 6
Project drawings 7
Checklists 8
PERFORM PRE-WELDING FIELD INSPECTION 9
Thickness Measurements (UT) 9
Repair Materials 11
Verification of Line Pressure 11
Proper Fit-Up of Components 12
PERFORM INSPECTION OF HOT TAP INSTALLATION 15
Appearance of the Weld Profile 15
Completed Weld of a Hot-Tap Sticker 16
Weld in Progress-Hot-Tap Reinforcement Pad 16
WITNESS TESTING OF HOT-TAP FIELD WELDS 20
Hydrotest Hot-Tap Sticker and Valve 20
Valve Body and Seat Test 20
Branch Connection Test 20
Reinforcing Pad or Ring Test 21
Tightness Test 21
High Pressure Closure Test 21
Test with Hot-Tap Machine Installed 21
NDT Test of Boss Plug Weld 21
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Analyze a Coupon Removed in a Hot-Tap Procedure 22

EXERCISE 1. REVIEW JOB FILE DATA 23
EXERCISE 2. REVIEW JOB FILE SIS AND WPS DATA 26
EXERCISE 3. PERFORM PRE-WELDING PROCEDURES 28
EXERCISE 4. PERFORM PRE-WELDING PROCEDURES 30
EXERCISE 5. INSPECT FIELD HOT TAP WELDS 32
EXERCISE 6. INSPECT FIELD HOT TAP WELDS 34
EXERCISE 7. WITNESS TESTING OF HOT TAP FIELD WELDS 35
EXERCISE 7. WITNESS TESTING OF HOT TAP FIELD WELDS 36
EXERCISE 8. PREPARE FINAL INSPECTION REPORT 37
WORK AID 1. CHECKLIST OF JOB FILE DOCUMENTS 41
WORK AID 2. HOW TO LOCATE MATERIALS STANDARDS FOR MATERIALS
USED IN A HOT-TAP 42
WORK AID 3. HOW TO LOCATE INFORMATION IN THE WPS 43
WORK AID 4. HOW TO COMPARE U.T. READINGS WITH SIS DATA 44
WORK AID 5. HOW TO COMPARE LINE PRESSURE AND TEMPERATURE WITH
THE SPECIFICATIONS FOR PRESSURE AND TEMPERATURE
DURING THE HOT-TAP 45
WORK AID 6. HOW TO SELECT AND DETERMINE PREHEAT TEMPERATURE
REQUIREMENTS FOR A ROOT PASS AND SUBSEQUENT PASSES
46
GLOSSARY 47
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OBJECTIVES
Terminal Objective
Upon completion of this module, the Participant will be able to inspect hot tap installation
in accordance with applicable standards.
Enabling Objectives
To achieve the Terminal Objective, the Participant will be able to accomplish the
following:
 Perform pre-inspection document review
 Perform pre-welding field inspection
 Perform inspection of hot-tap installation
 Witness pressure testing of hot tap field welds.
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PEW-403.02 PARTICIPANT INFORMATION
INTRODUCTION
It is often necessary to perform welding and tapping a branch connection on process

piping and pipelines while they are in service. This kind of welding situation is called hot
tapping. The inspection of hot-tap installation requires the application of engineering
and safety standards to ensure that these welds are performed correctly and safely.
This kind of inspection work is performed by Saudi Aramco Inspectors on all types of
piping, vessels, and cross-country pipelines, which contain hydrocarbon or other
products under pressure.
Hot taps present a greater hazard to personnel and adjacent equipment than welds on
equipment that is out of service. Therefore, the Inspector must verify that all people
assigned to the job are properly certified and are well informed of the procedures and
safety requirements.
Scope
The scope of this module will be limited to visual inspection of the preparation and
welding on equipment that is in service (i.e. hot-tap installations). Hot tap is the
technique of attaching a welded branch fitting to piping or equipment in service and
creating an opening in that piping or equipment by drilling or cutting a portion of the
piping or equipment within the attached fitting
An inspector has no direct control over contractor’s crews on the job site. However, he is
responsible to verify the correctness of the preparation and execution of their work. He
must also verify that the safety practices of the work crews meet the minimum standards
established by the company for the type of work being performed.
In order to carry out these responsibilities, the Inspector must understand the work that
will be performed and the Saudi Aramco and industry standards that govern the quality
and safety requirements of such work.
The Inspector must prepare reports and make recommendations based on his
inspection activities. Therefore, he must know where to find the latest company and
industry standards which apply to the work, and he must refer to them when necessary,
to support his conclusions.
2
PERFORM PRE-INSPECTION DOCUMENT REVIEW
There are many activities to be performed before proceeding to the job site. The
Inspector should locate and examine the job file. The job file contains the information the
Inspector needs to conduct an effective in-service weld inspection.
Review Job file
The Inspector must know where the job file is located and what documents are in the job
file. He must become familiar with the information contained in the job file documents.
The Inspector uses the information contained in the job file to plan and perform an in-
service weld inspection. The information required for the inspection may come from
many sources and the Inspector may have to obtain some items from Saudi Aramco
engineers, supervisors and contractor personnel.
The job file will normally be located in the Projects Inspector's office. The Inspector
should be aware however, that he may have to locate the necessary documents, and
build up a job file through his own efforts.
The job file, for the purpose of this module, should contain the following:
 WPS, PQR, Weld Map
 Welder Qualification Record (plus Welder Performance and Test Record card,
and Welder Job Clearance card)
 Safety Instruction Sheet (SIS), including UT Survey and UT Gauging sheets.
 Saudi Aramco Form 7627-Eng. (Hot-tap/Stopple Calculation & Reinforcement

Request).
 Project Drawings
 Checklists.
WPS/PQR/Weld Map
SAES-W-011 specifies that the contractor shall submit a weld map, table or fabrication
drawing that specifies where each welding procedure will be used. The weld map should
be submitted to Saudi Aramco Inspection along with the WPS and their PQR for each
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job or project. The weld map consists of drawings and/or isometric sketches of the
equipment and piping to be welded.
The weld map is used as a tracking document and as a permanent record to confirm the
location of all welds and the welder who performed them. The welding Inspector takes
the weld map to the job site and checks that the welder has marked his symbol on the
metal next to each weld. In the case of hot tap, it may be isometric drawing showing the
location of hot tap.
After review of WPS along with PQR, the authorized inspection representative will sign
form “Request for welding procedure Approval”. This form is given in SAES-W-011. The
inspector shall confirm the validity of the approval signature.
Note: For more information on WPS and PQR, refer to PEW-402.02 (Welding
Procedures and Welder qualifications).
Welder Qualification Record
Saudi Aramco requires a certified welder shall do the job. The welder shall possess
welder qualification card and JCC given by inspector. These welders shall be certified by
third party weld test centers, approved by Saudi Aramco. Inspector shall review these
documents for confirming his suitability.
Note: For more information on welder qualification record, refer to PEW-402.02

(Welding Procedures and Welder qualifications).
Safety Instruction Sheet (SIS)
A Safety Instruction Sheet is a document that specifies engineering and operating

requirements for process equipment, critical piping and pipelines (See Figure 1). Saudi
Aramco engineers prepare the SIS when new equipment is installed, and it is maintained
as a Saudi Aramco Standard Drawing with its own plant and drawing number. A SIS
specifies the original wall thickness, pressure ratings, etc., of the equipment or pipe
named in the document. It also specifies the pre-calculated thickness minimums (tm) for
pressure vessel and pipe walls.
The purpose of the SIS is to ensure that operating, maintenance, and inspection
personnel have the necessary information concerning safe operating limits, protective
devices, and any special safety precautions for certain pressurized and rotating
equipment in industrial plants and pipelines. The most important part of the SIS, for the
Inspector, is the Operating Limits section, which specifies t m's for designated areas of
pipe and equipment walls.
The SIS is provided by the proponent engineering organization and a copy of it should
be placed in the inspection job file.
4
Note: SAES-A-005 contains comprehensive information on the preparation,

meaning, use, and various kinds of Safety Instruction Sheets.
The SIS is used with a UT Gauging Sheet (to determine if actual measured wall
thicknesses and operating procedures fall within the limits specified by the SIS.
Figure 1. Safety instruction sheet (SIS)
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An actual thickness measurement is taken for every test point indicated on the UT
Survey Form (See Figure 2). These actual thickness measurements are recorded in the
column of the Gauging Sheet under the date they were taken.
S. A. Form 7627 (Hot-tap/Stopple & Reinforcement Calculation Request)
This form specifies safe design requirements for each hot-tap to be performed. It
contains critical information on field welding safety, job site layout, equipment
configuration and operating data. It also provides space for related inputs from all
organizations involved in the hot-tap project.
The purpose of this form is to specify the allowable pressures and flows, which must be
maintained during the welding and hot-tapping phases of the on-site work. SAEP - 311
specifies the maximum and minimum flow rates permissible during hot-tapping, as
follows:
 Liquid - 0.40 m/sec. minimum
4.50 m/sec. maximum
 Gas - 0.40 m/sec minimum
9.10 m/sec. maximum
The form also requires calculations and other inputs from all organizations participating
in the hot-tap job. These calculations should be submitted by representatives of the
following organizations:
 The initiating engineer from the proponent organization.
 The responsible engineer from Operations Engineering.
 The responsible inspection organization.
 The engineer from the engineering organization that is responsible for the hot-tap
or stopple.
Look at the completed S. A. Form 7627-Eng located in the sample job file. This is a
typical operational form from an actual project. It has inputs from the individuals and
organizations who are involved in the project.
 The initiating engineer is responsible for Section 1 and for the left hand Summary
Column.
 The Operations Engineer is responsible for Section 2.
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 The assigned welding Inspector is responsible for Section 3.
 Section 4 shall be completed by the Engineering Organization that is responsible

for the hot-tap or stopple project.
Note: SAEP -311 provides guidance for completing Saudi Aramco Form 7627-Eng
The completed S. A. Form 7627 should be obtained from the engineering organization
that is responsible for the hot-tap or stopple.
The Inspector uses this information to verify that the actual site conditions are within the
limits specified in S. A. Form 7627.
Project drawings
The drawings for an in-service welding job provide information about the location of the
job with respect to other adjacent equipment (refinery job) or to pipeline reference points
(cross-country job). The weld map is usually such a drawing; however, this information is
not always presented as a drawing. P&IDs can be used to specify the location of a
welding job within the refinery or with respect to other process equipment such as a
GOSP facility.
An isometric sketch (iso), provides more detail as to the location of the weld. For
example, an iso shows the height and position of a weld location with respect to the
ground.
Standard drawings for valves and other piping implements provide information about the
exact dimensions of the equipment to be used in the job. These drawings are most likely
to be provided when the weld is for hot-tap preparation.
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Checklists
A checklist is a complete series of items or areas that need to be inspected. The

checklist is the Inspector's key to an effective inspection.
The welding Inspector will be particularly concerned with four types of checklists. The In-
Process Welding Checklist and the Final Weld Inspection Checklist must be developed
by the Inspector. The Hot-tap Data & Checklist (Saudi Aramco Form 7235-Eng), and
Hot-tap Checklist (Appendix II, SAEP - 311, Saudi Aramco Form 7627-Eng) are available
in printed form.
The Inspector can develop his own inspection checklist with information that he obtains
from the contract documents.
The sample In-Process, Final Weld, and Hot-tap Inspection Checklists show many of the
areas you will need to check during a welding inspection. These lists are based on
typical jobs and are not complete for every kind of inspection. However, they provide
some general guidelines for checking procedures and welding variables.
Each Inspector must develop his own checklist based on the project that the supervisor
assigns. You must compare the welding conditions with the specifications throughout the
inspection process. The Inspector must constantly ask himself, 'Do the on-site conditions
match the specifications in the WPS?"
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PERFORM PRE-WELDING FIELD INSPECTION
The following activities outline the activities of the Inspector at the job site but prior to the
start of welding.
Thickness Measurements (UT)
The contractor shall inspect and determine the minimum pipe wall thickness at the tie-in
weld areas by a continuous UT scan along the lines to be welded. The UT record shall
be entered in the form shown in Figure 2. The area to be scanned shall include the weld
zone and 50 mm each of it. The minimum remaining wall thickness at the weld
connection area shall not be below minimum thickness tm and in all cases, no less than
5 mm.
The Inspector verifies that the thickness of the pipe is greater than the minimum allowed
for safe welding.
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Ultrasonic Thickness Measurements
Hot Tap #_________________

J.O./W.O. ______________PLANT #_______________ DWG. # ________________
Description (Job, Location, etc.) ___________________________________________
Diameter Grade Schedule Flange Rating

HEADER: _____________ ______________ _____________ ____________
STICKER _____________ ______________ _____________ ____________
HEADER MEASUREMENTS
(CONTINUOUS SCANNING)
Point A Min:__________ Max.:_________
Circle B Min:__________ Max:__________
Circle C Min:__________ Max:__________
Line D-D Min:__________ Max:__________
Line E-E Min:__________ Max:__________
180 deg. from Pt. A Min:__________ Max:__________
STICKER MEASUREMENT
Min:__________ Max.:__________
D E LOCATION-------DESCRIPTION
Point A------------Branch Center

Circle B-----------Branch Diameter
A Circle C-----------Reinfr. Pad Dia.
C
Line D-D----------Reinf. Sleeve Ends
FLOW B Line E-E----------Reinf. Sleeve Ends
D E
RESPONSIBLE PIPING & VALVES UNIT/M&CED/CSD: ENGINEER:
Figure 2. Saudi Aramco UT Survey form
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Repair Materials
The Inspector verifies that the base metals, welding filler metals and welding gases are
properly identified and conform to the WPS requirements. He inspects the base metal to
ensure that there are no discontinuities near the weld end preparation. The remainder of
the base metal is inspected for discontinuities during the final inspection.The Inspector
verifies that the contractor has provided materials that apply to the specified type of
weld.
The contract or job order specifications and the WPS specify the manufacturing, quality
and performance standards that apply to the job.
For hot-tap jobs, Saudi Aramco Form 7627 (Hot-tap/Stopple & Reinforcement
Calculation Request) and Saudi Aramco Drawing AB-36719 contain additional materials
standards.
Verification of Line Pressure
The Inspector must verify line pressure/flow before the contractor begins the tapping
operation. This is a critical safety factor.
Serious damage and injury may result from burn through, explosion and fire if line
pressure is not within specified limits when welding is in progress.
The Inspector must obtain existing pressure readings at the equipment location where
the hot-tap will be performed. He must compare these readings with the pressure/flow
limits specified in Saudi Aramco Form 7627.
Look in Section 4 of Saudi Aramco Form 7627-Eng, for the critical values that the
Inspector must verify. A separate form must be completed for each hot-tap performed.
Notice that the allowable pressures and flows are given for the following situations:
 Header pressure during welding.
 Header flow while welding or cutting coupon.
 Maximum allowable external pressure.
 Branch Flange/Wall test pressure limit (parameters).
 Header Flange/Wall test pressure limit (parameters).
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Note: SAEP -311 provides additional information about pressure and flow limits for
welding and hot-tapping of pipe and equipment
The Inspector must compare actual field pressures and flows with those specified in
section 4 of SAF 7627-Eng.
Proper Fit-Up of Components
The Inspector must verify the fit-up of all components to be welded.
He must check the weld end preparation to verify that it meets all of the requirements
specified by the welding procedure.
The Inspector must check cleanliness of the base metal on both sides of the joint to
verify that it meets procedure and specification requirements. Check for moisture,
contaminants such as grease, oil, and paint, scale, and corrosion products such as rust.
Verify that the weld joint fit-up meets procedure and specification requirements. Check
the root opening and the amount of mismatch (e.g., high-low).
Inspect tack welds prior to welding to verify that they are:
 Adequate to avoid distortion during welding.
 Not cracked.
 Adequately prepared in order to obtain complete fusion.
The inspector applies the following regulatory documents and drawings to inspect fit-up
for welding of Saudi Aramco hot-tap projects:
 SAES-L-052,
 SAES-W-010, SAES-W-11 and SAES W -012
 SAEP -311
Examples of fit-up problems are many and varied since each repair or installation project
has its own unique set of requirements. Requirements for welding operations that are
performed on a recurring basis are specified by Saudi Aramco General Instructions and
Standard Drawings.
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To ensure that the proper fit-up is in progress for the hot-tap connection (See also Figure
3), the Inspector must:
 Verify that the fitting is the proper size to accommodate the hot-tap machine.
 Verify that the welded branch or split tee is accurately positioned so that the axis
of the cutter will intersect the axis of the pipe or vessel being tapped, at a 90-
degree angle.
 Compare actual UT Measurements with min/max UT readings in Saudi Aramco

Form 7627, Section 3.
 Re-verify the branch position before welding (See Figure 4), including
Header/Branch root gap.
Prior to any welding the Inspector must verify the thickness of the weld area by
ultrasonic examination at 1- inch intervals along the line to be welded. The inspection
area should be marked for future reference and identification.
Figure 3. Hot tap connection
Note: When performing ultrasonic examination, enter the necessary data in the form
titled "Ultrasonic Thickness Measurements for Hot-Tap Connections,"
Appendix I, SAEP- 311.
The connection through which a hot-tap will be made must be inspected in accordance
with the following references:
 SAEP - 311, "Responsibilities."
 SAES-L-052, Para 4, 5 & 6
13
The Inspector calculates a specified preheat temperature from data contained in tables
located in Saudi Aramco Standard Drawing AE-036451. This drawing is titled, Preheat
Levels for Welding Carbon Steels, Including Low Hydrogen Processes. These tables
specify values for calculating the correct preheat levels for given materials.
SAES-W-011 & 12 provide a quick reference to the necessary procedures and preheat
values.
Look at the WPS located in the job folder. Note the following points:
 SAES-W-011 and SAES-W-012 should be included with the WPS because they
contain the information needed to determine the required welding preheat values
for the base metals which are specified in the WPS.
 The WPS specifies the type of base metal and the thickness range of that base
metal.
 The welding Inspector compares the type and maximum wall thickness of the
base metal specified in the procedure with the data in AE036451, SAES-W-O11,
and SAES-W-012. The information in these documents gives him the required
preheat temperatures for pipe or fittings.
Figure 4
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PERFORM INSPECTION OF HOT TAP INSTALLATION
In almost all hot-tapping jobs, the main problem areas are related to welding the branch
connection fitting on the pipeline. The branch connection is usually referred to as the
hot-tap sticker or as simply the sticker.
The welding Inspector must check for the following deficiencies in welding methods
while welding of the hot-tap sticker is in progress:
 Blow through.
 Improper weld gap.
 Incorrect welding speed.
 Low current.
 High current
 Faulty electrode manipulation.
 Incorrect electrode size.
 Incorrect electrode type.
These deficiencies can cause common weld defects such as lack of fusion,
undercut, and porosity, if not corrected quickly.
Appearance of the Weld Profile
The Inspector must visually inspect the weld bead for the desired characteristics as the
work progresses.
He checks all completed welds for overall profile, weld dimensions, unusual coloration
and discontinuities.
Sometimes the Inspector will see evidence of discontinuities in a completed weld. He

must call for non-destructive testing of the weld. The weld must be removed and re-
welded if it does not meet specifications.
15
When a radiography test of the weld is required, the welding Inspector must prepare the
request. Upon completion of the test, the Inspector will analyze the result. Welds that
contain deficiencies must be repaired. After repairs, the Inspector must perform another
visual and radiographic inspection of the weld.
Completed Weld of a Hot-Tap Sticker
A hot-tap procedure is often performed on pipelines or vessels that operate at high

pressures and high temperatures. The welding Inspector must carefully inspect the weld
that attaches a hot-tap sticker to a header pipe or a vessel.
The completed hot-tap sticker weld must be inspected for:
 Common weld cracking.
 Heat Affected Zone (HAZ) cracking.
 Lack of fusion.
 Undercut.
 Porosity.
The hot-tap procedure should commence only after the sticker weld has been thoroughly
inspected and approved.
Weld in Progress-Hot-Tap Reinforcement Pad
Installation without a reinforcement pad is specified for some hot-tap stickers and
installation with a reinforcement pad is specified for others. The reinforcing pad must be
welded separately and the welding procedures are similar to those for the weld of the
hot-tap sticker.
In most Saudi Aramco applications, the reinforcing pad is slipped down over the hot-tap
sticker until it seats on the exterior wall of the header pipe or vessel. Reinforcing pads
are fabricated specifically for a given job.
The welding Inspector must:
 Include the data for the pad when filling out.
 Obtain UT measurements in 1-inch increments around the entire perimeter of the

pad.
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 Verify correct bevel at the exterior edge of the pad.
 Verify correct root gap where the pad rings the base of the sticker.
 Verify that the welder meets all WPS weld requirements as he progresses with
the welding.
Figure 5A shows a welded branch connection without reinforcement.
Figure 5B shows an angular welded branch connection without added reinforcement.
Figure 5C shows a welded branch connection with a reinforcement pad. Notice that the
reinforcement pad requires a vent hole to allow gases to escape during the welding
process.
Figure 6 shows the various types of reinforcing pads used in Saudi Aramco.
17
Figure 5. Different types of welded branch connections
18
Figure 6. Different reinforcement pads used in Saudi Aramco (AB-036719)
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WITNESS TESTING OF HOT-TAP FIELD WELDS
Hydrotest Hot-Tap Sticker and Valve
The branch connection must be hydrotested, if required in the job specifications, before
cutting into the main line. A separate pressure test of the branch connection avoids the
need to test the entire system.
Hot-tap connections must be tested in accordance with, SAES-L-052, SAF-7627-Eng,

AB-036719, SAES-A-004, and SAEP 311.
The welding Inspector must witness and approve the following hydrostatic pressure
tests:
 Valve body and seat test
 Branch connection test
 Reinforcing pad or ring test
 Tightness test (reinforcing pad or ring)
 High pressure closure test
 Test with hot-tap machine installed
Valve Body and Seat Test
The purpose of the valve body and seat test is to verify a positive seal between the gate
and seat.
The Inspector must verify that a hydrostatic pressure test was performed. A tag must be
attached to the valve indicating the test date, the test pressure and the name of the
Inspector who performed the test.
Branch Connection Test
The purpose of the branch connection hydrostatic test is to verify the integrity of the
connection weld. In order to perform this test the open end of the branch connection
must be sealed with a blind flange. Verify that a boss is installed in the branch
connection as shown on Standard Drawing AB-036719.
Verify that the hydrostatic test pressure applied to the branch connection is the lower
value shown in 4.4c or 4.4e on Saudi Aramco Form 7627-Eng.
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Reinforcing Pad or Ring Test
SAEP-311 specifies that a pneumatic strength test of 25 psig must be applied to the
reinforcing pad or ring after installation.
Tightness Test
The pneumatic pressure for the reinforcing pad or ring test must then be reduced to 3-5
psig after strength test for a tightness test using a soap solution.
The Inspector must verify, in both of the preceding pneumatic pressure tests that
specified pressures were applied and that leakage did not occur during either test.
High Pressure Closure Test
The high-pressure closure test must be applied with the hot-tap valve in place on the
branch connection.
The Inspector must verify that the pressure applied in this test is the lower value shown
in 4.4c or 4.4d on Saudi Aramco Form 7627. Pressure must be applied in this test,
through a branch connection boss which is field installed.
Test with Hot-Tap Machine Installed
The hot-tap machine must be mounted onto the hot-tap valve, with the valve in the open
position and a full pressure hydrostatic test must be applied. The Inspector must verify
that the test pressure applied is the lower value shown in 4.4c or 4.4e on Saudi Aramco
Form 7627.
Note: When the foregoing tests are complete the Inspector must witness installation
of a bar stock plug in the branch connection boss, and seal welding of the
plug.
NDT Test of Boss Plug Weld
After completion of all tests, a bar stock plug that is installed in the branch connection
boss shall be seal welded. The Inspector, at his option, may call for a NDT test to be
applied to the branch connection plug weld to verify the integrity of the boss plug weld.
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Analyze a Coupon Removed in a Hot-Tap Procedure
Confirmation of the internal condition of the header and verification of actual header wall
thickness can be determined after a hot-tap procedure has been completed and the
cutout coupon has been removed.
The welding Inspector must examine the removed coupon to:
 Determine base metal laminations, if any.
 Evaluate the extent of internal corrosion in the header.
 Verify header wall thickness measurement for inspection records.
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PEW-403.02 PARTICIPANT EXERCISES
EXERCISE 1. REVIEW JOB FILE DATA
This exercise will familiarize you with the information contained in a typical Inspection
Job File.
Use the documents in the sample job file, the Information Sheet, and Work Aids 1 and 2
to answer the following questions.
1. When the welding Inspector is assigned to inspect a project, what is his first
duty?
2. What documents should the Inspector make sure are available for initial review?
3. When the welding Inspector is assigned an inspection project he may find a job
file assembled and ready for him, or he may be required to assemble the
necessary documents and make up his own job file.
True ___________
False __________
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4. According to SAES-W-011, what original or legible copies of documents must the

contractor provide in advance for review by the Inspector and placement in the
job file?
5. The welding Inspector checks the "Request for a Welding Procedure Approval" in
the job file. What is the main thing he is looking for?
6. How can the welding Inspector verify that the signature on a "Request for A
Welding Procedure Approval" form is an authorized signature?
7. What is the identification number of the WPS included in the sample job file?
8. Do the welding procedures specified by the WPS provide the requirements for
welding a particular joint?
9. What items of information does the WPS specify for a particular weld?
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10. A "Welding Procedure Qualification Record" laboratory test document must be

provided by the contractor to the job file to support the welding procedure
approval.
True _________
False ________
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EXERCISE 2. REVIEW JOB FILE SIS AND WPS DATA
This exercise will familiarize you with two specific documents that should be in the
typical inspection job file: the Safety Instruction Sheet (SIS) and Welding Procedure
Specifications (WPS).
Use the SIS and WPS in the sample job file, the Information Sheet, and Work Aid 3 to
answer the following.
1. What documents are used in connection with the Safety Instruction Sheet (SIS)
in the job file to determine if actual measured wall thicknesses are within
specified limits?
Refer to WPS to answer questions 2 through 10. 2. What welding rod is specified for
the root weld?
2. What welding rod is specified for the root weld?
3. What rod is specified for hot pass and filler beads?
4. What AMP range is specified for #4 filler bead?
5. What is the meaning of Weave Width, "3 X core dia.?
6. What is the angle specified for the beveled joint?
7. Is the specified welding progression uphill or downhill?
26
8. What standard is specified as the reference standard for preheat? Indicate page
number.
9. What electrical polarity is specified?
10. Why is electrode E-7010 specified for a root bead instead of E-6010?
11. Name the various types of inspection checklists that should be utilized by the
welding inspector to make sure that no items are overlooked in performing a
complete inspection.
27
EXERCISE 3. PERFORM PRE-WELDING PROCEDURES
At this point, the Inspector is on the job site but welding has not commenced. This
exercise will familiarize you with how to locate specific information and how to analyze
specific documents in order to perform the pre-welding procedures required by Saudi
Aramco.
Answer the following questions using the documents in the sample job file, the
Information Sheet, and Work Aids 4 and 5.
1. Look up the following information about 15-D-100:
 Actual thickness measurements taken at locations 5 and 6.
 Thickness minimum (tm) specified for the shell.
 Type of material used to fabricate the heads.
 Original nominal thickness specified for the heads.
2. According to SAES-L-052, Page 2, what thickness is specified as the minimum

allowable thickness for welding a hot-tap connection, under any circumstances?
3. What are the minimum and maximum flow rates specified by SAF-7627 for
header flow during welding (or cutting the coupon)?
4. What Saudi Aramco General Instruction specifies welder qualification

procedures?
28
5. Given the welder qualification card, answer the following questions: (Please
provide welder qualification card)
a. When does this card expire?
b. Which welding process(es) is this welder qualified to perform?
6. If a welder has not welded with any welding process for a period of 3 months or
more, is his welding qualification card still valid?
7. What must any welder do to re-validate his welder qualification card if it lapses?
8. Who is responsible to verify the proper fit-up of all components to be welded?
9. Hot-tap connections must be inspected before and during installation for

compliance with approved drawings and welding procedures. Which instruction
specifies this action?
10. What must the welding inspector verify according to SAES-L-052, Para. 4.1 ?
29
EXERCISE 4. PERFORM PRE-WELDING PROCEDURES
This exercise continues to familiarize you with how to locate specific information and
how to analyze specific documents in order to perform the pre-welding procedures
required by Saudi Aramco.
Information Sheet, and Work Aid 6.
1. What kind of welding operation is specified by Saudi Aramco Standard Drawing

#AB-36719?
2. The welding Inspector is responsible to check preheat and interpass

temperatures before and during the welding process.
True ________
False _______
3. What is the title of Saudi Aramco Standard Drawing #AE-036451? (Consists of 8

sheets)
4. What calculation can the Inspector make using the data contained in Saudi
Aramco Standard Drawing #AE-036451?
5. Given: WPS and attached SAES-W-012, Table 2. The base metal is API
Specification 5L GR X 60 pipe, 1.00 Inch thick. Materials and conditions are as
specified in SAES-W-012, including the Notes section. The hot pass will be made
within 5 minutes of completing the root pass. The weld is pipe-to-pipe. What is
the required minimum preheat in degrees Fahrenheit for:
a. Root pass?
b. Balance of weld?
30
6. Is it your job as welding Inspector to specify the correct electrodes for a particular
job?
7. Does every electrode have an individual identification number?
8. Referring to WPS, what type of shielding gas is required in the welding procedure
specifications?
9. Referring to WPS, does the specification for a hot pass electrode agree with the
classification in ASME Sec.ll, Part C?
31
EXERCISE 5. INSPECT FIELD HOT TAP WELDS
This exercise reinforces your ability to perform inspection procedures related to welds in
progress and completed welds of pipelines, hot-tap stickers, and hot tap reinforcement
pads.
Answer the following questions using the documents in the sample job file, the Information
Sheet, and Work Aid 6.
1. While welding is in progress, how will the Inspector check the voltage and
amperage actually produced by the welding machine?
2. According to WPS, what is the minimum interpass temperature in degrees

Fahrenheit to be maintained while performing fill welds on 1" thick, schedule X60
pipe wall? (1" thickness measured at the job site)
3. What is the definition of any interpass temperature range?
4. Who should check to make sure that the welder maintains the correct interpass
temperature during multiple-pass welds?
5. Who is responsible for controlling the interpass temperature during the welding
process?
6. If the welder discontinues welding operations for a period of time, which

temperature has to be re-established before he can resume welding?
7. What document specifies preheat and minimum and maximum interpass

temperatures?
32
8. Name two devices that the welding Inspector can use to verify that the correct
interpass temperature is being maintained.
33
EXERCISE 6. INSPECT FIELD HOT TAP WELDS
This exercise continues to reinforce your understanding of inspection procedures related

to welds in progress and completed welds of pipelines, hot-tap stickers, and hot-tap
reinforcement pads. Provide one WPS.
Information Sheet, and Work Aid 6 as needed.
1. What is the welding amperage range specified in WPS?
2. What is the voltage range specified in WPS?
3 What is the weld bead weave width specified in the WPS?
4. What is the type of current and the polarity specified in the WPS?
Current _________
Polarity _________
5. SAES-W-011 contains instructions for preheat and interpass temperature control.

Is it mandatory, or optional, to comply with these instructions?
6. What is the welding Inspector looking for while visually inspecting the in-process
weld?
7. The in-process welding Inspector sees evidence of discontinuities in a weld. Is he

authorized to call for additional non-destructive testing of the weld?
34
8. A weld rejected by the Inspector after radiography has now been repaired by the
welder and the Inspector has performed a visual inspection of the repair. Will it
be necessary to perform another radiographic inspection of the repaired weld?
9. When the welding Inspector desires a radiography test who prepares the
request?
10. What evidence should the inspector look for while analyzing a hot-tap coupon?
35
EXERCISE 7. WITNESS TESTING OF HOT TAP FIELD WELDS
This exercise reinforces your understanding of inspection procedures for witnessing

hydrotest of hot-tap sticker and valve, and pressure test of hot-tap reinforcement pad.
Answer the following questions using SAEP-311, the Information Sheet, and Work Aid as
needed.
1. What Saudi Aramco reference(s) specify inspection procedures for witnessing

hydrostatic testing of hot-tap connections?
2. According to SAEP-311, how shall the Inspector confirm that the hydrostatic test
pressure for a hot-tap connection is correct at the time of the test?
3. How many hydrostatic tests must be performed on a hot-tap valve prior to the
hot-tap procedure?
4. The welding Inspector must witness and approve the hydrostatic test(s) of the
equipment and connection of hot-taps in new project construction. (See SAEP-
311)
True ________
False _______
5. You notice that the test pressures specified in SAEP-311 for a hot-tap
reinforcement pad differ from the test pressures specified in SAES-L-052. Which
specifications should you follow?
36
EXERCISE 8. PREPARE FINAL INSPECTION REPORT
Prepare a Final Inspection Report using the hypothetical information provided below.
This hypothetical information represents observations recorded in the welding
Inspector's field notes. Use the example final inspection report located in the sample job
file as a guide.
 BI 3115, CN-37261/00.
 10" JUBAIUFG.
 JUBAIL PLANT TO JU'AYMAH POWER STATION.
 Report made out to Supt., Projects Inspection Div., Dhahran.
 10" pipeline bringing fuel gas from Jubail Gas Plant to Ju'aymah Pwr Station.
 Distance - 30km.
 Construction monitor - Ras Tanura Projects Inspection.
 Project Management Team - Pipelines & Wet Crude Dept.
 Contractor - Salem Abdulla Sheban Est.
 Materials used - 10" dia. FBE coated 0.500 wt. API-5L Grade 60 pipe.
 Procedures used - SMAW process with contractor welding procedures SAS# 18

(Rev. 2).
 Number of completed welds - 796.
 Number of welds radiographed - 89 (Radiography requirement 10% in

accordance with SAES-W-001). Radiographic reports included.
 Number of welds accepted - 87.
 Number of welds rejected and repaired - 2 (One weld was cut out).
 Hydrostatic testing - Entire pipeline pressurized. Strength Test: 1680 psig,

Tightness Test: 1600 psig.
37
 Common Welding Problems - Gusty winds caused arc shielding problem.
 Contractor Cooperation - Contractor was very cooperative.
 Job Start: May 1989 Finish: September 1989.
 Final Evaluation - Project completed on schedule, in compliance with all Saudi

Aramco specifications and design requirements.
38
FINAL INSPECTION REPORT
Supervisor
Projects Inspection Div.,
Description of Job
Materials Used On Job
Procedures Used
Number of Completed Welds
Number of Welds Radiographed
39
Number of Welds Accepted
Number of Welds Rejected and Repaired
Hydrostatic Testing
Common Welding Problems
Contractor Cooperation
Final Evaluation
40
PEW-403.02 PARTICIPANT WORKAIDS
WORK AID 1. CHECKLIST OF JOB FILE DOCUMENTS
Use this Work Aid to identify the documents for the job file and to determine who is
responsible to provide each document.
DOCUMENT SUPPLIED BY:
Request for Welding Procedure Welding Contractor through Saudi Aramco

Approval Projects Management. (SAES-W-011).
Welding Procedure Job Site Contractor through Saudi Aramco

Specifications (WPS) Projects Management. (SAES-W-011).
Procedure Qualification Record Job Site Contractor through Saudi Aramco

(PQR) Projects Management. (SAES-W-011).
Job Site Contractor through Saudi Aramco

Weld Map
Projects Management. (SAES-W-011).
Safety Instruction Sheet (SIS) Proponent Engineering Organization.
Saudi Aramco Form 7627, Hot-

tap/Stopple & Reinforcement Engineering Organization responsible for the
Calculation Request (If hot-tap or stopple.
inspecting a hot-tap procedure)
Welder Performance Test

Welding Contractor (SAES-W-011)
Record
Welder Qualification & Job

Carried by welder.
Clearance Cards
Proponent and/or Saudi Aramco PMT

Project drawings
41
WORK AID 2. HOW TO LOCATE MATERIALS STANDARDS

FOR MATERIALS USED IN A HOT-TAP
Use this Work Aid to find the materials standards that are specified in the project
documents located in the job file.
1. Check contract drawing(s).
 Look for notes next to materials installation locations.
 Look for special notes in margin of drawing(s).
 Look for drawing(s) which serve as materials specification sheet(s).
2. Check the contract document.
 Review the specifications section.
 Identify materials specifications and compare with any specifications

showing on the drawings.
3. Check the WPS, the SAF-7627, and Saudi Aramco Standard Drawing AB-36719.
 Look for materials standards specified in the above three documents.
Note: If materials specifications in the contract document disagree with specifications

on the drawing(s), the specifications on the drawing(s) shall rule.
42
WORK AID 3. HOW TO LOCATE INFORMATION IN THE WPS
Use this Work Aid to locate information in the WPS that relates to the inspection of in-
service welds and welding in progress.
Note: The specifications listed below are derived from a typical WPS from an actual
project. Compare the specifications below with the information contained in WPS
located in the Handout Package.
SECTION
INSPECTION ITEM SPECIFICATION
OF W P S
1. Welding Travel Speed 3-5 Inches Per Minute QW 410
2. Minimum Interpass Temp 68° F. QW 406
3. Welding Amperage Range 70-215 Amps OW 409
4. Welding Voltage Range 28-24 Volts QW 409
5. Weld Bead Weave Width 3 X Core Diameter QW 410
6. Type Current and Polarity DC and RP QW 409
43
WORK AID 4. HOW TO COMPARE U.T. READINGS WITH SIS

DATA
Use this Work Aid to locate thickness information as presented on an SIS and to make
the correct comparisons with thickness measurement data from corresponding UT
Survey and Gauging Sheets.
1. Check to ensure that the following documents are in your job file.
 SIS
 UT SURVEY SHEET
 UT GAUGING SHEET/ UT thickness measurements at hot tap location
2. Look at the test locations on the UT Survey Sheet
3. Check corresponding actual measured thickness at the same locations on the UT

Gauging Sheet
4. Compare the actual thickness measurements at each location with the

appropriate tm shown on the SIS in the Operating Limits section
44
WORK AID 5. HOW TO COMPARE LINE PRESSURE AND

TEMPERATURE WITH THE SPECIFICATIONS
FOR PRESSURE AND TEMPERATURE DURING
THE HOT-TAP
Use this Work Aid to help you select the required information from among the various
sections of Saudi Aramco Form 7627, "Hot-tap/Stopple & Reinforcement Calculation
Sheet". This information allows the Inspector to compare actual line pressure and
temperature with the specified pressure and temperature, during a hot-tap.
1. Take Saudi Aramco Form 7627-Eng out of the job file
2. Look at Block 2 (TO BE COMPLETED BY OPERATIONS ENGINEER).
3. Note the specified operating pressure and temperature. For example, SAF-7627-
Eng for job number 81274 specifies that the operating pressure should be 850
psig and the temperature should be 120 °F
4. Check the actual operating pressure and temperature or obtain readings from the
job site contractor or operations personnel.
5. Compare actual readings with the specified values found on SAF-7627-Eng.
45
WORK AID 6. HOW TO SELECT AND DETERMINE PREHEAT

TEMPERATURE REQUIREMENTS FOR A ROOT
PASS AND SUBSEQUENT PASSES
Use this Work Aid to select information from the WPS and SAES-W-011 and 012, and
determine preheat/interpass temperature requirements.
1. Locate WPS in the job file.
2. Note material specifications in WPS (OW-403, pipe, fittings etc.).
3. Note material thickness range that is specified in the WPS (QW-403).
4. Note measured actual base metal thickness (Measured at the job site).
5. Note the preheat requirement specified in the WPS (QW-406).
6. Note if preheat requirement in WPS refers you to "attachment".
7. Locate SAES-W-011 and 012, attached to WPS.
8. Note that material specifications of SAES-W-012, call for carbon steel materials
up through Grade X60. This corresponds to WPS (QW403).
9. Check (Notes) to verify:
 Weld type and position
 Approved electrodes
 Approved materials Grade
 Required timing of weld passes
 Any exceptions that apply
10. In column labeled “Wall Thickness”, locate dimension in inches, corresponding to

the actual measured maximum wall thickness of the base metal.
11. Move horizontally under the column headed by the specified fit-up, e.g. Pipe-to-
pipe or fittings.
12. Read preheat or minimum interpass temperature in °P or in °C as desired.
46
PEW-403.02 PARTICIPANT GLOSSARY
GLOSSARY
branch connection See "nozzle"
downstream Proceeding along a pipeline in the same direction as the

product flow.
header A large diameter pipe into which a number of smaller pipes

are installed in a perpendicular direction.
hoop stress Stress that acts on a pipe in a direction around its

circumference rather than in a longitudinal direction along
the length of the pipe. (i.e., if a pipe fails due to hoop
stress, it will fail in a direction around the pipe
circumference).
hot-tap The technique of attaching a welded branch fitting to piping

or equipment in service and creating an opening in that
piping or equipment by drilling or cutting a portion of the
piping or equipment within the attached fitting.
hydrostatic test A nondestructive test in which water or product fluids are

used under pressure, to test a product line, valves or
vessels for leaks. Refer to SAES-A-004 and API-598.
Interpass temperature The temperature at which the weld area must be before
the next weld pass is started. This may be stated as either
a minimum or a maximum.
k Pa kilo Pascal's - A unit of pressure. 1 - kPa is equal to 6.895

PSI.
laminations (pipe) Longitudinal separations within any "horizontal plane

section" of a pipe or vessel wall. May be one or several
overlapping separations within the pipe or vessel wall.
l eak With respect to pipelines: A break, split, crack or

perforation in the pipe wall or welded or flanged joint which
permits product or test fluid to escape into the surrounding
atmosphere.
mechanical Any type of physical damage to equipment
damage that is caused by other than erosion or corrosion. For

Example: scratching, bending, gouging, warping.
47
NDT Nondestructive testing. A method that determines internal

soundness without destroying product usefulness. NDT
assures the satisfactory performance for which, the
product was intended. i.e. visual, penetrant, magnetic
particle, ultrasonic, radiographic, hydrostatic tests etc.
Nominal pipe size (NPS) Normally, pipe is specified in terms of NPS. Nominal pipe
size (in inches) is somewhat different from the actual size
up to 12” NPS; it represents internal diameter and 14” and
above it represents outside diameter.
nozzle A pipe stub protruding from a product line or a vessel

(usually reinforced where it attaches to the line or vessel)
and flanged at the outer end (also called branch
connection).
Post-heating The heating of an assembly after welding. The types of

post heating encountered are stress relieving, normalizing,
and annealing. For PEW-302, post-weld heat treatment
shall refer to stress relieving.
Pre-heating The heating of a base metal to a specified elevated

temperature prior to welding.
PSIA Pounds per square inch ABSOLUTE. i.e. the pressure

above that of a perfect vacuum. It is the sum of gauge
pressure and atmospheric pressure.
PSIG Pounds per square inch gauge. i.e. pressure in pounds per
square inch above existing atmospheric pressure.
SACS Saudi Aramco Construction Standards.
SADP Saudi Aramco Design Practices.
SACS Saudi Aramco Construction Standards.
SADP Saudi Aramco Design Practices.
SAES Saudi Aramco Engineering Standards
scraper bars Steel guide bars installed in a longitudinal direction across

the opening in a pipeline where a branch line is connected
to a mainline. (This is so that a scraper when moving along
the main line, cannot alter it's path of travel and try to move
into the branch line, whereby it might get stuck).
48
SIS Safety Instruction Sheet, defined by SAES-A005, Saudi

Aramco specifications for process equipment and critical
piping.
SMYS Specified Minimum Yield Strength. (A specified yield factor

in kPa or psig, beyond which, a pipe or vessel under
internal pressure, may suffer deformation or rupture).
sticker (hot-tap) A branch pipe connection welded to an existing product

pipeline or vessel (see header). A hot-tap procedure is
performed through the sticker.
stress-relief Uniform heating to a specified temperature below the

critical temperature for a sufficient period of time to relieve
the major portion of residual stresses, followed by uniform
cooling.
system product The type of fluid that is being carried and processed in the
piping system of a petroleum processing facility.
ta Thickness, actual. The thickness actually measured on a

specific date, of the wall of a pipe or vessel.
tm Thickness, minimum. A dimension that is equal to the

minimum thickness of the wall of a pipe or vessel, below
which, the pipe or vessel must be removed from service.
to Thickness, original
tempilstik A crayon-like test device for checking pipe or vessel walls

to determine an approximate temperature range of the
metal. Tempilstiks are rated through a broad range of
temperatures. If stick is applied to metal, which is hotter
than the stick rating, the tempilstik will melt.
toxic Poisonous to the human body upon external and/or internal

contact.
upstream Proceeding along a pipeline against the direction of the

product flow.
weldolet The weldolet is a 90 degree fitting with the reinforcement

required to meet ASME and API codes included in the
design of the forged fitting. It is welded onto the surface of
the header pipe and a hot-tap can be performed through
the open neck of the weldolet if desired.
49

Inspect Hot Tap Installation: Saudi Aramco

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Training & Contractor Workforce Saudization Group

INSPECT HOT TAP

DATE REVISION DESCRIPTION PAGE(S) AFFECTED

12/06/04 COMPLETE REVISION ALL

MODULE COMPONENT PAGE

Analyze a Coupon Removed in a Hot-Tap Procedure 22

 Perform pre-inspection document review

 Perform pre-welding field inspection

 Perform inspection of hot-tap installation

 Witness pressure testing of hot tap field welds.

It is often necessary to perform welding and tapping a branch connection on process

PERFORM PRE-INSPECTION DOCUMENT REVIEW

Review Job file

 WPS, PQR, Weld Map

 Safety Instruction Sheet (SIS), including UT Survey and UT Gauging sheets.

 Saudi Aramco Form 7627-Eng. (Hot-tap/Stopple Calculation & Reinforcement

Welder Qualification Record

Note: For more information on welder qualification record, refer to PEW-402.02

Safety Instruction Sheet (SIS)

A Safety Instruction Sheet is a document that specifies engineering and operating

Note: SAES-A-005 contains comprehensive information on the preparation,

Figure 1. Safety instruction sheet (SIS)

S. A. Form 7627 (Hot-tap/Stopple & Reinforcement Calculation Request)

 Liquid - 0.40 m/sec. minimum

4.50 m/sec. maximum

 Gas - 0.40 m/sec minimum

9.10 m/sec. maximum

 The initiating engineer from the proponent organization.

 The responsible engineer from Operations Engineering.

 The responsible inspection organization.

 The Operations Engineer is responsible for Section 2.

 The assigned welding Inspector is responsible for Section 3.

 Section 4 shall be completed by the Engineering Organization that is responsible

A checklist is a complete series of items or areas that need to be inspected. The

PERFORM PRE-WELDING FIELD INSPECTION

Thickness Measurements (UT)

Ultrasonic Thickness Measurements

Hot Tap #_________________

Diameter Grade Schedule Flange Rating

Point A------------Branch Center

RESPONSIBLE PIPING & VALVES UNIT/M&CED/CSD: ENGINEER:

Figure 2. Saudi Aramco UT Survey form

Verification of Line Pressure

 Header pressure during welding.

 Header flow while welding or cutting coupon.

 Maximum allowable external pressure.

 Branch Flange/Wall test pressure limit (parameters).

 Header Flange/Wall test pressure limit (parameters).

Proper Fit-Up of Components

The Inspector must verify the fit-up of all components to be welded.

Inspect tack welds prior to welding to verify that they are:

 Adequate to avoid distortion during welding.

 Adequately prepared in order to obtain complete fusion.

 SAES-W-010, SAES-W-11 and SAES W -012

 Compare actual UT Measurements with min/max UT readings in Saudi Aramco

Figure 3. Hot tap connection

 SAEP - 311, "Responsibilities."

 SAES-L-052, Para 4, 5 & 6

PERFORM INSPECTION OF HOT TAP INSTALLATION

 Improper weld gap.

 Incorrect welding speed.

 Faulty electrode manipulation.