aws_api 1104 code clinic

STD.AWS API-M-ENGL O 07842b5 0537323 405

Code Clinic For Study of API Standard II04 Eighteenth Edition Welding of Pipelines and Related Faci lit ¡es

R E F E R E N C E M A N U A L

American Welding Society

COPYRIGHT American Welding Society, Inc.Licensed by Information Handling ServicesCOPYRIGHT American Welding Society, Inc.Licensed by Information Handling Services

Code Clinic

For Study of

API STANDARD 1104 EIGHTEENTH EDITION

Welding of Pipelines and Related Facilities

Pu bl is hed by American Welding Society

Education Department

American Welding Society


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DISCLAIMER

The American Welding Society Inc. assumes no responsibility for the information contained in this publication. An independent substantiating investigation should be made prior to reliance on or use of such information.

International Standard Book Number: 0-87171-581-3

American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126

O 1999 by American Welding Society Printed in the United States of America

Ail rights reserved. No part of this book may be reproduced in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage or retrieval system without permission in writing from the publisher.

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STDaAWS API-M-ENGL I 0784265 0517126 114

Author’s Notes

AWS has offered an AWS D1.l Code clinic for many years in conjunction with their Welding Inspection Seminar. During this time, interest in a corresponding seminar for API 1104, Welding of Pipelines and Related Facilities, has continued to grow. This AWS Code C l i n i c 4 P I 1104 Reference Manual has been developed to provide a text for such a seminar. It consists of an introduction and eleven modules. Modules 1 through 10 correspond to the ten sections in API 1104 and Module 11 addresses the Appendix. Exercise questions for Modules 1 through 10 are also included.

The author recognizes and appreciates the efforts of the AWS Education Department Staff in providing direction and coordination of this effort. Without their insight and professional assistance. this manual could not have been published.

Ken Jobes Ken Jobes & Associate, Inc.

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Table of Contents

Module

Introduction to the AWS Code Clinic for API Standard 1 104

1 . Section 1- General

~ 2 . Section2- Qualification of Welding Procedures for Welds Containing Filler-Metal Additives

3 . Section 3- Qualification of Welders

4 . Section 4- Design and

. Preparation of a Joint for . Production

Welding

Page

Aims and General Information ..................................................................... ix

1.1 1.2 1.3 1.4 1.5

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8

4.1 4.2 4.3 4.4 4.5 4.6

Introduction ............................................................................................. 1 Finding Code Provisions ......................................................................... 3 Code Reference Examples ...................................................................... 4 Special Notes .......................................................................................... 4 Foreword ................................................................................................. 4 Contents .................................................................................................. 6

scope .................................................................................................... 1-1

Equipment ............................................................................................ 1-1

Definition of Terms .............................................................................. 1-1 Referenced Publications ...................................................................... 1-1

Materials .............................................................................................. 1-1

Procedure Qualification ....................................................................... 2-1 Record .................................................................................................. 2-1 Procedure Specification ....................................................................... 2-1 Essential Variables ............................................................................... 2-1 Welding of Test Joints-Butt Welds .................................................... 2-2 Testing of Welded Joints-Butt Welds ................................................ 2-2 Welding of Test Joints-Fillet Welds .................................................. 2-3 Testing of Welded Joints-Fillet Welds .............................................. 2-3

General ................................................................................................. 3-1 Single Qualification ............................................................................. 3-1

Visual Examination .............................................................................. 3-1 Destructive Testing .............................................................................. 3-2 Radiography-Butt Welds Only .......................................................... 3-2 Retesting .............................................................................................. 3-2 Records ................................................................................................ 3-2

Multiple Qualification ......................................................................... 3-1

General ................................................................................................. 4-1 Alignment ............................................................................................ 4-1 Use of Lineup Clamp for Butt Welds .................................................. 4-1 Bevel .................................................................................................... 4-1 Weather Conditions .............................................................................. 4-1 Clearance ............................................................................................. 4-1

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Module

5 . S e c t i o n s Inspection and Testing of Production Welds

6 . Section 6- Acceptance Standards for Nondestructive Test i n g

7 . Section7- Repair and Removal of Defects

8 . Section&- Procedures for Nondestructive Testing

9 . Section9- Automatic Welding

Page

4.7 Cleaning Between Beads ..................................................................... 4-1 ~

4.9 Roll Welding ........................................................................................ 4-1 4.8 Position Welding .................................................................................. 4-1

4.10 Identification of Welds ......................................................................... 4-1 4.11 Pre- and Post-Heat Treatment .............................................................. 4-1

5.1 5.2 5.3 5.4

Rights of Inspection ............................................................................. 5-1

Qualification of Inspection Personnel ................................................. 5-1 Certification of Nondestructive Testing Personal ................................ 5-1

Methods of Inspection ......................................................................... 5-1

Exercise Questions ............................................................................... 5-1

6.1 General ................................................................................................. 6-1 6.2 6.3 Radiographic Testing ........................................................................... 6-1 6.4 6.5 Liquid Penetrant Testing ...................................................................... 6-2 6.6 Ultrasonic Testing ................................................................................ 6-3 6.7 Visual Acceptance Standards for Undercutting ................................... 6-3 -

Rights of Rejection .............................................................................. 6-1

Magnetic Particle Testing .................................................................... 6-2

7.1 7.2

Defects Other Than Cracks .................................................................. 7-1 Authorization and Procedure for Repair of Cracks ............................. 7-1

8.1 8.2 8.3 8.4

Radiographic Test Methods ................................................................. 8-1 Magnetic Particle Test Methods .......................................................... 8-3 Liquid Penetrant Test Methods ............................................................ 8-3 Ultrasonic Test Methods ...................................................................... 8-3

9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11

.

Acceptable Processes ........................................................................... 9-1 Procedure Qualification ....................................................................... 9-1 Record .................................................................................................. 9-1 Procedure Specification ....................................................................... 9-1 Essential Variables ............................................................................... 9-1 Qualification of Welding Equipment and Operators ........................... 9-2 Records of Qualified Operators ........................................................... 9-2 Inspection and Testing of Welds .......................................................... 9-2 Acceptance Standards for Nondestructive Testing .............................. 9-2

Radiographic Testing ........................................................................... 9-2

- Repair and Removal of Defects ........................................................... 9-2 -

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Section 1Ck Automatic Welding Without Filler-Metal Additions

Section 11- Appendix

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10.1 Acceptable Processes ......................................................................... 10-1 10.2 Procedure Qualification ..................................................................... 10-1 10.3 Record ................................................................................................ 10-1 10.4 Procedure Specification ..................................................................... 10-1 10.5 Essential Variables ............................................................................. 10-1

Qualification of Equipment and Operators ........................................ 10-1 Records of Qualified Operators ......................................................... 10-2 Quality Assurance of Production Welds ............................................ 10-2 Acceptance Standards for Nondestructive Testing ............................ 10-2

10.10 Repair and Removal of Defects ......................................................... 10-2 10.11 Radiographic Procedure ..................................................................... 10-2

10.6 10.7 10.8 10.9

........................................................................................................... 11-1

Exercise Questions ............................................................................ EQ-1

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STDIAWS API-M-ENGL 0784265 0517130 645

AWS CODE CLINIC-API STANDARD i i 04, Welding of Pipelines and Related Facilities, EIGHTEENTH EDITION, May 1994

AIMS AND GENERAL INFORMATION

This AWS Code Clinic, published by the Education Department of the American Welding Society, is designed to guide and assist quality professionals-Inspec- tors, Supervisors, etc.-as well as quality-conscious engineers and managers, in reading and understanding ‘codes’ in general. However, no book, guide, or text, can substitute for hands-on knowledge and experience. Working through the examples in the text and answering the questions at the end of each Module, is a vitally important part of this AWS Code Clinic.

This Clinic is comprised of an introductory module plus eleven (11) additional modules. Each module covers a specific code section or the appendix.

A set of exercise questions is provided at the for modules one (i) through ten (10) at the end of the text. Responding to the questions provides a valuable review of the module material.

Students are strongly advised to make their own notations on the applicable code figure, table, or reference in their copy of API 1104.

It is vital the student’s copy of the code is physically open to the page under consideration. Remembering excerpts from the code is neither necessary nor desirable. The aim of this Clinic is to become familiar with API Standard 1104. It is not the aim of this Clinic to encourage memorization of any part of the code.

The tables and figures should be carefully reviewed. Working with each of these tables and figures is beneficial and effective in developing skill in reading codes. The exercise questions also illustrate the type of question likely to be encountered in practice. It is suggested that these questions should be answered at the conclu- sion of each module.

The suggested study program is as follows:

Table 1.1-Suggested Code Clinic Study Program

1. Review the code section@) being considered; 2. Consider how the subject of the module is or may be applicable in practice; 3. Answer the exercise questions.

The American Welding Society appreciates feedback from participants in their educational programs.

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STD.AWS API-M-ENGL E 0784265 0537333 581 AWS D1.l Code Clinic Aims and General Information

Please send comments, etc., to

American Welding Society Education Department 550 N.W. LeJeune Road Miami, FL 33126

or call the Education Director at 1-800-443-9353.

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STD.AWS API-il-ENGL O 07842b5 0517132 418 0 API 1 104 Code Clinic

Introduction to the AWS Code Clinic for API Standard 1104

INTRODUCTION TO THE AWS CODE CLINIC FOR API STANDARD 1104

Introduction The AWS Code Clinic for API 1104 is designed to assist and guide quality professionals. The Clinic is particularly addressed to those whose primary task is estab- lishing ‘product quality.’ This Clinic employs the American Petroleum Institute Standard 1104, Welding of Pipelines and Related Facilities, Eighteenth Edition.

American Petroleum Institute Standard 1104 is representative of the principles involved in reading any code, standard, specification or guide. WhiIe each such document has a specific purpose, the principles of use are constant. The definitions given in Table 1.1 below show the differences.

Table 1 .l-Definitions of “Code” Documents

A Code is “a body of laws; as of a nation, state, or industry group; arranged systematically for ease of use and reference.” Examples include AWS D1.l , API 11 04, and ASME Section VIII.

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A Standard is “established for use as a ’rule’ or basis of comparison in measur- ing quality, quantity, content, relative value, etc.” ASTM Standards for various products such as ASTM A36 for weldable structural steels are examples.

A Specification is “a detailed description of parts of a whole; a statement or enumeration of parts of a whole; a statement or enumeration of particulars as to actual or required quality, size, etc.” AWS Filler Metal Specifications A 5 1 through A5.31 are examples.

A Guide (self-explanatory) is a document of the same class; AWS 81.11, Guide for the Visual Inspection of Welds, is an example.

Such documents are generally known as ‘codes’ or ‘specs.’ While, as stated above, it is neither necessary nor desirable, to memorize specific provisions, it is essential to know ones way about any document being so used. Even with regu- larly referenced ‘code’ provisions, the preferred practice is to ‘look it upJ each time. Factors inapplicable in other instances may apply in the circumstance being considered. Failure to refer to the ‘Code’ may result in oversight of some vital provision.

Remember-quality is ‘measurable conformance to specifications.’

To establish product quality, codes, standards and specifications are invoked or mandated by ‘purchasers.’ The designated document(s) thus become(s), the ‘code’ (or sometimes, the spec) to which the product(s) concerned must ‘conform.’ It is thus vital that quality professionals be able to read, understand and apply the provisions of the ‘governing code’ as set out in the applicable purchase order documentation. It is for this purpose, the current Clinic is presented. An example of such a code is API 1104, the title sheet for which is shown in Figure 1.1 on the following page.

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STD-AWS API-M-ENGL II 07842b5 0517133 354 = API 1 lo4 Code Clinic Introduction to the AWS Code Clinic for API Standard 11 04

Finding Code Provisions

Welding of Pipelines and Related Facilities

LipI STANUARU llü4 EIGHTEENTH EDITION. MAY 1994

Figure 1.1-Title Page from API 1104

To facilitate working with a ‘code,’ it is worthwhile to ‘index’ its sections. API 1104 has ten (10) sections. An index tab at the first page of each section simplifies usage. Likewise, experience will show certain tables and figures are used fre- quently. These may also be flagged for ease of use and reference. See Figure 1.2 on the following page.

Many ‘codes’ make extensive use of ‘footnotes.’ These are often explanatory or cover a ‘special case.’ In ‘reading’ any code, looking it up on each occasion avoids the risk of overlooking some essential qualification, perhaps mentioned only in a footnote.

For example, turn to page 7 in your copy of API 1104. See that some Filler Metal Group Numbers in Table 1 are followed by small letter superscripts. Each of these refer to a footnote which may change some aspect of the provision(s) extracted from the table.

The term ‘code provision’ is used to mean the specific text of a code. In API 1104, for example, paragraph (or subsection) 1.1 sets out the scope (application) of th code as a whole, and begins with the words, “This standard covers the gas and arc- welding of butt, fillet.. . ’’

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STD.AWS API-M-ENGL 0784265 0537334 290 API 1 1 o4 Code Clinic


Figure 1.2-Section ID ‘Tabs’

In utilizing a code (or specification), it is necessary to establish the requirement for the feature of interest. If a groove weld is being inspected, it may be necessary to know, for example, the height of weld reinforcement permitted.

The welding inspector would determine the requirements laid down in the code for this feature. To simplify use, the application provision would be identified by its section, subsection, paragraph or subparagraph number. This is known, for the purposes of this text, as the ‘reference.’

While it is possible to find a particular provision by thumbing through the code, a more reliable approach is to address the problem in a systematic manner. The method suggested to find a particular code provision is set out in Table 1.2 on the following page.

The method set out in Table 1.2 on the next page is effective in all cases. How- ever, finding a code provision is greatly facilitated if the inquirer has a ‘feel’ for the code or specification in use. By knowing the layout and the structure of a code, it is possible to greatly shorten the time taken to find any required provision. This will be illustrated in the example that follows.

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STD-AWS API-M-ENGL I 0784265 0537335 327 I API 1 lo4 Code Clinic Introduction to the AWS Code Clinic for API Standard 1104

Table 1.2-Finding a Specific Code Provision

1. Define the ‘question’ to be considered.

2. Analyze the ‘question’ to identify key words or expressions that may be found in the Contents.

3. Locate the key word(s) in the Contents to obtain a ‘reference’ to the required provision(s).

4. Look up the provision in the applicable code section.

5. Ensure (verify) the provision(s) found idare applicable (as per the purchase order or job specification) and address(es) the ‘question’ in its entirety.

NOTE: As originally published, many documents have printing errors. Codes are no exception. Always check for and mark in the code any changes that are given on any applicable ‘Errata Sheets.’

Code Reference Examp les

When a radiographic test method is requested by the company, how long after processing shall the images still be interpretable?

Key word(s): a) radiographic test method b) processed, handled, and stored

Check Contents: Radiographic Test Methods (Page vii, 8.1) and subhead- ing-Image Processing (8.1.11)

Look it up: Find reference 8.1.11, Page 35, first column.

Provision: ...p rocessed, handled, and stored so that the images are interpretable for at least 3 years after they are processed.

Special Notes

Foreword

Inside the front cover there are five notes. API addresses problems of a general nature. Local, State, and Federal laws and regulations should be reviewed with respect to particular circumstances such as training, equipment, health, and safety risks, No API publication can be construed as insuring anyone against liability. Generally, API Standards are reviewed and revised at least every five years. Any API 1104 edition will no longer be in effect five years after its publication date.

The purpose of this standard is to present methods for the production of high-quai- ity welds and radiographs. It is entirely voluntary and applies to welding of piping used in the compression, pumping, and transmission of petroleum products, and fuel gases.

Where changes have been made in old requirements, a vertical line appears in the- margin immediately adjacent to the paragraph affected.

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API 1104 Contents

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STD.AWS API-M-ENGL 0784265 0537336 ob3 m API 1104 Code Clinic


The Contents list provisions by subsection number and title. The corresponding pages are given in the column to the right of the desired subsection.

Following the listing of subsection titles is the APPENDIX-ALTERNATIVE ACCEPTANCE STANDARDS FOR GIRTH WELDS.

List of Figures, titled as in the text, are set out in the order of appearance in the code text.

List of Tables, titled as in the text, are set out in the order of appearance in the code text.

There are Ten Sections as follows:

1. General

2. Qualification of Welding Procedures for Welds Containing Filler-Metal Additives

3. Qualification of Welders

4. Design and Preparation of a Joint for Production Welding

5. Inspection and Testing of Production Welds

6. Acceptance Standards for Nondestructive Testing

7. Repair and Removal of Defects

8. Procedures for Nondestructive Testing

9, Automatic Welding

10. Automatic Welding Without Filler-Metal Additions

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STD.AWS API-M-ENGL 0784265 05LïL37 T T T API 1 104 Code Clinic

Module #1-API Standard 1104, Section l a e n e r a l

1. MODULE #I-API STANDARD 1104, SECTION 14ENERAL

1.1 Scope

1.2 Definition of Terms

1.3 Referenced Publlcatlons

- 1.4 Equipment

1.5 Materials

API 1104 states that it covers the gas and arc welding of butt, fillet, and socket welds in carbon and low-alloy steel piping used in compression, pumping, and transmission of crude petroleum, petroleum products, and fuel gases and, where applicable, welding on distribution systems.

This standard (code) also covers acceptance standards applied to production welds tested to destruction or inspected by radiography.

Welding terms used in connection with API 1104 are to be interpreted in accordance with ANSI/AWS A3.O-Standard Welding Terms and Definitions. Addi- tions and modifications are given in 1.2.2.

Subsection 1.2.2 provides a list of the most common terms that are used through- out the code. An example is 1.2.2.10, which states that the term ‘ ‘ ~ h u l l ~ ~ indicates a mandatory requirement. The term “should” indicates a recommended practice.

This subsection provides a list of standards, codes, and specifications used through out the code.

This subsection provides that gas and arc welding equipment be capable of operat- ing within the parameters established on the welding procedure.

Subsection 1.5.1 requires that pipe and fittings must conform to either API Speci- fication 5L or applicable ASTM specifications.

Subsection 1.5.2.1 lists permissible filler metal specifications and also states that other filler metals may be used as long as welding procedures utilizing them are qual if ied .

Subsection 1.5.2.2 deals with storage and handling of filler metals and fluxes.

Subsection 1.5.3 describes the type, purity, dryness, storage and handling requirements for shielding gases. They shall be of welding quality and be qualified for the material and welding process being used. As stated, gases of questionable purity shall not be used.

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STD-AWS API-M-ENGL = 0784265 05LïL38 936 API 1 104 Code Clinic

Module #2-API Standard 11 04, Section 24ualification of Welding Procedures for Welds Containing Filler-Metal Additives

2. MODULE #2-API STANDARD 1104, SECTION 24UALIFICATION OF WELDING PROCEDURES FOR WELDS CONTAINING FILLER-METAL ADDITIVES

2.1 Procedure Before production welding is started, a detailed welding procedure specification shall be written and qualified in order to demonstrate that sound welds with suitable mechanical properties can be made by the procedure. A sample Welding Pro- cedure Specification form is shown on pages 4 and 5 of the code.

Qualification

2.2 Record

2.3 Procedure Specification

2.4 Essential Variables

The details and results of this qualification test shall be recorded. A sample Cou- pon Test Report form is shown on page 6 of the code. It is suggested that one review these sample forms, keeping close attention to the information specified in 2.3 and 2.4.

Paragraph 2.3.2 lists that information to be included in the procedure specification. In particular 23.2.2, “Pipe and Fitting Materials’, states that when welding materials of two separate material groups, the procedure for the higher strength group shall be used. The diameters and wall thickness qualified shall be identified in the welding procedure. It is suggested that the same ranges for welder qualification be used. These will be discussed in Module 3. As illustrated in the sample form, the joint design, number of beads and sequence are given. If a lineup clamp is used, the minimum percentage of root-bead weld that is completed before the clamp is removed is recorded in the procedure.

This subsection deals with essential variables. A welding procedure must be requalified whenever changes in these variables go beyond the range allowed.

Base materials are divided into three (3) groups; ‘a,’ ‘b,’ and ‘c.’ Group ‘a’ materials have a specified minimum yield strength less than or equal to 42,000 psi. Group ‘b’ materials have a minimum yield strength greater than those in group “a” but less than 65,000 psi. For yield strengths greater than 65,000 psi, group ‘c,’ each grade shall have a separate qualification test.

The note included in 2.4.2.2 does not imply that base or filler metals of different analyses within a group can be substituted. Consideration of compatibility from the standpoint of mechanical properties should be given.

Although major changes in the joint design are essential variables, minor changes in the angle of bevel or the root face (land) are not. (2.4.2.3)

A change from one filler-metal group to another is an essential variable. Table 1- “Filler Metal Groups,” lists the groups, AWS Specifications, electrodes and fluxes associated with each group. A general footnote in Table 1 (page 7 of the code) indicates that other electrodes, fillers and fluxes may be used but require separate procedure qualification. (2.4.2.6)

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STD.AWS API-N-ENGL W 07842b5 0537339 872 API 1 104 Code Clinic Module #2-API Standard 11 04, Section 24ualification of Welding Procedures for Welds Containing Filler-Metal Additives

A change in direction welding qualified, i.e., vertical up (uphill) to vertical down (downhill), or vice versa is considered an essential variable. (2.4.2.9)

An increase or decrease in the shielding gas flow rate may be considered an essential variable if the change is sufficient. A change in the type of shielding gas is an essential variable. Table 1, Footnote 'a,' (page 7 of the code) covers the essential variables associated with shielding fluxes. (2.4.2.11)

2.5

2.6

Welding of Test J o¡ n t s-

Test joints shall be made using two pipe nipples and the parameters of the welding procedure.

Butt Welds

Testing of Welded Joints- Butt Welds

This subsection covers the type, number, location, and requirements of test specimens for qualifying a welding procedure. (Section 10 deals with testing requirements for automatic welding without filler-metal.)

Figure 3 (page S)-"Location of Test Specimens for Procedure Qualification: Test Butt Weld" shows the tests and location of each specimen in qualifying a procedure using two pipe nipples. Special attention should be given to the notes in Figure 3 which allow for rotation (Note 1) and only one full section tensile specimen for small diameters (Note 2).

Table 2 (page 9)-"Type and Number of Test Specimens for Procedure Qualifi- cation Test" gives outside diameter of pipe, wall thickness as qualified and type and number of specimens per test. Note 'u' says that for pipe less than or equal to 1-5/16 in. in diameter, one full section tensile specimen may be substituted for the two nick break and two root-bend test. Note 'b' deals with materials with specified minimum yield strengths of more than 42,000 psi.

Subsection 2.6.2 covers the Tensile-Strength Test. Tensile-strength specimens shall be approximately 9 in. long and 1 in. wide (2.6.2.1). The tensile strength shall be calculated by dividing the maximum load at failure by the area of the specimen before any load was supplied (2.6.2.2). In order for the test specimen to pass the requirements, the weld must be equal to or greater than the specified minimum tensile strength of the pipe material (2.6.23).

Subsection 2.6.3 describes the Nick-Break Test. It covers the preparation of the specimen in 2.6.3.1. There is an alternative method for testing specimens that may fail in the pipe instead of the weld. In this alternative method, a 1/16 in. notch may be put in the weld reinforcement. Also, when qualifying a procedure using a semiautomatic or automatic welding process, the specimens may be macroetched before being nicked.

After the specimen has been broken, the dimensions of any discontinuities shall - be measured. The acceptance criteria is listed in Subsection 2.6.33.

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STD.AWS API-fl-ENGL 0784265 05L7L40 594 I API 1 104 Code Clinic

Module #2-API Standard 1 104, Section 2-Qualification of Welding Procedures for Welds Containing Filler-Metal Additives

Subsection 2.6.4 deals with the Root-Bend and Face-Bend Tests. After the specimens have been cut and prepared properly (2.6.4.1), they should be bent into an approximately U shape in a guided bend test jig shown in Figure 9 (page 14 of the code). Note that the correct dimensions for both the plunger and the die are given.

The acceptance criteria for acceptance of root and face bends are given in 2.6.4.3. No discontinuity exceeding 1/8 in. or one half the nominal wall thickness, whichever is smaller, may be present in the weld or fusion zone. Special consideration is given to comer cracks.

Side-Bend Test specimens (2.6.5) are prepared in quite a different manner as described in 2.6.5.1. After the specimen has been removed, it shall be machined or ground to a 1/2 in. width before bending.

The acceptance criteria for the side bend specimens are the same as those given for root and side bends. See 2.6.5.3.

2.7 Welding of Test Test joints for fillet welds shall be made to one of the configurations shown in Figure 10 (page 15 of the code) in accordance with the details of the welding Joints-Fillet

Welds procedure.

2.8 Testing of Test specimen locations and number of specimens for nick-break test are shown in Figure 10 and Figure 11. Note that for pipe less than 2-3/8 in. in diameter, it may be necessary to make two test welds. Also note that the figures are for welder and procedure qualification.

Welded Joints- Fillet Welds

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The acceptance criteria for fillet welds are given in 2.8.3.

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3. MODULE #3-API STANDARD 1104, SECTION 3-QUALIFICATION OF WELDERS

3.1 General

3.2 Single Qualification

3.3 Multiple Qualification

3.4 Visual Examination

The purpose of the welder qualification is to determine the ability of the welder to make sound welds in accordance with a qualified welding procedure. When qualifying, the welder will use the same techniques to be used during production welding.

In single qualification, the welder shall make a test butt weld in either the rolled or fixed position. When in the fixed position, the axis of the pipe shall be in either the horizontal plane, the vertical plane or inclined from the horizontal plane a maximum of 45 degrees.

As in procedure qualification, welder qualification also has essential variables. For single qualification, these are listed under 3.2.2.

For multiple qualification a welder must pass two different types of qualification tests. The first shall be made in the fixed position or inclined from the horizontal plane a maximum of 45 degrees. The weld must be made on a pipe with a diameter of at least 6-3/8 in. and a wail thickness of at least 1/4 in. The second test consists of a welder laying out, cutting, fitting and welding a branch-on-pipe connection. Pipe diameter and wall thickness are the same as in the butt weld. The run-pipe axis shall be in the horizontal position with the branch pipe vertical downward from the run. Visual acceptance criteria are given in 3.3.1.

Figure 12 shows the location of test specimens for the butt-weld test.

For the branch-on-pipe connection, the location of test specimens are shown in Figure 10.

Subsection 3.3.2 states that a welder who has qualified on pipe equal to or greater than 12-3/4 in. in diameter, in both the butt weld test and the branch-on-pipe test is qualified to weld in all positions, on all wall thicknesses, joint designs and fittings on all pipe diameters. A welder who completes both tests successfully on pipe less than 12-3/4 in. in diameter, is qualified to weld on all wall thicknesses, joint designs, and fittings, but is limited to pipe diameters less than or equal to that in which he/she qualified. The essential variables that require requalification are also listed in this subsection.

The requirements for successful visual examination of welder qualification test specimens are given in this subsection. It should be noted here that there were no visual acceptance criteria given in Section 2 for procedure qualification. Section 3.4 addresses cracks, inadequate penetration, burn through and other discontinuities. Undercutting shall not exceed 1/32 in. or 12.5 percent of pipe wall thickness, whichever is smaller. No more than 2 in. of undercut in any continuous 12 in. of weld is permitted.

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S T D AWS API-U-ENGL II 0784265 0517142 367 API 11 04 Code Clinic Module # S A P I Standard 1104, Section 3-Qualification of Welders

3.5 Destructive Test i ng

Table 3 (page 19 of the code) gives the type and number of test specimens required for welder qualification. Notice that the type of destructive tests used ir. welder qualification are the same as are used in procedure qualification, except that an equal number of nick-break specimens may be substituted for the tensile strength specimens per 3.5.2.

The preparation and acceptance criteria for destructive tests used for welder qualification are the same as the requirements for procedure qualification in Section.2.

3.6 Radiography- This subsection allows a company to qualify welders on butt welds using radiography in lieu of destructive tests. Butt Welds Only

3.7 Retesting A welder is permitted one retest without penalty if both the company and contrac- tor agree that conditions beyond the control of the welder may have affected the test results. In all other instances, a welder who fails a welder qualification test may not retest until the welder has submitted evidence of additional training that is acceptable to the company.

3.8 Records Records shall be kept of ail tests given to each welder and the results of each test. A list of welder qualifications and the procedures for which they qualified shall be maintained.

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STD-AWS API-M-ENGL m 0784265 OS17143 27'3 API 1 104 Code Clinic

Module #GAPI Standard 1 104, Section &Design and Preparation of a Joint for Production Welding

4. MODULE #4-API STANDARD 1104, SECTION ADESIGN AND PREPARATION OF A JOINT FOR PRODUCTION WELDING

4.1 General

4.2 Alignment

4.3 Use of Lineup Clamps for Butt Welds

4.4 Bevel

4.5 Weather Conditions

4.6 Clearance

4.7 Cleaning Between Beads

4.8 Position Welding

4.9 Roll Welding

- 4.1 O Identification of Welds

The surfaces to be welded shall be smooth, uniform, and free from laminations, tears, scale, slag, grease, paint or other deleterious material that might adversely affect welding.

Alignment of abutting ends of pipe the same nominal wall thickness shall not exceed 1/16 in. Larger offset caused by dimensional variations shall be equally distributed around the circumference of the pipe.

Use of lineup clamps is permitted in API 1104. This section deals with when to remove the lineup clamp and amount of root bead completion required.

Both mill bevels and field bevels are permitted as long as they conform to procedure specifications.

Welding shall not be done when weather conditions are such as to negatively affect the quality of the completed weld, as determined by the owner or owner's representative.

When welding is being performed above ground, the working clearance around the pipe at the weld should not be less than sixteen (16) in. When welding is being performed in a trench, the bell hole will be large enough to provide the welder(s) access to the joint.

Slag and scale shall be removed from each bead prior to continuation of welding. Methods should be specified in the welding procedure specification. For automatic and semi-automatic welding, surface porosity clusters, bead starts, and high points shall be removed by grinding prior to welding over them.

For position welding, the finished weld shall have a substantially uniform cross section around the entire circumference of the pipe. ' h o beads shall not be started in the same location. At no point shall the finished weld be below the outside surface of the pipe and it should not have a weld reinforcement (crown) exceeding 1/16 in. It should be approximately l/8 in. wider than width of original groove.

The requirements are essentially the same as for position welding, except that the pipe is rolled during welding as opposed to being fixed.

Each welder shall identify hidher work as prescribed by the company (owner).

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STD-AWS API-M-ENGL 0784265 0517144 L3T

APfi104 Code Clinic Module # S A P I Standard 1104, Section &Inspection and Testing of Production Welds

5. MODULE #+API STANDARD 1104, SECTION +INSPECTION AND TESTING OF PRODUCTION WELDS

5.1 Rightsof The owner may require inspection by nondestructive or destructive methods either during the welding process or after the welding has been completed. Inspection

5.2 Methods of The nondestructive testing method used will be specified by the company. Welds will be evaluated either using Section 6, ACCEPTANCE STANDARDS for NONDESTRUCTIVE TESTING, or by the Appendix. Usually the Appendix is used for a more extensive weld evaluation.

Inspection

5.3 Qualification of Inspection

Documentation of the qualifications of visual inspection personnel shall be retained by the company and shall include the following as a minimum:

a. Education and Experience b. Training c. Results of any qualification examinations

Personnel

5.4 Certification of Nondestructive Testing

Nondestructive testing personnel shall be certified in accordance with ASNT recommended practice SNT-TC-1A. Only Level II or Level III personnel shall interpret any test results. (5.4.1)

A record of certified nondestructive testing personnel shall be retained by the company. Level I and Level II personnel shall be recertified at least every three years and Level III personnel at least every five years. (5.4.2)

. Personnel

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STD.AWS API-N-ENGL 07842b5 0517145 07b M API 1 104 Code Clinic

Module # G A P I Standard 1 104, Section &Acceptance Standards for Nondestructive Testing

6. MODULE # G A P I STANDARD 1104, SECTION +ACCEPTANCE STANDARDS FOR NONDESTRUCTIVE TESTING

6.1

6.2

6.3

General The acceptance standards presented in this section apply to discontinuities located by radiography, magnetic particle, liquid penetrant and ultrasonic test methods. They may also be applied to visual inspection.

Rights of Rejection

The company reserves the right to reject any weld even though that weld may appear to meet the acceptance criteria given, if, in its opinion, the depth of the discontinuity may be detrimental.

Radiographic Test i ng

Subsection 6.3.1 addresses inadequate penetration. Inadequate penetration without high-low (IP) is shown in Figure 13 on page 23 of M I 1104. The acceptance criteria are also given in this section.

Inadequate penetration due to high-low (IPD) is addressed in Subsection 6.3.2 and illustrated in Figure 14 on page 24 of API 1104.

Incomplete fusion (IF) Is defined in Subsection 633 as a discontinuity between the weld metal and the base metal that is OPEN TO THE SURFACE and is illustrated in Figure 15 of API 1104.

Incomplete fusion due to cold lap (IFD), Subsection 63.4, is a discontinuity between two adjacent weld beads or between the weld metal and the base metal and IS NOT open to the surface. See Figure 16 of API 1104.

Subsection 6.3.5 covers internal concavity (IC) and is depicted in Figure 17 of API 1104. Internal concavity (IC) is acceptable as long as the density of the radiograph showing internal concavity does not exceed that of the thinnest adjacent base metal.

Burnthrough (BT) is defined in Subsection 6.3.6 as a portion of the root bead where excessive penetration has caused the weld puddle to be blown into the pipe. The unacceptability of BT is based on the outside diameter of the pipe and the dimensions of the burn through. The acceptance criteria are given in paragraph 6.3.6.2 and 6.3.63 of API 1104.

Subsection 63.7 describes slag inclusions as nonmetallic solid material trapped in the weld metal or between the weld metal and the pipe. API breaks slag inclusions into two main groups, elongated slag inclusions ( S I ) and isolated slag inclusions (ISI). ESI’s may be continuous or broken and are usually found at the fusion zone, whereas ISI’s are irregular in shape and are found anywhere in the weld.

Acceptance criteria for slag inclusion also depends on the outside diameter of the pipe and are given in 6.3.7.2 and 6.3.7.3 of API 1104.

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STD.AWS API-M-ENGL û7842b5 051714b TO2 API 1 104 Code Clinic Module # G A P I Standard 1 104, Section Wcceptance Standards for Nondestructive Testing

Porosity is defined in Subsection 6.3.8 as gas trapped by solidifying weld metal before it has had a chance to rise to the surface of the molten weld puddle a m escape. There may be individual or scattered porosity (P), cluster porosity (CP), or hollow-bead porosity (HB). Each type of porosity is described and acceptance criteria given in paragraphs 6.3.8.2,6.3.8.3, and 63.8.4 of API 1104. Figures 18 and 19 of API 1104 illustrate acceptable limits of scattered porosity.

Cracks, Subsection 63.9, are unacceptable except for shallow crater or star cracks whose length is 5/32 in. or less in length.

Subsection 6.3.10 defines undercutting and gives the acceptance criteria for undercutting adjacent to the cover pass (EU), and undercutting adjacent to the root pass (IU). Undercut is a discontinuity found adjacent to the toe of the weld. The acceptance in regards to the length of undercut is given in this subsection but the depth is addressed in the visual acceptance standards in Subsection 6.7.2 and is given in Table 4 on page 29 of API 1104.

Subsection 6.3.11 addresses the accumulation of discontinuities (AD) excluding IPD, EU, and IU.

Pipe or fitting discontinuities such as arc burns, long seam discontinuities, and other discontinuities detected by radiography shall be reported to the company -

and repaired or removed as directed by the company. (6.3.12)

6.4 Magnetic Particle Classification of indications found by magnetic particle testing (MT) are addressed in Subsection 6.4.1. Indications with a maximum dimension of 1/16 in. shall be classified as nonrelevant and need not be addressed. Any larger indication shall be regarded as relevant until further evaluation determines it is not relevant. Relevant indications are those caused by discontinuities. Linear indications are indications in which the length is more than three times the width. Rounded indications are indications whose length is less than or equal to three times their width.

Test i ng

Acceptance standards for relevant indications are given in Subsection 6.4.2.

Pipe or fitting discontinuities such as arc burns, laminations, long seam discontinuities, and other discontinuities detected by MT shall be reported to the company and repaired or removed as directed by the company. (6.4.3)

6.5 Liquid Penetrant The requirements for liquid penetrant testing (Pï) are the same as those for MT and are repeated here only to reference the proper subsections. Testing

- Classification of indications found by PT are addressed in Subsection 6.5.1. Indi- cations with a maximum dimension of 1/16 in. shall be classified as nonrelevai and need not be addressed. Any larger indication shall be regarded as relevanr- until further evaluation determines it is not relevant. Relevant indications are

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STD-AWS API-1-ENGL 0784265 0537147 749 API 1 104 Code Clinic

Module #GAPI Standard 11 04, Section &Acceptance Standards for Nondestructive Testing

those caused by discontinuities. Linear indications are indications in which the length is more than three times the width. Rounded indications are indications whose length is less than or equal to three times their width.

Acceptance standards for relevant indications are given in Subsection 6.5.2.

Pipe or fitting discontinuities such as arc bums, laminations, long seam discontinuities, and other discontinuities detected by MT shall be reported to the company and repaired or removed as directed by the company. (6.53)

6.6 Ultrasonic Testing

When using ultrasonic testing (UT), all indications that produce a response greater than 20 percent of the reference level shall be investigated to determine the location, shape, extent and type of reflection. The acceptance criteria are given in Subsection 6.6.2.

Pipe or fitting discontinuities such as arc bums, laminations, long seam discontinuities, and other discontinuities detected by MT shall be reported to the company and repaired or removed as directed by the company. (6.6.3)

6.7 Visual Undercutting has previously been defined in Subsection 63.10. The acceptance standards given in this section supplement, but do not replace those found else- where in API 1104. (6.7.1)

When visual and mechanical means are used to determine depth, undercutting adjacent to the cover or root beads shall not exceed the limits given in Table 4 of API 1104. When both mechanical and radiographic measurements are available, the mechanical measurements shall govern.

Acceptance Standards for Undercutting

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STD-AWS API-M-ENGL 0784265 05L7L48 885 API 1 lo4 Code Clinic

Module # 7 4 P I Standard 1 104, Section 7-Repair and Removal of Defects

7. MODULE #7-API STANDARD 1104, SECTION 7-REPAIR AND REMOVAL OF DEFECTS

7.1 Defects Other Subsection 7.1.1 states that defects, other than cracks, in the weld root and/or in the filler beads may be repaired with prior company authorization. Defects, other than cracks, in the cover pass do not need prior authorization. Any and all repairs shall meet the acceptability standards in Section 6, as applicable.

Than Cracks

Before repairs are made, the defect shall be completely removed to sound metal. Ail slag and scale shall be removed and preheat may be required by the company. (7.1.2)

All repairs shall be inspected by the same means previously used. (7.13)

7.2 Authorization Cracked welds shall be removed unless permitted by 63.9 or the appendix or when permitted by the company. Cracks may be repaired provided the following criteria are met:

a. The length of the crack is less than eight (8) percent of the weld length.

and Procedure for Repair of Cracks

b. A complete repair procedure has been developed and documented. The repair procedure shall include the following:

1. Method of exploration of crack area 2. Method of crack removal 3. Preheat and interpass temperature requirements 4. Welding procedure and type of electrodes 5. Postweld heat treatment requirements

c. The repair is made under the supervision of a technician who is experienced in welding repair techniques.

d. The weld is made by a qualified welder

e. The repair groove is examined by MT or FT to assure removal of the crack.

7-1


8. MODULE # G A P I STANDARD 1104, SECTION &-PROCEDURES FOR NONDESTRUC- TIVE TESTING

8.1 Radiographic Test Methods

Section 8 deals mostly with the radiographic test method, but other nondestructive test methods are addressed. It details the requirements for producing radiographic images on film or other media through the use of x-rays or gamma rays.

Subsection 8.1.1 calls for a detailed radiographic procedure to be established and recorded. This subsection also gives the criteria to be used to evaluate the quality of the radiographic image on film or other media.

Paragraph 8.1.2.2 details the minimum procedure requirements for film radiography.

When film radiography is being used, the type of radiation, and the size of focal point are required to be in the procedure. If x-rays are being used, the voltage rat- ing of the equipment is to be recorded in the procedure.

Film brand, type and number of frames per cassette are recorded as well as the way the film will be viewed when a multiple-film technique is used.

The procedure for film radiography shall address exposure geometry. The distance from the source to the film, relative position of the film, weld, source, penetrameters, reference markers and number of exposures for a complete weld are all listed in the procedure.

Both hole type and wire type penetrameters are permitted. When the hole type are used, the type of material, identifying number and essential hole are specified. For wire type, the type of material, identifying ASTM set letter and essential wire are specified in the procedure.

Additional procedure considerations include intensifying screens, exposure conditions, processing, materials to be radiographed and heat shields.

Other imaging media, Paragraph 8.1.2.3, requires procedures to include similar details as film radiography, but also include the system used for image collection, processing, viewing and storage.

Exposure geometry, Subsection 8.13, is also divided into requirements for film radiography and other imaging media and addresses such items as: where the source is located (on the inside or outside of the pipe), the distance of the source to the weld surface, how many exposures are required and how many degrees must separate each exposure.

For film radiography, Paragraph 8.1.3.1, the minimum distance from the source to the object will be determined by the formula:

D = St/k

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STD.AWS API-M-ENGL 0764265 0517150 433 = API 1 104 Code Clinic Module #û-APi Standard I 1 04, Section &Procedures for Nondestructive Testing

Abbreviations for the following should be reviewed and combinations understood:

Single Wail Exposure SWE

Double Wall Exposure DWE Double Wall Viewing DWV

Single Wall Viewing swv

The final acceptance of the exposure geometry shall be based on the ability to see the correct penetrameter and the essential hole or wire.

For other imaging media, Paragraph 8.1.3.2, the final acceptance of the exposure geometry shall be based on the ability to see the prescribed penetrameter image and the required essential hole or wire diameter.

Hole type penetrameters shall conform to ASTM E 142 or the standard penetrameter shown in Figure 20 of API 1104. Wire type penetrameters shall conform to ASTM E 747. (Subsection 8.1.4)

The maximum thickness of a hole type penetrameter is based on the thickness of the pipe wall or the weld. Table 5 of API 1104 shows the thickness of the pipe wall or weld, the corresponding maximum thickness of penetrameter, and the pen- -

etrameter identifying number for ASTM E 142 penetrameters. Table 6 shows th; same for Figure 20 penetrameters. Shims placed under the penetrameter are per- -

mitted when weld thickness is used to determine penetrameter number. Penetram- eters thinner than those specified in Tables 5 and 6 may be used. The essential hole for hole type penetrameters is the 2T hole. For Figure 20 penetrameters, the 2T hole need not be less than 1/16 in. in diameter. (Paragraph 8.1.5.1)

Table 7 of API 1104 shows the essential wire diameter, based on the thickness of the weld of ASTM E 747 wire penetrameters. (8.1.5.2)

Except when heat shields are used, penetrameters are placed in contact with the pipe. Paragraph 8.1.6.1 outlines the placement of penetrameters for film radiography with regards to the type of shot being made and the type of penetrameter being used.

Paragraph 8.1.6.2 details penetrameter placement for other imaging media.

Level II or III radiographers shall interpret the radiographic images of production welds and report all unacceptable discontinuities to the company. (Subsection 8.1.7)

- Except for small localized areas caused by irregular weld configurations, th transmitted density in the area of interest of transparent-based film shall not bb- less than 1.8 and no greater than 4.0. The reflected density for opaque-based film

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~ ~ ~

STD-AWS API-M-ENGL = 0784265 0517151 37T API 1 104 Code Clinic

Module #8-API Standard 1 104, Section &Procedures for Nondestructive Testing

shall not be less than 0.5 nor greater than 1.5. Transmitted densities through small localized areas have different limits as given in Paragraph 8.1.10.1 of API 1104.

The radiographer shall be responsible for protection and monitoring of every per- son working with or near radiation sources. (Paragraph 8.1.13)

8.2 Magnetic Particle Test Method

8.3 Liquid Penetrant Test Method

8.4 Ultrasonic Test Method

All MT shall be performed to a written procedure and meet the requirements of ASTM E 709.

All Fï shall be performed to a written procedure and meet the requirements of ASTM E 165.

All UT shall be performed to a written procedure and meet the requirements of ASTM E 164.

All nondestructive testing being performed shall demonstrate that the proposed procedures will produce acceptable results.

8-3


STD=AWS API-M-ENGL 0784265 0537152 206 API 1104 Code Clinic

Module # S A P I Standard 1 104, Section &Automatic Welding

9. MODULE #S-API STANDARD 1104, SECTION &AUTOMATIC WELDING

9.1 Acceptable Automatic welding shall be done with one or more of the following welding Processes processes:

Submerged Arc Welding-SAW Gas Metal Arc Welding-GMAW Gas Tungsten Arc Welding-GTAW Flux Cored Arc Welding-FCAW

9.2 Procedure Qualif ¡cation

9.3 Record

This section requires that a procedure must be established and qualified in order to demonstrate that welds with suitable mechanical properties and soundness may be made using the procedure.

The results of these qualification tests shall be recorded. A sample welding procedure specification form is shown in Figure 1, pages 4 and 5 of API 1104. A sample procedure qualification record form is shown in Figure 2, page 6 of API 1104. This form may also be used for welder qualification. It is suggested that one review these sample forms, keeping close attention to the information specified in Subsections 9.4 and 9.5.

9.4 Procedure Subsection 9.4.2 lists that information to be included in the procedure specification. In particular Paragraph 9.4.2.2, Pipe and Fitting Materials, states that the materials to be welded shall be identified in the procedure. Materials may be grouped as in 2.4.2.2 provided qualification is made on the material with the high- est specified minimum yield strength within the group.

Specification


This section deals with essential variables. An essential variable is a variable which when changed beyond certain limits, a new procedure qualification is required.

For the purpose of procedure qualification, base materials have been divided into three groups in Paragraph 9.5.2.2, based on yield strength. The first group has a specified minimum yield strength less than or equal to 42,000 psi. The second group has a minimum yield strength greater than those in the first group, but less than 65,000 psi. For yield strengths greater than 65,000 psi, each grade shall have a separate qualification test.

The note included in Paragraph 9.5.2.2 states that this grouping does not imply that base or filler metals of different analyses within a group can be substituted. Consideration should be given to the compatibility from the standpoint of mechanical properties.

In regards to joint design, major changes constitutes an essential variable.

A change from one filler-metal group to another is an essential variable.

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STD-AWS API - I -ENGL II 0784265 0517153 142 API 1 104 Code Clinic Module e A P I Standard 1104, Section &Automatic Welding

A change in the size of filler metal is an essential variable.

A change in direction of welding from vertical uphill to vertical downhill, or vice versa, is considered an essential variable.

A increase or decrease in the range of shielding gas flow rate constitutes an essential variable. A change in the type of shielding gas or percentage composition is an essential variable.

Table 1, Footnote “a” on Page 7 of API 1104 covers the essential variables associated with shielding fluxes.

9.6 Qualification of Welding Equipment and Operators

Qualification of both the welding equipment and the welding operator shall be made using a qualified welding procedure. If the welding procedure involves more than one operator, then each operator shall be qualified on the welding unit that will be used in production welding.

Welding procedures and qualification of welders shall meet the requirements of Subsection 3.4 through 3.7 of API 1104.

9.7 Record of Qualified Operators

Records shall be made and kept of each qualification test and the test results. Although a sample form is given in Figure 2, Page 6, of API 1104, it should be modified to suit the needs of the company. A list of qualified welding operator. and the procedures for which they are qualified shall be maintained.

9.8 Inspection and Production welds shall be inspected and tested in accordance with Section 5 of Testing of Welds API 1104.

9.9 Acceptance The acceptance standards for nondestructive testing shall be in accordance with Section 6 of API 1104 or, at the company’s option, the Appendix. Standards for

Nondestructive Testing

9.10 Repair and Removal of Defects

Repair and removal of defects shall be in accordance with Section 7 of API 1104. In addition, if the repair is made with a process other than that used on the original weld, a separate established and qualified procedure shall be used.

9.1 1 Radiographic Radiographic testing shall be in accordance with Subsection 8.1 of API 1104. Testing

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STD-AWS API-M-ENGL M 0784265 05L7154 089 m API 1104 Code Clinic

Module #i S A P I Standard 1 104, Section 1 &Automatic Welding Without Filler-Metal Additions

10. MODULE #1&API STANDARD 1104, SECTION 10-AUTOMATIC WELDING WITHOUT FILLER-METAL ADDITIONS

10.1 Acceptable Automatic welding without filler metal additions shall be limited to the flash butt Processes welding process.

10.2 Procedure As in all welding, before production welding begins a qualified welding procedure must be approved. Qualif kat ion

Procedure qualification requires that the weld be radiographed prior to performing any of the required mechanical tests and meet the acceptance criteria of Subsec- tion 10.9. (Paragraph 10.2.2)

The number and location of test specimens differ in this section from those of pre- vious sections. For location, refer to Figures 21,22, and 23 on pages 40 through 42 of API 1104. For type and number of tests required, refer to 'Igble 8 on page 44 of API 1104. Preparation of specimens are specified in Paragraphs 10.23.2 through 10.23.4. (Paragraph 10.2.3.1)

Tensile specimens shall be prepared and tested in accordance with Section 2 of API 1104. The requirements for acceptable tensile specimens are found in Para- graph 10.2.3.2.3.

Nick-Break Tests are covered under Paragraph 10.23.3.

Notice that for the nick-break, the size of the specimen is larger than those in pre- vious sections. Note also that the sides of the specimen shall be macroetched to locate the fusion zone.

Side bend specimens, Paragraph 10.2.3.4, shall be prepared and evaluated in accordance with the requirements of Section 2 of API 1104.

10.3 Record The details of each qualified procedure shall be recorded, addressing as a minimum, all of items listed in Subsection 10.4 of API 1104.

10.4 Procedure Since automatic welding without filler metal is somewhat a unique welding process, the procedure specification requirements in this subsection are unique to this type of welding.

Specification


The list of essential variables addressed in this subsection are also unique to automatic welding without filler metal.

10.6 Qualification Qualification of both the welding equipment and the welding operator shall be made using the proper welding procedure. The completed weld shall be subject to both radiography and mechanical testing as specified in Subsection 10.2.

- of Welding Equipment and -

Operators

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STD.AWS API-M-ENGL 07642b5 0517155 T15 API 1 104 Code Clinic Module #1 O-API Standard 11 04, Section 1 &Automatic Welding Without Filler-Metal Additions

10.7 Records of Records shall be made and kept of each qualification test and the test results. Although a sample form is given in Figure 2, Page 6, of N I 1104, it should be modified to suit the needs of the company. A list of qualified welding operators and the procedures for which they are qualified shall be maintained.

Qualified Operators

10.8 Quality The company reserves the right to inspect all welds by either nondestructive or destructive methods, or both.

Paragraph 10.8.2 of API 1104 states that the welding operator shall monitor the procedure parameters on strip chart recorder. The recorded values of the welding parameters shall be a basis for acceptance or rejection of the weld.

Assurance of

Welds Production

Paragraph 10.8.3 states that welds shall be inspected visually and radiograph- ically after flash removal and postweld heat treatment are complete.

Both inside and outside reinforcement can be grounds for rejection. API 1104 states in Paragraph 10.8.4, that the reinforcement on the inside diameter of the pipe shall not exceed 1/16 in. and on the outside diameter, weld reinforcement shall not exceed 1/8 in.

As a minimum, all completed flash butt welds shall be subject to postweld heat treatment above the lower transformation temperature (Ac3 line) after welding is complete. Cooling after such heat treatment shall be controlled or done in still air. The heat treatment cycle shall be documented on a strip-chart recorder. (Para- graph 10.8.5)

10.9 Acceptance The acceptance criteria for nondestructive testing of flash butt welds are given in Paragraph 10.9.2 and apply to radiography and other nondestructive testing methods. They may also be applied to visual inspection.

Standards for Nondestructive Testing

10.1 O Repair and Removal of Defects

This subsection addresses repairing and removing defects. Minor surface flaws may be removed by grinding, provided the minimum wall thickness of the pipe is not violated. Unacceptable defects may be removed by grinding, chipping, goug- ing, or a combination of these methods. Weld repair shall be in accordance with Section 7 of API 1104, but requires prior agreement by the company.

Repair of porosity found in flash butt welds is not permitted.

10.1 1 Radiographic Procedure

Radiographic testing shall be in accordance with Subsection 8.1 of API 1104.

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STDIAWS API-N-ENGL 07842b5 053735b 953 API 1 104 Code Clinic

Module #i 1-API Standard 11 04, Appendix-Alternative Acceptance Standards for Girth Welds

11. MODULE #i 1-API STANDARD 1104, APPENDIX-ALTERNATIVE ACCEPTANCE STANDARDS FOR GIRTH WELDS

The Appendix is an Alternative Acceptance Standard for Girth Welds. The use of the Appendix for evaluation of any or all flaws, including circumferential cracks, is completely at the company’s option.

The use of phrases using the wordfluw is not intended to imply a defective condi- tion of any lack of weld integrity.

The primary purpose of the Appendix is to define, on the basis of a technical analysis, the effect of various types, sizes, and shapes of anomalies on the suitabil- ity of the whole weld for a specific service.

11-1


STD-AWS API-U-ENGL = 078Y2b5 0537357 898 API 1 104 Code Clinic

Exercise Questions

FXERCISE QUESTIONS-MODULE #1

1.1 What does the term ‘position welding’ mean?

A. Welding with an all position welding electrode only B. Welding is carried out with pipe assembly rotated C. Applies when welding is done with a semiautomatic process D. Welding is carried out with pipe assembly stationary E. Welding done without a welding procedure

1.2 Shielding gases used to shield the arc, should never be:

A. An inert type gas B. Gas mixtures C. Field intermixed D. Kept in containers in which they are supplied E. Both A and B above

1.3 Carbon Steel Electrodes for Flux Cored Arc Welding can be found in what specification?

A. AWSA3.0 B. AWSA5.20 C. API 5L D. ASTME164 E. Ail of the above

1.4 Filler metals that are coated shall be protected from:

A. Dust B. Strong magnetic fields C. Excessive ultraviolet rays D. Excessive moisture E. None of the above

EQ-1


S T D e A W S API-fl-ENGL M 0784265 0517158 724 API 1 104 Code Clinic Exercise Questions

EXERCISE QUESTIONS-MODULE #2

2.1 API 1104 has grouped base material into three distinct groups. In group ‘b’ the specified minimum yield strength is:

A. Less than or equal to 42,000 pounds per square inch (psi) B. Greater than 42,000 psi but less than 65,000 psi C. Greater than 42,000 psi but less than 68,000 psi D. Greater than 289.58 MPa but less than 448.16 MPa E. BothBandD

2.2 For materials with specified minimum yield strengths more than 42 kips, the minimum number of tensile tests required idare?

A. W o B. One C. None are required D. Four E. None of the above

2.3 When preparing a tensile specimen for testing: -

A B, C. D E.

-_ A notch approximately 1/8 in. shall be cut into each side of the weld Ail reinforcement shall be machined or ground smooth A transverse notch shall be cut into the weld Weld reinforcement should not be removed on either side The specimen shall be bent in a guided bend jig

2.4 AWS Specification A5.20 is used for welding:

A. Pipe-both uphill and downhill B. Pipe in 2G position only C. Root pass welding only D. Electrodes in group 3 E. Both A and B above

2.5 When performing a nick-break test, the exposed area of fracture shall be at least how wide?

A. 1/2 in. wide B. 3/4 in. wide C. 5/8 in. wide D. 1-112 in. wide E. No requirement for fracture width

EQ-2


STD.AWS API-M-ENGL 07842b5 0537359 bb O m API 1 104 Code Clinic

Exercise Questions


3.1 When automatic or semiautomatic welding is used, filler wire protruding into the inside of the pipe:

A. Is not permitted B. Length of protrusion shall not exceed 1/16 in. C. Length of protrusion shall not exceed 0.79 mm D. Shall be kept to a minimum E. Both B and C above

3.2 For welder qualification on pipe greater than 4-1/2 in. in diameter, but less than or equal to 12-3/4 in. in diameter, the number of destructive test required are:

A. Four B. Six C. Same as procedure qualification D. Sixteen E. Depends on the wall thickness of the pipe

3.3 In branch-on-pipe connection qualification, the finished weld:

A. Shall exhibit a neat, uniform appearance B. Shall exhibit no burn-through C. No nick-break tests are required D. Shall not contain any burn-through exceeding 1/4 in. E. Both A and D above

EQ-3


STD.AWS API-M-ENGL 0784265 05L7LbO 382 API 1104 Code Clinic Exercise Questions


4.1 For position welding, the maximum reinforcement permitted is:

A. No more than the thickness of the pipe B. Depends on the amount of pipe offset C. 1/16 in. maximum D. 1/16 in. minimum E. Up to the welder’s discretion

4.2 Who determines that the weather conditions are unsuitable for welding?

A. Theowner B. The welder C. The welder’s supervisor D. The company E. A and D above

4.3 Which of the following are acceptable means for welders to identify their work?

A. Stenciling their identification symbol adjacent to the weld B. Recording their identification symbol on a weld “map” C. Writing their identification symbol adjacent to the weld using a permi’

nent marker D. Recording their identification on a traveler E. Any of the above methods as prescribed by the owner or owner’s

represen ta tive

EQ-4


S T D - A W S API-M-ENGL 0784265 05L7LbL 219 m API 1 104 Code Clinic

Exercise Questions


5.1 Who determines the frequency of inspection?

A. The welder B. The inspector C. The QC Manager D. The owner E. None of the above

5.2 Which of the following destructive or nondestructive testing methods may not be used?

A. Visual Inspection B. Radiographic Inspection C. Trepanning D. Penetrant Testing E. Bend Specimens

5.3 Nondestructive testing personnel, other than visual inspection personnel, shall be qualified in accordance with which of the following?

A. ASNT SNT-TC-1A B. ASME Section V C. ASTM 265E D. ASME Section IX E. None of the above

5.4 How often must Level III nondestructive testing personnel be recertified?

A. Every year B. Every two years C. Every three years D. Every four years E. Every five years

EQ-5


~

STD.AWS API-M-ENGL 0 0784265 05171rb2 155 m API 11 04 Code Clinic Exercise Questions

EXERCISE QUESTIONS-MODULE fi

6.1

6.2

6.3

6.4

6.5

The maximum width of an isolated slag inclusion in a weld on a pipe whose outside diameter is 6.625 in. is:

A. 1/16in. B. 118 in. C. 112 in. D. 1.59 mm E. Both B and D above

The maximum length of a crater crack is:

A. 118 in. B. 5/32 in. C. No cracks are allowed D. 112 the width of the bead E. Craters in welds cannot crack

When using ultrasonic testing, linear indications buried within the weld are unacceptable if they:

A. Exceed 2 in. in total length in a continuous 12 in. length of weld B. Exceed 5/32 in. C. Exceed 8 percent of the weld length D. Exceed 6 percent of the weld length E. Both A and C above

When inspecting a weld on 1/2 in. thick pipe, you measure some undercut at the face of the weld. The undercut mechanically measures 1/64 in. deep and approximately 6 in. long. The undercut is:

A. Not acceptable B. Must first be checked against radiograph measurements C. Is unacceptable because it exceeds 2 in. D. Is acceptable E. Undercut cannot be produced on face side of weld

Linear indications are those indications whose:

A. Length is more than three times its width B. Length is equal to its width C. Length is more than four times its width D. Width is equal to its length E. Length is less than its width

EQ-6


STD.AWS API-M-ENGL m 0784265 05L7Lb3 O92 API 1104 Code Clinic

Exercise Questions

- EXERCISE QUESTIONS-MODULE #7

7.1 Defects other than cracks require which of the following?

A. Prior company authorization if the defect is in the cover pass. B. No authorization regardless of location. C. No authorization if the defect is in the cover pass. D. Prior company authorization if the defect is in the root pass. E. C and D above

7.2 Cracked welds may be repaired provided which of the following criteria are met?

A. The length of the crack is less than eight (8) percent of the weld length B. The weld is made by a qualified welder C. A complete repair procedure has been developed and documented D. Ail of the above E. B and C above

EQ-7


STDmAWS API-I-ENGL = 0784265 05L7Lb4 T28 API 1 104 Code Clinic Exercise Questions


8.1 A radiographic test method using gamma radiation is being used to test a weld. When wire type penetrameters are used, the image of the essential diameter shall be:

A. The thickness of the penetrameter B. 2T hole C. Clear across the entire area of interest D. 1T hole E. Wire type penetrameters are not permitted in API 1104

8.2 Who shall interpret the radiographic film of production welds?

A. Level I B. Level I or Level II C. The inspector D. Level II or Level III E. TheCWI

8.3 When hole type penetrameters are based on weld thickness:

A. Choice of penetrameter shall be increased to next higher identification number.

B. Only wire type penetrameters are used when weld thickness is considered. C. Shimmed penetrameters are used. D. Weld must be ground flush before any radiography is performed E. The 4T hole must be visible

8.4 A weld was made on a pipe that had a wall thickness measurement of .432 in. What ASTM E142 penetrameter wound be used for this radiograph?

A. #15 B. #i0 C. #17 D. #7 E. Letter B

8.5 The abbreviation DWEISWV stands for?

A. Double-wall exposure for single-wall viewing B. Double-wall exposure for double-wall viewing C. Single-wall exposure for single-wall viewing D. Double-wall exposure on shielded weld V grooves E. Double-weld exposure for single welded viewing

EQ-8


STD-AWS API-M-ENGL 0784265 0517165 964 API 1104 Code Clinic

Exercise Questions

‘XERCISE QUESTIONS-MODULE #9

9.1 In automatic welding, the travel speed:

A. Is recorded in millimeters only B. Need not be addressed if current and volts are recorded C. Is recorded in inches only D. Must be recorded for each pass E. Both A and C above

9.2 Of the following which is not considered an essential variable?

A. Wall thickness B. Direction of welding C. Cleaning D. Welding Process E. Pipe diameter

9.3 In automatic welding, radiographic testing shall be in accordance with:

A. Section 9.6 B. Section 8.1 C. Section 8.4 D. Section 6.3 E. Section 2.5

EQ-9


STD.AWS API-M-ENGL = 0 7 8 4 2 6 5 05171bb 8TO API 1 104 Code Clinic Exercise Questions

- EXERCISE QUESTIONS-MODULE #IO

10.1 When evaluating a nick break specimen that was preformed on a flash butt weld, the maximum size slag inclusion allowed is:

A. 1/2 in. in length B. 1/32 in. in depth C. 1/2 in. in width D. 1/8 in. in length and width E. Both A and C above

10.2 Procedure qualification tests for a flash butt weld are being performed on a pipe that has an outside diameter of 20 in. What is the total number of specimens that will be tested?

A. 16 B. 24 C. 40 D. 32 E. 28

10.3 In flash butt welding all of the following are essential variables except: - ~

A. Welding position B. Axial speed tolerances C. Pipe material D. Pipe wall thickness E. Filler metal

10.4 A single IS1 in a flash butt weld shall not exceed:

A, 3/8 in. in length B. 1/2 in. C. 1/8 in. in length D. 1/16 in. in length E. No IS1 is allowed

10.5 When nondestructive testing is being performed on a flash butt weld:

A. It must be performed when weld is still hot B. After flash is removed C. Before heat treatment is complete D. After post heat treatment is complete E. Both B and D above

EQ-10


STD-AUS API-M-ENGL W 07842b5 0517167 737 API-11 o4 Code Clinic

Answer Key to Exercise Questions

Answer Key for API-1104 Code Clinic Reference Manual

Module #i Module #2 Module #3 1.1) D 2.1) E 3.1) D 1.2) c 2.2) B 3.2) B 1.3) B 2.3) D 3.3) E 1.4) D 2.4) C

2.5) B

Module #4 Module #5 Module #6 4.1) C 5.1) D 6.1) B 4.2) E 5.2) C 6.2) B 4.3) E 5.3) A 6.3) E

5.4) E 6.4) D 6.5) A

Module #8 Module #9 Module w7 7.1) E 8.1) C 9.1) D 7.2) D 8.2) D 9.2) C

8.3) C 9.3) B 8.4) B 8.5) A

Module #10 10.1) D 10.2) B 10.3) E 10.4) C 10.5) E


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