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, Florida 33126

© 2001 by American Welding Society Printed in the United States of America

All 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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Author’s Notes AWS has offered an AWS D1.1 Code Clinic for many years in conjunction with their Welding Inspection Seminar. During this time, interest in a corresponding seminar for API Standard 1104, Welding of Pipelines and Related Facilities, has continued to grow. This AWS Code Clinic – API Standard 1104 Reference Manual has been developed to provide a written text for such a seminar. It consists of modules and review questions and a system to index your code to make finding information faster and easier. The author recognizes Mr. Ken Jobes of Ken Jobes & Associates, Inc. for his work in the development of the manual as it related to the 18th edition. His professional efforts provided a good foundation for this manual. Scott C. Helzer PhD, CWI, CWE WQS, Inc. 2001

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TABLE OF CONTENTS AIMS AND GENERAL INFORMATION 1 INTRODUCTION TO THE AWS CODE CLINIC FOR API 1104 2 Introduction Definition of Documents Finding Code Provisions Code Reference Example API 1104 Special Notes Foreword API 1104 Contents CHANGES FROM THE 18th EDITION TO THE 19th EDITION of API 1104 5 Module #1 - API STANDARD 1104 9

SECTION 1 - GENERAL Scope

SECTION 2 – REFERENCED PUBLICATIONS Referenced Publications

SECTION 3- DEFINITION OF TERMS Definition of Terms

SECTION 4- SPECIFICATIONS Equipment Materials

Exercise Questions Module #2 - API STANDARD 1104 15

SECTION 5 - QUALIFICATION OF WELDING PROCEDURES FOR WELDS CONTAINING FILLER - METAL ADDITIVES Procedure Qualification Record Procedure Specification Essential Variables Welding of Test Joints - Butt Welds Testing of Welded Joints - Butt Welds Welding of Test Joints - Fillet Welds Testing of Welded Joints - Fillet Welds

Exercise Questions Module #3 - API STANDARD 1104 20

SECTION 6 - QUALIFICATION of WELDERS

General Single qualification Multiple Qualification Visual Examination Destructive Testing Radiography - Butt Welds Only

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Retesting Records

Exercise Questions

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Module #4 - API STANDARD 1104 23 SECTION 7 - DESIGN AND PREPARATION OF A JOINT FOR PRODUCTION WELDING

General Alignment Use of Lineup Clamp for Butt Welds Bevel Weather Conditions Clearance Cleaning Between Beads Position Welding Roll Welding Identification of Welds Pre and Post-Heat Treatment

Exercise Questions Module #5 - API STANDARD 1104 25 SECTION 8 - INSPECTION AND TESTING OF PRODUCTION WELDS

Rights of Inspection Methods of Inspection Qualification of Inspection Personnel Certification of Nondestructive Testing Personal

Exercise Questions Module #6 - API STANDARD 1104 28

SECTION 9 - ACCEPTANCE STANDARDS FOR NONDESTRUCTIVE TESTING General Rights of Rejection Radiographic Testing Magnetic Particle Testing Liquid Penetrant Testing Ultrasonic Testing Visual Acceptance Standards for Undercutting

Exercise Questions Module #7 - API STANDARD 1104 36 SECTION 10 - REPAIR AND REMOVAL OF DEFECTS

Defects Other Than Cracks Authorization and Procedure for Repair of Cracks

Exercise Questions Module #8 - API STANDARD 1104 38 SECTION 11 - PROCEDURES FOR NONDESTRUCTIVE TESTING

Radiographic Test Methods Magnetic Particle Test Methods Liquid Penetrant Test Methods Ultrasonic Test Methods

Exercise Questions

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Module #9 - API STANDARD 1104 44

SECTION 12 - AUTOMATIC WELDING Acceptable Processes Procedure Qualification Record Procedure Specification Essential Variables Qualification of Welding Equipment and Operators Records of Qualified Operators Inspection and Testing of Welds Acceptance Standards for Nondestructive Testing Repair and Removal of Defects Radiographic Testing

Exercise Questions Module #10 - API STANDARD 1104 47 SECTION 13 - AUTOMATIC WELDING WITHOUT FILLER - METAL ADDITIONS

Acceptable Processes Procedure Qualification Record Procedure Specification Essential Variables Qualification of Equipment and Operators Records of Qualified Operators Quality Assurance of Production Welds Acceptance Standards for Nondestructive Testing Repair and Removal of Defects Radiographic Procedure

Exercise Questions Module #11 - API STANDARD 1104 51

APPENDIX A – ALTERNATE ACCEPTANCE STANDARDS FOR GIRTH WELDS Module #12 - API STANDARD 1104 52

APPENDIX B – IN-SERVICE WELDING

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AWS CODE CLINIC - API STANDARD 1104, “Welding of Pipelines and Related Facilities”, NINETEENTH EDITION, SEPTEMBER 1999 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 - Inspectors, 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 API 1104 Code Clinic study guide is comprised of an introductory module, conversion notes to go from the 18th edition to the 19th edition, eleven (11) modules. Each module covers a specific code section or the appendix. A set of exercise questions is provided at the end of each module. 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 following each module also illustrate the type of question likely to be encountered in practice. It is suggested that these questions should be answered at the conclusion of each module.

The suggested study program is as follows: 1. Review of Code Section(s) being considered;

2. Consider how the subject of the Module is or may be applicable in practice;

3. Answer the exercise questions. Table 1.1 - Suggested Code Clinic Study Program The American Welding Society appreciates feedback from participants in their education programs. Please send comments, etc., to: American Welding Society Education Department 550 NW LeJeune Rd Miami Fl 33126 or call the Education Department at: 1-800-443-9353

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INTRODUCTION TO THE AWS CODE CLINIC FOR API 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 establishing 'product quality'. This Clinic employs the American Petroleum Institute Standard 1104, Welding of Pipelines and Related Facilities, Nineteenth Edition. American Petroleum Institute 1104 is representative of the principles involved in reading any Code, Standard, Specification or guide. While each such document has a specific purpose, the principles of use are constant. The following definitions show the differences.

Definitions of 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 D1.1, API 1104 and ASME Section VIII. A STANDARD is “established for use as a ‘rubasis of comparison in measuring 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 A5.1, through A5.31, are examples. A guide (self-explanatory) is a document of the same class; AWS B1.11 - Guide for the Visual Examination of Welds, as 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 regularly referenced ‘code’ provisions, the preferred practice is to ‘look it up’ each time. Factors inapplicable in other instances may apply to the circumstance being considered. Failure to refer to the ‘Code’ may result in oversight of some vital provision.

Figure 1.1 - Title Page From API 1104 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 previous page. To facilitate working with a ‘code’, it is worthwhile to ‘index’ its sections. API 1104 has thirteen (13) sections plus two (2) appendices. An index tab at the first page of each section simplifies usage. Likewise, experience will show certain tables and figures are used frequently. These may also be

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flagged for ease of use and reference. See Figure 1.2 below.

Figure 1.2 - Section ID ‘Tabs’

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 refers to a footnote, which may change some aspect of the provision(s) extracted from the table. FINDING CODE PROVISIONS 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 the code as a whole, and begins with the words, “This standard covers the gas and arc welding of butt, fillet . . .”. 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, its section, subsection, paragraph or subparagraph number would identify the application provision. 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 below. 1. Define the information you are seeking and convert it into a ‘question’ using code terms.

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

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 is/are applicable (as per the purchase order or job specification) and address(es) the ‘question’ in its entirety. Table 1.2 - Finding a Specific Code Provision The method set out in Table 1.2 above is effective in all cases. However, 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. 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

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CODE REFERENCE EXAMPLE When the company requests a radiographic test method, how long after processing shall the images still be interpretable? Key words: a) radiographic test method b) processed, handled, and stored Check Contents: Section 11 – Procedures for Nondestructive Testing (Page vi) and subheading 11.1 - Radiographic Test Methods. Look it up: Find reference 11.1.11, Image Processing (Page 34), first column. Provision: ...processed, handled, and stored so that the images are interpretable for at least 3 years after they are produced. API 1104 SPECIAL NOTES 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. FOREWORD The purpose of this standard is to present methods for the production of high-quality 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. API 1104 CONTENTS 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 thirteen sections plus to appendices as follows:

1. General 2. Referenced Publications 3. Definition of Terms 4. Specifications 5. Qualification of Welding Procedures for

Welds Containing Filler-Metal Additives 6. Qualification of Welders 7. Design and Preparation of a Joint for

Production Welding 8. Inspection and Testing of Production

Welds 9. Acceptance Standards for Nondestructive

Testing 10. Repair and Removal of Defects 11. Procedures for Nondestructive Testing 12. Automatic Welding 13. Automatic Welding Without Filler-Metal

Additions Appendix A – Alternative Acceptance Standards

for Girth Welds Appendix B – In-Service Welding.

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API 1104 18th Edition (OLD) API 1104 19th Edition (NEW) Section / Subsection 18th Edition Title & Subsection 19th Edition Page Number 19th EditionSECTION 1 1 GENERAL 1

1.1 1.1 Scope 1

1.3 2 REFERENCED PUBLICATIONS 1

1.2 3 DEFINITION OF TERMS 21.2.1 3.1 General 21.2.2 3.2 Definitions 2

4 SPECIFICATIONS 21.4 4.1 Equipment 21.5 4.2 Materials 2

SECTION 2 5 QUALIFICATION OF WELDING PROCEDURES FOR WELDS CONTAINING FILLER-METAL ADDITIVES32.1 5.1 Procedure Qualification 32.2 5.2 Record 32.3 5.3 Procedure Specification 32.4 5.4 Essential Variables 62.5 5.5 Welding of Test joints - Butt Welds 72.6 5.6 Testing of Welded Joints - Butt Welds 82.7 5.7 Welding of Test Joints - Fillet Welds 132.8 5.8 Testing of Welded Joints - Fillet Welds 15

SECTION 3 6 QUALIFICATIONS OF WELDERS 153.1 6.1 General 153.2 6.2 Single Qualification 153.3 6.3 Multiple Qualification 163.4 6.4 Visual Examination 163.5 6.5 Destructive Testing 183.6 6.6 Radiography - Butt Welds Only 193.7 6.7 Retesting 193.8 6.8 Records 19

Changes From the API 1104 18th Edition to the 19th Edition Portions of the 1104 standard have been changed from the 18th ed. To the 19th Edition in the codebook the changes have been designated using a side bar in the margin. In many cases the changes are merely editorial and in other cases like Appendix B entire new sections have been added to the code. Most note able of the code changes is the expansion of the code from ten (10) major sections to thirteen (13) sections, the additions of Appendix B and a substantial amount of material in the ultrasonic inspection area. The three additional sections of the code happened as a

result of breaking the general section of the code into 4 separate parts, general, referenced publications, Definition of Terms and Equipment. If the reader was accustomed to using the 18th Edition of the code the following chart has been provided to aid the reader in the use of the 19th Edition. The table is formatted with the old section number on the left and the new section number on the right with the content topic area in the middle. If you cannot find the sub topic listed in the content column, many of them have been removed from the contents section, making your tabbing of the code an even greater benefit.

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SECTION 4 7 DESIGN AND PREPARATION OF A JOINT FOR PRODUCTION WELDING 194.1 7.1 General 194.2 7.2 Alignment 194.3 7.3 Use of Lineup Clamp for Butt Welds 194.4 7.4 Bevel 194.5 7.5 Weather Conditions 194.6 7.6 Clearance 194.7 7.7 Cleaning Between Welds 204.8 7.8 Position Welding 204.9 7.9 Roll Welding 204.1 7.10 Identification of Welds 20

4.11 7.11 Pre- and Post - Heat Treatment 20

SECTION 5 8 INSPECTION AND TESTING OF PRODUCTION WELDS 205.1 8.1 Rights of Inspection 205.2 8.2 Methods of Inspection 205.3 8.3 Qualification of Inspection Personnel 205.4 8.4 Certification of Nondestructive Testing Personnel 21

SECTION 6 9 ACCEPTANCE STANDARDS FOR NONDESTRUCTIVE TESTING 216.1 9.1 General 216.2 9.2 Rights of Rejection 216.3 9.3 Radiographic Testing 216.4 9.4 Magnetic Particle Testing 276.5 9.5 Liquid Penetrant Testing 276.6 9.6 Ultrasonic Testing 276.7 9.7 Visual Acceptance Standards for Undercutting 28

SECTION 7 10 REPAIR AND REMOVAL OF DEFECTS 297.1.1 10.1 Authorization for Repair 29

7.2 10.2 Repair Procedure 297.1.3 10.3 Acceptance Criteria 297.2-C 10.4 Supervision 297.2-D 10.5 Welder 29

SECTION 8 11 PROCEDURES FOR NONDESTRUCTIVE 298.1 11.1 Radiographic Test Methods 298.2 11.2 Magnetic Particle Test Method 348.3 11.3 Liquid Penetrant Test Methods 348.4 11.4 Ultrasonic Test Methods 34

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SECTION 9 12 AUTOMATIC WELDING 379.1 12.1 Acceptable Processes 379.2 12.2 Procedure Qualification 389.3 12.3 Record 389.4 12.4 Procedure Specification 389.5 12.5 Essential Variables 399.6 12.6 Qualification of Welding Equipment and Operators 409.7 12.7 Records of Qualified Operators 409.8 12.8 Inspection and Testing of Production Welds 409.9 12.9 Acceptance Standards for Nondestructive Testing 40

9.10 12.10 Repair and Removal of Defects 409.11 12.11 Radiographic Testing 40

SECTION 10 13 AUTOMATIC WELDING WITHOUT FILLER-METAL ADDITIONS 4010.1 13.1 Acceptable Processes 4010.2 13.2 Procedure Qualification 4010.3 13.3 Record 4610.4 13.4 Procedure Specification 4610.5 13.5 Essential Variables 4610.6 13.6 Qualification of Equipment and Operators 4610.7 13.7 Records of Qualified Operators 4610.8 13.8 Quality Assurance of Production Welds 4610.9 13.9 Acceptance Standards for Nondestructive Testing 47

10.10 13.10 Repair and Removal of Defects 4710.11 13.11 Radiographic Procedure 47

APPENDIX A APPENDIX A ALTERNATE ACCEPTANCE STANDARDS FOR GIRTH WELDS 49A.1 A.1 General 49A.2 A.2 Additional Requirements for Stress Analysis 49A.3 A.3 Welding Procedure 50A.4 A.4 Qualification of Welders 54A.5 A.5 Inspection and Acceptable Limits 54A.6 A.6 Record 55A.7 A.7 Example 55A.8 A.8 Repairs 59A.9 A.9 Nomenclature 59

NEW APPENDIX B IN-SERVICE WELDING 61NEW B.1 General 61NEW B.2 Qualification of In-Service welding Procedures 62NEW B.3 In-Service Welder Qualification 63NEW B.4 Suggested In-Service Welding Practices 64NEW B.5 Inspection and Testing of In-Service Welds 67NEW B.6 Standards of Acceptability: Nondestructive testing (Including Visual) 67NEW B.7 Repair and Removal of Defects 67

FIGURES Figures

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FIGURES Figures1 1 Sample Procedure Specification Form 42 2 Sample Coupon Test Report 53 3 Location of Test Butt-Weld Specimens for Procedure Qualification Test 94 4 Tensile - Strength Test Specimen 105 5 Nick - Break Test Specimen 106 6 Root- and Face- Bend Test Specimen: Wall Thicknesses Less Than or Equal to 0.500 in. (12.7 mm) 117 7 Side Bend Test Specimen : Wall Thickness Greater Than 0.500 in. (12.7 mm) 128 8 Dimensioning of Imperfections in Exposed Weld Surfaces 129 9 Jig for Guided-Bend Tests 13

10 10 Location of Nick-Break Test Specimens: Fillet-Weld Procedure and Welder Qualification Test Welds 1411 11 Location of Nick-Break Test Specimens: Fillet-Weld Procedure and Welder Qualification Test Welds

Including Size to Size, Branch-Connection Welder Qualification Test 1412 12 Location of Test Butt-Weld Specimens for Welder Qualification Test 1713 13 Inadequte Penetration Without High-Low (IP) 2114 14 Inadequte Penetration Due to High-Low (IPD) 23

NEW 15 Inadequte Cross Penetration (ICP) 2315 16 Incomplete Fusion at Root of Bead or Top of Joint (IF) 2316 17 Incomplete Fusion Due to Cold Lap (IFD) 2317 18 Internal Concavity (IC) 2318 19 Maximum Distribution of Gas Pockets: wall Thicknesses Less Than or Equal to 0.500 in. (12.7mm) 2519 20 Maximum Distribution of Gas Pockets: Wall Thicknesses Greater Than 0.500 in. (12.7 mm) 2620 21 Standard Penetrameter 32

NEW 22A Reference Block for Manual UT 36NEW 22B Establishing Distance, Refracted Angle, and Velocity 37NEW 22C Transfer Procedure 37

21 23 Location of Test Butt-Weld Specimens for Flash Weld Procedure Qualification Test: Outside Diameter Greater Than 18 in. (475mm) but Less Than or Equal to 24 in. (610 mm) 42

22 24 Location of Test Butt-Weld Specimens for Flash Weld Procedure Qualification Test: Outside Diameter Greater Than 24 in. (610mm) but Less Than or Equal to 30 in. (6762 mm) 43

23 25 Location of Test Butt-Weld Specimens for Flash Weld Procedure Qualification Test: Outside Diameter Greater Than 30 in. (6762 mm) 44

24 26 Two Inch Nick-Break Test Specimen 45A-1 A-1 Location of CTOD Test Specimens 51A-2 A-2 Machining Objective for CTOD Test Specimen With Resped to Pipe Wall 52A-3 A-3 Location of Notch for Weld-Metal Specimen 52A-4 A-4 Location of Notch for Heat Affected Zone Specimen 52A-5 A-5 Alternativee Acceptance Criteria for Circumferential Panar Imperfections 53A-6 A-6 Criteria for Evaluation of Imprerfection Interaction 56A-7 A-7 Length Limit for Deep Imperfections in Heavy-Wall Pipe 58A-8 A-8 Nomenclature for Dimensions of Surface and Burried Imperfections 59

NEW B-1 Examples of Typical Temper-Bead Deposition Sequences 61NEW B-2 Suggested Procedure and Welder Qualification Test Assembly 64NEW B-3 Location of Test Specimens - In-Service Welding Procedure Qualification Test 65NEW B-4 Macro Test Specimen - In-Service Welds 66NEW B-5 Face Bend test Specimen 66NEW B-6 Reinforcing Pad 67NEW B-7 Reinforcing Saddle 68NEW B-8 Encirclement Sleeve 68NEW B-9 Encirclement Tee 69NEW B-10 Encirclement Sleeve and Saddle 69NEW B-11 Encirclement Saddle 70

TABLES Tables1 1 Filler Metal Groups 72 2 Type and Number of Test Specimens for Procedure Qualification Test 83 3 Type and Number of Butt-Weld Test Specimens per Welder for Welder Qualification Test and Destructive

Testing of Production Welds 184 4 Maximum Dimensions of Undeercutting 295 5 Thickness of Pipe Versus Thickness of ASTM E 1025 Penetrameter 316 6 Thickness of Pipe Versus Thickness of Penetrameter 327 7 Thickness of Pipe Versus Thickness of ASTM E 747 Wire Penetrameter 328 8 Type and Number of Test Specimens for Procedure Qualification Test (Flash Weld Only) 41

A-1 A-1 Acceptance limits for Burried Volumetric Imperfections 54A-2 A-2 Acceptance Limits for Unrepaired Arc Burns 55A-3 A-3 Imperfection Length Limits 57A-4 A-4 Allowable Imperfection Dimensionss for Example 58A-5 A-5 Acceptable Planar Imperfection Dimensions for Example 58A-6 A-6 Example Alternativee Acceptance Criteria 59

NEW B-1 Type and Number of Specimens - In-Service welding procedure Qualification Test 65

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MODULE #1 - AWS CODE CLINIC FOR THE STUDY OF API 1104 SECTION 1 - GENERAL 1.1 Scope. API 1104 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 and in service welding. SECTION 2 – REFERENCED PUBLICATIONS This subsection provides a list of standards, codes and specifications used through out the code. The list is shown in table One. SECTION 3 – DEFINITION OF TERMS 1.2 Definition of Terms. Welding terms used in connection with API 1104 are to be interpreted in accordance with ANSI/AWS A3.0 - Standard Welding Terms and Definitions. Additions and modifications are given in 3.2. Subsection 3.2 provides a list of the most common terms that are used throughout the code. An example is 3.2.16, which states that the term “shall” indicates a mandatory requirement. The term “should” indicates a recommended practice. SECTION 4 - SPECIFICATIONS 4.1 Equipment. This subsection provides that gas and arc-welding equipment be capable of operating within the parameters established on the welding procedure. 4.2 Materials. Subsection 4.2.1 requires that pipe and fittings must conform to either API Specification 5L or applicable ASTM specifications. Subsection 4.2.2.1 lists permissible filler metal specifications and also states that other filler metals may be used as long as welding procedures utilizing them are qualified. Table One places the filler materials in groups that directly relate to welder qualifications and process applications.

Subsection 4.2.2.2 deals with storage and handling of filler metals and fluxes. Subsection 4.2.3 describes the type, purity and dryness and 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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GENERAL EXERCISE QUESTIONS - MODULE #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 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 3. Carbon Steel Electrodes for Flux Cored Arc Welding can be found in what specification? A. AWS A3.0 B. AWS A5.20 C. API 5L D. ASTM E 164 E. All of the above 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

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Exercise Questions— API Standard 1104 - Section One - General 1.1 What topics does API 1104 cover? A. Gas welding of butt welds B. Arc welding of fillet and socket welds C. Welding carbon and low-alloy steels D. Welding petroleum pipelines E. All of the above 1.2 Which nondestructive testing method is specified in API 1104? A. Nick-break test B. Bend test for butt welds only C. Radiographic examination D. Metallurgical evaluation E. All of the above 1.3 Which welding process is specifically mentioned for use with this Code? A. Flash butt B. Submerged Arc C. Oxyacetylene D. Gas Metal Arc E. All of the above 1.4 It is stated in 1.1 Scope that SI units are acceptable to use with this Code. A. True B. False

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Exercise Questions— API Standard 1104 - Section Two - Referenced Publications 2.1 Which of the referenced codes is published by a foreign society? A. ASTM E 164 B. API Spec 5L C. AWS A5.28 D. BSI BS 7448 E. none of the above 2.2 Which organization publishes most of the inspection codes cited in API 1104? A. API B. ASNT C. ASTM D. AWS E. NACE 2.3 Which organization publishes most of the filler metal specifications for this Code? A. AWS B. ASNT C. ASTM D. BSI E. NACE 2.4 Which organization publishes a document on personnel certification used by this Code? A. API B. ASNT C. AWS D. BSI E. NACE

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Exercise Questions— API Standard 1104 - Section Three - Definition of Terms 3.1 The term that best describes an acceptable weld flaw is: A. defect B. imperfection C. indication D. concavity E. ridge 3.2 API 1104 uses the definitions of welding terms published by which organization? A. API B. ASNT C. AWS D. BSI E. NACE 3.3 What process uses equipment that controls only the filler metal feed? A. roll welding B. submerged arc welding C. gas tungsten arc welding D. semiautomatic welding E. root bead welding 3.4 The process where the pipe remains stationary during welding is called: A. automatic welding B. position welding C. roll welding D. root bead welding E. semiautomatic welding

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Exercise Questions— API Standard 1104 - Section Four - Specifications 4.1 API 1104 applies to pipe welding that conforms to which specifications? A. AWS 5.28 B. BSI BS 7448 C. API Specification 5L D. applicable ASTM E. Both C&D 4.2 Once opened, where shall SMAW filler metals ending with numbers 5,6,8 be stored? A. in ambient air B. electrode oven C. shipping container D. old refrigerator with 200 watt light bulb E. special plastic bags 4.3 What determines the tip size for gas welding equipment? A. manufacturer’s instructions B. trial and error C. welding procedure D. engineering drawing E. pressure of the gas 4.4 Coated filler metals and fluxes are sensitive to: A. ambient humidity B. overheating C. hydrogen cracking D. inert gases E. active gases

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MODULE #2 - AWS CODE CLINIC FOR THE STUDY OF API 1104 SECTION 5 - QUALIFICATION OF WELDING PROCEDURES FOR WELDS CONTAINING FILLER-METAL ADDITIVES 5.1 Procedure Qualification. 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. 5.2 Record. The details and results of this qualification test shall be recorded. A sample welding procedure specification form and a coupon test report are shown on pages 4 and 5 of the code respectively and also in Figures One and Two at the right of this column. It is suggested that one review this sample form, keeping close attention to the information specified in 5.3.2. 5.3 Procedure Specification. Subsection 5.3.2 lists that information to be included in the procedure specification. In particular 5.3.2.2, “Pipe and Fitting Materials” states that when welding materials they may be grouped, provided that the qualification test is made on the highest specified minimum yield strength in the group. The diameters and wall thickness qualified will be discussed in section 6. 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. 5.4 Essential Variables. 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 (290 MPa). Group ‘b’ materials have minimum yield strength greater than those in group “a” but less than 65,000 PSI (448 MPa). For yield strengths greater than 65,000 PSI (488 MPa), group ‘c’, each grade shall have a separate qualification test. The note included in 5.4.2.2 does not imply that base or filler metals of different analyses within a group can be substituted, however compatibility of mechanical properties should be considered

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Although major changes in the joint design are essential variables, minor changes in the angle of bevel or the root face (land) are not per 5.4.2.3. 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. (5.4.2.6) A change in the direction of welding was qualified, i.e. vertical up (uphill) to vertical down (downhill), or vice versa is considered an essential variable. (5.4.2.9) 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. (5.4.2.11) 5.5 Welding of Test Joints – Butt Welds Test joints shall be made using two pipe nipples and the parameters of the welding procedure. 5.6 Testing of Welded Joints - Butt Welds This subsection covers the type, number, location, and requirements of test specimens for qualifying a welding procedure. (Section 13 deals with testing requirements for automatic welding without filler-metal). Figure 3 (page 9 in the code and to the right of this column) - “Location of Test Specimens for Procedure Qualification: Test Butt Weld” shows the test and location of each specimen in qualifying a procedure using two pipe nipples. Special attention should be given to the notes in Figure 3 that allow for rotation (Note 1) and only one full section tensile specimen for small diameters (Note 2). Table 2 (page 8) - “Type and Number of Test Specimens for Procedure Qualification Test” gives outside diameter of pipe, wall thickness qualified and type and number of specimens per test. Note ‘a’ says that for pipe less than or equal to 1-5/16" (33.4 mm) in diameter, one full section tensile

specimen may be substituted for the two nick break and two root-bend tests. Note ‘b’ deals with materials with specified minimum yield strengths of more than 42,000 PSI (290 MPa). Subsection 5.6.2 covers the Tensile-Strength Test. Tensile-strength specimens shall be approximately 9 inches (230 mm) long and 1 inch (25.4 mm) wide (5.6.2.1). The tensile strength shall be calculated by dividing the maximum load at failure by the area of the specimen before any load was supplied (5.6.2.2). In order for the test specimen to pass the requirements, the weld must be equal or greater than the specified minimum tensile strength of the pipe material 5.6.2.3).

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Subsection 5.6.3 describes the nick-break test as shown in Figure 5 to the right. It covers the preparation of the specimen in 5.6.3.1. 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"(1.6mm) notch may be put in the weld reinforcement. Also, when qualifying a procedure using a semiautomatic or automatic welding process the specimens may be macro etched before being nicked. After the specimen has been broken, the dimensions of the discontinuities shall be measured. The acceptance criterion is listed in Subsection 5.6.3.3. Subsection 5.6.4 deals with the root-bend and face-bend tests. After the specimens have been cut and prepared properly 5.6.4.1), they should be bent into an approximately U shape in a guided bend test jig shown in Figure 9 at the right. 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 5.6.4.3. No discontinuity exceeding 1/8" (3mm) or one half the nominal wall thickness, whichever is smaller, may be present in the weld or fusion zone. Special consideration is given to corner cracks. Side-bend test specimens (5.6.5) are prepared in quite a different manner as describes in 5.6.5.1. After the specimen has been removed, it shall be machined or ground to a 1/2" (13 ~ mm) width before bending. The acceptance criteria for the side bend specimens are the same as those given for root and side bends. See 5.6.4.3. 5.7 Welding of Test Joints – Fillet Welds Test joints for fillet welds shall be made to one of the configurations shown in Figure 10 in accordance with the details of the welding procedure. 5.8 Testing of Welded Joints –Fillet Welds Test specimen locations and number of specimens for nick-break test are shown in Figure 10 and Figure 11. Note that pipe less than 2 3/8" (60.3 mm) in diameter, it may be necessary to make two test welds. Also note that the figures are for welder and procedure qualification. The acceptance criteria for fillet welds are given in 5.8.3.

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GENERAL EXERCISE QUESTIONS - Code Clinic MODULE #2 1. API 1104 has grouped base material into three distinct groups. In group ‘ the specified minimum

yield strength is: A. less than or equal to 42,000 (290 MPa) pounds per square inch B. greater than 42,000 PSI (290 MPa) but less than 65,000 PSI (448 MPa) C. greater than 42,000 PSI (290 MPa) but less than 68,000 PSI (469 MPa) D. greater than 289.58 MPa but less than 448.16 MPa E. both B and D 2. When conducting a procedure qualification on materials with outside diameters greater than 135

mm, the number of tensile test(s) required is/are? A. two B. one C. none are required D. four E. none of the above 3. When preparing a tensile specimen for testing: A. A notch approximately 1/8" shall be cut into each side of the weld B. The specimen must be machined C. May be oxygen cut with no further preparation provided sides are parallel and smooth D. Weld reinforcement should not be removed on either side E. Both C&D 4. AWS Specification A5.1 and A5.5 are used for welding: A. Using the SMAW process B. Pipe in 2G position only C. Root pass welding only D. Electrodes in groups 1 – 2 - 3 E. Both A and D above 5. When performing a nick-break test, the exposed area of fracture shall show complete penetration

and fusion. The greatest dimension of any gas pocket shall not exceed ? A. 1/16" wide B. 2% of the exposed surface area C. 5/8" wide D. 1/2" wide E. Both A & B are correct

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Exercise Questions - API Standard 1104 - Section 5 Qualification of Welding Procedures for Welds Containing Filler-Metal Additives 5.1 API 1104 groups base metals into three groups based on their minimum yield strength. Which of the following is defined as Group A?

A. less than 42 000 psi B. less than or equal to 42 000 psi C. greater than 65 000 psi D. greater than 42 000 psi and less than 65 000 psi E. greater than 85 000 psi

5.2 For metals with specified minimum yield strengths greater than 42 000 psi, what is the minimum number of tensile tests required? A. none B. one C. two D. four E. more than four 5.3 When preparing a tensile specimen for testing: A. cut a 1/8-in. notch into each side of the weld B. machine or grind all reinforcements smooth C. cut a transverse notch into the weld D. weld reinforcement should not be removed on either side E. bend the specimen in a guided bend jig 5.4. AWS Specification A5.20 is used for welding: A. pipe in both uphill and downhill positions B. pipe in 2G position only C. root pass welding only D. electrodes in group 3 E. both A and B above are correct 5.5 When performing a nick-break test, the exposed area of fracture shall be at least how wide? A. 1/2 in. B. 3/4 in. C. 5/8 in. D. 1-1/2 in. E. a dimension is not specified

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MODULE #3 - AWS CODE CLINIC FOR THE STUDY OF API 1104 SECTION 6 - QUALIFICATION OF WELDERS 6.1 General. 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 technique he/she will use during production welding. 6.2 Single Qualification. 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, the welder qualification also has essential variables. For single qualification, these are listed under 6.2.2. 6.3 Multiple Qualifications. 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 - 5/8" (168.3 mm) and a wall thickness of at least 1/4" (6.4 mm). 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 6.3.1 also. Figure 12 at the right 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 6.3.2 states that a welder who has qualified on pipe equal to or greater than 12-3/4" (323.9 mm) 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" (323.9 mm) in diameter, is qualified to weld on all wall thicknesses, joint designs, and fittings, but 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. 6.4 Visual Examination. 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"(0.8 mm) or 12.5 percent of pipe wall thickness, whichever is smaller. No more than 2 inches (50 mm) of undercut in any continuous 12-inches (300 mm) of weld is permitted.

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6.5 Destructive Testing. Table 3 above gives the type and number of test specimens required for welder qualification. Notice that the type of destructive tests used in 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 6.5.2. The preparation and acceptance criteria for destructive tests used for welder qualification are the same as the requirements for procedure qualification in Section 5. 6.5.3 For the tensile strength test if any of the reduced section tensiles or the full section tensiles in the weld or at the weld juncture the welder shall be disqualified. 6.5.4 The nick break specimen shall be prepared as in Figure Five and evaluated as in Figure Eight below. If the broken surface shows any imperfections that exceed those in 5.6.3.3 the welder shall be disqualified. 6.6 Radiography - Butt Welds Only. This subsection allows a company to qualify welders on butt welds using radiography in lieu of destructive tests. 6.7 Retesting. A welder is permitted one retest without penalty if both the company and contractor 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. 6.8 Records. Records shall be kept of all 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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GENERAL EXERCISE QUESTIONS - Code Clinic MODULE #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" C. Length of protrusion shall not exceed 0.79 mm D. Shall be kept to a minimum E. Both B and C above 2. For welder qualification on pipe greater than 4 1/2" in diameter, but less than or equal to 12-3/4" in

diameter, the number of destructive test specimens required are? A. 4 B. 6 C. Same as procedure qualification D. 16 E. Depends on the wall thickness of the pipe 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 test is required D. Shall not contain any burn-through exceeding 1/4" E. Both A and D above Exercise Questions— API Standard 1104 Section 6 Qualification of Welders 6.1 A welder shall be requalified whenever which of the following occurs? A. a change from vertical uphill to vertical downhill B. a change of filler metal classification from Group 1 to Group 3 C. a change from one process to another D. when all of the above change at the same time E. all of the above 6.2 Which of the following is not specified as a requirement for visual weld inspection? A. free from cracks B. inadequate penetration C. free of burn-through D. filler wire protrudes less than 1/8 in. into inside of pipe E. neat appearance 6.3 For multiple qualification, a welder shall be required to perform (select two): A. make a butt weld in the fixed position B. prepare a full-sized branch-on-pipe connection C. join pipes greater than 4.5-in. OD D. demonstrate nondestructive testing skills E. both A&B

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MODULE #4 - AWS CODE CLINIC FOR THE STUDY OF API 1104 SECTION 7 - DESIGN AND PREPARATION OF A JOINT FOR PRODUCTION WELDING 7.1 General. The surfaces to be welded shall be smooth, uniform, and free from lamination, tears, scale, slag, grease, paint or other deleterious material that might adversely affect welding. 7.2 Alignment. Alignment of abutting ends of pipe the same nominal wall thickness shall not exceed 1/8” (3 mm). Larger offset caused by dimensional variations shall be equally distributed around the circumference of the pipe. 7.3 Use of Lineup Clamps for Butt Welds. 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. 7.4 Bevel. Both mill bevels and field bevels are permitted as long as they conform to procedure specifications. 7.5 Weather Conditions. 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. 7.6 Clearance. When welding is being performed above ground, the working clearance around the pipe at the weld should not be less than sixteen inches (400 mm). When welding is being performed in a trench the bell hole will be large enough to provide the welder(s) access to the joint. 7.7 Cleaning Between Beads. 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. 7.8 Position Welding. For position welding the finished weld shall have a substantially uniform cross section around the entire circumference of the pipe. Two 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

should not have a weld reinforcement (crown) exceeding 1/16 inch (1.6 mm). It should be approximately 1/8 inch (3.2 mm) wider than width of the original groove. 7.9 Roll Welding. The requirements are essentially the same as for position welding, except that the pipe is rolled during welding as oppose to being fixed. 7.10 Identification of Welds. Each welder shall identify his/her work as prescribed by the company (owner). 7.11 Pre- and Post-Heat Treatment. Preheat and post weld heat treatment requirements shall be specified in the welding procedure specification.

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GENERAL EXERCISE QUESTIONS - Code Clinic MODULE #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" maximum D. 1/16" minimum E. Up to the welders’ discretion 2. When pipe is welded above ground, the working clearance around the pipe should not be less than? A. 450 mm B. 400 mm C. 18 inches D. 16 inches E. B and D above 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 permanent marker D. Recording their identification on a traveler E. Any of the above methods as prescribed by the owner or owner’s representative Exercise Questions—API Standard 1104 Section #7 Design and Preparation of a Joint for Production Welding 7.1 Who shall decide when weather conditions are suitable for welding? A. the project engineer B. the company C. the supervisor of welding D. the contractor E. the quality assurance head 7.2 How many root-bend specimens are required for 8-in. OD pipe with wall thicknesses <12.7 mm according to data in Table 3? A. none B. 1 C. 2 D. 3 E. 4 7.3 What is the total number of test specimens required for 8-in. OD pipe with wall thicknesses <12.7 mm according to data in Table 3? A. 2 B. 3 C. 4 D. 5 E. 6 7.4 Pipe ends of the same thickness should not be offset by more than: A. 1/16 in. B. 1/32 in. C. 1/8 in. D. 1/4 in. E. no offset is permitted

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MODULE #5 - AWS CODE CLINIC FOR THE STUDY OF API 1104 SECTION 8 - INSPECTION AND TESTING OF PRODUCTION WELDS 8.1 Rights of Inspection. The owner may require inspection by nondestructive or destructive methods either during the welding process or after the welding has been completed. 8.2 Methods of Inspection. The company will specify the nondestructive testing method used. 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. 8.3 Qualification of Inspection Personnel. 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 8.4 Certification of Nondestructive Testing Personnel. 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. (8.4.1) The company shall retain a record of certified nondestructive testing personnel. Level I and Level II personnel shall be recertified at least every three years and Level III personnel at least every five years. (8.4.2)

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GENERAL EXERCISE QUESTIONS - Code Clinic MODULE #5 1. Who determines the type of inspection to be done? A. The welder B. The inspector C. The QC Manager D. The owner/company E. None of the above 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 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. ACCP E. A & D above 4. How often must Level III nondestructive testing personnel be re-certified? A. Every year B. Every two years C. Every three years D. Every four years E. Every five years

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Exercise Questions— API Standard 1104 Section #8 Inspection and Testing of Production Welds 8.1 Who determines the frequency of inspections? A. the welder B. the chief inspector C. the quality assurance head D. the company E. the contractor 8.2 Documentation of inspection personel qualifications shall include? A. Education and Experience B. Training C. Results of an oral exam D. all of the above E. only A&B 8.3 Level II and III NDT personnel shall be certified to: A. any recognized national certification program acceptable to the company B. ASNT - SNT-TC-1A C. any pertinent AWS program D. the contractor’s in-house certification program E. both A&B are acceptable 8.4 How often shall Levels I and II NDT personnel be recertified? A. every year B. every 2 years C. at least every 3 years D. at the chief inspector’s option E. as specified in the contract

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MODULE # 6 - AWS CODE CLINIC FOR THE STUDY OF API 1104 SECTION 9 - ACCEPTANCE STANDARDS FOR NONDESTRUCTIVE TESTING 9.1 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. 9.2 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. 9.3 Radiographic Testing Subsection 9.3.1 addresses inadequate penetration. Inadequate Penetration without high-low (IP) is shown in Figure 13 on page 21 of API 1104. The acceptance criteria are also given in this section. Inadequate penetration due to high-low (IPD) is addressed in Subsection 9.3.2 and illustrated in Figure 14 on page 23 of API 1104. Inadequate cross penetration (ICP) is defined in Subsection 9.3.3 as a subsurface imperfection between the first inside pass and the first outside pass caused by inadequately penetrating the land faces. ICP is illustrated in Figure 15 page 23. Incomplete fusion (IF) is defined in Subsection 9.3.4 as a discontinuity between the weld metal and the base metal that is OPEN TO THE SURFACE and is illustrated in Figure 16. Incomplete fusion due to cold lap (IFD), Subsection 9.3.5, 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 17 of API 1104.

Figure 13: Inadequate Penetration Without High Low (IP)

Figure 14: Inadequate Penetration due to High Low (IPD)

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Subsection 9.3.6covers internal concavity (IC) and is depicted in Figure 18 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. Burn through (BT) is defined in Subsection 9.3.7 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 criterion is given in paragraph 9.3.7.2 and 9.3.7.3. Subsection 9.3.8 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 (ESI) and isolated slag inclusions (ISI). ESI’s as shown Figure A1 may be continuous or broken and are usually found at the fusion zone, whereas ISI’s as shown Figure A2 are irregular in shape and are found anywhere in the weld. Acceptance criteria for slag inclusion also depend on the outside diameter of the pipe and are given in 9.3.8.2 and 9.3.8.3 of API 1104.

Figure 18: Internal Concavity (Suck Back) (IC)

Auxiliary Figure A2: Isolated Slag Inclusions (ISI’s)

Auxiliary Figure A1: Elongated Slag Inclusion (Wagon Tracks) (ESI’s)

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Porosity is defined in Subsection 9.3.9 as gas trapped by solidifying weld metal before it has had a chance to rise to the surface of the molten weld puddle and escape. There is individual or scattered porosity (P) as shown Figure A3, cluster porosity (CP) as shown Figure A4 , and hollow-bead porosity (HB) as shown Figure A5. Each type of porosity is described and acceptance criteria given in paragraphs 9.3.9.2, 9.3.9.3 and 9.3.9.4 of API 1104. Figures 19 and 20 of API 1104 illustrate acceptable limits of scattered porosity.

Auxiliary Figure A4: Cluster Porosity (CP)

Auxiliary Figure A3 Individual Porosity or Scattered Porosity (P)

Auxiliary Figure A5: Hollow Bead Porosity (HB)

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Cracks as shown in Figure A6, Subsection 9.3.10, are generally unacceptable except for shallow crater or star cracks whose length is 5/32 inch (4 mm) or less in length. Subsection 9.3.11 defines undercutting and gives the acceptance criteria for undercutting adjacent to the cover pass (EU) as shown in Figure A7, and undercutting adjacent to the root pass (IU) as shown in Figure A8. 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 Subsection 9.7.2 and is given in Table 4 on page 29 of API 1104. Subsection 9.3.12 addresses the accumulation of discontinuities (AI) 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. (9.3.13)

Auxiliary Figure A6: Cracks (C)

Auxiliary Figure A7: Undercutting Adjacent to the Cover Pass (EU)

Auxiliary Figure A8: Undercutting Adjacent to the Root Pass (IU)

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9.4 Magnetic Particle Testing Classification of indications found by magnetic particle testing (MT) is addressed in Subsection 9.4.1. Indications with a maximum dimension of 1/16" (1.6 mm) 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. Acceptance standards for relevant indications are given in Subsection 9.4.2. 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. (9.4.3) 9.5 Liquid Penetrant Testing The requirements for liquid penetrant testing (PT) are the same as those for MT and are repeated here only to reference the proper subsections Classification of indications found by PT are addressed in Subsection 9.5.1. Indications with a maximum dimension of 1/16" (1.6 mm) 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. Acceptance standards for relevant indications are given in Subsection 9.5.2. 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. (9.5.3)

9.6 Ultrasonic Testing When using ultrasonic testing (UT), all indications that produce a response are not necessarily defects. Changes in geometry, changes in weld profile, capping passes, internal chamfering, can all cause ultrasonic wave mode conversion. Subsection 9.6.1.2 defines linear indications as those with their greatest dimension in the weld length direction. Subsection 9.6.1.3 defines transverse indications as those with their greatest dimension across the weld. Subsection 9.6.1.4 defines volumetric indications as three-dimensional indications. These indications may be caused by single or multiple inclusions. The acceptance criterion for UT inspection is given in Subsection 9.6.2.

9.6.2.1 – Cracks (C) 9.6.2.2 – Linear Surface Indications (LS) 9.6.2.3 – Linear Buried (LB) 9.6.2.4 - Transverse Indications (T) 9.6.2.5 - Volumetric Cluster (VC) 9.6.2.6 - Volumetric Individual (VI) 9.6.2.7 – Volumetric Root (VR)

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. (9.6.3)

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9.7 Visual Acceptance Standards for Undercutting Undercutting has previously defined in Subsection 9.3.11. The acceptance standards given in this section supplement, but do not replace those found elsewhere in API 1104. (9.7.1) 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 as shown below. When both mechanical and radiographic measurements are available, the mechanical measurements shall govern.

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GENERAL EXERCISE QUESTIONS - MODULE #6 1. The maximum width of an isolated slag inclusion in a weld on a pipe whose outside diameter is

6.625" is: A. 1/16 inch B. 1/8 inch C. 1/2 inch D. 1.59 mm E. Both B and D above 2. The maximum length of a crater crack is: A. 1/8 inch B. 5/32 inch C. no cracks are allowed D. 1/2 the width of the bead E. craters in welds cannot crack 3. When using ultrasonic testing, linear indications buried within the weld are unacceptable if they: A. Exceed 2 inches in total length in a continuous 12-inch length of weld B. Exceed 5/32 inch C. Exceed 8 percent of the weld length D. Exceed 6 percent of the weld length E. Both A and C above 4. When inspecting a pipe weld you measure some undercut at the face of the weld. The undercut

mechanically measures 1/64 inch deep and approximately 6 inches long. The undercut is: A. Not acceptable B. Must first be checked against radiograph measurements C. Unacceptable because it exceeds 2 inches D. IAcceptable E. Undercut cannot be produced on face side of weld 5. 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

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Exercise Questions— API Standard 1104 Section #9 Acceptance Standards for Nondestructive Testing 9.1 Incomplete fusion is a defect when the length of an individual indication exceeds: A. 1/8 in. B. 25% of wall thickness C. 1/4 in. D. 1.0 in. E. no incomplete fusion is permitted 9.2 Porosity is: A. evidence of gas trapped in the cooling metal B. displays spherical indications C. cause for reject if a single pore is larger than 1/8 in. D. of the types P, CP, HB E. all of the above 9.3 Which of the following apply to an ESI? A. a nonmetallic solid trapped in the weld metal B. broken slag lines C. an indication usually found at the fusion zone D. an irregularly shaped inclusion E. all of the above 9.4 What condition causes the weld pool (puddle) to be blown into the pipe? A. rapid uphill vertical welding B. nonmetallic solids in the base metal C. excessive travel speed D. burn-through E. excessive pipe wall thickness 9.5 Which of the following apply to star cracks? A. caused by vibrations during welding B. caused by metal contractions during solidification C. caused by inclusions D. generally weaken the weld excessively E. are usually ground out and repaired

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MODULE #7 - AWS CODE CLINIC FOR THE STUDY OF API 1104 SECTION 10 - REPAIR AND REMOVAL OF DEFECTS 10.1 AUTHORIZATION FOR REPAIR Subsection 10.1.1 Cracks. It is stated that cracked welds shall be removed from the line unless permitted by 9.3.10, or when the company authorizes repair. Cracks may be repaired if they do not exceed 8% of the weld length. Any and all repairs shall meet the acceptability standards in Section 9. Subsection 10.1.2 Defects Other Than Cracks It is stated 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 9. Before repairs are made, the defect shall be completely removed to sound metal. All slag and scale shall be removed and preheat may be required by the company. All repairs shall be inspected by the same means previously used. 10.2 Authorization and Procedure for Repair of Cracks. Cracked welds shall be removed unless permitted by 6.3.9 or the appendices 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) per cent of the weld length. 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. Post weld 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 bt MT or PT to assure removal of the crack.

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EXERCISE QUESTIONS - MODULE #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 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. All of the above E. B and C above Exercise Questions— API Standard 1104 Section #10 Repair and Removal of Defects 10.1 Upon visual detection of a weld defect, what should the inspector do? A. send it to production for repair B. have it removed from the line – unless permitted by 9.3.10 C. submit it for additional nondestructive testing D. A&C above E. send it to the company representative 10.2 Repaired welds should: A. meet the standards of acceptability of Section 9 B. be examined by the company representative C. be submitted for radiographic inspection D. ground smooth with a minimum of metal removal E. be reinspected by a Level III inspector 10.3 Which of the following is NOT required in a weld repair procedure? A. method of defect removal B. preheat requirements C. specification information contained in 5.3.2 D. company approval of the process E. all of the above are required

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MODULE #8 - AWS CODE CLINIC FOR THE STUDY OF API 1104 SECTION 11 - PROCEDURES FOR NONDESTRUCTIVE TESTING 11.1 Radiographic Test Methods Section 11 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 11.1.1 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 11.1.2.2 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 rating 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 is 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 11.1.2.3, require procedures to include similar details as film radiography, but also include the system used for image collection, processing, viewing and storage.

Exposure geometry, Subsection 11.1.3, 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 11.1.3.1, the minimum distance from the source to the object will be determined by the formula:

D=St/k

Abbreviations for the following should be reviewed and combinations understood: Single Wall Exposure SWE Single Wall Viewing SWV Double Wall Exposure DWE Double Wall Viewing DWV 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 11.1.3.2, 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 E1025 or the standard penetrameter shown in Figure 21 of API 1104. Wire type penetrameters shall conform to ASTM E747. (Subsection 11.1.4)

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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 penetrameter identifying number for ASTM E1025 penetrameters. Table 6 shows the same for Figure 21 penetrameters. Shims placed under the penetrameter are permitted when weld thickness is used to determine penetrameter number. Penetrameters 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 21 penetrameters, the 2T hole need not be less than 1/16 inch in diameter. (Paragraph 11.1.5.1) Table 7 of API 1104 shows the essential wire diameter, based on the thickness of the weld of ASTM E 747 wire penetrameters. (11.1.5.2) Except when heat shields are used, penetrameters are placed in contact with the pipe. Paragraph 11.1.6.1 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 11.1.6.2 details penetrameter placement for the imaging media. Level II or III radiographers shall interpret the radiographic images of production welds and report all unacceptable discontinuities to the company. (Subsection 11.1.7) Except for small localized areas caused by irregular weld configurations, the transmitted density in the area of interest of transparent-based film shall not be less than 1.8 and no greater than 4.0. The reflected density for opaque-based film 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 11.1.10.1 of API 1104. The radiographer shall be responsible for protection and monitoring of every person working with or near radiation sources. (Paragraph 11.1.13)

11.2 Magnetic Particle Test Method. All MT shall be performed to a written procedure and meet the requirements of ASTM E 709. 11.3 Liquid Penetrant Test Method. All PT shall be performed to a written procedure and meet the requirements of ASTM E 165.

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11.4 Ultrasonic Test Method. All UT shall be performed to a written procedure and meet the requirements set forth in 11.4.1 to 11.4.9. All surfaces scanned shall be in the uncoated condition and all welds shall be ground flush with the pipe surface. Procedure Records shall be in the form of both writing and sketches.

11.4.2 Ultrasonic Procedure As a minimum the procedure for ultrasonic testing of welds shall include the following specific application details:

⇒ Type of welds to be tested, joint

preparation dimensions and welding processes.

⇒ Material type (i.e., size, grade, thickness, process of manufacturing per API Spec 5L

⇒ Scanning surface preparation/condition.

⇒ Stage at which examination is to be performed

⇒ Ultrasonic Instrument/System and probes (i.e., manufacturer, type, size, etc.).

⇒ Automatic or Manual.

⇒ Couplant. ⇒ Testing

Technique: § Angles. § Frequencies (MHz). § Temperatures and ranges. § Scanning patterns and speeds. § Reference datum and location

markers (i.e., root face and circumferential locations).

⇒ Reference Standards-detail sketches showing plan-view and cross-section-view dimensions of production- material reference-standard blocks and all reference reflectors.

⇒ Calibration requirements-the interval at which calibration of the instrument or system is required, the sequence of set-up calibration prior to inspecting welds, including all standard calibration blocks to be used, the reference sensitivity reflectors to be used, the reference sensitivity- level setting (i.e., DAC or TCG), and the intervals for verification of calibration settings.

⇒ Scanning level-the sensitivity setting in decibels (dB) to be added to the reference sensitivity for scanning.

⇒ Evaluation level-the level or height of echoes detected during scanning at which further evaluation is required, and any sensitivity adjustment to be made before evaluating for acceptance or rejection.

⇒ Recording of results-type of record (e.g., sketch, thermal printer, compact disc, etc.) and whether all reflectors or only unacceptable reflectors will be recorded.

⇒ Ultrasonic Examination Report-an example of the examination reports.

11.4.3 Ultrasonic Testing Personnel Requirements An NDT Level III in the ultrasonic method shall develop the application technique and prepare and approve the testing procedure. Only Level II or III certified personnel shall calibrate equipment and interpret the test results. NDT Level II or III personnel in ultrasonics shall perform the test and evaluate the results per the acceptance/rejection criteria.

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11.4.4 Qualification of the Testing Procedure Prior to final written approval, the company shall require the contractor to demonstrate the application of the procedure and ultrasonic systems. A procedure qualification report shall be generated and the results documented prior to use on actual field welds. The qualification process shall be as follows: a. Welds (minimum of 2 per welding procedure) containing defects and acceptable imperfections shall be prepared from b. Radiographs shall be made of the welds and the results documented. c. The UT procedure shall be applied, within the detailed temperature ranges, and the results documented and compared with the radiographs. d. Differences in detection results shall be documented. e. Use of the UT procedure on production welding shall be based on the capability of the implemented UT method/tech- to: 1) circumferentially locate, 2) size for length, 3) determine depth from O.D. surface, and 4) axially (weld cross section) locate required imperfections/defects in the test samples. 11.4.5 API Sensitivity Reference Standard Manual ultrasonic testing sensitivity shall be based on a two or three point reference level (i.e., distance amplitude correction [DAC] or time corrected gain [TCG]) derived from an N10 notch introduced into a sample of the pipe to be inspected. The highest point of the DAC/TCG shall not be less than 80% of full screen height. The reference standard shall also be used to determine the actual sound beam velocity, refracted angle and sound path distance in the pipe material to be inspected.

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EXERCISE QUESTIONS - MODULE #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 pentrameters are not permitted in API 1104 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. The CWI 3. When the selection of a 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 4. A weld was made on a pipe that had a wall thickness measurement of 15 millimeters. What ASTM

E1025 penetrameter would be used for this radiograph? A. #15 B. #20 C. #17 D. #7 E. Letter B 5. The abbreviation DWE/SWV 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

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Exercise Questions—API Standard 1104 Section #11 Procedures for Nondestructive Testing 11.1 Figure 21 tells us that a standard penetrameter has: A. hole A equal to 2T B. hole B equal to 1T C. hole C equal to 4T D. no hole need be less than 1/4 in. E. A, B, C above 11.2 Ultrasonic testing personnel Level III: A. are permitted to calibrate equipment B. are permitted to interpret test results C. may be required to demonstrate skills for the company representative D. shall develop the application technique and approve testing procedure E. all of the above 11.3 In Table 6, the penetrameter to use to test pipe with a 0.432-in. wall thickness is identified by what number? A. 5 B. 10 C. 12 D. 15 E. 17 11.4 In Table 7, the essential wire penetrameter diameter to use for a pipe wall thickness of 0.55 in. is: A. 0.008 in. B. 0.010 in. C. 0.013 in. D. 0.016 in. E. 0.020 in. 11.5 What conditions must be considered when using ultrasonic testing on in-service welds? A. the equipment is difficult to operate B. operators require considerable experience C. results are nonuniform from unit to unit D. surface imperfections can interfere with its use E. surfaces must be coated prior to testing

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MODULE #9 - AWS CODE CLINIC FOR THE STUDY OF API 1104 SECTION 12 - AUTOMATIC WELDING 12.1 Acceptable Processes. Automatic welding shall be done with one or more of the following welding processes: Submerged Arc Welding - SAW Gas Metal Arc Welding - GMAW Gas Tungsten Arc Welding - GTAW Flux Cored Arc Welding - FCAW 12.2 Procedure Qualification. 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. 12.3 Record. The results of this qualification test shall be recorded. A sample welding procedure specification form is shown in Figure 1, page 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 this sample form, keeping close attention to the information specified in Subsection 5.3.2. 12.4 Procedure Specification. Sub-section 9.4.2 lists that information to be included in the procedure specification. In particular Paragraph 5.3.2.2, Pipe and Fitting Materials, states that the materials to be welded shall be identified in the procedure. When welding materials of different groups based on yield strength (See Paragraph 5.4.2.2), the procedure for the higher strength group shall be used. The diameters and wall thickness qualified shall be identified. 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. 12.5 Essential Variables. 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 12.5.2.2, based on yield strength. The first group has a specified minimum yield strength less than or equal to 42,000 PSI (290 MPa). The second group has a minimum yield strength

greater than those in the first group, but less than 65,000 PSI (488 MPa). For yield strengths greater than 65,000 PSI (488 MPa), each grade shall have a separate qualification test. The note included in Paragraph 12.5.2.2 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, a major change constitutes an essential variable. A change from one filler-metal group to another is an essential variable. 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. An increase or decrease in the range of shielding gas flow rates 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. 12.6 Qualification of Welding Equipment and Operators Qualification of both the welding equipment and the welding operator shall be made using the proper 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 6.4 through 6.7 of API 1104. 12.7 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 7; of API 1104, it should be modified to suit the needs of the company. A list of qualified welding operators and

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the procedures for which they are qualified shall be maintained. 12.8 Inspection and Testing of Welds Production welds shall be inspected and tested in accordance with Section 8 of API 1104. 12.9 Acceptance Standards for Nondestructive Testing The acceptance standards for nondestructive testing shall be in accordance with Section 9 of API 1104 or, at the company’s option, the appendix. 12.10 Repair and Removal of Defects Repair and removal of defects shall be in accordance with Section 13 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. 12.11 Radiographic Testing. Radio- graphic testing shall be in accordance with Subsection 11.1 of API 1104.

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EXERCISE QUESTIONS - MODULE #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 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 Exercise Questions— API Standard 1104 Section #12 Automatic Welding With Filler Metal Additions 12.1 For automatic pipe welding, a lineup clamp: A. must be used B. must be of the internal type C. must be of the external type D. is optional, as required E. must be specified in the procedure 12.2 Which of the following is not an essential variable? A. pipe wall thickness B. direction of welding C. postweld cleaning D. welding process E. pipe diameter 12.3 Radiographic testing shall be in accordance with: A. Section 6.4 B. Section 11.1 C. Section 13.9 D. Section 9.3.10

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MODULE #10 - AWS CODE CLINIC FOR THE STUDY OF API 1104 SECTION 13 - AUTOMATIC WELDING WITHOUT FILLER-METAL ADDITIONS 13.1 Acceptable Processes. Automatic welding without filler metal additions shall be limited to the flash butt welding process. 13.2 Procedure Qualification. As in all welding, before production welding begins a qualified welding procedure must be approved. Procedure qualification requires that the weld be radiographed prior to performing any of the required mechanical tests and meet the acceptance criteria of Subsection 13.9. (Paragraph 13.2.2) The number and location of test specimens differ in this section from those of previous sections. For location, refer to Figures 23, 24, and 24 on pages 42through 44 of API 1104. For type and number of tests required, refer to Table 8 on page 41 of API 1104. Preparation of specimens is specified in Paragraphs 13.2.3.2 through 13.2.3.4. (Paragraph 13.2.3.1) Tensile specimens shall be prepared and tested in accordance with Section 2 of API 1104. The requirements for acceptable tensile specimens are found in Paragraph 13.2.3.2.3. Nick-Break Tests are covered under Paragraph 13.2.3.3. Notice that for the nick-break, the size of the specimen is larger than those in previous sections. Note also that the sides of the specimen shall be macro etched to locate the fusion zone. Side bend specimens, Paragraph 13.2.3.4, shall be prepared and evaluated in accordance with the requirements of Section 5 of API 1104. 13.3 Record. The details of each qualified procedure shall be recorded, addressing as a minimum, all of items listed in Subsection 13.4 of API 1104. 13.4 Procedure Specification. 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. 10.5 Essential Variables. The list of essential variables addressed in this subsection are also unique to automatic welding without filler metal. 13.6 Qualification of Welding Equipment and Operators 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 13.2. 13.7 Records 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 operators and the procedures for which they are qualified shall be maintained. 13.8 Quality Assurance of Production Welds The company reserves the right to inspect all welds by either nondestructive or destructive methods, or both. Paragraph 13.8.2 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. Paragraph 13.8.3 states that welds shall be inspected visually and radiographically after flash removal and post weld heat treatment are complete. Both inside and outside reinforcement can be grounds for rejection. API 1104 states in Paragraph 13.8.4, that the reinforcement on the inside diameter of the pipe shall not exceed 1/16 inch and on the outside diameter, weld reinforcement shall not exceed 1/8 inch.

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As a minimum, all completed flash butt welds shall be subject to post weld 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. (Paragraph 13.8.5) 13.9 Acceptance Standards for Non-destructive Testing The acceptance criteria for nondestructive testing of flash butt welds are given in Paragraph 13.9.2 and apply to radiography and other nondestructive testing methods. They may also be applied to visual inspection. 13.10 Repairs 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, gouging, or a combination of these methods. Weld repair shall be in accordance with Section 10 of API 1104, but requires prior agreement by the company. Repair of porosity found in flash butt welds is not permitted. 13.11 Radiographic Procedure. Radio- graphic testing shall be in accordance with Subsection 11.1 of API 1104.

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EXERCISE QUESTIONS - MODULE #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 inch in length B. 1/32 inch in depth C. 1/2 inch in width D. 1/8 inch in length and width E. Both A and C above 2. Procedure qualification tests for a flash butt weld are being performed on a pipe that has an outside

diameter of 20 inches. What is the total number of specimens that will be tested? A. 16 B. 24 C. 40 D. 32 E. 28 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 4. A single ISI in a flash butt weld shall not exceed: A. 3/8 inch in length B. 1/2 inch C. 1/8 inch in length D. 1/16 inch in length E. No ISI is allowed 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

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Exercise Questions— API Standard 1104 Section #13 Automatic Welding Without Filler Metal Additions 13.1 Table 8 requires how many test specimens for qualifying flash weld procedures? A. 24 total for 19-in. OD pipe B. 32 total for 29-in. OD pipe C. 40 total for 32-in. OD pipe D. 4 tensile strength specimens required for all sizes E. all of the above 13.2 Which of the following is not an essential variable for flash butt welds? A. welding position B. axial speed tolerances C. pipe material D. pipe wall thickness E. filler metal 13.3 As a minimum all completed flash butt welds shall: A. be heated above the Ac3 temperature B. use controlled cooling C. use strip recorder to document heat treating D. be heat treated again if out of spec E. all of the above 13.4 Which of the following methods is not specified in flash butt repair procedures: A. grinding B. chipping C. gouging D. surface etching E. cleaning 13.5 When should NDT be performed on a flash butt weld? A. immediately after welding B. after flash removal and heat treatment C. before final heat treatment D. after final heat treatment E. not specified

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MODULE #11 - AWS CODE CLINIC FOR THE STUDY OF API 1104 APPENDIX A - ALTERNATIVE ACCEPTANCE STANDARDS FOR GIRTH WELDS The company has the option to use the alternative acceptance standards detailed in this Appendix A in lieu of using Section 9, the acceptance standards normally used. The alternate technique used is fracture mechanics analysis and fitness-for-purpose criteria. Engineers will appreciate this mathematical approach. For simplification, the appendix restricts the mathematics to the U.S. Customary Units (in.-lb), although it is acceptable to make the evaluations with all values expressed in SI (metric units). The fitness-for-purpose criteria provide more generous allowable imperfection sizes, but only when additional procedure qualifications tests, stress analyses, and inspections are performed. It does not prevent the use of Section 9. To use this Appendix, the company must perform a stress analysis to determine the maximum axial design stresses for the pipeline. The total axial stress acting on an imperfection also includes a residual stress from welding, which, in the case of welds that are not thermally stress relieved, may approach the yield strength of the material. This appendix does not cover Welds subjected to applied axial strain of more than 0.5%. This Appendix may be specified for the evaluation of any or all imperfections, including circumferential cracks; however, this Appendix covers only circumferential welds between pipes of equal nominal wall thickness. Welds in pump or compressor stations are excluded, as are fittings and valves in the mainline. Repair welds are also excluded. Included are discussions on the environmental effects on in-service pipelines, including fatigue, CO2, H2S, sustained-load cracking, stress corrosion cracking, and the interaction of adjacent imperfections. The controls of the variables necessary to ensure an acceptable level of fracture toughness in a welding procedure are more stringent than those controlling welding procedures without minimum toughness requirements.

An extensive mathematical discussion is presented for calculating the extent of various imperfection interactions based on types, sizes, and shapes of the imperfections.

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MODULE #12 - AWS CODE CLINIC FOR THE STUDY OF API 1104 APPENDIX B – In Service Welding Appendix B is a new addition to the API Standard 1104; i.e., it appears for the first time in the Nineteenth Edition. Appendix B covers highly specialized practices for making weld repairs to pipelines and piping systems that contain petroleum products or fuel gases that may be flowing or pressurized. This appendix does not apply to pipelines that are out of service or have never been commissioned into service. Obviously, the first concern when welding a pressurized pipe is to avoid burning through. Burning-through is unlikely, however, if the wall thickness is 1/4 in. or greater, and low-hydrogen electrodes (EXX18 type) are used with normal welding practices. The second concern is to avoid hydrogen cracking, since welds made on in-service pipe cool very quickly. Three conditions must be satisfied simultaneously for hydrogen cracking to occur. These are: 1) hydrogen in the weld; 2) the development of a crack-susceptible weld microstructure; and 3) tensile stress acting on the weld. The last sections of this appendix address the suggested in service welding practices and the qualification test requirements. Additional guidance is available in API Recommended Practice 2201

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Section #1 1.1—E 1.2—C 1.3—E 1.4—A Section #2 2.1—D 2.2—B 2.3—A 2.4—B Section #3 3.1—B 3.2—C 3.3—D 3.4—B Section #4 4.1— E 4.2—B 4.3—C 4.4—A

Section #5 5.1—B 5.2— B 5.3— D 5.4—C 5.5—B Section #6 6.1—E 6.2—D 6.3—A, B Section #7 7.1—B 7.2—C 7.3—E 7.4—C Section #8 8.1—D 8.2—D 8.3—E 8.4—C

Section #9 9.1—D 9.2—E 9.3—E 9.4—D 9.5—B Section #10 10.1—B 10.2—A 10.3—E Section #11 11.1—E 11.2—E 11.3—B 11.4—D 11.5—D Section #12 12.1—E 12.2—C 12.3—B

Section #13 13.1—E 13.2—E 13.3—E 13.4—D 13.5—B

Answers to API Standard 1104 Section

Exercise Questions

Answers to API Standard 1104 Code Clinic MODULE

Questions

Module #1 1.D 2.C 3.B 4.D Module #2 1.E 2.A 3.E 4.E 5.E Module #3 1.D 2.B 3.E

Module #4 1.C 2.E 3.E Module #5 1.D 2.C 3.E 4.E Module #6 1.B 2.B 3.E 4.D 5. A

Module #7 1.E 2.D Module #8 1.C 2.D 3.C 4.B 5.A Module #9 1.D 2.C 3.B

Module #10 1.D 2.B 3.E 4.C 5.E