api 1104 manual refer en cia

Code Clinic For Study of

API 1104 Welding of Pipelines and Related Facilities - Nineteenth Edition

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

American Welding Society

Copyright American Welding Society Provided by IHS under license with AWS

Not for ResaleNo reproduction or networking permitted without license from IHS

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Code Clinic For Study of

API STANDARD 11 04 NINETEENTH EDITION

Welding of Pipelines and Related Faci I it ¡es

Published by American Welding Society

Education Department

American Weldina Society



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DISC LAI MER

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: 0-871 71 -581 -3

American Welding Society 550 N.W. LeJeune Road

Miami, Florida 331 26

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

All rights reserved. No pari 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.l Code Clinic for many years in conjunction with their Welding Inspection Seminar. During this time, interest in a corresponding seminar for API Standard 1 104, Welding of Pipelines and Related Facilities, has continued to grow. This A WS Code Clinic - APl Standard 7 704 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 18'h 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

INTRODUCTION TO THE AWS CODE CLINIC FOR API 1104

Introduction Definition of Documents Finding Code Provisions Code Reference Example API 1104 Special Notes Foreword API 1104 Contents

CHANGES FROM THE 18" EDITION TO THE 1 gth EDITION of API 1 104

Module #1 - API STANDARD 11 04

SECTION 1 - GENERAL

SECTION 2 - REFERENCED PUBLICATIONS

SECTION 3- DEFINITION OF TERMS

SECTION 4- SPECIFICATIONS

Scope

Referenced Publications

Definition of Terms

Equipment Materials

Exercise Questions


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


SECTION 6 - QUALIFICATION of WELDERS General Single qualification Multiple Qualification Visual Examination Destructive Testing Radiography - Butt Welds Only Retesting Records

Exercise Questions

1

5

9

15

20

ii



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Module #4 - API STANDARD 11 04 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


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


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


SECTION 10 - REPAIR AND REMOVAL OF DEFECTS Defects Other Than Cracks Authorization and Procedure for Repair of Cracks

Exercise Questions


36

38

SECTION 11 - PROCEDURES FOR NONDESTRUCTIVE TESTING Radiographic Test Methods Magnetic Particle Test Methods Liquid Penetrant Test Methods Ultrasonic Test Methods

Exercise Questions

iii



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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 #1 O - API STANDARD 11 04 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


APPENDIX A - ALTERNATE ACCEPTANCE STANDARDS FOR GIRTH WELDS


APPENDIX B - IN-SERVICE WELDING

iV



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AWS CODE CLINIC - API STANDARD 11 04, “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 A WS Code Clinic.

This API 1104 Code Clinic study guide is comprised of an introductory module, conversion notes to go from the 1 8‘h edition to the lgth 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 1 104.

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 11 04. 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:

in practice;

I 3. Answer Neexercice 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 FI 33126

or call the Education Department at: 1 -800-443-9353

1



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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 facilifies, 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 Óf laws; as of a natron, state or industry group; arranged systematically for ease of use and reference”. Examples include AWS

parts of a whore; 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 Specificatbns A5.1, through A5.31, are examples. A guide (self-explanatory) is a document of the same class; AWS B1.ll - Guide for the Visual Examination I &i“ ” of Welds, . as an

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.

Welding of Pipelines and Related Facilities

API STANDARD 1104 NINETEEKFH EDITION, SEPTEMBER 1999

Figure 1 .I - 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

2



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flagged for ease of use and reference. See Figure .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 11 04. 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 buff, 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.

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 Sheets’.

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

API 11 04 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 1 104 CONTENTS

Following the listing of subsection titles is the

STANDARDS FOR GIRTH WELDS. APPENDIX - ALTERNATIVE ACCEPTANCE

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.

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

Appendix A - Alternative Acceptance Standards

Appendix B - In-service Welding.

Qualification of Welding Procedures for Welds Containing Filler-Metal Additives

Additions

for Girth Welds

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

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Changes From the API 1104 18* Edition to the 19* Edition Portions of the 1 104 standard have been changed from the 1 8'h ed. To the 1 9Ih 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

1.3

1.2 I 7 1

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 1 8'h Edition of the code the following chart has been provided to aid the reader in the use of the 19* Edition. The table is formatied 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.

2 REFERENCED PUBLICATIONS 1

3 DEFINITION OF TERMS 2 7 1 r--l 2

1.2.2

1.4 1.5

SECTION 2

3.2 Definitiais 2

4 !iÌPEcIFlc"4TIoNS 2 4.1 Equipment 2 4.2 Materials 2

5 QUALJFlCATION OF WELDING PROCEDURES FOR WELDS CONTAINING FKLFA-METAL ADDlTlW43

2.31 5.3 RocedureSpecification 13 I 2.4 2.5 2.6 2.7 2.8

5.4 Essaitial Variables 6 7

5.6 Testing of Welded Joints - Butt Welds 8 5.7 Welding of Test Joints - Fiileî Welds 13 5.8 Testing of Welded Joints - Fillet Welds 15

5.5 Welding ofTm joints -Butt Welds

SE(JII0N 3 3.1 3.2 3.3 3.4

6 QiJALiFíCAïïONS OF WELDERS 15 6.1 General 15 6.2 Single Qdificarion 15 6.3 Multiple@aiificatian 16 6.4 Visual Examinaiion 16

5

3.6 3.1 3.8

6.6 Radiqaphy ~ Butt Welds Only 19 6.1 Retesting 19 6.8 Records 19



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I l 17 DESM;N AND PREPARATION OF A JOINT FOR PRODUCIION WEDING SECTION4 I19

SECIION 5 5.1

8 IMSPECIION AND TESIWG OF PRODUCIION WELDS 20 8.1 Rights oílnspecrjai 20

I

6.1 9.1 General 21 6.2 9.2 Rights OfRejectim 21 6.3 9.3 RadiOgraphicTeStiOg 21 6.4 9.4 Magnetic Particle Testing 27 6.5 9.5 LiquidPendmniTesting 27

5.2 5.3 5.4

6

8.2 Methodsofhspectiai 20 8.3 Qniirkatioa ofhspectim Rrsonnel 20 8.4 Certification oí Nmidesmictive Testing P e r m e l 21



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7



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cation test w e m 114

ilificntinn Test Welds l i 9 IO 11

12 13 14

113 I. 1

9 Jig for Guided-Bend Tesu 10 Location of Nick-Break Test Specimens: Fillet-Weld Procedure and Welder Qualifi I I Location of Nick-Break Test Specimens: Fillet-Weld Procedure and Welder Q W . . ~

12 Location of Test Butt-weld Specimens for Welder Qualification Test

14 hadequte Penemtion Due to High-Low (IF'D)

' - . ... .~-.

'*' ' ' I hcluding Size to Size. Branch-Connection Welder Qualification Test 14

17 21 23

13 Inadequte Penetration Wilhait €liii:h-Low (IP)

..

NEW NEW NEW NEW NEW

8-7 Reinforcing Saddle 68 B-8 Encirclement Sleeve 68 B-9 Encirclement Tee 69 B-IO Encirclement Sleeve and Saddle 69 B-1 1 Encirclement Saddle 70

t I 2 3

1 Filler Metal Groups 7 2 Type and N u m k ofTest Specimens for Procedure Qualification Test 8 3 Type and Number of Buli-Weld Test Specimens per Welder for Welder Qualification Test and Destructive

8

Testing of Production Welds 18 4 4 Maximum Dimensions of Undeercutting 5 5 Thickness of Pipe Versus Thickness of ASTM E 1025 Penetrameter 6 6 Thickness of Pipe Versus Thickness of Peneumcrer 7 7 Thickness ofPipe Versus Thickness of ASTM E 147 Wire Peneirmeter 8 8 Type and Number ofTest Specimens for Procedure Qualification Test (Flash Weld Only)

29 3 1 32 32 4 1 54 55

A-l A-I Acceptance limits for Bunied Volumeuic Imperfections

r A-2 A-2 Acceptance Limits for Unrepaired Arc Bums

A-4 A-5 A-6

NEW

A-4Ällowable ImperfectionDimensiooss for Example 58 A-5 Acceptable Planar Imperfection Dimensions for Example 58

59 B-l Type and Number of Specimens - In-service welding procedure Qualification Test 65 A-6 Example Alternativee Acceptance Criteria



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MODULE #1- AWS CODE CLINIC FOR THE STUDY OF API 11 04 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 11 04 are to be interpreted in accordance with ANSVAWS 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 “shoulú” 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 Materiais. Subsection 4.2.1 requires that pipe and fittings must conform to either API Specification 5L or applicable ASTM specif ications.

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.

Table 1-Filler Metal Groups ~

AWS

I AS. I

Flux‘ Grtnip Spcciticaiion Elccirodc EWIO. EM1 I

2

3

4=

Sh

h

7

X

9

A5.5

A5.5

AS.1 orA5.5 AS.5

AS. I7

AS. I X AS. I X A 5 . 3 AS.7X

A 5 2

A5.20

AS29

€7010. E701 I

EXOIO. EXQI I Eyo I o

E7015 E7016. E701X EX015. EXOl6. EXüIX

EYO I X

E U . P6XZ ELXK F6X0 ELI2 F6X2

EMSK R X Z

EM13K R X ? EMISK

EMI2K mxn

ER70S-7 ER7OS-6

ERXOS-DZ ERWS-G

RCW. RGhS

. EóIT-CSd E7 IT-GS“

E71T8-K6

A529 E9 I n - G

Note: Oihcr electrodes. tiller rneds. and Iluxes may hc uscd hui require p par aie procedure quilificatiun. =Any combination of flux and electrode in Group 4 niay hc used to qualify a proccdure. The cornhination shall he idenrified hy its complete AWS classification number. such us F7AO-EL12 or F6A2- EMI7K. Only suhstituiions ihai resuli in Lhc urne AWS classification numher arc pcrmiited wilhwt rcqualitiuiiun. hA shielding gas (see 5.4.2.101 shall bc urd wiih the elecvndcs in Group 5. ‘ln the Ilux designation. lhe X can hc eiihrr an X ur P for As Welded or Posi-Weld Heat-Trcaied. dFor rtx>i-pasi welding only.

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GENERAL EXERCISE QUESTIONS - MODULE #1

1. What does the term 'position welding' mean?

A. B. C. D. E.

Welding with an all position welding electrode only Welding is carried out with pipe assembly rotated Applies when welding is done with a semiautomatic process Welding is carried out with pipe assembly stationary 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. E.

Kept in containers in which they are supplied 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 .l What topics does API 11 04 cover?

A. Gas welding of butt welds 6. 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. AI1 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 6. 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 1 104?

A. API B. ASNT C. ASTM D. AWS E. NACE

I 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? I

l A. API B. ASNT C. AWS D. BSI E. NACE

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Exercise Questions- API Standard 11 04 - 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 1 1 04 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 11 04 - Section Four - Specifications

4.1 API 1 104 applies to pipe welding that conforms to which specifications?

A. AWS 5.28 B. BSI BS 7448 C. API Specification 5L D. applicable A S T M E. Both C&D

4.2 Once opened, where shall S M A W 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 IC’. 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 IC’, 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

R.2<*L. MIs4zdwJ ll(Y.52

PROCEDURE SPECIFICATON NO.

i L

dol, am- .n lo< .i-. * ELECTRODE SU€ ANO NUMBER OF BEADS

I E ! + & S I I -“e. I

Figure 2-Sample Gown Tes1 Repon

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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. (5.4.2.1 1)

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).

Figure 34.œalion of Tes1 Bun-Weld Specimens for Procedure Oualdicalan Test

16



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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.

Figure Hick-BreakTesi -¡men

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 1 O 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.

n

appro.

Figure 1 l-iocation of Nick-Break Test Specimens: Fillel-Weld Procedure and Welder Qualification Test WeidS. Including Sizelo-Sue. Branch-Connection Welder ûuaiification Test

17



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GENERAL EXERCISE QUESTIONS - Code Clinic MODULE #2

1. API 1 104 has grouped base material into three distinct groups. In group 'b'the specified minimum yield strength is:

A. B. C. D. E. both €3 and D

less than or equal to 42,000 (290 MPa) pounds per square inch greater than 42,000 PSI (290 MPa) but less than 65,000 PSI (448 MPa) greater than 42,000 PSI (290 MPa) but less than 68,000 PSI (469 MPa) greater than 289.58 MPa but less than 448.16 MPa

2. When conducting a procedure qualification on materials with outside diameters greater than 135 mm, the number of tensile test(s) required Ware?

A. two B. one C. none are required D. four E. none of the above

3. When preparing a tensile specimen for testing:

A. B. C. D. E. Both C&D

A notch approximately 1/8" shall be cut into each side of the weld The specimen must be machined May be oxygen cut with no further preparation provided sides are parallel and smooth Weld reinforcement should not be removed on either side

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 i1 6" wide B. C. 518" wide D. 1 /2" wide E.

2% of the exposed surface area

Both A & B are correct

18



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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 O00 psi B. less than or equal to 42 O00 psi C. greater than 65 O00 psi D. greater than 42 O00 psi and less than 65 O00 psi E. greater than 85 O00 psi

5.2 For metals with specified minimum yield strengths greater than 42 O00 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. 112 in. B. 314 in. C. 518 in. D. 1-112 in. E. a dimension is not specified

19



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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.

Fqure 12-Location o1 Tes: Bun-Weld Specimens lor Welder üualilicalionTes1

20



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Table 3-Type and Number of Butt-weld Test Specimens per Welder for Welder Qualification Test and Destructive Testing of Production Welds

Outsidc Diamcicr ol' Pipe

Inchcs Millimcucs Sucngth B r e d Bcnd Bend Bcnd Tina1

Wal1 Thickncss 5 0.500 in. (12.7 mmi c 2.375 < ho.3 o 2 2 o o 43

I.3754.5(X) 60.3-3Z3.Y o - o o 1 > .~.S(XLI 2.750 I I 4.-~323.9 2 I - o o h

> 12.750 > 323.9 4 4 - 2 o I2 Wall Thickncss > 0.500 in. ( 12.7 mm)

5 4.500 5 114.3 o 2 o o 2 4 > 4.W-12.750 > I14.?-323.9 2 2 o o - h

> 12.750 > 323.9 4 4 o o 4 I ,

Numher of Specimens

Tcnsilc Nicl- Rooi Face Sidc

> > 7

7

7

3For pipc Icss ihm or cqual io 1.315 in. (33.4 mm) in ouiside dimcicr. spccimcns from two wcldr or onc full-sceciion icnsilc-sircngih spccimcn s h ~ l l hc iakcn.

6.5 Destructive Testing. Table 3 above gives is acceptable to the company. 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 for which they qualified shall be maintained. specimens may be substituted for the tensile strength specimens per

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

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 weid 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.

Separation M L Lengm

6.6 Radiography - Butt Welds Only. This Niuc: A hrokcn nick-hrck wsi spccimcn i b shown: however. h i s meihal oí dimensioning subsection allows a company to qualify welders

on butt welds using radiography in lieu of applies dso 10 hrukcn tensile md tillet weld mi specimens.

Figure &Dimensioning of Imperfections in Exposed Weld Surfaces 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

21



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

A. Is not permitted B. C. D. E.

Length of protrusion shall not exceed 1 /16" Length of protrusion shall not exceed 0.79 mm Shall be kept to a minimum 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 1 104 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 118 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

2 2



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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 11 04. 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 specif ¡cations.

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.

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 hisíher work as prescribed by the company (owner).

7.1 1 Pre- and Post-Heat Treatment. Preheat and post weld heat treatment requirements shall be specified in the welding procedure specification.

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

2 3



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1. For position welding, the maximum reinforcement permitted is:

A. B. C. 1 /16” maximum D. 1/16” minimum E.

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

No more than the thickness of the pipe Depends on the amount of pipe offset

Up to the welders’ discretion

2.

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

A. B. C. D. E.

Stenciling their identification symbol adjacent to the weld Recording their identification symbol on a weld “map” Writing their identification symbol adjacent to the weld using a permanent marker Recording their identification on a traveler Any of the above methods as prescribed by the owner or owner’s representative

Exercise Questions-API Standard 11 04 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 512.7 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 512.7 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

2 4



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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-1 A. Only Level II or Level 111 personnel shall interpret any test results. (8.4.1)

The company shall retain a record of certified nondestructive testing personnel. Level I and Level I l 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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1. Who determines the type of inspection to be done?

A. Thewelder B. The inspector C. The QC Manager D. The ownerkompany 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

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

3.

A. ASNT SNT-TC-IA B. ASME Section V C. ASTM 265E D. ACCP E. A & D above

4. How often must Level 111 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

2 6 Copyright American Welding Society Provided by IHS under license with AWS


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Exercise Questions- API Standard 1 1 04 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 Ill NDT personnel shall be certified to:

A. any recognized national certification program acceptable to the company

C. any pertinent AWS program D. the contractor’s in-house certification program E. both A&B are acceptable

B. ASNT - SNT-TC-1A

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

27



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MODULE # 6 - AWS CODE CLINIC FOR THE STUDY OF API 11 04

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 11 04. 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 1 104.

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 i 104.

, I

Cold lap between adjacent beads

Cold lap between weld bead and parent maierial

Noie: The cold lap shown is not sudaceionnecid.

Figure 17-incomplete Fusion Due to Cold Lap (IFD) 2 8 Copyright American Welding Society

Provided by IHS under license with AWSNot for ResaleNo reproduction or networking permitted without license from IHS

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Subsection 9.3.6covers internal concavity (IC) and is depicted in Figure 18 of API 11 04. 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). ESl’s as shown Figure A l may be continuous or broken and are usually found at the fusion zone, whereas ISl’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.

29 Copyright American Welding Society Provided by IHS under license with AWS


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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.



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Cracks as shown in Figure A6, Subsection 9.3.1 O, are generally unacceptable except for shallow crater or star cracks whose length is 5/32 inch (4 mm) or less in length.

Subsection 9.3.1 1 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 (lu) 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 lu.

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. (9.3.1 3)



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9.4 Magnetic Particle Testing 9.6 Ultrasonic 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.

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)





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9.7 Visual Acceptance Standards for Undercutìing

Undercutting has previously defined in Subsection 9.3.1 1. 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.

Table &Maximum Dimensions of undercutting

Dcpth Lcngth > '/32 in. (0.8 mm) or > 12.5% ol' pipe wall ihick- ness, whichcvcr is smallcr.

> '/a in. (0.4 mm) or > hr/r-i?.S% ihickncss, whichcvcr i s smallcr.

I '/a in. (0.4 mm) or 5 6% of pipc wall ihickncss. whichcvcr is smallcr.

Noi acccpiablc.

7 in. ( 5 0 mm) in u coniinuous I2-in. 1300-mm) wcld Icngih or onc-sixth ihc wcld lcngth. which- c w r is >mullcr.

Acccpiahlc. rcigardlcss oï Icngih.

pipc wall



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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. 111 6 inch B. 118 inch C. 112 inch D. 1.59mm E. Both B and D above

2. The maximum length of a crater crack is:

A. 118 inch B. 5/32 inch C. no cracks are allowed D. E.

1/2 the width of the bead craters in welds cannot crack

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

A. B. Exceed 5/32 inch C. D. E.

Exceed 2 inches in total length in a continuous 12-inch length of weld

Exceed 8 percent of the weld length Exceed 6 percent of the weld length Both A and C above

4. When inspecting a pipe weld you measure some undercut at the face of the weld. mechanically measures 1/64 inch deep and approximately 6 inches long. The undercut is:

The undercut

A. Not acceptable B. C. D. IAcceptable E.

Must first be checked against radiograph measurements Unacceptable because it exceeds 2 inches

Undercut cannot be produced on face side of weld

5. Linear indications are those indications whose:

A. 8. C. D. E.

Length is more than three times its width Length is equal to its width Length is more than four times its width Width is equal to its length Length is less than its width



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Exercise Questions- API Standard 11 04 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. 114 in. D. 1 .O 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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SECTION 10 - REPAIR AND REMOVAL OF DEFECTS

10.1 AUTHORIZATION FOR REPAIR

Subsection 10.1.1 Cracks. It is stated that experienced in welding repair cracked welds shall be removed from the line unless permitted by 9.3.1 O, or when the company authorizes repair. Cracks may be repaired if they d. The weld is made by a qualified welder do not exceed 8% of the weld length. Any and all repairs shall meet the acceptability standards in e. The repair groove is examined bt MT Section 9. or PT to assure removal of the crack.

techniques.

Subsection 10.1.2 Defects Other Than Cracks It is stated that defects, other than cracks, in the weld root andor 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

4. Welding procedure and type of

5. Post weld heat treatment

requirements

electrodes

requirements

c. The repair is made under the supervision of a technician who is



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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 11 04 Section #1 O

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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SECTION 11 - PROCEDURES FOR NONDESTRUCTIVE TESTING

1 1.1 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.

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 11 04. Wire type penetrameters shall conform to ASTM E747. (Subsection 11.1.4)

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.



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Transmitted densities through small localized areas have different limits as given in Paragraph 11.1.10.1 of API 1104.

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 speciíied 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 S.1)

Table 7 of API 1104 shows the essential wire diameter, based on the thickness of the weld of ASTM E 747 wire penetrameters. (1 1.1 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)

The radiographer shall be responsible for protection and monitoring of every person working with or near radiation sources. (Paragraph 1 1.1.1 3)

Table 5-rn-S 01 Pipe Versus Thdness of ASTM E 1025 Pewrameier

Table 7-lñickmtss of PIPE Vmus h m e l e r of ASTM E 747 Wire Penatrameler

> 0.WJlS > 6.c95 n.o10 0.25 A a B 20.3lM.m >95-lLl 0013 0.33 B ,0.Sma7yi > 12.1-1'4.1 0.016 0.41 8 ~0.l~I.lXU > 19.1-25.4 0.020 051 B > I.mO-I IUI >3.C5U.B 0.ITS O . N B

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.

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.



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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 ali 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 (Le., manufacturer, type, size, etc.). Automatic or Manual. Couplant. Testing Technique:

Angles.

Temperatures and ranges. Scanning patterns and speeds.

9 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.

. Frequencies (MHz).

Scanning ievel-the sensitivity setting in decibels (dB) to be added to the reference sensitivity for scanning. Evaluation ievel-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 ali 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 I I I 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 li 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 methodtech- 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.

NI

End view

f

Figure 22A-Reterence Bod< for Manual UT

I B I I u- . . 1

I

I " '.



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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. B. 2T hole C. D. 1T hole E.

The thickness of the penetrameter

Clear across the entire area of interest

Wire type pentrameters are not permitted in API 1104

2. Who shall interpret the radiographic film of production welds?

A. Level I B. C. The inspector D. E. The CWI

Level I or Level II

Level II or Level III

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 E l 025 penetrameter would be used for this radiograph?

A. #15 B. #20 C. #17 D. #7 E. Letter B

5. The abbreviation DWUSWV stands for?

A. B. C. D. E.

Double-wall exposure for single-wall viewing Double-wall exposure for double-wall viewing Singie-waii exposure for singie-wall viewing Double-wall exposure on Shielded Weld V Grooves 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 111:

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 0.43241-1. wail 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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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. Subsection 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 11 04 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 11 04.

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 11 04, 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 11 04.

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.

12.1 O 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.

12.1 1 Radiographic Testing. Radio- graphic testing shall be in accordance with Subsection 11.1 of API 1 104.



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1. In automatic welding, the travel speed:

A. B. C. D. E.

Is recorded in millimeters only Need not be addressed if current and volts are recorded Is recorded in inches only Must be recorded for each pass 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


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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SECTION 13 - AUTOMATIC WELDING WITHOUT FILLER-METAL ADDITIONS type of welding.

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 11 04.

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 11 04.

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

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 11 04, 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

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

Welds

Paragraph 13.8.2 of API 11 04 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.

13.1 1 Radiographic Procedure. Radio- graphic testing shall be in accordance with Subsection 11.1 of API 1104.



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EXERCISE QUESTIONS - MODULE #1 O

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

the maximum

A. 1/2 inch in length B. 1/32 inch in depth C. 1/2 inch in width D. E.

1/8 inch in length and width 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 IS1 in a flash butt weld shall not exceed:

A. 3/8 inch in length B. li2 inch C. 1/8 inch in length D. 1/16 inch in length E. No IS1 is allowed

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

A. B. After flash is removed C. D. E.

It must be performed when weld is still hot

Before heat treatment is complete After post heat treatment is complete Both B and D above

49



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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 294-1. OD pipe C. 40 total for 324-1. 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

50



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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 An extensive mathematical discussion is Appendix A in lieu of using Section 9, the presented for calculating the extent of various acceptance standards normally used. The imperfection interactions based on types, sizes, alternate technique used is fracture mechanics and shapes of the imperfections. analysis and fitness-for-purpose criteria. Engineers will appreciate this mathematical approach. For simplification, the appendix restricts the mathematics to the US. Customary Units (in.-lb), although it is acceptable to make

(metric units). I the evaluations with all values expressed in SI

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.

I

I

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%.

i

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, COZ, 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.

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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

Table 51-Type and Number of Specirnen+ln-Service Welding Procedure QualificationTest

N ~ C or specimnsa 0

Wail Thicbiess Wcld Type Tensile Nick-Break RmFknd FaceBend SideBend MUcn>Tes< Toid 5 0.SW inch Groove 2 2 2 2 8

(12.7 mm) Slave 4b 4 4 12 Bmch 4h 4 4 12

> 0.Mo inch Groove 2 3 4 8 ( 1 2 . 7 ~ ) Skew 4b 4 4 12

Branch 4b 4 4 I2

.For pipc or branch diurnefer less chnn or equal to 4.500 in. (1 14.3 mm), two welds may be requircd bAt the owner's Option. the remaining ponion of cher spcCimenï, m y be prepared for and suhmiucd io hc face-bd test (sce B.2.45) after they m submined to the nick-break tes^

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Answers to API Standard 1104 Section Exercise Questions

Section #I 1 .l-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 3.4-8

Section #4 4.1- E 4.2-8 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 Section #13 9.1-D 13.1-E 9.2-E 13.2-E 9.3-E 13.3-E 9.4-D 13.4-D 9.5-B 13.5-B

Section #lo 10.1-B 10.2-A 10.3-E

Section #11 11 .I-E 11.2-E 11.3-8 11.4-D 11.5-D

Section #12 12.1-E 12.2-c 12.3-B

1 ~~ ~~~~~

Answers to API Standard 1104 Code Clinic MODULE Questions

Module #1 1 .D 2.c 3.B 4.0

Module #2 1 .E 2.A 3.E 4. E 5.E Module #3 1 .D 2.8 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 3.8

Module #1 o 1 .D 2.8 3. E 4.c 5.E

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