API 1104-22nd Edition (July 2021) Welding of Pipelines and Related - PDF

Special Notes API publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed. The use of API publications is voluntary. In some cases, third parties or authorities having jurisdiction ma...

Special Notes API publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed. The use of API publications is voluntary. In some cases, third parties or authorities having jurisdiction may choose to incorporate API standards by reference and may mandate compliance. Neither API nor any of API’s employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication. Neither API nor any of API’s employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights. 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Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard. Classified areas may vary depending on the location, conditions, equipment, and substances involved in any given situation. Users of this Standard should consult with the appropriate authorities having jurisdiction. Users of this Standard should not rely exclusively on the information contained in this document. Sound business, scientific, engineering, and safety judgment should be used in employing the information contained herein. All rights reserved. No part of this work may be reproduced, translated, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 200 Massachusetts Avenue, NW, Suite 1100, Washington, DC 20001. Copyright © 2021 American Petroleum Institute Foreword This standard was prepared by a formulating committee that included representatives of the API, the American Gas Association (AGA), the Pipe Line Contractors Association (PLCA), the American Welding Society (AWS), and the American Society for Nondestructive Testing (ASNT), as well as representatives of pipe manufacturers and individuals associated with related industries. The purpose of this standard is to present methods for the production of high quality welds through the use of qualified welders using approved welding procedures, materials, and equipment. Its purpose is also to present inspection methods to ensure the proper analysis of welding quality through the use of qualified technicians and approved methods and equipment. It applies to both new construction and in-service welding. The use of this standard is entirely voluntary and is intended to apply to welding of piping used in the compression, pumping, and transmission of crude petroleum, petroleum products, fuel gases, carbon dioxide, and nitrogen and, where applicable, to distribution systems. This standard represents the combined efforts of many engineers who are responsible for the design, construction, and operation of oil and gas pipelines, and the committee appreciatively acknowledges their wholehearted and valuable assistance. Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent. The verbal forms used to express the provisions in this document are as follows. Shall: As used in a standard, “shall” denotes a minimum requirement in order to conform to the standard. Should: As used in a standard, “should” denotes a recommendation or that which is advised but not required in order to conform to the standard. May: As used in a standard, “may” denotes a course of action permissible within the limits of a standard. Can: As used in a standard, “can” denotes a statement of possibility or capability. This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which this publication was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 200 Massachusetts Avenue, Suite 1100, Washington, DC 20001. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director. Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is published annually by API, 200 Massachusetts Avenue, Suite 1100, Washington, DC 20001. Suggested revisions are invited and should be submitted to the Standards Department, API, 200 Massachusetts Avenue, Suite 1100, Washington, DC 20001, [email protected]. iii Contents Page 1 Scope.................................................................................. 1 2 Normative References.................................................................... 1 3 Terms, Definitions, Acronyms, and Abbreviations............................................. 2 3.1 Terms and Definitions..................................................................... 2 3.2 Acronyms and Abbreviations.............................................................. 8 4 Specifications.......................................................................... 11 4.1 Equipment............................................................................. 11 4.2 Materials............................................................................... 12 5 Qualification of Welding Procedures with Filler Metal Additions................................ 13 5.1 Procedure Qualification.................................................................. 13 5.2 Record................................................................................ 13 5.3 Welding Procedure Specification.......................................................... 13 5.4 Essential Variables...................................................................... 19 5.5 Welding of Test Joints-Butt Welds......................................................... 22 5.6 Testing of Welded Joints-Butt Welds....................................................... 22 5.7 Welding of Test Joints-Branch and Fillet Welds.............................................. 30 5.8 Testing of Welded Joints-Branch and Fillet Welds............................................ 31 6 Qualification of Welders.................................................................. 32 6.1 General................................................................................ 32 6.2 Single Qualification...................................................................... 33 6.3 Multiple Qualification.................................................................... 36 6.4 Visual Examination...................................................................... 40 6.5 Destructive Testing...................................................................... 40 6.6 Nondestructive Testing (NDT)-Butt Welds Only.............................................. 41 6.7 Retesting and Disposition of Test Results................................................... 42 6.8 Records............................................................................... 42 7 Design and Preparation of a Joint for Production Welding..................................... 42 7.1 General................................................................................ 42 7.2 Alignment.............................................................................. 42 7.3 Use of Lineup Clamp for Butt Welds........................................................ 43 7.4 Bevel.................................................................................. 43 7.5 Weather Conditions...................................................................... 43 7.6 Clearance.............................................................................. 43 7.7 Cleaning Between Beads................................................................. 43 7.8 Position and Roll Welding................................................................ 43 7.9 Identification of Welds................................................................... 44 7.10 Preheat, Interpass Temperature, Postheat, and PWHT......................................... 44 8 Inspection and Testing of Production Welds................................................. 44 8.1 Rights of Inspection..................................................................... 44 8.2 Methods of Inspection................................................................... 44 8.3 Qualification of Inspection Personnel....................................................... 44 8.4 Certification of NDT Personnel............................................................ 45 9 Acceptance Standards for NDT............................................................ 45 9.1 General................................................................................ 45 9.2 Rights of Rejection...................................................................... 45 v Contents Page 9.3 Radiographic Testing.................................................................... 46 9.4 Magnetic Particle Testing................................................................. 52 9.5 Liquid Penetrant Testing.................................................................. 53 9.6 Ultrasonic Testing....................................................................... 54 9.7 Visual Acceptance Standards for Undercutting.............................................. 56 9.8 Visual Acceptance Standards for Internal Concavity.......................................... 56 10 Repair and Removal of Weld Defects....................................................... 56 10.1 General................................................................................ 56 10.2 Repair Requirements.................................................................... 57 10.3 Repair Procedure........................................................................ 58 10.4 Repair Welder Qualification............................................................... 67 10.5 Inspection of Repair Welding.............................................................. 71 10.6 NDT and Weld Repair Acceptance Criteria................................................... 71 11 Procedures for Nondestructive Testing (NDT)................................................ 71 11.1 General................................................................................ 71 11.2 Magnetic Particle Testing Method.......................................................... 83 11.3 Liquid Penetrant Testing Method.......................................................... 83 11.4 Ultrasonic Testing Methods............................................................... 83 12 Mechanized Welding with Filler Metal Additions.............................................. 94 12.1 Acceptable Processes................................................................... 94 12.2 Procedure Qualification.................................................................. 94 12.3 Record................................................................................ 95 12.4 Welding Procedure Specification.......................................................... 95 12.5 Essential Variables...................................................................... 99 12.6 Testing of Welded Joints-Butt Welds...................................................... 102 12.7 Qualification of Welding Operators........................................................ 107 12.8 Records of Qualified Operators........................................................... 111 12.9 Inspection and Testing of Production Welds................................................ 111 12.10Acceptance Standards for NDT........................................................... 111 12.11Repair and Removal of Defects........................................................... 111 12.12Radiographic Testing................................................................... 111 12.13Ultrasonic Testing...................................................................... 111 Annex A (normative) Alternative Acceptance Standards for Girth Welds............................. 112 Annex B (normative) In-service Welding........................................................ 137 Annex C (normative) Requests for Interpretation and Requests for Revision to the Document.......... 161 Bibliography............................................................................... 163 Figures 1 Sample Qualification Weld Report Form.................................................... 15 2 Sample Welding Procedure Specification Form.............................................. 16 3 Location of Test Butt Weld Specimens for Procedure Qualification Test......................... 23 4 Tension Test Specimen................................................................... 25 5 Nick Break Test Specimen................................................................ 27 6 Dimensioning of Imperfections in Exposed Weld Surfaces..................................... 28 7 Root and Face Bend Test Specimen: Wall Thicknesses Less than or Equal to 0.500 in. (12.7 mm).... 28 vi Contents Page 8 Jig for Guided-bend Tests................................................................ 29 9 Side Bend Test Specimen: Wall Thicknesses Greater than 0.500 in. (12.7 mm).................... 30 10 Location of Nick Break Test Specimens: Branch and Fillet Weld Procedure and Welder Qualification Test Welds....................................................... 30 11 Location of Nick Break Test Specimens: Branch and Fillet Weld Procedure and Welder Qualification Test Welds, Including Size-to-size Branch Connection Welder Qualification Test...... 31 12 Location of Test Butt Weld Specimens for Welder Qualification Test (Full Circumference).......... 38 13 Location of Test Butt Weld Specimens for Welder Qualification Test (Half Circumference).......... 39 14 Inadequate Penetration Without High-low................................................... 46 15 Inadequate Penetration Due to High-low.................................................... 46 16 Inadequate Cross Penetration............................................................. 47 17 Incomplete Fusion at Root of Bead or Top of Joint........................................... 47 18 Incomplete Fusion Due to Cold Lap........................................................ 48 19 Internal Concavity....................................................................... 48 20 Maximum Distribution of Gas Pockets: Wall Thickness (t) less than or equal to 0.500 in. (12.7 mm).. 50 21 Maximum Distribution of Gas Pockets: Wall Thickness (t) Greater Than 0.500 in. (12.7 mm)......... 51 22 Hardness Locations for Full-thickness Repair Procedure Qualification.......................... 64 23 Hardness Locations for External Partial-thickness Repair Procedure Qualification at Weld......... 64 24 Hardness Locations for Cover Pass Repair Procedure at Weld Centerline........................ 65 25 Hardness Location for Back Weld Repair or Internal Partial-Thickness Repair Procedure at Weld Centerline....................................................................... 65 26 Hardness Locations for Cover Pass Repair Procedure at Fusion Line........................... 66 27 Hardness Locations for External Partial-Thickness Repair at Fusion Line........................ 66 28 Calculation for Determining Beam Width.................................................... 75 29 Example of Reference Standard for Manual Ultrasonic Testing................................. 89 30 Example: Establishing Distance, Refracted Angle, and Velocity................................. 89 31 Example: Attenuation and Transfer Procedure............................................... 90 32 Example: V Prep Reference Standard—Example Reflector Positioning.......................... 93 33 Example: J and K Prep Reference Standard—Reflector Positioning............................. 93 34 Example—J Prep Reference Standard—Top View............................................ 93 35 Sample Coupon Test Report.............................................................. 96 36 Sample Welding Procedure Specification Form.............................................. 97 37 Location of Test Butt Weld Specimens for Procedure Qualification Test........................ 104 38 Tension Test Specimen.................................................................. 105 39 Root and Face Bend Test Specimen: Wall Thicknesses Less Than or Equal to 0.500 in. (12.7 mm).. 106 40 Jig for Guided-bend Tests............................................................... 106 41 Side Bend Test Specimen: Wall Thicknesses Greater than 0.500 in. (12.7 mm)................... 107 A.1 Top View (Width in Circumferential Direction) of the Tensile Test Specimen..................... 118 A.2 Charpy Specimen and V-notch Location for HAZ Impact Testing............................... 119 A.3 Orientation of CTOD Test Specimen....................................................... 120 A.4 Machining Objective for CTOD Test Specimen with Respect to Pipe Wall........................ 121 A.5 Location of Notch for Weld Metal Specimen................................................ 122 A.6 Location of Notch for Heat-affected Zone Specimen......................................... 122 A.7 Option 1 Imperfection Limits for CTOD ≥ 0.010 in. (0.25 mm).................................. 124 A.8 Option 1 Imperfection Limits for 0.004 in. (0.10 mm) ≤ CTOD < 0.010 in. (0.25 mm)................ 125 A.9 Allowable Imperfection Size Curves Before and After Height Adjustment....................... 128 A.10 Schematic Overview of the Option 2 Procedure............................................. 128 A.11 Criteria for Evaluation of Imperfection Interaction........................................... 136 B.1 Examples of Typical Temper Bead Deposition Sequences.................................... 138 Contents Page B.2 An Example of Procedure and Welder Qualification Test Assembly............................ 143 B.3 Suggested Location of Test Specimens.................................................... 144 B.4 Suggested Location of Test Specimens for Weld Deposition Repair............................ 145 B.5 Example Macro Test Specimen—In-service Fillet Welds...................................... 147 B.6 Face Bend Test Specimen............................................................... 149 B.7 Reinforcing Pad........................................................................ 153 B.8 Reinforcing Saddle..................................................................... 154 B.9 Encirclement Sleeve.................................................................... 154 B.10 Encirclement Tee....................................................................... 155 B.11 Encirclement Sleeve and Saddle.......................................................... 155 B.12 Encirclement Saddle.................................................................... 156 Tables 1 Essential Variables for Qualification of Welding Procedure Specifications....................... 20 --`,`````,,,,,,`,`,,,`,,,```,`,-`-`,,`,,`,`,,`--- 2 Filler Metal Groups...................................................................... 22 3 Type and Number of Test Specimens for Procedure Qualification Test........................... 24 4 Filler Metal Groups for Welder Qualification................................................. 33 5 Qualified Thickness Range for Single Qualification Test....................................... 35 6 Qualification Scope for Single Qualification Test Using a Branch Connection..................... 36 7 Type and Number of Butt Weld Test Specimens per Welder for Welder Qualification Test and Destructive Testing of Production Welds................................ 41 8 Maximum Dimensions of Undercutting..................................................... 56 9 Essential Variables for Qualification of Repair Welding Procedure Specifications................. 60 10 Repair Type Qualification Matrix........................................................... 60 11 Type and Number of Butt Weld Test Specimens per Repair Type for Repair Procedure............. 62 12 Repair Weld Maximum Hardness Values, Non-Sour Service, HV10.............................. 67 13 Repair Welder Qualification Scope......................................................... 68 14 Type and Number of Butt Weld Test Specimens per Repair Type for Repair Welder Qualification.... 69 15 Essential Variables for Repair Welders...................................................... 70 16 Repair Welder Qualification Matrix......................................................... 71 17 ASTM E747 Wire Type IQI Selection........................................................ 77 18 ISO Wire Type IQI Selection............................................................... 77 19 ASTM E1025 Hole Type IQI Selection....................................................... 77 20 Essential Variables for the Qualification of Mechanized Welding Procedure Specifications........ 100 21 Filler Metal Groups..................................................................... 102 22 Type and Number of Test Specimens for Procedure Qualification Test.......................... 103 23 Type and Number of Test Specimens for Welding Operator Qualification Test................... 109 A.1 Essential Variables for Qualification of Welding Procedure Specifications in Accordance with this Annex........................................................................ 116 A.2 Allowed Range of Variation from the Targeted Mean Values for a Lot Defined by Controlled Chemical Composition........................................................ 117 A.3 Initial Allowable Imperfection Size for Pr = 0.825............................................. 126 A.4 Example Acceptance Table.............................................................. 128 A.5 Acceptance Limits for Buried Volumetric Imperfections...................................... 133 A.6 Acceptable Limits for Unrepaired Arc Burns................................................ 133 B.1 Essential Variables for Qualification of Welding Procedure Specifications in Accordance with this Annex........................................................................ 140 B.2 Essential Variables Applicable to Procedure and Welder Qualification.......................... 141 B.3 Type and Number of Specimens—In-service Welding Procedure Qualification Test............... 146 Contents Page B.4 Weld Maximum Hardness Values, Non-Sour Service, HV..................................... 148 B.5 Type and Number of Test Specimens for Longitudinal Groove Seam—Welder Qualification........ 152 B.6 Essential Variables for Qualification of Repair Welding Procedure Specifications in Accordance with this Annex........................................................... 158 B.7 Type and Number of Specimens—In-service Welding Repair Procedure Qualification Test......... 159  Welding of Pipelines and Related Facilities 1 Scope This standard covers the gas and arc welding of butt, branch, and fillet welds in carbon and low-alloy steel pipe and piping components used in the compression, pumping, and transmission of crude petroleum, petroleum products, fuel gases, carbon dioxide, nitrogen, and, where applicable, covers welding on distribution systems. It applies to both new construction and in-service welding. The welding may be done by a shielded metal arc welding, submerged arc welding, gas tungsten arc welding, gas metal arc welding, flux- cored arc welding, plasma arc welding, or oxyacetylene welding process, or by a combination of these processes using a manual, semiautomatic, or mechanized welding technique or a combination of these techniques. The welds may be produced by position or roll welding or by a combination of position and roll welding. This standard also covers the procedures for radiographic, magnetic particle, liquid penetrant, and ultrasonic testing, as well as the acceptance standards to be applied to production welds tested to destruction or inspected by radiographic, magnetic particle, liquid penetrant, ultrasonic, and visual testing methods. The values stated in either U.S. customary units (USC) or metric units (SI) are to be regarded separately as standard. Each system is to be used independently of the other, without combining values in any way. The figures depicted in this standard are not drawn to scale. It is intended that all work performed in accordance with this standard meets or exceeds the requirements of this standard. While this standard is comprehensive, it may not address all issues that may arise. The absence of guidance or requirements is not to be considered prohibitive to a particular activity or approach that is based upon sound engineering judgment. For example, other industry standards, reliable engineering tests and analyses, or established industry practices may provide useful reference to establish sound engineering judgment. 2 Normative References The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. API Specification 5L, Specification for Line Pipe ASNT1 SNT-TC-1A, Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing ASTM2 E23, Standard Test Methods for Notched Bar Impact Testing of Metallic Materials ASTM E165, Standard Test Method for Liquid Penetrant Examination ASTM E384, Standard Test Method for Knoop and Vickers Hardness of Materials ASTM E709, Standard Guide for Magnetic Particle Testing ASTM E747, Standard Practice for Design, Manufacture and Material Grouping Classification of Wire Image Quality Indicators (IQI) Used for Radiology 1 American Society for Nondestructive Testing, 1711 Arlingate Lane, Columbus, Ohio 43228-0518, www.asnt.org. 2 ASTM International, 100 Barr Harbor Drive, West Conshohocken, Pennsylvania 19428, www.astm.org. 2 API STANDARD 1104 ASTM E1025, Standard Practice for Design, Manufacture, and Material Grouping Classification of Hole-Type Image Quality Indicators (IQI) Used for Radiography AWS A3.03, Standard Welding Terms and Definitions AWS A5.1, Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding AWS A5.2, Specification for Carbon and Low-Alloy Steel Rods for Oxyfuel Gas Welding AWS A5.5, Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding AWS A5.17, Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc Welding AWS A5.18, Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding AWS A5.20, Specification for Carbon Steel Electrodes for Flux Cored Arc Welding AWS A5.28, Specification for Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding AWS A5.29, Specification for Low-Alloy Steel Electrodes for Flux Cored Arc Welding AWS A5.32, Welding Consumables – Gases and Gas Mixtures for Fusion Welding and Allied Processes AWS A5.36, Specification for Carbon and Low-Alloy Steel Flux Cored Electrodes for Flux Cored Arc Welding and Metal Cored Electrodes for Gas Metal Arc Welding BS EN ISO 156534, Metallic Materials. Method of Test for the Determination of Quasistatic Fracture Toughness of Welds ISO 19232-15, Non-destructive testing—Image quality of radiographs—Part 1: Image quality indicators (wire type)—Determination of image quality value NACE MR0175/ISO6 15156 (all parts), Petroleum and Natural Gas Industries—Materials for use in H2S- containing Environments in Oil and Gas Production 3 Terms, Definitions, Acronyms, and Abbreviations 3.1 Terms and Definitions For the purposes of this standard, the welding terms and definitions given in AWS A3.0 and the following shall apply. When identical terms are defined in AWS A3.0 and this standard, the following definitions shall apply. 3.1.1 automated ultrasonic testing AUT A term that covers a wide range of ultrasonic testing systems and techniques utilizing automated mechanical scanners while recording ultrasonic results. 3 American Welding Society, 550 NW LeJeune Road, Miami, Florida 33126, www.aws.org. 4 British Standards Institution, Chiswick High Road, London W4 4AL, United Kingdom, www.bsi-global.com. 5 International Organization for Standardization, 1, ch. de la Voie-Creuse, Case postale 56, CH-1211 Geneva 20, Switzerland, www.iso.org. 6 NACE International (formerly the National Association of Corrosion Engineers), 1440 South Creek Drive, Houston, Texas 77218-8340, www.nace.org.  WELDING OF PIPELINES AND RELATED FACILITIES 3 3.1.2 back weld A weld made at the back side of a groove weld as part of the original weld. 3.1.3 back weld repair A repair weld made at the back side of a groove weld to repair a defect (or defects) in a completed weld. NOTE A back weld repair is not a back weld 3.1.4 branch weld A completed groove and/or fillet weld joining a set-on or set-in branch pipe or a set-on or set-in branch fitting to a run pipe. 3.1.5 burn-through BT A portion of the root bead where excessive penetration has caused the weld puddle to be blown into the pipe or fitting. 3.1.6 burn-through (in-service welds) An event that occurs during in-service welding when the welding arc causes the pipe wall to be breached. 3.1.7 company The owner company or the engineering agency in charge of construction. NOTE A company may act through an inspector or another authorized representative. 3.1.8 contractor An entity that includes the primary contractor and any subcontractors engaged in work covered by this standard. 3.1.9 cover pass repair A repair to the weld face, primarily located within the external reinforcement, but that may extend into the base material and/or weld metal (e.g., including external undercut). 3.1.10 defect An imperfection of sufficient magnitude to warrant rejection based on the acceptance criteria in this standard. 3.1.11 double repair The second repair in a previously repaired area of a completed weld; typically referred to as a “repair of a repair” or a “re-repair.” 3.1.12 elongated linear indication An indication with its greatest dimension in the weld length direction that exceeds three times its width. 3.1.13 full-thickness repair A repair weld originating from the weld face that penetrates completely through the weld thickness after creating an open root without backing. 4 API STANDARD 1104 3.1.14 grinding Mechanical means to remove material using abrasive methods. 3.1.15 half-circumference dual-welder qualification Activity consisting of two welders welding on opposite sides of a full circumference pipe nipple. NOTE This is regionally known as “brother-in-law” welding. 3.1.16 half-value layer HVL The thickness of an absorbing material required to reduce the intensity of a beam of incident radiation to one half of its original intensity. 3.1.17 heat input The measure of energy transferred during welding. NOTE See 5.3.2.6 for equations used to calculate heat input. 3.1.18 hollow bead (porosity) HB The elongated linear porosity that occurs in the root bead. 3.1.19 imperfection A dscontinuity or irregularity that is detectable by methods outlined in this standard. 3.1.20 inadequate cross penetration ICP A subsurface lack of bond imperfection between the first inside pass and the first outside pass. 3.1.21 inadequate penetration due to high-low IPD The condition that exists when one edge of the root is exposed (or unbonded) because an adjacent pipe or fitting is misaligned. 3.1.22 inadequate penetration without high-low IP Incomplete filling of the weld root. 3.1.23 incomplete fusion IF A surface imperfection between the weld metal and the base material that is open to the surface. 3.1.24 incomplete fusion due to cold lap IFD An imperfection between two adjacent weld beads or between the weld metal and the base metal that is not open to the surface.  WELDING OF PIPELINES AND RELATED FACILITIES 5 3.1.25 indication The response or evidence from nondestructive testing. 3.1.26 instantaneous energy Energy that is calculated at every instant in which current and voltage are sampled during arc welding prior to averaging instead of being calculated using average current and average voltage. 3.1.27 instantaneous power Power that is calculated at every instant in which current and voltage are sampled during arc welding prior to averaging instead of being calculated using average current and average voltage. 3.1.28 internal concavity IC A root bead that is fused to and that completely penetrates the pipe wall thickness along both sides of the bevel, but whose center is below the inside surface of the pipe wall. NOTE The magnitude of concavity is the perpendicular distance between an axial extension of the pipe wall surface and the lowest point on the weld bead surface. 3.1.29 interpass temperature The temperature at a location near the start position of the welding arc(s) recorded immediately before initiating the next pass or passes (multi-arc processes). 3.1.30 linear indication An indication with its greatest dimension in the weld length direction. 3.1.31 mechanized welding The process where parameters and torch guidance are controlled mechanically or electronically, but may be manually varied during welding to maintain the specified welding conditions. 3.1.32 multiple repairs More than one individual repair area location in a completed weld. 3.1.33 non-waveform-controlled process A welding process in which arc voltage and/or arc current are maintained at a stable condition (for example, constant voltage spray gas metal arc welding or constant current gas tungsten arc welding). 3.1.34 partial-thickness repair A repair weld that originates from the weld face or root bead surface extending into the weld but does not completely penetrate through the weld thickness. 3.1.35 porosity Gas trapped by solidifying weld metal before the gas has a chance to rise to the surface of the molten puddle and escape. 6 API STANDARD 1104 3.1.36 position welding Welding in which the pipe or assembly is not rotating while the weld is being deposited. 3.1.37 postheat Heating a completed weld to temperatures intended to accelerate hydrogen diffusion. NOTE Postheat is not PWHT (see 3.1.38). 3.1.38 postweld heat treatment PWHT Heating a completed weld to temperatures intended to result in stress relief, tempering, normalizing, or other metallurgical changes. 3.1.39 preheat temperature The minimum temperature of the base material in the volume surrounding the point of welding immediately before welding is started. In a multipass weld, it is also the minimum temperature immediately before the second and subsequent passes are started. 3.1.40 qualified welder A welder who has demonstrated the ability to produce welds that meet the requirements of Section 5, Section 6, Section 10, or Annex B of this standard. 3.1.41 qualified welding operator A welding operator who has demonstrated the ability to produce welds that meet the requirements of Section 12 of this standard. 3.1.42 qualified welding procedure specification A tested and proven detailed method by which sound welds with suitable mechanical properties can be produced. 3.1.43 radiographer A person who performs radiographic operations. 3.1.44 repair Any grinding or welding on a completed weld to correct an individual defect or accumulation of defects in the weld that has been rejected by visual or nondestructive testing in accordance with acceptance criteria in this standard. 3.1.45 repair area One individual repair location in a completed weld that may include a single defect or accumulation of defects. 3.1.46 repair procedure A tested and proven detailed method by which sound repairs with suitable mechanical properties can be produced.  WELDING OF PIPELINES AND RELATED FACILITIES 7 3.1.47 repair weld A weld made to repair a defect (or defects) found by visual testing and/or other nondestructive testing methods in a completed weld. NOTE A welder may check their work visually throughout the welding process and after welding has been completed, and perform rework as necessary. 3.1.48 rework During the welding or after the weld has been completed, the removal of an imperfection that requires grinding and/or welding that is performed prior to nondestructive testing. NOTE Rework is not a repair. Once a weld is judged as either acceptable or unacceptable by visual testing and/or a nondestructive testing method, any modification performed to the weld is deemed a repair. 3.1.49 roll welding Welding in which the pipe or assembly is rotated while the weld metal is being deposited at or near the top center. 3.1.50 root bead The first or stringer bead that initially joins two sections of pipe, a section of pipe to a fitting, or two fittings. 3.1.51 rounded indication An indication where the length is three times the width or less. 3.1.52 segment A piece of base metal (pipe nipple or fitting) consisting of less than a full circumference section. 3.1.53 semiautomatic welding Arc welding with equipment that controls only the filler metal feed. The advance of the welding arc is manually controlled. 3.1.54 slag inclusion A nonmetallic solid entrapped in the weld metal or between the weld metal and the parent material. Slag inclusions may be elongated slag inclusions (ESIs) or isolated slag inclusions (ISIs). 3.1.55 stacked defects Individual imperfections aligned in the radial (through-thickness) direction, at the same circumferential location, and that exceed the acceptance criteria of this standard. 3.1.56 test joint Pipe nipples, segments of pipe nipples, fittings, segments of fittings, or any combination thereof joined for the purpose of qualifying welding procedures or welders and welding operators. 3.1.57 total image unsharpness the blurring of test object features in a radiographical image resulting from any cause(s). 8 API STANDARD 1104 3.1.58 transverse indication An indication with its greatest dimension across the weld. 3.1.59 undercutting A groove melted into the parent material adjacent to the toe or root of the weld and left unfilled by weld metal. External undercutting (EU) is adjacent to the cover pass and internal undercutting (IU) is adjacent to the root bead. 3.1.60 UT qualification A process carried out by the company of evaluating evidence, provided by the ultrasonic contractor, that the UT system can provide accurate detection and sizing in accordance with the requirements of 9.6 and/or Annex A. 3.1.61 UT system Equipment utilized for ultrasonic testing. 3.1.62 visual examination or testing Visual evaluation of the surface of a weld by qualified personnel (see 8.3) to evaluate the presence of surface discontinuities (see 6.4 and 9.7) and to determine the disposition of the weld (i.e., weld acceptability). 3.1.63 volumetric indication An indication that is three-dimensional. 3.1.64 waveform-controlled process A welding process in which cyclic arc voltage and/or arc current wave shapes are controlled (for example, pulsed spray gas metal arc welding or controlled short-circuit gas metal arc welding). 3.1.65 weld A remelted and metallurgically altered area where two parts (for the purposes of this standard, typically two sections of pipe, a section of pipe to a fitting, or two fittings) are joined by melting a portion of each part by heating with an electric arc or flame source. 3.1.66 welder A person who makes a weld. 3.1.67 weld face An edxposed surface of a weld on the side from which welding was done. 3.2 Acronyms and Abbreviations For the purposes of this standard, the following acronyms and abbreviations apply. A welding current (amp) AC alternating current AUT automated ultrasonic testing BT burn-through  WELDING OF PIPELINES AND RELATED FACILITIES 9 C carbon CCD charge coupled device CE carbon equivalent CMOS complimentary metal-oxide semiconductor CO2 carbon dioxide Cr chromium CTOD crack tip opening displacement Cu copper CVN Charpy V-Notch D pipe outer diameter (in. or mm) DAC distance amplitude correction DC direct current DDA digital detector array DWE double-wall exposure DWV double-wall viewing D/t pipe diameter-to-wall thickness ratio ECA engineering critical assessment EI instantaneous energy measurement (kilojoules) ESI elongated slag inclusion EU external undercut EW electric resistance or electric induction weld FAC failure assessment curve FAD failure assessment diagram FCAW-S self-shielded flux-cored arc welding FPD flat panel detector GMAW-S short-circuiting gas metal arc welding HAZ heat-affected zone HB hollow bead porosity HI heat input 10 API STANDARD 1104 H2S hydrogen sulfide HVL half-value layer IC internal concavity ICP inadequate cross penetration ID inside diameter IF incomplete fusion IFD incomplete fusion due to cold lap IP inadequate penetration without high-low IPD inadequate penetration due to high-low IQI image quality indicator ISI isolated slag inclusion IU internal undercut L weld length (in. or mm) LB linear buried LDA linear diode array LS linear surface Mn manganese Mo molybdenum MPS manufacturing procedure specification MUT manual ultrasonic testing NDT nondestructive testing Ni nickel OD outside diameter OFW oxy-fuel welding PI instantaneous power measurement (watts or joules per second) PIP phosphor imaging plate PWHT postweld heat treatment RTR real-time radiography S welding arc speed (in. per minute or mm per minute)  WELDING OF PIPELINES AND RELATED FACILITIES 11 SAWH submerged-arc helical weld SAWL submerged-arc longitudinal weld SCC stress corrosion cracking SMTS specified minimum tensile strength SMYS specified minimum yield strength SWE single-wall exposure SWV single-wall viewing t specified pipe wall thickness (in. or mm) T transverse TCG time-corrected gain Ts arc time (seconds) UT ultrasonic testing V vanadium V welding arc voltage (volt) VC volumetric cluster VI volumetric individual VR volumetric root WPS welding procedure specification Y/T yield-to-tensile ratio σt, ultimate tensile strength of the pipe material (ksi or MPa) σy, specified minimum yield strength of the pipe material, or SMYS (ksi or MPa) 4 Specifications 4.1 Equipment Welding equipment, both gas and arc, shall be of a size and type suitable for the work and shall be maintained in a condition that ensures acceptable welds, continuity of operation, and safety of personnel. Arc welding equipment shall be operated within the amperage and voltage ranges given in the qualified welding procedure specification. Gas welding equipment shall be operated with the flame characteristics and tip sizes given in the qualified welding procedure specification. Equipment that does not meet these requirements shall be repaired or replaced. 12 API STANDARD 1104 4.2 Materials Pipe and Piping Components This standard applies to the welding of pipe and piping components that conform to material and product specifications including, but not limited to: a) API specifications, b) ASME international specifications, c) ASTM international specifications, d) Manufacturers Standardization Society (MSS) specifications, e) American National Standards Institute (ANSI) specifications. This standard also applies to materials with chemical and mechanical properties that comply with one of the specifications listed in items a) through e) above, even though the material is not manufactured in accordance with the specification. Filler Metals and Fluxes 4.2.2.1 Types All filler metals and fluxes shall conform to one of the following, except as provided below: a) AWS A5.1; b) AWS A5.2; c) AWS A5.5; d) AWS A5.17; e) AWS A5.18; f) AWS A5.20; g) AWS A5.23; h) AWS A5.28; i) AWS A5.29; j) AWS A5.36. Filler metals and fluxes that do not conform to the specifications listed may be used, provided they have been utilized during welding procedure qualification. 4.2.2.2 Storage and Handling Filler metals and fluxes shall be stored and handled to avoid damage to them and to the containers in which they are shipped. Filler metals and fluxes in opened containers shall be protected from deterioration, and filler metals that are coated shall be protected from excessive changes in moisture. Filler metals and fluxes that show signs of damage or deterioration shall not be used.  WELDING OF PIPELINES AND RELATED FACILITIES 13 Shielding Gases 4.2.3.1 Types The purity and dryness of these atmospheres influence resulting weldments and should be of values suitable for the process and the materials to be welded. The shielding atmosphere to be used shall be qualified for the material and the welding process. Atmospheres for shielding an arc are of several types and should consist of inert gases, active gases, or mixtures of inert and active gases. 4.2.3.2 Storage and Handling Shielding gases shall be kept in the containers in which they are supplied, and the containers shall be stored in a manner compliant with the applicable safety regulations and manufacturer’s recommendations. Gases shall not be field intermixed in their containers. Gases of questionable purity and those in containers that show signs of damage shall not be used. 5 Qualification of Welding Procedures with Filler Metal Additions 5.1 Procedure Qualification This section shall apply to the qualification of welding procedures using manual welding and semiautomatic welding processes with filler metal additions. When a welding procedure specification uses a combination of manual/semiautomatic and mechanized welding, the requirements of Section 5 and Section 12 shall apply to their portions of the welding procedure specification. NOTE 1 Section 12 applies to the qualification of welding procedures using mechanized welding with filler metal additions. Before production welding is started, a detailed welding procedure specification shall be established and qualified to demonstrate that sound welds with suitable mechanical properties (such as strength, ductility, and hardness) can be made by the procedure. The acceptance of the procedure qualification welds shall be determined by destructive testing in accordance with 5.6 or 5.8 as applicable. NOTE 2 Multiple qualification welds may be combined to qualify a range of essential variables within one welding procedure specification. 5.2 Record The details of each procedure qualification shall be recorded. The record shall document at a minimum the actual observed values for the variables to be specified per 5.3 and the complete results of the procedure qualification tests. The record shall be maintained as long as the procedure is in use. NOTE An example of an acceptable form is shown in Figure 1. 5.3 Welding Procedure Specification General The welding procedure specification shall include the information specified in 5.3.2 where applicable. NOTE An example of an acceptable form is shown in Figure 2. 14 API STANDARD 1104 Specification Information 5.3.2.1 Process The specific process, method of application, or combination thereof shall be identified. 5.3.2.2 Materials The SMYS range of the materials to which the procedure applies shall be specified. 5.3.2.3 Diameters and Wall Thicknesses The ranges of specified outside diameters (ODs) and specified wall thicknesses over which the procedure is applicable shall be specified. 5.3.2.4 Joint Design and Weld Shape and Size The specification shall include a sketch or sketches of the joint that show tolerances for the angle of bevel, the size of the root face, and the root opening or the space between abutting members. The tolerance ranges for cap height and width shall be specified for groove welds. The shape and size tolerance ranges of fillet welds shall be shown. If a backing is used, the type shall be specified. 5.3.2.5 Filler Metal, Flux, and Number of Beads The sizes and classification of the filler metal and flux and the minimum number and sequence of beads shall be specified. When different numbers of beads and sequences of beads apply to different thickness ranges within the specified thickness range on the WPS, the number of beads and sequences shall be designated for company-defined subsets of the thickness range.  WELDING OF PIPELINES AND RELATED FACILITIES 15 QUALIFICATION WELD REPORT Date Test No. Test Type: Procedure Welder Location _________________________________________________________ Welder(s) _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Material Grade 1 ____________________ Material Grade 2 ____________________ Outside Diameter Wall Thickness ______________________________________________ Joint Type Bevel Angle _________________________________________________ Backing Type (if applicable) Roll or Fixed Position________________________________________ RECORDED WELDING PARAMETERS Pass Process and Filler Metal Shielding Preheat / Voltage Amperage Travel Speed Heat Input Direction of Classification Gas type Interpass Welding and and flow rate Temperature Diameter or Shielding Flux Root Bead Second Bead Note: Number of weld beads are not intended to be limited by this table and the table should be adjusted to present all required passes. Time Between Passes: Root bead to 2nd bead: , 2nd bead to 3rd bead: __________________________________________ Cooling Method (if applicable) PWHT____________________________________________________ MECHANICAL TEST RESULTS TENSILE TESTS Report Number: NICK BREAK TESTS Report Number: Tensile Tensile Tensile Tensile Specimen Nick Nick Nick Nick Nick Nick Nick Nick Specimen Number 1 2 3 4 Number 1 2 3 4 5 6 7 8 Location Location Original specimen Result dimensions Original specimen area BEND TESTS Report Number: Specimen Maximum load Type and Number Tensile strength Location Fracture location Result Remarks Test made at Date __________________________________________________ Tested by Supervised by ____________________________________________ NOTE See 5.2; the use of this sample form does not exclude adding other details. Figure 1—Sample Qualification Weld Report Form 16 API STANDARD 1104 NOTE See 5.3.1; the use of this sample form does not exclude adding other details. Figure 2—Sample Welding Procedure Specification Form  WELDING OF PIPELINES AND RELATED FACILITIES 17 5.3.2.6 Electrical Characteristics The current and polarity shall be specified, and the range of voltage and amperage for each type and size of electrode, rod, or wire shall be shown. NOTE Consult the filler metal manufacturer’s recommended ranges for guidance. The specified ranges need not replicate either the recommended ranges or the observed ranges used in welding procedure qualification. When required by Table 1, the heat input and the method of calculating heat input shall be specified. Heat input for non-waveform-controlled processes shall be calculated per Equation (1): 60VA HI  (1) 1000 S where HI = heat input (kilojoules per in. or kilojoules per mm) V = average welding arc voltage (volt) A = average welding current (amp) S = average travel speed (in. per minute or mm per minute) Heat input for waveform-controlled processes shall be calculated per Equation (2) or Equation (3): EI HI  (2) L where HI = average heat input (kilojoules per in. or kilojoules per mm) EI = average instantaneous energy measurement (kilojoules) L = weld length (in. or mm) PI TS HI  (3) 1000 L where HI = average heat input (kilojoules per in. or kilojoules per mm) PI = average instantaneous power measurement (watt) Ts = arc time (seconds) L = weld length (in. or mm) 5.3.2.7 Flame Characteristics For the oxy-fuel welding process, the specification shall indicate whether the flame is neutral, carburizing, or oxidizing. The size of the orifice in the torch tip for each size of rod or wire shall be specified. 18 API STANDARD 1104 5.3.2.8 Position The specification shall indicate roll or fixed position welding. 5.3.2.9 Direction of Welding The specification shall indicate whether the welding is to be performed in the vertical up, vertical down, or horizontal direction. 5.3.2.10 Time Between Passes When using EXX10 or EXX11 electrodes, the maximum time between the completion of the root bead and the start of the second bead, as well as the maximum time between the completion of the second bead and the start of the third bead, shall be specified. The time shall be expressed as minutes or hours. 5.3.2.11 Type and Removal of Lineup Clamp The specification shall indicate whether the lineup clamp is to be internal or external, or if no clamp is required. If a clamp is used, the minimum percentage of root bead completed before the clamp is released shall be specified. 5.3.2.12 Cleaning and/or Grinding The specification shall indicate whether power tools or hand tools are to be used for cleaning, grinding, or both. 5.3.2.13 Preheat and Interpass Temperature The method of heating and minimum preheat temperature immediately before welding is started shall be specified. The maximum interpass temperature shall be specified. 5.3.2.14 Shielding Gas and Flow Rate The shielding gas classification and the range of flow rates shall be specified. 5.3.2.15 Shielding Flux When applicable, the type of shielding flux shall be specified. 5.3.2.16 Speed of Travel The range for speed of travel, in inches or millimeters per minute, shall be specified for each pass or grouping of passes. Specified ranges for speed of travel need not replicate, but should be representative of the speed of travel used during procedure qualification. 5.3.2.17 Method of Cooling After Welding If forced cooling is to be used, the specification shall designate the type of cooling after welding, such as forced cooling with water, as well as the maximum weld temperature prior to deliberate cooling. 5.3.2.18 Postheating for Hydrogen Diffusion When used during qualification, the minimum temperature and time at temperature range of any postheating for hydrogen diffusion shall be specified.  WELDING OF PIPELINES AND RELATED FACILITIES 19 5.3.2.19 Postweld Heat Treatment (PWHT) The details of the PWHT procedure shall be specified in the WPS. PWHT procedures shall include method of application, heating rate, temperature range, time at temperature, and cooling rate. 5.4 Essential Variables General Welding procedure specifications shall be limited by the applicable essential variables provided in Table 1. Changes to essential variables shall necessitate requalification of the welding procedure specification or establishment and qualification of a new welding procedure specification. Essential Variable Categories The variables and qualification ranges specified in Table 1 are separated into two different categories. Category I essential variables shall apply when specified hardness and/or toughness values are not required by the company. Category II essential variables shall apply when hardness and/or toughness requirements are specified by the company.  20 API STANDARD 1104 Table 1—Essential Variables for Qualification of Welding Procedure Specifications Category II Welding Category I (Hardness Variable Change Requiring Requalification (Standard and/or Subsectiona WPS) Toughness) a) A change in welding process for any given pass or pass grouping (i.e., fill 5.4.2.1 X X passes or cap passes). Welding Process b) A change between manual application or semiautomatic application. X X a) A change in base material “nominal SMYS” greater than that of the base material used during qualification. When a procedure qualification test uses two different “nominal SMYS” materials, the procedure shall only be qualified to weld joints where at least one of the base materials is equal to X X or less than the lowest “nominal SMYS” base material used during qualification and the other no greater than the maximum of the combination. b,c,d 5.4.2.2 b) Where t is the nominal pipe wall thickness used in procedure Base Material qualification, a change that falls outside the following ranges: i. t to 2t when t < 0.154 in. (3.9 mm) X ii. 0.154 in. (3.9 mm) to 2t when 0.154 (3.9 mm) ≤ t ≤ 1.00 in. (25.4 mm) iii. 0.5t to unlimited when t > 1.00 in. (25.4 mm) c) A change in nominal wall thickness plus or minus 25 % of the nominal X thickness used during qualification. 5.4.2.3 a) A change from fillet weld to groove weld, but not vice versa. X X Joint Design b) A major change in joint type. e X X 5.4.2.4 The deletion or change of backing material (steel, ceramic, non-ferrous, etc.). f X X Backing Material 5.4.2.5 A change in position from roll welding to fixed position, but not vice versa. X X --`,`````,,,,,,`,`,,,`,,,```,`,-`-`,,`,,`,`,,`--- Position a) A change in filler metal grouping(s) as specified in Table 2 when base X material SMYS is less than the “nominal SMYS” of Grade X65. b b) A change in sequence of deposition of filler metal groups when multiple filler metal groups are used for a single weld when base material SMYS is X less than the “nominal SMYS” of Grade X65. b c) A change in filler metal classification when base material SMYS is greater X than or equal to the “nominal SMYS” of Grade X65. b,g d) A change in sequence of deposition of filler metal classifications when multiple filler metal classifications are used for a single weld when base X material is greater than or equal to the “nominal SMYS” of Grade X65. b e) When the filler metal used during qualification is from group 1 through 3 in Table 2 and the base material SMYS is less than the “nominal SMYS” of Grade X65, any change in chemical composition designator 5.4.2.6 or optional supplemental designator for toughness except for the following: X Filler Metal i. the addition of the optional supplemental designator for toughness (-1); ii. a change in chemical composition designator within the group, A1, C1, C2, C3, C1L, C2L, C3L, M, P1, P2. h f) When the filler metal during qualification has a G suffix designator only, a X X change in the manufacturer or trade name. g) When the filler metal used is not identified in Table 2, a change in AWS specification, AWS classification, or, for filler metals not having an X X assigned AWS specification or classification, a change in the nominal composition. h) A change in filler metal classification. g X i) A change in sequence of deposition of filler metal classifications when X multiple filler metal classifications are used for a single weld.  WELDING OF PIPELINES AND RELATED FACILITIES 21 Table 1—Essential Variables for Qualification of Welding Procedure Specifications (continued) Category II Welding Category I (Hardness Variable Change Requiring Requalification (Standard and/or Subsectiona WPS) Toughness) a) A change in shielding gas classification in accordance with AWS A5.32. X X 5.4.2.7 b) A change in shielding gas flow rate greater than 20 % below the nominal X X flow rate recorded during procedure qualification. Shielding Gas c) The deletion of or change in nominal composition of backing gas when X X backing gas is used during qualification. a) A change in current/polarity type (DCSP/DCEN, DCRP/DCEP, AC). X X 5.4.2.8 b) A change to or from a waveform-controlled process. X X Electrical Characteristics i c) A change in heat input exceeding ± 20 % of that recorded during X qualification. j a) Any decrease in minimum base material preheat temperature below the X X base material preheat temperature recorded during qualification. k 5.4.2.9 b) When preheat is not applied to the qualification test weld, the minimum Preheat temperature specified on the procedure shall be no less than the lesser of Temperature X X 60 °F (16 °C) or the actual base material temperature recorded prior to qualification welding. a) An increase in base material interpass temperature to greater than 500 °F X X 5.4.2.10 (260 °C). k,l,m Interpass b) An increase in base material interpass temperature greater than 100 °F Temperature (55 °C) above the maximum base material interpass temperature X recorded during procedure qualification. k,l,m 5.4.2.11 When using a temper bead technique, a change in bead deposition sequence. X X Pass Sequence a) The addition or deletion of deliberate cooling methods. X X 5.4.2.12 b) A change in the method of deliberate cooling after welding, resulting in a X X Cooling higher rate of cooling. c) An increase in the maximum weld temperature prior to deliberate cooling. X X a) The elimination of postheating for the purpose of promoting hydrogen X X diffusion. 5.4.2.13 b) A reduction in postheating temperature greater than 60 °F (33 °C) from X X Postheating that used during qualification. c) Any reduction in postheating time at temperature from that used during X X qualification. 5.4.2.14 a) The addition or deletion of PWHT. X X Postweld Heat b) When applied, a change in PWHT procedure. X X Treatment a The subsection numbers in this column are provided for referencing purposes. b “Nominal SMYS” is in reference to the material grade and intended to negate the slight differences in actual SMYS between material type of the same grade. For example, an API 5L X60 pipe and an ASTM A860 WPHY 60 fitting shall both be considered to have a “nominal SMYS” of 60 ksi. c In addition to SMYS, base material manufacturing process, heat treating process, carbon equivalent, and chemical composition should be considered for impact to mechanical properties and weld crack susceptibility. d When base material used during qualification has multiple grade markings, prior to qualification the company should designate the material as one single grade. e Major joint types are square, closed square, single-bevel, single-J, double-bevel, double-J, single-V, single-U, double-V, double-U. A change to or from a compound bevel within a major joint type is not considered a major change in joint type. f This requirement applies to the root pass only. Weld metal is not considered weld backing. g The chemical composition designator is part of the AWS classification. h For example, a change in suffix designator from A1 to B3, or vice versa, constitutes an essential variable. A change from A1 to C3, or vice versa, does not constitute an essential variable. i Unless otherwise specified by company requirements, the above noted parameters should be recorded as averages representative of a weld pass or specific segment of a weld pass. Sampling of parameters for waveform-controlled processes should be at a sampling frequency no less than 10 kHz. The method used for recording and calculating heat input during production monitoring should be the same as that used during procedure qualification. j As defined and calculated in 5.3.2.6. k Procedures may be qualified with different interpass temperatures throughout the weld sequence. l When procedures are qualified with different interpass temperatures throughout the weld sequence, the interpass temperatures shall be specified accordingly. m Interpass temperatures shall be measured immediately prior to the start of subsequent weld passes. 22 API STANDARD 1104 Table 2—Filler Metal Groups Group AWS Specification AWS Classification A5.1 E6010, E6011 1 A5.5 E7010-A1, E7010-P1, E7011-A1 2 A5.5 E8010-P1 A5.1 E6018, E7015, E7016, E7018, E7018M, E7016-1, E7018-1 E7015-C1L, E7016-C1L, E7018-C1L, 3 E7015-C2L, E7016-C2L, E7018-C2L, A5.5 E7018-C3L, E8016-C1, E8018-C1, E8016-C2, E8018-C2, E8016-C3, E8018-C3, E8018-P2, E8045-P2 A5.18 ER70S-2, ER70S-3, ER70S-6 a ER70S-A1, 5 A5.28 ER80S-D2, ER80S-Ni1, ER80S-Ni2, ER80S-Ni3 6 A5.2 RG60, RG65 E71T-1C, E71T-1M, A5.20 E71T-9C, E71T-9M, E71T-12C, E71T-12M, E71T-12M-J 7 E71T-1C, E71T-1M, A5.36 E71T-9C, E71T-9M, E71T-12C, E71T-12M, E71T-12M-J E81T-1Ni1C, E81T-1Ni1M, 8 A5.29 E81T1-1Ni2C, E81T-1Ni2M, E81T-1K2C, E81T-1K2M a A shielding gas (see 5.4.2.7) is required for use with the electrodes in Group 5. 5.5 Welding of Test Joints—Butt Welds To weld the test joint for butt welds, two pipe nipples shall be joined. 5.6 Testing of Welded Joints—Butt Welds Preparation To test the butt-welded joint, test specimens shall be cut from the locations shown in Figure 3. The minimum number of test specimens and the tests to which they shall be subjected are given in Table 3. For pipe less than 2.375 in. (60.3 mm) in OD, two test joints shall be made to obtain the required number of test specimens. For pipe less than or equal to 1.315 in. (33.4 mm) in diameter, one full-section tensile strength specimen shall be tested. The full-section specimen shall be tested in accordance with 5.6.2.2 and shall meet the requirements of 5.6.2.3. All specimens shall be air cooled to ambient temperature prior to being tested.  WELDING OF PIPELINES AND RELATED FACILITIES 23 When required by the company, the company shall specify the details of specimen preparation, testing, and acceptance criteria for measurement of hardness or toughness. NOTE At the company’s option, the locations may be rotated, provided they are equally spaced around the pipe; however, specimens do not include the longitudinal weld. Figure 3—Location of Test Butt Weld Specimens for Procedure Qualification Test 24 API STANDARD 1104 Table 3—Type and Number of Test Specimens for Procedure Qualification Test Outside Diameter of Pipe Number of Specimens in. mm Tensile Strength Nick Break Root Bend Face Bend Side Bend Total Wall Thickness ≤ 0.500 in. (12.7 mm) < 2.375 < 60.3 0a 2b 2 0 0 4c 2.375 to 4.500 60.3 to 114.3 0a 2b 2 0 0 4 > 4.500 to 12.750 >114.3 to 323.9 2 2b 2 2 0 8 >12.750 > 323.9 4 4b 4 4 0 16 Wall Thickness > 0.500 in. (12.7 mm) ≤ 4.500 ≤ 114.3 0b 2b 0 0 2 4 > 4.500 to 12.750 > 114.3 to 323.9 2 2 b 0 0 4 8 > 12.750 > 323.9 4 4b 0 0 8 16 a For materials with nominal SMYS greater than Grade X42, a minimum of one tensile test is required. b Nick break tests are not required for procedure qualification butt welds, provided procedure welds are examined by radiography or ultrasonic testing (UT) and are found acceptable per Section 9. When radiography or UT results are unacceptable, the procedure is rejected. c One nick break and one root bend specimen are taken from each of two test welds, or for pipe less than or equal to 1.315 in. (33.4 mm) in diameter, one full-section tensile strength specimen is take. Tensile Strength Test 5.6.2.1 Preparation The full-thickness tensile strength test specimens shall be either of the types shown in Figure 4. a) The sides of the full section specimen shown in Figure 4 a) shall be smooth and parallel. NOTE 1 A specimen may be cut using any method, and no other preparation is needed unless the sides are notched or are not parallel. b) The reduced section specimens shall be prepared as shown in Figure 4 b). NOTE 2 The weld metal reinforcement may be removed. 5.6.2.2 Method The tensile strength test specimens shall be broken under tensile load using equipment capable of measuring the load at which failure occurs. The tensile strength shall be computed by dividing the maximum load at failure by the smallest cross-sectional area of the specimen, as measured before the load is applied. 5.6.2.3 Requirements The tensile strength of the weld shall be greater than or equal to the specified minimum tensile strength (SMTS) of the pipe material, but need not be greater than or equal to the actual tensile strength of the material. If the specimen breaks outside the weld (i.e., in the parent metal) at a tensile strength not less than 95 % of that of the SMTS of the pipe material, the weld shall be accepted as meeting the requirements. If the specimen breaks in the weld and the observed strength is greater than or equal to the SMTS of the pipe material and meets the soundness requirements of 5.6.3.3, the weld shall be accepted as meeting the requirements.  WELDING OF PIPELINES AND RELATED FACILITIES 25 If the specimen breaks in the weld and below the SMTS of the pipe material, the weld shall be set aside, and a new test weld shall be made. When welding material of different grades, the SMTS of the lower grade shall be used as the acceptance criteria. NOTE Any specimen that fails due to improper specimen preparation or testing may be replaced and retested. Figure 4—Tension Test Specimen Nick Break Test 5.6.3.1 Preparation The nick break test specimens (see Figure 5, top) shall be approximately 9 in. (230 mm) long and approximately 1 in. (25 mm) wide, and may be cut by any means. They shall be notched on each side at the center of the weld metal, and each notch shall be approximately 1/8 in. (3 mm) deep, and the edges shall be smooth and parallel. NOTE 1 Nick break specimens prepared in this manner from welds made with certain mechanized and semiautomatic processes may fail through the pipe instead of the weld. When previous testing experience indicates that failures through the pipe can be expected, the external reinforcement may be notched to a depth of not more than 1/16 in. (1.6 mm), measured from the original weld surface (see Figure 5, bottom). 26 API STANDARD 1104 NOTE 2 At the company’s option, nick break specimens for qualification of a procedure using a semiautomatic or mechanized welding process may be macroetched prior to being nicked. 5.6.3.2 Method The nick break specimens shall be broken through the weld by any convenient method (i.e., pulling, bending, or striking). This does not exclude other testing methods. The exposed area of the fracture shall be at least ¾ in. (19 mm) wide. 5.6.3.3 Requirements The exposed surfaces of each nick break specimen shall show complete penetration and fusion. The greatest dimension of any gas pocket shall not exceed 1/16 in. (1.6 mm), and the combined area of all gas pockets shall not exceed 2 % of the exposed surface area. Slag inclusions shall not be more than 1/32 in. (0.8 mm) in depth and shall not be more than 1/8 in. (3 mm) or one-half the specified wall thickness in length, whichever is smaller. There shall be at least ½ in. (13 mm) separation between adjacent slag inclusions of any size. The dimensions should be measured as shown in Figure 6. Fisheyes, as defined in AWS A3.0, are not cause for rejection. For a test weld diameter greater than 12 ¾ in. (323.9 mm), if only one nick break specimen fails, the company shall have the discretion to either consider the weld unacceptable or to replace the specimen with two additional nick break specimens from locations as close as possible to the failed specimen. If either of the replacement nick break specimens fail, the weld shall be considered unacceptable.  WELDING OF PIPELINES AND RELATED FACILITIES 27 Weld reinforcement not removed on either side of specimen Figure 5—Nick Break Test Specimen 28 API STANDARD 1104 Figure 6—Dimensioning of Imperfections in Exposed Weld Surfaces Root and Face Bend Test 5.6.4.1 Preparation The root and face bend test specimens (see Figure 7) shall be approximately 9 in. (230 mm) long and approximately 1 in. (25 mm) wide, and their long edges shall be rounded. They may be cut by any means. The cover and root bead reinforcements shall be removed flush with the surfaces of the specimen. These surfaces shall be smooth, and any scratches that exist shall be light and transverse to the weld. The specimen shall not be flattened prior to testing. Figure 7—Root and Face Bend Test Specimen: Wall Thicknesses Less than or Equal to 0.500 in. (12.7 mm) 5.6.4.2 Method The root and face bend specimens shall be bent with the weld transverse to the longitudinal axis of the specimen. Face bend specimens shall be bent so that the face is centered on the bend radius and becomes the convex surface of the bend specimen. Root bend specimens shall be bent so that the root is centered on  WELDING OF PIPELINES AND RELATED FACILITIES 29 the bend radius and becomes the convex surface of the bend specimen. The company shall specify the bend test fixture and bend radii. The radii shall not be greater than the radii specified in Figure 8. NOTE This figure is not drawn to scale. Radius of plunger, A = 1 ¾ in. (45 mm); radius of die, B = 2 5/16 in. (60 mm); width of die, C = 2 in. (50 mm). Figure 8—Jig for Guided-bend Tests 5.6.4.3 Requirements The bend test shall be considered acceptable if no crack or other imperfection exceeding 1/8 in. (3 mm) or one-half the specified wall thickness, whichever is smaller, in any direction is present in the weld or between the weld and the fusion zone after bending. Cracks that originate on the outer radius of the bend along the edges of the specimen during testing and that are less than ¼ in. (6 mm), measured in any direction, shall not be considered unless obvious imperfections are observed. For a test weld diameter greater than 12 ¾ in. (323.9 mm), if only one bend specimen fails, the company shall have the discretion to consider the weld unacceptable or to replace the failed specimen with two additional specimens from locations adjacent to the failed specimen. If either of the replacement bend test specimens fails, the weld shall be considered unacceptable. Side Bend Test 5.6.5.1 Preparation The side bend test specimens (see Figure 9) shall be approximately 9 in. (230 mm) long and approximately ½ in. (13 mm) wide, and their long edges shall be rounded. They shall be machine cut, or they may be cut by other means to approximately a ¾-in. (19-mm) width and then machined or ground to the ½-in. (13-mm) width. The sides shall be smooth and parallel. The cover and root bead reinforcements shall be removed flush with the surfaces of the specimen. 5.6.5.2 Method The side bend specimens shall be bent with the weld transverse to the longitudinal axis of the specimen. Side bend specimens shall be bent so that one of the side surfaces is centered on the bend radius and becomes the convex surface of the bend specimen. The company shall specify the bend radii. The radii shall not be greater than the radii specified in Figure 8. 5.6.5.3 Requirements Each side bend specimen shall meet the root and face bend test requirements specified in 5.6.4.3. 30 API STANDARD 1104 For a test weld diameter greater than 12 ¾ in. (323.9 mm), if only one side bend specimen fails, the company shall have the discretion to consider the weld unacceptable or to replace the failed specimen with two additional side bend specimens from locations adjacent to the failed specimen. If either of the replacement side bend test specimens fails, the weld shall be considered unacceptable. NOTE All dimensions are approximate. Figure 9—Side Bend Test Specimen: Wall Thicknesses Greater than 0.500 in. (12.7 mm) 5.7 Welding of Test Joints—Branch and Fillet Welds To weld the test joint for a branch or fillet weld, a weld shall be made to one of the configurations shown in Figure 10. NOTE This figure shows the location of test specimens for joints with an OD greater than or equal to 2.375 in. (60.3 mm). Figure 10—Location of Nick Break Test Specimens: Branch and Fillet Weld Procedure and Welder Qualification Test Welds  WELDING OF PIPELINES AND RELATED FACILITIES 31 5.8 Testing of Welded Joints—Branch and Fillet Welds Preparation To test the branch or fillet-welded joint, test specimens shall be cut from the joint at the locations shown in Figure 10. At least four specimens shall be taken and prepared as shown in Figure 11. NOTE The specimens may be cut by any means. The specimens should be at least 1 in. (25 mm) wide and long enough so that they can be broken in the weld. For pipes less than 2.375 in. (60.3 mm) in OD, specimens shall be cut from the same general location. It may be necessary to make two test welds to obtain the required number of test specimens; two specimens shall be removed from each of the two test welds. The specimens shall be air cooled to ambient temperature prior to testing. When required by the company, the company shall specify the details of specimen preparation, testing, and acceptance criteria for measurement of hardness or toughness. Method The branch or fillet weld specimens shall be broken in the weld by any convenient method. ° ° NOTE The methods of notching and cutting the specimens shown in the figure are not intended to preclude the use of other methods approved by the company. Figure 11—Location of Nick Break Test Specimens: Branch and Fillet Weld Procedure and Welder Qualification Test Welds, Including Size-to-size Branch Connection Welder Qualification Test Requirements The exposed surfaces of each specimen shall show: a) complete penetration and fusion; 32 API STANDARD 1104 b) the greatest dimension of any gas pocket shall not exceed 1/16 in. (1.6 mm); c) the combined area of all gas pockets shall not exceed 2 % of the exposed surface area; d) slag inclusions shall not be more than 1/32 in. (0.8 mm) in depth and shall not be more than 1/8 in. (3 mm) or one half the specified wall thickness in length, whichever is smaller; and e) there shall be at least 1/2 in. (13 mm) separation between adjacent slag inclusions. The dimensions should be measured as shown in Figure 6. 6 Qualification of Welders 6.1 General The purpose of the welder qualification test shall be to determine the ability of welders to make sound welds. Each welder shall be qualified according to the applicable requirements of 6.2 through 6.8 be