Welding of Pipelines and Related Facilities

API STANDARD 1104

NINETEENTH EDITION, SEPTEMBER 1999 ERRATA 1, OCTOBER 31, 2001

Welding of Pipelines and Related Facilities

Pipeline Segment

API STANDARD 1104

NINETEENTH EDITION, SEPTEMBER 1999 ERRATA 1, OCTOBER 31, 2001

SPECIAL NOTES

API publications necessarily address problems of a general nature. With respect to partic- ular circumstances, local, state, and federal laws and regulations should be reviewed.

API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local, state, or fed- eral laws.

Information concerning safety and health risks and proper precautions with respect to par- ticular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet.

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 prod- uct covered by letters patent. Neither should anything contained in the publication be con- strued as insuring anyone against liability for infringement of letters patent.

Generally, API standards are reviewed and revised, reaf?rmed, or withdrawn at least every

?ve years. Sometimes a one-time extension of up to two years will be added to this review cycle. This publication will no longer be in effect ?ve years after its publication date as an operative API standard or, where an extension has been granted, upon republication. Status of the publication can be ascertained from the API Pipeline Segment [telephone (202) 682- 8000]. A catalog of API publications and materials is published annually and updated quar- terly by API, 1220 L Street, N.W., Washington, D.C. 20005.

This document was produced under API standardization procedures that ensure appropri- ate noti?cation and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this standard or com- ments and questions concerning the procedures under which this standard was developed should be directed in writing to the general manager of the Pipeline Segment, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the general manager.

API standards are published to facilitate the broad availability of proven, sound engineer- ing and operating practices. These standards are not intended to obviate the need for apply- ing sound engineering judgment regarding when and where these standards should be utilized. The formulation and publication of API standards is not intended in any way to inhibit anyone from using any other practices.

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All rights reserved. No part of this work may be reproduced, 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, 1220 L Street, N.W., Washington, D.C. 20005.

Copyright ? 1999 American Petroleum Institute

FOREWORD

This standard was prepared by a formulating committee that included representatives of the American Petroleum Institute, the American Gas Association, the Pipe Line Contractors Association, the American Welding Society, and the American Society for Nondestructive Testing, 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 quali?ed 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 quali?ed technicians and approved methods and equip- ment. 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 prod- ucts, 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 apprecia-

tively acknowledges their wholehearted and valuable assistance.

From time to time, revisions of this standard will be necessary to keep current with tech- nological developments. The committee is always anxious to improve this standard and will give full consideration to all comments received.

An appeal of any API standards action by an interested party shall be directed to the API. API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this

publication may con?ict.

Suggested revisions are invited and should be submitted to the general manager of the Pipeline Segment, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005.

ATTENTION USERS: Portions of this standard have been changed from the previous edi- tion. The locations of changes have been marked with a bar in the margin, as shown to the left of this paragraph. In some cases, the changes are signi?cant, while in other cases the changes re?ect minor editorial adjustments. The bar notations are provided as an aid to users as to those parts of the standard that have been changed from the previous edition, but API makes no warranty as to the accuracy of such bar notations.

API-AGA JOINT COMMITTEE ON OIL AND GAS PIPELINE FIELD WELDING PRACTICES

H. Charles Price, Chairman George K. Hickox, Vice-Chairman

Frank R. Orr, Secretary

American Petroleum Institute

Donald Drake Gary E. Merritt David Noble Gary Perkins

American Gas Association

Marshall L. Farley Alan C. Holk Frank R. Orr Eugene L. Smith

American Society for Nondestructive Testing

David L. Culbertson

C. P. Woodruff, Jr. Scott M. Metzger William R. Tignor

American Welding Society

W. L. Ballis George K. Hickox Chuck Brashears Robert R. Wright

National Electrical Manufacturers Association

Craig Dallman

Pipe Manufacturers Frank M. Christensen Murali D. Tumuluru Martin A. Francis James P. Snyder, II

Pipeline Contractors Association

Ralph Pendarvis

H. Charles Price Don Thorn Bill Marhofer

Members Emeritus

John K. McCarron

R. B. Gwin

M. Jordan Hunter

E. L. Von Rosenberg Dale Wilson

CONTENTS

Page

1. GENERAL 1

   1. Scope 1

2. REFERENCED PUBLICATIONS 1

3. DEFINITION OF TERMS 2

   1. General 2

   2. De?nitions 2

4. SPECIFICATIONS 2

   1. Equipment 2

   2. Materials 2

5. QUALIFICATION OF WELDING PROCEDURES FOR WELDS CONTAINING FILLER-METAL ADDITIVES 3

   1. Procedure Quali?cation 3

   2. Record 3

   3. Procedure Speci?cation 3

   4. Essential Variables 6

   5. Welding of Test Joints?Butt Welds 7

   6. Testing of Welded Joints?Butt Welds 8

   7. Welding of Test Joints?Fillet Welds 13

   8. Testing of Welded Joints?Fillet Welds 15

6. QUALIFICATION OF WELDERS 15

   1. General 15

   2. Single Quali?cation 15

   3. Multiple Quali?cation 16

   4. Visual Examination 16

   5. Destructive Testing 18

   6. Radiography?Butt Welds Only 19

   7. Retesting 19

   8. Records 19

7. DESIGN AND PREPARATION OF A JOINT FOR PRODUCTION WELDING. . 19 7.1 General 19

1. Alignment 19

2. Use of Lineup Clamp for Butt Welds 19

3. Bevel 19

4. Weather Conditions 19

5. Clearance 19

6. Cleaning Between Beads 20

7. Position Welding 20

8. Roll Welding 20

9. Identi?cation of Welds 20

10. Pre- and Post-Heat Treatment 20

1. INSPECTION AND TESTING OF PRODUCTION WELDS 20

   1. Rights of Inspection 20

   2. Methods of Inspection 20

   3. Quali?cation of Inspection Personnel 20

   4. Certi?cation of Nondestructive Testing Personnel 21

2. ACCEPTANCE STANDARDS FOR NONDESTRUCTIVE TESTING 21

   1. General 21

   2. Rights of Rejection 21

   3. Radiographic Testing 21

   4. Magnetic Particle Testing 27

   5. Liquid Penetrant Testing 27

   6. Ultrasonic Testing 27

   7. Visual Acceptance Standards for Undercutting 28

3. REPAIR AND REMOVAL OF DEFECTS 29

   1. Authorization for Repair 29

   2. Repair Procedure 29

   3. Acceptance Criteria 29

   4. Supervision 29

   5. Welder 29

4. PROCEDURES FOR NONDESTRUCTIVE TESTING 29

   1. Radiographic Test Methods 29

   2. Magnetic Particle Test Method 34

   3. Liquid Penetrant Test Method 34

   4. Ultrasonic Test Methods 34

5. AUTOMATIC WELDING 37

   1. Acceptable Processes 37

   2. Procedure Quali?cation 38

   3. Record 38

   4. Procedure Speci?cation 38

   5. Essential Variables 39

   6. Quali?cation of Welding Equipment and Operators 40

   7. Records of Quali?ed Operators 40

   8. Inspection and Testing of Production Welds 40

   9. Acceptance Standards for Nondestructive Testing 40

   10. Repair and Removal of Defects 40

   11. Radiographic Testing 40

6. AUTOMATIC WELDING WITHOUT FILLER-METAL ADDITIONS 40

   1. Acceptable Processes 40

   2. Procedure Quali?cation 40

   3. Record 46

   4. Procedure Speci?cation 46

   5. Essential Variables 46

   6. Quali?cation of Equipment and Operators 46

   7. Records of Quali?ed Operators 46

   8. Quality Assurance of Production Welds 46

   9. Acceptance Standards for Nondestructive Testing 47

   10. Repair and Removal of Defects 47

   11. Radiographic Procedure 47

APPENDIX A ALTERNATIVE ACCEPTANCE STANDARDS FOR

GIRTH WELDS 49

1. General 49

2. Additional Requirements for Stress Analysis 49

3. Welding Procedure 50

4. Quali?cation of Welders 54

5. Inspection and Acceptable Limits 54

6. Record 55

7. Example 55

8. Repairs 59

9. Nomenclature 59

APPENDIX B IN-SERVICE WELDING 61

1. General 61

2. Quali?cation of In-Service Welding Procedures 62

3. In-Service Welder Quali?cation 63

4. Suggested In-Service Welding Practices 64

5. Inspection and Testing of In-Service Welds 67

6. Standards of Acceptability: Nondestructive Testing (Including Visual) 67

7. Repair and Removal of Defects 67

Figures

1. Sample Procedure Speci?cation Form 4

2. Sample Coupon Test Report 5

3. Location of Test Butt-Weld Specimens for Procedure Quali?cation Test 9

4. Tensile-Strength Test Specimen 10

5. Nick-Break Test Specimen 10

6. Root- and Face-Bend Test Specimen: Wall Thicknesses Less Than or Equal to 0.500 in. (12.7 mm) 11

7. Side-Bend Test Specimen: Wall Thicknesses Greater than 0.500 in.

   (12.7 mm) 12

8. Dimensioning of Imperfections in Exposed Weld Surfaces 12

9. Jig for Guided-Bend Tests 13

10. Location of Nick-Break Test Specimens: Fillet-Weld Procedure and Welder Quali?cation Test Welds 14

11. Location of Nick-Break Test Specimens: Fillet-Weld Procedure and Welder Quali?cation Test Welds, Including Size-to-Size, Branch-Connection Welder Quali?cation Test 14

12. Location of Test Butt-Weld Specimens for Welder Quali?cation Test 17

13. Inadequate Penetration Without High-Low (IP) 21

14. Inadequate Penetration Due to High-Low (IPD) 23

15. Inadequate Cross Penetration (ICP) 23

16. Incomplete Fusion at Root of Bead or Top of Joint (IF) 23

17. Incomplete Fusion Due to Cold Lap (IFD) 23

18. Internal Concavity (IC) 23

19. Maximum Distribution of Gas Pockets: Wall Thicknesses Less Than or Equal to 0.500 in. (12.7 mm) 25

20. Maximum Distribution of Gas Pockets: Wall Thicknesses Greater Than

    0.500 in. (12.7 mm) 26

21. Standard Penetrameter 32

22A Reference Block for Manual UT 36

22B Establishing Distance, Refracted Angle, and Velocity 37

vii

22C Transfer Procedure 37

1. Location of Test Butt-Weld Specimens for Flash-Weld Procedure Quali?cation Test: Outside Diameter Greater Than 18 in. (457 mm)

   but Less Than or Equal to 24 in. (610 mm) 42

2. Location of Test Butt-Weld Specimens for Flash-Weld Procedure Quali?cation Test: Outside Diameter Greater Than 24 in. (610 mm)

   but Less Than or Equal to 30 in. (762 mm) 43

3. Location of Test Butt-Weld Specimens for Flash-Weld Procedure

   Quali?cation Test: Outside Diameter Greater Than 30 in. (762 mm) 44

4. Two-Inch Nick-Break Test Specimen 45

1. Location of CTOD Test Specimens 51

2. Machining Objective for CTOD Test Specimen With Respect to Pipe Wall 52

3. Location of Notch for Weld-Metal Specimen 52

4. Location of Notch for Heat-Affected Zone Specimen 52

5. Alternative Acceptance Criteria for Circumferential Planar Imperfections 53

6. Criteria for Evaluation of Imperfection Interaction 56

7. Length Limit for Deep Imperfections in Heavy-Wall Pipe 58

8. Nomenclature for Dimensions of Surface and Buried Imperfections 59

1. Examples of Typical Temper-Bead Deposition Sequences 61

2. Suggested Procedure and Welder Quali?cation Test Assembly 64

3. Location of Test Specimens?In-Service Welding Procedure

   Quali?cation Test 65

4. Macro Test Specimen?In-Service Welds 66

5. Face-Bend Test Specimen 66

6. Reinforcing Pad 67

7. Reinforcing Saddle 68

8. Encirclement Sleeve 68

9. Encirclement Tee 69

10. Encirclement Sleeve and Saddle 69

11. Encirclement Saddle 70

Tables

1. Filler Metal Groups 7

2. Type and Number of Test Specimens for Procedure Quali?cation Test 8

3. Type and Number of Butt-Weld Test Specimens per Welder for Welder Quali?cation Test and Destructive Testing of Production Welds 18

4. Maximum Dimensions of Undercutting 29

5. Thickness of Pipe Versus Thickness of ASTM E 1025 Penetrameter 31

6. Thickness of Pipe Versus Thickness of Penetrameter 32

7. Thickness of Pipe Versus Diameter of ASTM E 747 Wire Penetrameter 32

8. Type and Number of Test Specimens for Procedure Quali?cation Test

(Flash Weld Only) 41

1. Acceptance Limits for Buried Volumetric Imperfections 54

2. Acceptance Limits for Unrepaired Arc Burns 55

3. Imperfection Length Limits 57

4. Allowable Imperfection Dimensions for Example 58

5. Acceptable Planar Imperfection Dimensions for Example 58

6. Example Alternative Acceptance Criteria 59

B-1 Type and Number of Specimens?In-Service Welding Procedure

Quali?cation Test 65

viii

Welding of Pipelines and Related Facilities

1. General

   1.1 SCOPE

   This standard covers the gas and arc welding of butt, ?llet, and socket welds in carbon and low-alloy steel piping used in the compression, pumping, and transmission of crude petro- leum, petroleum products, fuel gases, carbon dioxide, and 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, ?ux-cored arc welding, plasma arc welding, oxyacetylene welding, or ?ash butt welding process or by a combination of these processes using a manual, semi- automatic, or automatic 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 test- ing methods.

   The values stated in either inch-pound units or SI units are to be regarded separately as standard. Each system is to be used independently of the other, without combining values in any way.

   Processes other than those described above will be consid- ered for inclusion in this standard. Persons who wish to have other processes included shall submit, as a minimum, the fol- lowing information for the committee?s consideration:

   1. A description of the welding process.

   2. A proposal on the essential variables.

   3. A welding procedure speci?cation.

   4. Weld inspection methods.

   5. Types of weld imperfections and their proposed accep- tance limits.

   6. Repair procedures.

   It is intended that all work performed in accordance with this standard shall meet or exceed the requirements of this standard.

   
   

2. Referenced Publications

The following standards, codes, and speci?cations are cited in this standard:

API

Spec 5L Speci?cation for Line Pipe

ASNT1

RP SNT-TC-1A Personnel Quali?cation and Certi?cation in Nondestructive Testing

ACCP ASNT Central Certi?cation Program

ASTM2

E 164 Standard Practice for Ultrasonic Contact Examination of Weldments

E 165 Standard Test for Liquid Penetrant Examination

E 709 Standard Guide for Magnetic Particle Examination

E 747 Standard Practice for Design, Manufac- tue and Material Grouping Classi?cation of Wire Image Quality Indicators (IQI) Used for Radiology

E 1025 Standard Practice for Design, Manufac- ture, and Material Grouping Classi?cation of Hole-Type Image Quality Indicators (IQI) Used for Radiology

AWS3

A3.0 Welding, Terms and De?nitions

A5.1 Covered Carbon Steel Arc Welding Electrodes

A5.2 Iron and Steel Oxyfuel Gas Welding Rods

A5.5 Low Alloy Steel Covered Arc Welding Electrodes

A5.17 Carbon Steel Electrodes and Fluxes for Submerged Arc Welding

A5.18 Carbon Steel Filler Metals for Gas Shielded Arc Welding

A5.20 Carbon Steel Electrodes for Flux Cored Arc Welding

A5.28 Low Alloy Steel Filler Metals for Gas Shielded Arc Welding

A5.29 Low Alloy Steel Electrodes for Flux Cored Arc Welding

BSI4

BS 7448: Part 2 Fracture Mechanics Toughness Tests Part 2, Method for Determination of Klc Criti- cal CTOD and Critical J Values of Welds in Metallic Materials

1American Society for Nondestructive Testing, Inc., 1711 Arlingate Lane, P.O. Box 28518, Columbus, Ohio 43228-0518.

2American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, Pennsylvania 19428-2959.

3American Welding Society, 550 N.W. LeJeune Road, Miami, Florida 33126.

4British Standards Institution, British Standards House, 389 Chiswick High Road, London, W4 4AL, United Kingdom.

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