M00044230
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API Std 1104 Welding of Pipelines and Related Facilities, 22nd Edition
standard by American Petroleum Institute, 07/01/2021
This standard covers the gas and arc welding of butt, fillet, and socket welds in carbon and low-alloy steel piping used in the compression, pumping, and transmission of crude petroleum, 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, flux-cored arc welding, plasma arc welding, oxyacetylene welding, or flash butt welding process, or by a combination of these processes using a manual, semiautomatic, mechanized, 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 testing methods.
It is intended that all work performed in accordance with this standard shall meet or exceed the requirements of this standard.
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API STANDARD 1104
TWENTY-SECOND EDITION, JULY 2021
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.
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Copyright © 2021 American Petroleum Institute
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.
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Suggested revisions are invited and should be submitted to the Standards Department, API, 200 Massachusetts Avenue, Suite 1100, Washington, DC 20001, standards@api.org.
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Page
Scope 1
Normative References 1
Terms, Definitions, Acronyms, and Abbreviations 2
Terms and Definitions 2
Acronyms and Abbreviations 8
Specifications 11
Equipment 11
Materials 12
Qualification of Welding Procedures with Filler Metal Additions 13
Procedure Qualification 13
Record 13
Welding Procedure Specification 13
Essential Variables 19
Welding of Test Joints-Butt Welds 22
Testing of Welded Joints-Butt Welds 22
Welding of Test Joints-Branch and Fillet Welds 30
Testing of Welded Joints-Branch and Fillet Welds 31
Qualification of Welders 32
General 32
Single Qualification 33
Multiple Qualification 36
Visual Examination 40
Destructive Testing 40
Nondestructive Testing (NDT)-Butt Welds Only 41
Retesting and Disposition of Test Results 42
Records 42
Design and Preparation of a Joint for Production Welding 42
General 42
Alignment 42
Use of Lineup Clamp for Butt Welds 43
Bevel 43
Weather Conditions 43
Clearance 43
Cleaning Between Beads 43
Position and Roll Welding 43
Identification of Welds 44
Preheat, Interpass Temperature, Postheat, and PWHT 44
Inspection and Testing of Production Welds 44
Rights of Inspection 44
Methods of Inspection 44
Qualification of Inspection Personnel 44
Certification of NDT Personnel 45
Acceptance Standards for NDT 45
General 45
Rights of Rejection 45
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Page
Radiographic Testing 46
Magnetic Particle Testing 52
Liquid Penetrant Testing 53
Ultrasonic Testing 54
Visual Acceptance Standards for Undercutting 56
Visual Acceptance Standards for Internal Concavity 56
Repair and Removal of Weld Defects 56
General 56
Repair Requirements 57
Repair Procedure 58
Repair Welder Qualification 67
Inspection of Repair Welding 71
NDT and Weld Repair Acceptance Criteria 71
Procedures for Nondestructive Testing (NDT) 71
General 71
Magnetic Particle Testing Method 83
Liquid Penetrant Testing Method 83
Ultrasonic Testing Methods 83
Mechanized Welding with Filler Metal Additions 94
Acceptable Processes 94
Procedure Qualification 94
Record 95
Welding Procedure Specification 95
Essential Variables 99
Testing of Welded Joints-Butt Welds 102
Qualification of Welding Operators 107
Records of Qualified Operators 111
Inspection and Testing of Production Welds 111
Acceptance Standards for NDT 111
Repair and Removal of Defects 111
Radiographic Testing 111
Ultrasonic 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
Sample Qualification Weld Report Form 15
Sample Welding Procedure Specification Form 16
Location of Test Butt Weld Specimens for Procedure Qualification Test 23
Tension Test Specimen 25
Nick Break Test Specimen 27
Dimensioning of Imperfections in Exposed Weld Surfaces 28
Root and Face Bend Test Specimen: Wall Thicknesses Less than or Equal to 0.500 in. (12.7 mm) 28
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Page
Jig for Guided-bend Tests 29
Side Bend Test Specimen: Wall Thicknesses Greater than 0.500 in. (12.7 mm) 30
Location of Nick Break Test Specimens: Branch and Fillet Weld Procedure
and Welder Qualification Test Welds 30
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
Location of Test Butt Weld Specimens for Welder Qualification Test (Full Circumference) 38
Location of Test Butt Weld Specimens for Welder Qualification Test (Half Circumference) 39
Inadequate Penetration Without High-low 46
Inadequate Penetration Due to High-low 46
Inadequate Cross Penetration 47
Incomplete Fusion at Root of Bead or Top of Joint 47
Incomplete Fusion Due to Cold Lap 48
Internal Concavity 48
Maximum Distribution of Gas Pockets: Wall Thickness (t) less than or equal to 0.500 in. (12.7 mm) . . 50
Maximum Distribution of Gas Pockets: Wall Thickness (t) Greater Than 0.500 in. (12.7 mm) 51
Hardness Locations for Full-thickness Repair Procedure Qualification 64
Hardness Locations for External Partial-thickness Repair Procedure Qualification at Weld 64
Hardness Locations for Cover Pass Repair Procedure at Weld Centerline 65
Hardness Location for Back Weld Repair or Internal Partial-Thickness Repair Procedure
at Weld Centerline 65
Hardness Locations for Cover Pass Repair Procedure at Fusion Line 66
Hardness Locations for External Partial-Thickness Repair at Fusion Line 66
Calculation for Determining Beam Width 75
Example of Reference Standard for Manual Ultrasonic Testing 89
Example: Establishing Distance, Refracted Angle, and Velocity 89
Example: Attenuation and Transfer Procedure 90
Example: V Prep Reference Standard—Example Reflector Positioning 93
Example: J and K Prep Reference Standard—Reflector Positioning 93
Example—J Prep Reference Standard—Top View 93
Sample Coupon Test Report 96
Sample Welding Procedure Specification Form 97
Location of Test Butt Weld Specimens for Procedure Qualification Test 104
Tension Test Specimen 105
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
Top View (Width in Circumferential Direction) of the Tensile Test Specimen 118
Charpy Specimen and V-notch Location for HAZ Impact Testing 119
Orientation of CTOD Test Specimen 120
Machining Objective for CTOD Test Specimen with Respect to Pipe Wall 121
Location of Notch for Weld Metal Specimen 122
Location of Notch for Heat-affected Zone Specimen 122
Option 1 Imperfection Limits for CTOD ≥ 0.010 in. (0.25 mm) 124
Option 1 Imperfection Limits for 0.004 in. (0.10 mm) ≤ CTOD < 0.010 in. (0.25 mm) 125
Allowable Imperfection Size Curves Before and After Height Adjustment 128
Schematic Overview of the Option 2 Procedure 128
Criteria for Evaluation of Imperfection Interaction 136
Examples of Typical Temper Bead Deposition Sequences 138
Page
An Example of Procedure and Welder Qualification Test Assembly 143
Suggested Location of Test Specimens 144
Suggested Location of Test Specimens for Weld Deposition Repair 145
Example Macro Test Specimen—In-service Fillet Welds 147
Face Bend Test Specimen 149
Reinforcing Pad 153
Reinforcing Saddle 154
Encirclement Sleeve 154
Encirclement Tee 155
Encirclement Sleeve and Saddle 155
Encirclement Saddle 156
Tables
Essential Variables for Qualification of Welding Procedure Specifications 20
Filler Metal Groups 22
Type and Number of Test Specimens for Procedure Qualification Test 24
Filler Metal Groups for Welder Qualification 33
Qualified Thickness Range for Single Qualification Test 35
Qualification Scope for Single Qualification Test Using a Branch Connection 36
Type and Number of Butt Weld Test Specimens per Welder for Welder
Qualification Test and Destructive Testing of Production Welds 41
Maximum Dimensions of Undercutting 56
Essential Variables for Qualification of Repair Welding Procedure Specifications 60
Repair Type Qualification Matrix 60
Type and Number of Butt Weld Test Specimens per Repair Type for Repair Procedure 62
Repair Weld Maximum Hardness Values, Non-Sour Service, HV10 67
Repair Welder Qualification Scope 68
Type and Number of Butt Weld Test Specimens per Repair Type for Repair Welder Qualification 69
Essential Variables for Repair Welders 70
Repair Welder Qualification Matrix 71
ASTM E747 Wire Type IQI Selection 77
ISO Wire Type IQI Selection 77
ASTM E1025 Hole Type IQI Selection 77
Essential Variables for the Qualification of Mechanized Welding Procedure Specifications 100
Filler Metal Groups 102
Type and Number of Test Specimens for Procedure Qualification Test 103
Type and Number of Test Specimens for Welding Operator Qualification Test 109
Essential Variables for Qualification of Welding Procedure Specifications in Accordance
with this Annex 116
Allowed Range of Variation from the Targeted Mean Values for a Lot Defined by
Controlled Chemical Composition 117
Initial Allowable Imperfection Size for Pr = 0.825 126
Example Acceptance Table 128
Acceptance Limits for Buried Volumetric Imperfections 133
Acceptable Limits for Unrepaired Arc Burns 133
Essential Variables for Qualification of Welding Procedure Specifications in Accordance
with this Annex 140
Essential Variables Applicable to Procedure and Welder Qualification 141
Type and Number of Specimens—In-service Welding Procedure Qualification Test 146
Page
Weld Maximum Hardness Values, Non-Sour Service, HV 148
Type and Number of Test Specimens for Longitudinal Groove Seam—Welder Qualification 152
Essential Variables for Qualification of Repair Welding Procedure Specifications
in Accordance with this Annex 158
Type and Number of Specimens—In-service Welding Repair Procedure Qualification Test 159
Welding of Pipelines and Related Facilities
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.
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.