By Authority Of THE UNITED STATES OF AMERICA Legally Binding Document By the Authority Vested By Part 5 of the United States Code § 552(a) and Part 1 of the Code of Regulations § 51 the attached document has been duly INCORPORATED BY REFERENCE and shall be considered legally binding upon all citizens and residents of the United States of America. HEED THIS NOTICE: Criminal penalties may apply for noncompliance. e Document Name: CFR Section(s): Standards Body: Official Incorporator: THE EXECUTIVE DIRECTOR OFFICE OF THE FEDERAL REGISTER WASHINGTON, D.C. Welding of Pipelines and Related Facilities Pipeline Segment API STANDARD 1104 NINETEENTH EDITION, SEPTEMBER 1999 ERRATA 1, OCTOBER 31,2001 American Petroleum Institute Helping You Get The Job Done Right,;;M Reproduced By IHS Wilh The Permission Of API Under Royalty Agreement SPECIAL NOTES API publications necessarily address problems of a general nature. 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Copyright © 1999 American Petroleum Institute FOREWORD This standard was prepared by a fonnulating 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 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 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 conflict. 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. A7TENT/ON 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 significant, while in other cases the changes reflect 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. iii API-AGA JOINT COMMITTEE ON OIL AND GAS PIPELINE FIELD WELDING PRACTICES H. Charles Price, Chainnan George K. Hickox, Vice-Chainnan 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 Thom Bill Marhofer Members Emeritus Jolm K. McCarron RB. Gwin M. Jordan Hunter E. L. Von Rosenberg Dale Wilson iv CONTENTS Page GENERAL ........................................................... . 1.1 Scope .......................................................... . 2 REFERENCED PUBLICATIONS ......................................... 1 3 DEFINITION OF TERMS ............................................... 2 3.1 General ......................................................... 2 3.2 Definitions ...................................................... 2 4 SPECIFICATIONS ..................................................... 2 4.1 Equipment. ...................................................... 2 4.2 Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 5 QUALIFICATION OF WELDING PROCEDURES FOR WELDS CONTAINING FILLER-METAL ADDITIVES ........................................... 3 5.1 Procedure Qualification ............................................ 3 5.2 Record .......................................................... 3 5.3 Procedure Specification ............................................ 3 5.4 Essential Variables ................................................ 6 5.5 Welding of Test Joints-Butt Welds .................................. 7 5.6 Testing of Welded Joints-Butt Welds ................................ 8 5.7 Welding of Test Joints-Fillet Welds ................................. 13 5.8 Testing of Welded Joints-Fillet Welds ............................... 15 6 QUALIFICATION OF WELDERS ....................................... 15 6.1 General ........................................................ 15 6.2 Single Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15 6.3 Multiple Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16 6.4 Visual Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16 6.5 Destructive Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18 6.6 Radiography-ButtWelds Only .................................... 19 6.7 Retesting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 6.8 Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 7 DESIGN AND PREPARATION OF A JOINT FOR PRODUCTION WELDING .. 19 7.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 7.2 Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 7.3 Use of Lineup Clamp for Butt Welds ................................. 19 7.4 Bevel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 7.5 Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 7.6 Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 7.7 Cleaning Between Beads .......................................... 20 7.8 Position Welding ................................................. 20 7.9 Roll Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20 7.1 0 Identification of Welds ............................................ 20 7.11 Pre-and Post-Heat Treatment ...................................... 20 8 INSPECTION AND TESTING OF PRODUCTION WELDS .................. 20 8.1 Rights of Inspection .............................................. 20 v Page 8.2 Methods of Inspection ............................................ 20 8.3 Qualification of Inspection Personnel ................................ 20 8.4 Certification of Nondestructive Testing PersOlmel ...................... 21 9 ACCEJYTANCESTANDARDS FOR NONDESTRUCTNETESTING .......... 21 9.1 General ........................................................ 21 9.2 Rights of Rejection ............................................... 21 9.3 Radiographic Testing ............................................. 21 9.4 Magnetic Particle Testing .......................................... 27 9.5 Liquid Penetrant Testing .......................................... 27 9.6 Ultrasonic Testing ................................................ 27 9.7 Visual Acceptance Standards for Undercutting ......................... 28 10 REPAIR AND REMOVAL OF DEFECTS ................................. 29 10.1 Authorization for Repair .......................................... 29 10.2 Repair Procedure ................................................ 29 10.3 Acceptance Criteria .............................................. 29 10.4 Supervision..................................................... 29 10.5 Welder.................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29 ] ] PROCEDURES FOR NONDESTRUCTNE TESTING ...................... 29 11.1 Radiographic Test Methods ........................................ 29 11.2 Magnetic Particle Test Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34 11.3 Liquid Penetrant Test Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34 1 I .4 Ultrasonic Test Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34 12 AUTOMATICWELDING .............................................. 37 12.1 Acceptable Processes ............................................. 37 12.2 Procedure Qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 38 ] 2.3 Record.................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 38 12.4 Procedure Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 38 ] 2.5 Essential Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 39 12.6 Qualification of Welding Equipment and Operators ..................... 40 12.7 Records of Qualified Operators ..................................... 40 12.8 Inspection and Testing of Production Welds ........................... 40 12.9 Acceptance Standards for Nondestructive Testing ...................... 40 12.10 Repair and Removal of Defects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 12.11 Radiographic Testing ............................................. 40 13 AUTOMATIC WELDING WITHOUT FILLER-METAL ADDITIONS ......... 40 13.1 Acceptable Processes ............................................. 40 13.2 Procedure Qualification ........................................... 40 13.3 Record ......................................................... 46 13.4 Procedure Specification ........................................... 46 13.5 Essential Variables ............................................... 46 13.6 Qualification of Equipment and Operators ............................ 46 13.7 Records of Qualified Operators ..................................... 46 13.8 Quality Assurance of Production Welds .............................. 46 13.9 Acceptance Standards for Nondestructive Testing ...................... 47 13.10 Repair and Removal of Defects ..................................... 47 13.11 Radiographic Procedure ...... , .................................... 47 vi Page APPENDIX A ALTERNATIVE ACCEPTANCE STANDARDS FOR GIRTH WELDS ............................................ 49 A. I General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 A.2 Additional Requirements for Stress Analysis .......................... 49 A.3 Welding Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50 A.4 Qualification of Welders ........................................... 54 A.5 Inspection and Acceptable Limits ................................... 54 A.6 Record ......................................................... 55 A.7 Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55 A.S Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 59 A.9 Nomenclature ................................................... 59 APPENDIX B IN-SERVICE WELDING .................................... 61 B.l General ........................................................ 61 B.2 Qualification of In-Service Welding Procedures ........................ 62 8.3 In-Service Welder Qualification ..................................... 63 B.4 Suggested In-Service Welding Practices .............................. 64 B.5 Inspection and Testing of In-Service Welds ............................ 67 B.6 Standards of Acceptability: Nondestructive Testing (Including Visual) ...... 67 B.7 Repair and Removal of Defects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 67 Figures 1 Sample Procedure Specification Form .................................. 4 2 Sample Coupon Test Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3 Location of Test Butt-Weld Specimens for Procedure Qualification 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. (12.7mm) ................................................ 11 7 Side-Bend Test Specimen: Wall Thicknesses Greater than 0.500 in. (12.7 mm) ....................................................... 12 S 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 Qualification Test Welds ............................................ 14 11 Location of Nick-Break Test Specimens: Fillet-Weld Procedure and Welder Qualification Test Welds, Including Size-to-Size, Branch-Connection Welder Qualification Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14 12 Location of Test Butt-Weld Specimens for Welder Qualification Test ........ 17 13 Inadequate Penetration Without High-Low (lP) .......................... 21 14 Inadequate Penetration Due to High-Low (IPD) ......................... 23 15 Inadequate Cross Penetration (lCP) ................................... 23 16 Incomplete Fusion at Root of Bead or Top of Joint (IF) ................... 23 17 Incomplete Fusion Due to Cold Lap (IFD) .............................. 23 IS Intemal Concavity (lC) ............................................. 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 Page 22C Transfer Procedure ................................................ 37 23 Location of Test Butt-Weld Specimens for Flash-Weld Procedure Qualification Test: Outside Diameter Greater Than 18 in. (457 mm) but Less Than or Equal to 24 in. (610 mm) ..... , ....................... 42 24 Location of Test Butt-Weld Specimens for Flash-Weld Procedure Qualification Test: Outside Diameter Greater Than 24 in. (610 mm) but Less Than or Equal to 30 in. (762 mm) ............................. 43 25 Location of Test Butt-Weld Specimens for Flash-Weld Procedure Qualification Test: Outside Diameter Greater Than 30 in. (762 mrn) ......... 44 26 Two-Inch Nick-Break Test Specimen .................................. 45 A-I Location of CTOD Test Specimens ........... , ....................... 51 A-2 Machining Objective for CTOD Test Specimen With Respect to Pipe Wall .... 52 A-3 Location of Notch for Weld-Metal Specimen ............................ 52 A-4 Location of Notch for Heat-Affected Zone Specimen ..................... 52 A-5 Altemative Acceptance Criteria for Circumferential Planar Imperfections ..... 53 A-6 Criteria for Evaluation of Imperfection Interaction ....................... 56 A-7 Length Limit for Deep Imperfections in Heavy-Wall Pipe ................. 58 A-8 Nomenclature for Dimensions of Surface and Buried Imperfections ......... 59 B-1 Examples of Typical Temper-Bead Deposition Sequences ................. 61 B-2 Suggested Procedure and Welder Qualification Test Assembly .............. 64 B-3 Location of Test Specimens-In-Service Welding Procedure Qualification Test. ............ , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 65 B-4 Macro Test Specimen-In-Service Welds .............................. 66 B-5 Face-Bend Test Specimen ...... , .................................... 66 B-6 Reinforcing Pad .............. , .................................... 67 B-7 Reinforcing Saddle ........... , .................................... 68 B-8 Encirclement Sleeve .......... , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 B-9 Encirclement Tee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 B-10 Encirclement Sleeve and Saddle ...................................... 69 B-l1 Encirclement Saddle ............................................... 70 Tables I Filler Metal Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2 Type and Number of Test Specimens for Procedure Qualification Test ........ 8 3 Type and Number of Butt-Weld Test Specimens per Welder for Welder Qualification 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 Qualification Test (Flash Weld Only) ................................................. 41 A-I Acceptance Limits for Buried Volumetric Imperfections ................... 54 A-2 Acceptance Limits for UnrepairedArc Bums ........................... 55 A-3 Imperfection Length Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 A-4 Allowable Imperfection Dimensions for Example ........................ 58 A-5 Acceptable Planar Imperfection Dimensions for Example ................. 58 A-6 Example Altemative Acceptance Criteria ............................... 59 B-1 Type and Number of Specimens-In-Service Welding Procedure Qualification Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 viii Welding of Pipelines and Related Facilities 1 General ASNTI RP SNT-TC-IA Personnel Qualification and Certification 1.1 SCOPE ill Nondestructive Testing This standard covers the gas and arc welding of butt, fillet, ACCP ASNT Central Certification Program and socket welds in carbon and low-alloy steel piping used in ASTM2 the compression, pumping, and transmission of cmde petro E 164 Standard Practice for Ultrasonic Contact leum, petroleum products, fuel gases, carbon dioxide, and Examination of Weldments nitrogen and, where applicable, covers welding on distribution E 165 Standard Test for Liquid Penetrant systems. It applies to both new constmction and in-service Examination welding.The welding may be done by a shielded metal-arc E709 Standard Guide for Magnetic Particle welding, submerged arc welding, gas tungsten-arc welding, Examination gas metal-arc welding, flux-cored arc welding, plasma arc E747 Standard Practice for Design, Manu/ac welding, oxyacetylene welding, or flash butt welding process tue and Material Grouping Classification or by a combination of these processes using a manual, semi q/ Wire Image Quality Indicators (IQI) automatic, or automatic welding technique or a combination of Usedfor Radiology these techniques. The welds may be produced by position or E 1025 Standard Practice for Design, Manufac roll welding or by a combination of position and roll welding. ture, and Material Grouping Classification This standard also covers the procedures for radiographic, of Hole-T.vpe Image Quality Indicators (IQI) UsedfiJr Radiology magnetic particle, liquid penetrant, and ultrasonic testing as well as the acceptance standards to be applied to production AWS3 welds tested to destmction or inspected by radiographic, A3.0 Welding, Terms and Definitions magnetic particle, liquid penetrant, ultrasonic, and visual test A5.I Covered Carbon Steel Arc Welding ing methods. Electrodes The values stated in either inch-pound units or SI units are A';.2 Iron and Steel Oryfuel Gas Welding Rods to be regarded separately as standard. Each system is to be A5.5 Low Alloy Steel Covered Arc Welding used independently of the other, without combining values in Electrodes any way. AS. 17 Carbon Steel Electrodes and Flu.xes for Processes other than those described above will be consid Submerged Arc Welding ered for inclusion in this standard. Persons who wish to have AS.I8 Carbon Steel Filler Metals for Gas other processes included shall submit, as a minimum, the fol Shielded Arc Welding lowing infonnation for the committee's consideration: AS.20 Carbon Steel Electrodes for Flux Cored Arc Welding a. A description of the welding process. AS.28 Low Alloy Steel Filler Metals for Gas b. A proposal on the essential variables. Shielded Arc Welding c. A welding procedure specification. AS.29 Low Alloy Steel Electrodes for FilL>< Cored Arc Welding d. Weld inspection methods. e. Types of weld imperfections and their proposed accep BSI4 tance limits. BS 7448: Part 2 Fracture Mechanics Toughness Tests Part f. Repair procedures. 2, Methodfor Determination of K/c Criti It is intended that all work perfonned in accordance with this cal CTOD and Critical J Values qfWelds in Metallic Materials standard shall meet or exceed the requirements of this standard. lAmerican Society for Nondestructive Testing, Inc., 1711 Arlingate 2 Referenced Publications Lane, P.O. Box 28518, Columbus, Ohio 43228-0518. 2American Society for Testing and Materials, 100 Barr Harbor The following standards, codes, and specifications are Drive, West Conshohocken, Pennsylvania 19428-2959. cited in this standard: 3American Welding Society, 550 N.W. Lejeune Road, Miami, Florida 33126. API 4British Standards Institution. British Standards House. 389 Spec 5L Specification for Line Pipe Chiswick High Road, London, W4 4AL, United Kingdom.