Welding Processes, Inspection, and Metallurgy API RECOMMENDED PRACTICE 577 SECOND EDITION, DECEMBER 2013 --``,`````,,,,`,`,,,,,```,,,,``,-`-`,,`,,`,`,,`--- Copyright American Petroleum Institute Provided by IHS under license with API Licensee=Khalda Petroleum/5986215001, User=ElDeeb, mohamed No reproduction or networking permitted without license from IHS Not for Resale, 01/22/2014 05:23:44 MST 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. 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. 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The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices. wAisn asyrro amlenalty,n ourerf asgcputouanrreasrnib tmeleea rftokhirna gct o seumqcpuhli yppimnroged nwut ciotthsr mdaolal titenhr efiaa lcastp icpnol icncoafonbrflmoer mtroea qtnhuceire ea mwpipethlnic ttsah beol efm tAahPrakIti nssgttaa rnneddqaaurriddre.. mAePnIt sd ooef sa nn AotP rI esptarensdeanrdt, --``,`````,,,,`,`,,,,,```,,,,``,-`-`,,`,,`,`,,`--- 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, 1220 L Street, NW, Washington, DC 20005. Copyright © 2013 American Petroleum Institute Copyright American Petroleum Institute Provided by IHS under license with API Licensee=Khalda Petroleum/5986215001, User=ElDeeb, mohamed No reproduction or networking permitted without license from IHS Not for Resale, 01/22/2014 05:23:44 MST Foreword 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. 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. 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GeAaSWxnuPeatng--``,`````,,,,`,`,,,,,```,,,,``,-`-`,,`,,`,`,,`---enIs ugnehSaesritnalsialoygltnlen ytbdo,d yoan A frr,A dP euDPsvIp C iI ss,Dt iot12oae 20ntnpw20sda 0o0ara t5rLymrd,ee sSes a tnitaranrsternv, e eimdtt teear,a delrNeyd vp Wasibeh@new,od Wnaae espddah id .sa(ooeh2nrudi0gndl d2.tg o )rt beot6hevn8ii ,ss 2sDe u-rd8eCb,0vm i20reei00twat0.e f0fcdAi5ry mc.tcoleea d.tt ah,S leoot agrSt uwtoasifn t ohdAfda PtrrhaId ewsp npuD ubaebltiplc iclaaeartaittomisonten sen cvtaa,e nnrAdy bP fmeIi,v aae1ts e2cyr2eeia0ratl rsaLs i n.i sSeA tdrp e oufernbotel,mi -sNth imtWehdee, iii Copyright American Petroleum Institute Provided by IHS under license with API Licensee=Khalda Petroleum/5986215001, User=ElDeeb, mohamed No reproduction or networking permitted without license from IHS Not for Resale, 01/22/2014 05:23:44 MST --``,`````,,,,`,`,,,,,```,,,,``,-`-`,,`,,`,`,,`--- Copyright American Petroleum Institute Provided by IHS under license with API Licensee=Khalda Petroleum/5986215001, User=ElDeeb, mohamed No reproduction or networking permitted without license from IHS Not for Resale, 01/22/2014 05:23:44 MST Contents Page 1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 Normative References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 Terms, Definitions, and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3.1 Terms and Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3.2 Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4 Welding Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.2 Tasks Prior to Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --``,`````,,,,`,`,,,,,```,,,,``,-`-`,,`,,`,`,,`--- 4444455......361745 WTNGSTNaaaDoeessfnnElekkd-et ssCiEyrn a oUDxgPlna pu r.Pmf eor.oir cnni.ron am .gcC eu. ea rWot. sin Com.es cn.elep ed.srs lsti.ei n .f..ta igi...cno ...aOdn ...t piDo...o e...fen r...Wf a e.... tce....i otl....ds n.... is.....n ......g ...... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... 21212223618133 5.2 Shielded Metal Arc Welding (SMAW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5.3 Gas Tungsten Arc Welding (GTAW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5.4 Gas Metal Arc Welding (GMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.5 Flux Cored Arc Welding (FCAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.6 Submerged Arc Welding (SAW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.7 Stud Arc Welding (SW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.8 Plasma Arc Welding (PAW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 5.9 Electrogas Welding (EGW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6 Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.2 Welding Procedure Specification (WPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.3 Procedure Qualification Record (PQR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6.4 Reviewing a WPS and PQR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6.5 Tube-to-Tubesheet Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 7 Welding Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 7.2 P-Number Assignment to Base Metals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 7.3 F-Number Assignment to Filler Metals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 7.4 AWS Classification of Filler Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 7.5 A-Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 7.6 Filler Metal Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 7.7 Consumable Storage and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 8 Welder Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 8.2 Welder Performance Qualification (WPQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 8.3 Reviewing a WPQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 9 Non-destructive Examination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 v Copyright American Petroleum Institute Provided by IHS under license with API Licensee=Khalda Petroleum/5986215001, User=ElDeeb, mohamed No reproduction or networking permitted without license from IHS Not for Resale, 01/22/2014 05:23:44 MST Page 9.1 Discontinuities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 9.2 Materials Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 9.3 Visual Examination (VT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 9.4 Magnetic Particle Examination (MT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 9.5 Alternating Current Field Measurement (ACFM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 9.6 Liquid Penetrant Examination (PT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 9.7 Eddy Current Examination (ET). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 9.8 Radiographic Examination (RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 9.9 Ultrasonic Examination (UT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 9.10 Hardness Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 9.11 Pressure and Leak Testing (LT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 9.12 Weld Inspection Data Recording. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 10 Metallurgy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 10.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 10.2 The Structure of Metals and Alloys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 10.3 Physical Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 10.4 Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 10.5 Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 10.6 Postweld Heat Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 10.7 Hardening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 10.8 Material Test Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 10.9 Weldability of Metals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 10.10Weldability of high-alloys108 11 Refinery and Petrochemical Plant Welding Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 11.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 11.2 Hot Tapping and In-Service Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 11.3 Lack of Fusion with GMAW-S Welding Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 11.4 Caustic Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Annex A (normative) Terminology and Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Annex B (normative) Actions to Address Improperly Made Production Welds . . . . . . . . . . . . . . . . . . . . . . . . 120 Annex C (informative) Welding Procedure Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Annex D (normative) Guide To Common Filler Metal Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 F123ABini--``,`````,,,,`,`,,,,,```,,,,``,-`-`,,`,,`,`,,`---gbnulieroSSGexgs MMTErAaAA (pWiWWnhf y oWWWr.me ee.l llad.dd t.iiii nvnn. ge.gg ) . E EE.. ql..xe u..ac i..mpt ..rm po.. ld..ee ..en R.. t D...e u...p ..r.o i...nr ...tg ...o W...f .. . R e... lT...d ...iR n... eg... s... u.... l....t ....s .... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ...11 2242444654 4 GTAW Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5 GMAW Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 6 GMAW Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 7 FCAW Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 8 FCAW Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 9 FCAW Welding, Self-shielded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 vi Copyright American Petroleum Institute Provided by IHS under license with API Licensee=Khalda Petroleum/5986215001, User=ElDeeb, mohamed No reproduction or networking permitted without license from IHS Not for Resale, 01/22/2014 05:23:44 MST Page 10 SAW Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 11 Comparison of the Gas Tungsten Arc and Plasma Arc Welding Processes. . . . . . . . . . . . . . . . . . . . . . . 35 12 Electrogas Welding with a Solid Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 13 Typical Discontinuities Present in a Single Bevel Groove Weld in a Butt Joint . . . . . . . . . . . . . . . . . . . . 50 14 Direct Visual Examination Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 15 Inspector’s Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 16 Bridge Cam Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 17 Adjustable Fillet Weld Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 18 Skew—T Fillet Weld Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 19 Weld Fillet Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 20 Weld Fillet Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 21 Weld Size Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 22 Hi-Lo Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 23 Surface-breaking Discontinuity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 24 Subsurface Discontinuity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 25 Weld Discontinuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 26 Flux Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 27 Detecting Discontinuities Transverse to Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 28 Detecting Discontinuities Parallel to the Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 29 Pie Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 30 Fluorescent Penetrant Technique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 31 IQI (Penetrameter) Common Hole Diameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 32 IQI (Penetrameter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 33 Single-wall Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 34 Double-wall Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 35 Incomplete or Lack of Penetration (LOP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 36 Interpass Slag Inclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 37 Cluster Porosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 38 Lack of Side Wall Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 39 Elongated Slag (Wagon Tracks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 40 Burn-through. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 41 Offset or Mismatch with Lack of Penetration (LOP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 42 Excessive Penetration (Icicles, Drop-through) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 43 Internal (Root) Undercut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 44 Transverse Crack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 45 Tungsten Inclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 46 Root Pass Aligned Porosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 47 A-scan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 48 B-scan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 49 C-scan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 50 D-scan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 51 S-scan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 52 TOFD D-scan Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 53 TOFD B-scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 54 TOFD Transducer Arrangement and Ultrasonic Energy Beam Propagation. . . . . . . . . . . . . . . . . . . . . . . 85 55 DAC Curve for a Specified Reference Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 56 DAC Curve for an Unknown Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 57 Location of Hardness Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 vi-i-``,`````,,,,`,`,,,,,```,,,,``,-`-`,,`,,`,`,,`--- Copyright American Petroleum Institute Provided by IHS under license with API Licensee=Khalda Petroleum/5986215001, User=ElDeeb, mohamed No reproduction or networking permitted without license from IHS Not for Resale, 01/22/2014 05:23:44 MST Page A.1 Joint Types and Applicable Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 A.2 Symbols for Various Weld Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 A.3 Supplementary Symbols for Welds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 A.4 Standard Weld Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 A.5 Groove Weld Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 A.6 SMAW Welding Electrode Identification System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 A.7 GMAW/GTAW/PAW Welding Electrode Identification System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 A.8 FCAW Welding Electrode Identification System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 A.9 SAW Welding Electrode Identification System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 A.10 EGW Welding Electrode Identification System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 B.1 Suggested Actions for Welds Made by an Incorrect Welder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 B.2 Steps to Address Production Welds Made by an Improper Welding Procedure. . . . . . . . . . . . . . . . . . . 121 C.1a Sample WPS #CS-1, Page 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 C.1b Sample WPS #CS-1, Page 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 C.2a Sample PQR #CS-1, Page 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 C.2b Sample PQR #CS-1, Page 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 C.3a Shielded Metal-Arc Welding (SMAW) Checklist, Page 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 C.3b Shielded Metal-Arc Welding (SMAW) Checklist, Page 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 C.4a Example of Completed Shielded Metal-Arc Welding (SMAW) Checklist, Page 1 of 2. . . . . . . . . . . . . . 131 C.4b Example of Completed Shielded Metal-Arc Welding (SMAW) Checklist, Page 2 of 2. . . . . . . . . . . . . . 132 Tables 1 P-Number Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2 Common Types of Discontinuities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 3 Commonly Used NDE Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 4 Capability of the Applicable Inspection Method for Weld Type Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5 Capability of the Applicable Inspection Method vs. Discontinuity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6789111102--``,`````,,,,`,`,,,,,```,,,,``,-`-`,,`,,`,`,,`--- RWBDACRSoeieresissnnTlcduudeMo llliCnttlt ss EitHro ia9oonnac4ffurs k dANiI tQtnTipoheIeepnasssstl- i (tdsCcMsP eaoL.ea stm.inyi tmo.re muEn.it trc.x os oat.i n ismff.v ol tAy.e er i . c ntE ESe.c nxtar.ee sca .pMe )om.tl aaus.. i nt n..ni ecn..at re.e. ti Riar../oe Rle.. nd oef.. i jr...nwe ...Pic in...trt hg.i..o o ...dWS n...u e e...Cc r.l..vt d r....ii itc....ne e....gr s....i aP..... ......r o...... c...... .e..... ..s.... ..s.... ..e.... ...s... ...... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... ....... .....11 90690954444872 13 Hot Tapping/In-service Welding Hazards Associated with Some Particular Substances . . . . . . . . . . . .111 D.1 Common Welding Consumables for SMAW of Carbon and Low-allow Steel . . . . . . . . . . . . . . . . . . . . . 140 D.2 Common Welding Consumables for SMAW of Carbon and Low-allow Steel . . . . . . . . . . . . . . . . . . . . . 141 D.3 Copper-nickel and Nickel-based Alloys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 D.4 Classification Changes in Low-alloy Filler Metal Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 viii Copyright American Petroleum Institute Provided by IHS under license with API Licensee=Khalda Petroleum/5986215001, User=ElDeeb, mohamed No reproduction or networking permitted without license from IHS Not for Resale, 01/22/2014 05:23:44 MST Welding Processes, Inspection, and Metallurgy 1 Scope This recommended practice (RP) provides guidance to the API authorized inspector on welding inspection as encountered with fabrication and repair of refinery and chemical plant equipment and piping. This RP includes descriptions of common welding processes, welding procedures, welder qualifications, metallurgical effects from welding, and inspection techniques to aid the inspector in fulfilling their role implementing API 510, API 570, API 653 and API 582. The level of learning and training obtained from this document is not a replacement for the training and experience required to be a certified welding inspector under one of the established welding certification programs such as the American Welding Society (AWS) Certified Welding Inspector (CWI), or Canadian and European equivalent schemes such as CWB, CSWIP, PCN, or EFW. This RP does not require all welds to be inspected; nor does it require welds to be inspected to specific techniques and extent. Welds selected for inspection, and the appropriate inspection techniques, should be determined by the welding inspectors, engineers, or other responsible personnel using the applicable code or standard. The importance, difficulty, and problems that could be encountered during welding should be considered by all involved. A welding engineer should be consulted on any critical, specialized or complex welding issues. 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 510, Pressure Vessel Inspection Code: Maintenance, Inspection, Rating, Repair, and Alteration API 570, Piping Inspection Code: Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems API Recommended Practice 574, Inspection Practices for Piping System Components API Recommended Practice 578, Material Verification Program for New and Existing Alloy Piping Systems API Recommended Practice 582, Recommended Practice and Supplementary Welding Guidelines for the Chemical, Oil, and Gas Industries API Standard 650, Welded Steel Tanks for Oil Storage API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction API Recommended Practice 2201, Procedures for Welding or Hot Tapping on Equipment in Service ASME Boiler and Pressure Vessel Code 1 B31.3, Process Piping Section VIII, Rules for Construction of Pressure Vessels Section IX, Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators Section XI, Rules for Inservice Inspection of Nuclear Power Plant Components Practical Guide to ASME Section IX, Welding Qualifications 1 ASME International, 3 Park Avenue, New York, New York 10016-5990, www.asme.org. 1 --``,`````,,,,`,`,,,,,```,,,,``,-`-`,,`,,`,`,,`--- Copyright American Petroleum Institute Provided by IHS under license with API Licensee=Khalda Petroleum/5986215001, User=ElDeeb, mohamed No reproduction or networking permitted without license from IHS Not for Resale, 01/22/2014 05:23:44 MST 2 API RECOMMENDED PRACTICE 577 ASNT Central Certification Program CP-189 2, Standard for Qualification and Certification of Nondestructive Testing Personnel ASNT Central Certification Program SNT-TC-1A, Personnel Qualification and Certification in Nondestructive Testing ASTM A106 3, Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service ASTM A335, Standard Specification for Seamless Ferritic Alloy-Steel Pipe for High-Temperature Service ASTM A956, Standard Test Method for Leeb Hardness Testing of Steel Products ASTM A1038, Standard Practice for Portable Hardness Testing by the Ultrasonic Contact Impedance Method ASTM E94, Standard Guide for Radiographic Examination ASTM E1316, Standard Terminology for Nondestructive Examinations AWS A5.XX 4, Series of Filler Metal Specifications CASTI 5, Guidebook to ASME Section IX—Welding Qualifications EN 473 6, Qualification and Certification of NDT Personnel—General Principles ISO 9712 7, Non-destructive testing—Qualification and certification of personnel NACE SP 0472 8, Methods and Controls to Prevent In-Service Environmental Cracking of Carbon Steel Weldments in Corrosive Refining Environments WRC Bulletin 342 9, Stainless Steel Weld Metal: Prediction of Ferrite Content 3 Terms, Definitions, and Acronyms 3.1 Terms and Definitions For the purposes of this document, the following definitions apply. 3.1.1 ACFM The alternating current field measurement (ACFM) method is an electromagnetic inspection technique which can be used to detect and size surface breaking (or in some cases near surface) defects in both magnetic and non-magnetic materials. 2 American Society for Nondestructive Testing, 1711 Arlingate Lane, P.O. Box 28518, Columbus, Ohio 43228, www.asnt.org. 3 ASTM International, 100 Barr Harbor Drive, West Conshohocken, Pennsylvania 19428, www.astm.org. 4 American Welding Society, 550 NW LeJeune Road, Miami, Florida 33126, www.aws.org. 5 CASTI Publishing, Inc. 10566, 114 Street, Edmontom, Alberta, T5H 3J7, Canada. 6 European Committee for Standardization, Avenue Marnix 17, B-1000, Brussels, Belgium, www.cen.eu. 7 International Organization for Standardization, 1, ch. de la Voie-Creuse, Case postale 56, CH-1211, Geneva 20, Switzerland, www.iso.org. 8 NACE International (formerly the National Association of Corrosion Engineers), 1440 South Creek Drive, Houston, Texas 77218-8340, www.nace.org. 9 The Welding Research Council, 3 Park Avenue, 27th Floor, New York, New York 10016-5902, www.forengineers.org. --``,`````,,,,`,`,,,,,```,,,,``,-`-`,,`,,`,`,,`--- Copyright American Petroleum Institute Provided by IHS under license with API Licensee=Khalda Petroleum/5986215001, User=ElDeeb, mohamed No reproduction or networking permitted without license from IHS Not for Resale, 01/22/2014 05:23:44 MST