Api 1104 21st edition pdf download

The time delay specified in Page 57, Section Page 85, Section A. Page , Section B. Page , Figure B. Tests may be performed in other positions that qualify the procedure for that position only. Tests may be performed in other positions which will qualify the welder for that position only. Open navigation menu.

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Sign, fax and printable Form Popularity api pdf free download form. One shall be within 1 in. When the film length to be interpreted is 5 in.

When a repaired weld is radiographed, an additional IQI shall be placed across each repaired area. Separate blocks shall be made of the same or radiographically similar material and may be used to facilitate IQI positioning. The thickness of the separate block material should be the same as the thickness of the weld. The IQI may be placed above the surface of the pipe or held in position between the surface of the pipe and the imager by a fixture attached to the imager or scanning device.

Acceptability of such IQI placement shall be demonstrated during procedure qualification. Radiographers shall report to the company all defects observed in the images unless the company requires that all imperfections observed be reported. The radiographer shall indicate whether the weld meets the requirements of Section 9. The company shall determine the final disposition of the weld.

The company may specify the identification procedure to be used. Whenever more than one image is used to inspect a weld, identification markers shall appear on each image and adjacent images shall overlap.

The last reference marker on each end of the image shall appear on the appropriate adjacent images in a way that establishes that no part of the weld has been omitted.

If any question arises about the condition of the unexposed film, sheets from the front and back of each package or a length of film equal to the circumference of each original roll shall be processed in the normal manner without exposure to light or radiation. If the processed film shows fog, the entire box or roll from which the test film was removed shall be discarded, unless additional tests prove that the remaining film in the box or roll is free from preexposure fog exceeding 0.

It shall be equipped to prevent light, coming from around the outer edge of the radiograph or through low density portions of the radiograph, from interfering with interpretations. The protection and monitoring shall comply with applicable federal, state, and local regulations. The company and the NDT contractor should agree on the magnetic particle testing procedure or procedures prior to the performance of production testing. The company shall require the contractor to demonstrate that the proposed procedures will produce acceptable results and shall require the contractor to use such procedures for production testing.

The company and the NDT contractor should agree on the liquid penetrant testing procedure or procedures prior to the performance of production testing.

The use of ultrasonic testing and the scope of its use shall be at the option of the company. The company and the ultrasonic contractor should agree on the ultrasonic procedures before the performance of production testing. The company shall require the ultrasonic contractor to demonstrate the proposed procedures to produce acceptable and accurate results and shall require the contractor to use such procedures for production testing.

Caution is advised when this method is applied to in-service weld inspection due to potential parent material and surface imperfections that can interfere with the use of the ultrasonic technique. All surfaces to be ultrasonically scanned shall be in the uncoated condition. For new construction projects, the coating cutback bare pipe length at pipe ends necessary for ultrasonic scanning should be specified prior to the pipe being coated.

Pipe seams should be ground flush with the pipe surface for the distance necessary for ultrasonic scanning. The record shall be in the form of both writing and sketches. The ultrasonic testing personnel shall perform examinations in accordance with qualified and approved procedures see Personnel responsible for testing shall be capable of determining the acceptability of circumferential butt welds in accordance with the acceptance criteria as listed in 9.

The company has the right, at any time, to require personnel to demonstrate their capabilities to perform to the requirements of the qualified procedure. A procedure demonstration report shall be generated and the results documented prior to use on actual field welds. The demonstration process shall be as follows. Changes in wall thickness, bevel design, acoustic velocity, welding process, repair welds, and other variables that can have an effect on the detectability and resolution of the system shall require additional demonstration welds from other corresponding approved welding procedures.

Welder qualification welds may be used. Differences in detectability and resolution between ultrasonics and radiography shall be noted. If required by the company, destructive testing of the weld sample shall be made to discover or confirm the results. In addition, the procedure shall accurately determine the acceptability of welds in accordance with the criteria listed in 9. The reference standard shall also be used to determine the actual sound beam velocity, refracted angle, and sound path distance in the pipe material to be inspected.

Unknown velocity and refracted angle shall be determined when welds in pipe of different chemistry specifications, wall thickness, diameter or from more than one pipe and rolling or piercing manufacturer are to be inspected. This may be accomplished by using two probes of the same nominal angle and frequency with the probes directed toward one another see Figure When a difference is noted in velocity, angle, or sound path distance, another reference standard shall be made from the different pipe material.

For automated ultrasonic testing and when required by the company for manual ultrasonic testing, flat bottom holes shall be machined into a sample of the pipe to be inspected. This sample shall be used as calibration reflectors in addition to the N10 notches at the inside and outside surfaces.

The diameter of each flat bottom hole should be approximately equal to the thickness of one welding fill pass. The flat reflecting surface of each hole shall be installed at the same angle and position as the weld joint preparation for each fill pass required by the welding procedure.

Additionally, planar reflectors or flat bottom holes shall be installed at the weld centerline position with their flat reflecting surfaces vertical to the weld. All reflectors should be spaced apart so that no two will be within the beam spread of one probe simultaneously.

For testing on other than new construction, a pipe sample of the same grade, wall thickness, and OD as the pipe to be inspected shall be used to make the reference standard. A transfer technique using probes of the same nominal angles and frequencies to be used for inspection shall be carried out to determine actual full skip distance, actual refracted angle, and attenuation in the material to be inspected see Figure All interfering partial and full beam reflectors shall be noted datum location and distance from the weld edge and recorded on the examination record.

The company may elect to waive this requirement in lieu of lamination checks performed by the mill. Verify that the outside notch echo peak is at or near zero depth reading. This will establish that refracted angle and velocity settings are sufficiently accurate. Automated ultrasonic testing of the parent material shall be performed by using the same calibration method and evaluation level as that used for manual compression wave or by a different technique if demonstrated to be equal to or better than the manual method.

Measure the surface distance between the transducer exit points. Half the surface distance divided by measured wall thickness equals the refracted angle tangent. Without changing instrument settings, repeat this process on pipe with unknown velocity, refracted angle, and attenuation to determine any differences.

Figure 29—Transfer Procedure After the reference sensitivity, scanning sensitivity, and evaluation sensitivity and levels have been established, they shall be qualified and then incorporated into the final procedure and in the final qualification report.

Evaluation sensitivity should be the same as scanning sensitivity. Other automated techniques, reference reflectors, reference sensitivities, scanning sensitivities, evaluation sensitivities, and evaluation levels may be used if demonstrated to be equivalent to the pulse-echo technique for the detection and evaluation of weld imperfections.

Two pipe lengths, full joints or nipples, shall be joined by following all the details of the welding procedure specification. The quality of the weld shall be determined by both destructive and nondestructive testing and shall meet the requirements of 5.

Should a welding procedure qualification utilize a manual weld or semiautomatic pass as outlined in These procedures shall be adhered to except where a change is specifically authorized by the company, as provided for in This record shall show complete results of the procedure qualification test. This record shall be maintained as long as the procedure is in use. This shall include the type of welding technology and a description of the equipment to be utilized.

Materials may be grouped see 5. V or U , the angle of bevel, and the size of the root face and root opening. If a backup is used, the type shall be designated. These may include the location and angle of arc for submerged arc welding, the contact-tube-to-work distance, and the oscillation width and frequency.

Changes other than those listed in NOTE The groupings specified above in Changes in filler metal may be made within the groups specified in An increase or decrease in the range of flow rates established for the shielding gas also constitutes an essential variable.

A change in the method of cooling after welding resulting in a higher rate of cooling also requires requalification of the welding procedure. The completed weld shall be tested by destructive methods, nondestructive methods, or both, and shall meet the requirements of 6.

Should a welding procedure qualification utilize a manual or semiautomatic pass as outlined in The tensile strength tests shall not be replaced by nick break tests see 6. Prior to the start of welding, each welding operator shall have received adequate training in the operation of the welding equipment.

If the welding procedure involves more than one operation, welding operators shall be qualified on the type of welding equipment that will be used in production welding. Changes in the essential variables described in Welders shall be qualified if all tests are acceptable.

This form should be developed to suit the needs of the company but must be sufficiently detailed to demonstrate that the qualification test meets the requirements of this standard. A list of qualified operators and the procedures for which they are qualified shall be maintained.

An operator may be required to requalify if a question arises about their competence. At least two welds shall be made by joining pipe lengths, full joints, or nipples and by following all the details of the welding procedure specification. The quality of the weld shall be determined by both destructive and nondestructive testing and shall meet the requirements of The minimum number of specimens and the tests to which they are to be subjected are given in Table These specimens shall be prepared and tested as specified in If the specimen breaks in the weld or fusion zone, the observed strength is greater than or equal to the SMTS of the parent metal, and the weld meets the requirements for soundness given in The sides of the specimen shall be macroetched to locate the fusion line.

Edges of the specimen shall be smooth and parallel. Nick Break Test Specimen This record shall show complete results of the procedure qualification test and shall be maintained as long as the procedure is in use.

Changes other than those given in The completed weld shall be tested by both radiographic and mechanical test methods, as specified in Each operator shall have received adequate training in the operation of the equipment prior to the start of welding and shall be thoroughly familiar with the equipment they operate.

The frequency of such additional inspections and tests shall be as specified by the company. If any of the welding parameters deviate beyond the tolerances specified in the welding procedure specification, the weld shall be unacceptable. If the strip chart is found to be unacceptable after welding has been completed, the joint shall be rejected and removed from the line.

Other nondestructive tests may also be required by the company. Each production weld shall meet the requirements of The heat treatment cycle shall be documented using a strip chart recorder, and any deviation beyond the ranges specified for heating time, maximum temperature, or cooling rate shall be cause for reheat treatment.

Repair by welding is permitted only by agreement with the company. Such criteria have provided an excellent record of reliability in pipeline service for many years. The use of fracture mechanics analysis and fitness-for-purpose criteria for determining acceptance criteria is an alternative method and incorporates the evaluation of both imperfection height and imperfection length. Typically, but not always, the fitness-for-purpose criteria provide more generous allowable imperfection length.

Additional qualification tests, stress analysis, and inspection are required to use the fitness-for-purpose criteria. Performing analysis based on the principles of fitness-for-purpose is alternatively termed engineering critical assessment, or ECA. The fitness-for-purpose criteria in the prior versions of this annex required a minimum crack tip opening displacement CTOD toughness of either 0. Improvements in welding consumables and with more precise welding procedures, especially, with the increased use of mechanized welding devices have resulted in higher and more uniform toughness and ductility in most welds.

At the same time, toughness values below 0. Welds with CTOD toughness below 0. The acceptance criteria are revised so that they are commensurate with the measured toughness and applied load levels. This annex includes three options for the determination of acceptance limits of planar imperfections.

In numerical order, the options are increasingly complex in application but offer wider range of applicability. Option 1 provides the simplest methodology. Option 2 allows for the full utilization of the toughness of the materials thus providing a more accurate criterion but requires more calculation. The first two options were developed with a single set of underlying procedures but are limited to applications with a low to moderate fatigue loading as described in A.

Option 3 is not prescriptive, and its consistency could be significantly less than Options 1 and 2. Option 3 should only be exercised, when necessary, by skilled practitioners with demonstrated knowledge of fracture mechanics and pipeline load analysis. With these three options, this current revision of the annex should provide a more complete approach to determine inspection and acceptance limits for imperfections.

It is usually impractical to qualify individual pipeline welds for the alternative acceptance limits after a defect under Section 9 is detected, because destructive testing is required to establish the required mechanical properties for the welding procedure under consideration. This annex provides procedures to determine the maximum allowable imperfection sizes. It does not prevent the use of Section 9 for determining imperfection acceptance limits for any weld. In this annex, the use of the phrase imperfection acceptance limits and other phrases containing the word imperfection is not intended to imply a defective condition or any lack of weld integrity.

All welds contain certain features variously described as artifacts, imperfections, discontinuities, or flaws. These terms are widely accepted and used interchangeably.

The primary purpose of this annex is to define, on the basis of a technical analysis, the effect of various types, sizes, and shapes of such anomalies on the suitability of the whole weld for a specific service.

Wang and M. DOT Agreement No. The stress analysis shall include stresses during pipeline installation and stresses induced by operational and environmental conditions. Under typical onshore construction conditions, the highest axial stress may occur during the pipe lowering-in process. The lowering-in stress is predominantly controlled by the lift height of the pipe relative to the bottom of the trench. The stresses from horizontal directional drilling can be estimated from the curvature of the pipe path, pull force, and the interaction between the pipe and surrounding soil including friction.

The maximum axial design stress is the maximum total axial stress at any given time during the design life of the pipeline. This spectrum shall include but is not limited to stresses imposed by hydrostatic testing, operation pressure, installation stresses, and where applicable, thermal, seismic, and subsidence stresses. The spectrum should consist of several cyclic axial stress levels and the number of cycles applicable to each. If the stress levels vary from cycle to cycle, a suitable counting method, such as the rainflow method, should be used to determine cyclic stress levels and cycle count.

Liu, Y. Wang, and G. Using actual stress-strain relations may result in the overestimation of the applied load level, as the flow stress is computed from the minimum specified values e.

In the absence of contaminating elements, oil and hydrocarbons are considered no worse than air. Water, brine, and aqueous solutions that contain CO2 or H2S may, however, increase the growth rate. It is normal for minor amounts of these components to be present in nominally noncorrosive pipelines.

When the concentration of either CO2 or H2S exceeds typical historical levels experienced in noncorrosive pipelines, this annex shall not be used, unless evidence exists that the proposed levels do not result in acceleration of fatigue crack growth or adequate corrosion inhibition is applied.

The effects of environment on fatigue crack growth external to the pipe at girth welds are normally mitigated by external coating and cathodic protection and do not limit the use of this annex. These environments typically contain H2S but may contain strong hydroxides, nitrates, or carbonates. When these materials are present inside the pipe, a minimum threshold stress shall be established, and this annex shall not be used if the calculated stress exceeds the threshold value.

Although external exposure to carbonates and nitrates in the soil has been shown to produce stress corrosion cracking SCC in a small number of cases, the cracking is normally axial and is associated with circumferential stress rather than axial stress. However, circumferential SCC failures may occur at locations where longitudinal stresses have increased over the life of the pipeline, for example, at overbends above unstable slopes.

The frequency and severity of SCC can be mitigated by the use of proper coating and proper cathodic protection. The use of this annex is not precluded when direct exposure to the aggressive environment is prevented by a coating designed to resist the environment. The determination of residual stress is not required under these conditions.

The effects of residual stress shall be evaluated for all time- dependent failure mechanisms, such as fatigue. An appropriate quality control program shall be established to ensure welding is performed within the parameters of the qualified welding procedure. Qualification of welding procedures to be used with this annex shall be in accordance with Section 5 or Section 12 of this standard, with the additional mechanical property testing in accordance with A. Chemistry compositions requirements shall be based on heat analysis results.

Minor changes in the angle of bevel or the land of the welding groove that do not yield a change in the range of qualified heat input are not essential variables. The following lot definitions within AWS A5. S1 lot definitions are acceptable when the conditions of the lot definition are agreed upon between supplier and purchaser. For filler metals identified by heat number, a change of heat number will require requalification.

For solid wire and metal-cored wires, the allowed controlled composition variation in each element about its targeted mean value is shown in Table A. Table A. It is not necessary to test welds made with all possible combinations of pipe material. The specimens shall be prepared in accordance with the requirements of Figure A. The weld reinforcement shall be removed.

The ends of the specimens shall be sufficient for the grips. Figure A. Although tensile specimen failure in the weld is acceptable, provided the strength requirement is met, gross weld strength undermatching should be avoided. Both retest specimens shall meet the SMTS of the pipe material.

If either retest specimen fails to meet the minimum tensile strength requirement, no retesting is permitted. The largest size specimens permitted by the pipe wall thickness should be used. For each of these positions, three specimens shall have the V-notch placed in the weld centerline; and the other three shall have the V-notch placed in the HAZ as shown in Figure A.

An example of assessing weld strength undermatching is given in Y. Wang, M. Liu, D. Horsley, and G. The retest requirements are as follows: a the three retest specimens shall be extracted from a location as close as possible to the location of the specimen that generated the low result, b the absorbed energy of all three retest specimens shall meet or exceed 30 ft-lb 40 J.

If the above retest criteria are satisfied, the Charpy results are acceptable. If the above criteria are not satisfied, no further retesting is permitted and the weld is rejected. As shown in Figure A. The specimen thickness see Figure A. For weld metal tests, the notch and fatigue crack tip should be located at the center of the weld and completely in weld metal see Figure A. Multiple specimen sampling of the cap pass coarse grain HAZ should be avoided.

No more than one specimen should be devoted to the cap pass HAZ. To identify coarse grain HAZ regions, it may be useful to conduct a microhardness survey to locate the coarsest HAZ regions that have undergone the least amount of tempering by subsequent weld passes. Each set of tests of weld metal or HAZ shall consist of at least three valid specimen tests performed at or below the minimum design temperature. After testing, particular attention should be given to the qualification criteria in The test report shall also include a legible copy of the load-displacement record and a record of the appearance of the fracture surfaces; the latter requirement can be satisfied by a clear photograph of one or both fracture surfaces or by retaining one or both fracture surfaces properly preserved and identified for direct observation.

Unless otherwise specified by the company, the notch location shall be defined as weld positional per BS EN ISO , that is, no postweld metallography is required.

For mechanized welding, each operator shall be qualified in accordance with Conventional radiography, as described in The use of conventional radiography see Option 1 is a simplified approach in graphical format. It relies on theoretically sound and experimentally validated plastic collapse criteria, and has been modified by the Option 2 approach when appropriate.

Option 2 is in the form of a failure assessment diagram, or FAD. The FAD format allows the simultaneous consideration of brittle fracture, plastic collapse, and the interaction between those two failure modes elastic-plastic fracture. Options 1 and 2 are limited to pipelines with limited fatigue loads as specified in A. Option 3 permits the use of validated fitness-for-purpose procedures when the cyclic loading exceeds the spectrum requirements of Options 1 and 2.

The Options 2 and 3 procedures may be applied at any CTOD toughness level greater than the minimum required value of 0. Additional testing and validation may be necessary to use the alternative acceptance criteria in this annex. When the CTOD toughness is equal to or greater than 0. If the load level is not given in Figure A. The acceptable imperfection size may be more limiting than that from the Option 2 procedure as the limits in Figure A. The total imperfection length shall be no greater than The allowable height of the buried imperfections is treated the same as the allowable height of the surface-breaking imperfections.

The built-in safety factor in the acceptable imperfection size can accommodate certain amount of undersizing of imperfection height without negatively impacting weld integrity. The assumed height uncertainty is the lesser of 0. No reduction in allowable imperfection size is necessary if the allowance for inspection alternatively termed inspection error is better than the assumed height uncertainty.

The allowable imperfection height shall be reduced by the difference between the allowance for inspection and the assumed height uncertainty if the above condition cannot be met. A 24 in.

OD pipeline with a specified wall thickness WT of 0. After reviewing A. Weld test data conducted per the requirements of the annex indicate that the minimum CTOD value is 0. These parameters are summarized as follows: Pipe OD: 24 in.

Pipe WT 0. The allowable imperfection size is tabulated in Table A. The allowable height quantities, shown in the second column of Table A. Allowance for inspection i. However, a project with a heavier wall thickness may have more rows in a similar table. The FAC is a locus that defines the critical states in terms of the stress and toughness ratios. The stress ratio defines the likelihood of plastic collapse.

It defines the likelihood of brittle fracture. Proficiency and understanding of fracture mechanics is necessary to ensure the procedure is applied correctly. A validated computer program should greatly simplify the computation. The following steps may be followed.

Step 1 Select an imperfection size as a start point. Step 3 If the assessment point falls inside the safe region, increase the imperfection length and repeat Step 2. Step 4 If the assessment point falls outside the safe region, decrease the imperfection length and repeat Step 2.

Start from the imperfection length determined in Item a and repeat Step 2. Step 6 Make a table of critical imperfection height and length. Step 7 Apply a safety factor of 1. Step 8 Make necessary adjustment to the draft table to ensure detectability of the selected inspection methods 17 and sound welding practice.

No reduction in allowable imperfection size is necessary if the allowance for inspection is better than the assumed height uncertainty. The maximum allowable height may be reduced if such a large value is judged unnecessary by sound welding practice.

The Option 3 procedures are permitted when significant imperfection growth is expected. Subject to company approval, validated fitness-for-purpose procedures may be used to develop imperfection acceptance criteria. One of the most widely accepted procedures is BS Any selected procedure shall be taken as a whole in developing the acceptance criteria with appropriate considerations of safety factors.