API Standard 1104 - Welding of Pipeline and Related # section on essential variables for Weld Procedure Qualifications, Section 126.96.36.199, states a change from one group to another.However, this section does not specify which group.Is the first group specified in Table 2 which is
12.7 mm and
12.7 mm? Or is it the group specified under Welder Qualification Tests which is
4.8 mm, 4.8 mm - 19 mm, and .-00;,00;.-00; 00;--00; 00;,00; 19 mm?The groups are not specified in API-1104, they are to be selected by the user.
See Para.188.8.131.52.110418th1104-I-01-96The essential variable list in Section 2.4 for Weld Procedure Qualification does not cover diameter groupings although Welder Qualification Tests do have groupings.Is it correct in saying that qualifying a procedure on 2" diameter would qualify, say, a 40" diameter butt weld provided all other essential variables were Qualification Tests for Automatic Welding Section 9.7 does not specify any essential variables for Welder Qualification Tests.Is this correct?Welder Qualification Tests for Automatic Welding - Since Para.
9.6 provides that both the equipment and the operator are qualified at the same time, the Essential Variables specified in Para.9.5 apply.110418th1104-I-01-96Weld Procedure Qualification - Automatic Welding Under Section 9, this appears to be leaving the groupings of diameters and wall thickness to the Contractor as it states this will be stated in the WPS.Should these groupings be per API 1104 and/or Company requirements?Weld Procedure Qualification for Automatic Welding - The groupings are left to the writer of the procedure of the requirements of paragraph 184.108.40.206.c with respect to cluster porosity is required since the collective aggregate size of porosity is being interpreted differently by different inspectors.If the cluster porosity cannot be proven to be in the finish pass, the criteria of Para.220.127.116.11 applies.If Para.18.104.22.168c applies, then figures 18 and 19 must be used even if the indication on the radiograph has been defined as cluster porosity.110418th1104-I-02-96With similar size porosity all falling into the medium category, the density which is in the assorted chart cannot be defined.
When a cluster of 5 to 7 pores cannot fit into an inscribed circle on the fine chart, the client is rejecting it even though there is no other porosity within the entire radiograph.An attached sketch illustrates the condition.If the size of the porosity is the size shown in the "medium" charts of Figures 18 and 19, then that is the chart which must be used as the acceptability standard.110418th1104-I-04-96If the Company has not required the use of a line-up clamp in its project specific specification, does API 1104 require the use of a clamp?No.See Para.22.214.171.12410418th1104-I-04-96As paragraph 4.3 is concerning butt welds, is this indicating that a clamp must be used for butt welds and that the weld procedure specification (as discussed in 126.96.36.199) for butt welds must reflect this?Para.4.3 requires that the use of line-up clamps must be in accordance with the procedure specification.
If the procedure specification does not require a line-up clamp, then none needs to be used when making the production weld.See Para.
188.8.131.52.110418th1104-I-04-96Why is a clamp required for a weld procedure qualification, when the pipe nipples for the WPS will have been cut from the same length of pipe and hence the dimension fit up will be very good; whereas, the field fit ups are from pipes that will vary in dimension, ovality, etc.?A line-up clamp is not required for the weld procedure qualification.See Para. of what the form of words that API 1104 uses, what was the intention of the committee in regard to the use of clamp for butt weld joints?We cannot comment on the intention of the committee, only what is written.110418th1104-I-04-96API 1104 only discusses the clamp as a method of weld alignment.If API 1104 permits the use of other methods of alignment, why are they not discussed and parameters given for their use, removal, etc.? If other methods are permitted, what are they and what other parameters govern their use?API 1104 does not discuss specific types of line-up clamps, only the method, i.e.
internal, external or no clamp.110418th1104-I-05-96If a tensile strength is conducted for welder qualification, what information should be recorded regarding the test? Currently, (a) I documenting the load, and (d) calculate the tensile strength of the specimen, documenting the computed tensile strength.If it meets the required specified minimum tensile strength of the material, it is accepted.But this is not a requirement of welder qualification is it? It appears to me, that all that is required for welder qualification is for the tensile specimen to break outside the weld zone or meet nick-break requirements if it does break in the weld zone, and the documentation is accepted or rejected and nothing else.
Is this correct?Paragraph 3.5.3 requires that the soundness requirements of Paragraph 184.108.40.206 be met.The tensile strength need not be calculated.It is therefore not necessary to measure the tensile specimen or to record the breaking load.Only the results of the examination per Paragraph 220.127.116.11 need to be recorded.
Paragraph 3.5.3 requires that the soundness requirements of Paragraph 18.104.22.168 be met.The tensile strength need not be calculated.
It is therefore not necessary to measure the tensile specimen or to record the breaking load.
Only the results of the examination per Paragraph 22.214.171.124 need to be recorded.110418th1104-I-0810-961) Do a procedure and welder qualification on a butt weld, according to API 1104, qualify for unlimited fillet welds as it does with other codes such as ASME XI.1) PROCEDURE QUALIFICATION One of the essential variables listed in Paragraph 2.4 is 126.96.36.199 "Joint Design." Here it states that a major change in joint design constitutes an essential variable.A change from a butt to a fillet weld is a major change in joint design, thus requiring that a new procedure be qualified.WELDER QUALIFICATION
If a welder qualifies by making a butt weld per Paragraph 3.2 "Single Qualification," that welder is subject to the essential variables listed in 3.3.2.
Here in subparagraph "g," it states that a change in joint design constitutes an essential variable.A change from a butt to a fillet weld is a major change in joint design.That welder would therefore, not be qualified to make fillet welds.
(2) Paragraph 4.3 requires that the use of line-up clamps must be in accordance with the procedure specification.If the procedure specification does not require a line-up clamp then none needs to be used when making the production weld.See Paragraph 188.8.131.52.(3) A line-up clamp is not required for the weld procedure qualification.See Paragraph 184.108.40.206.
(4) We cannot give advice on the use of clamps, only interpret what is written.(5) API 1104 does not discuss specific types of line-up clamps, only the method, i.e., internal, external, or no clamp.
This covers every possible method.110418th1104-I-0913-96On samples extracted such that their length is parallel to the pipe axis, are shear values required from testing?
Is pipe mill roll direction relevant to the testing of site-produced vertical butt welds?The API-1104 Standard does not require charpy testing.Therefore, we cannot respond to your examples of repair situations that could arise are attached.
They are labeled Examples 1, 2, 3, and 4 and are only scenarios and are not actual cases that have occurred on any project.Please review the four examples.In each example, is the repair acceptable in accordance with sections 6 and 7 of API Standard 1104?Example 1 Yes.
Example 2 Yes, assuming that "Clause 6.3.2.a" in the first sentence was intended to be 220.127.116.11.
Example 3 Yes.
Example 4 Depends upon the diameter of the pipe.
See paragraphs 6.3.4.c and is the definition of the words "injurious Defect" as they are used in paragraph 7.1
.2, Removal and Preparation For Repair, API Standard 1104, 18th - May 1994?Any defect that exceeds the standards of is the definition of the words "Sound Metal" as they are used in paragraph 7.1.2, Removal and Preparation For Repair, API Standard 1104, 18th - May 1994?Sound metal, as used in Paragraph 7.1.2, is the metal that remains after the injurious defect has been removed.110418th1104-I-1019-96Paragraph 18.104.22.168 states that nick-break samples shall be broken by:
) pulling in a tensile machineb) supporting at each end and striking the middle;c) supporting one end and striking the other end.
Is it the intent of the code to specifically rule out other methods of causing fracturing through the weldment?Paragraph 22.214.171.124 provides only three methods of breaking a nick break coupon so that it is all that can be used .
However, your point is very understandable so we are sending your letter to the Welding Procedures and Welder Qualifications subcommittee for review and possible revision to the I use a fillet weld procedure qualified using a non-bevel lap fillet to complete a 45 degree single bevel fillet weld? And, vice versa.Paragraph 126.96.36.199 "Joint Design" specifies that a major change in joint design constitutes an essential variable thus requiring requalification.
A change from a non-bevel lap fillet weld to a bevel fillet weld is a major change as it involves a bevel in addition to the fillet.
However, if the same procedure is qualified on a bevel fillet weld, the same procedure can be used to weld a lap fillet because in the qualified procedure, once the bevel is filled, the joint design remaining is essentially the same as that of a lap joint.API Standard 1104 - Welding of Pipeline and Related Facilities+A3API Standard 1104 - Welding of Pipeline and Related qualifying welding procedures for fillet welds, one must note the range of wall thickness and diameters over which the procedure is applicable.Is API 1104 referring to the wall thickness and diameter of the branch or header Section 3.2.2 and 3.3.2 for multiple qualification of welders, is it correct in understanding that a welder who has successfully completed the multiple qualification tests using filler metal from the group 1, (example E-6010& E-7010), in the downhill travel progression would also be required to successfully complete those same two tests using filler metal from the group 3, (E-7018), in the uphill travel technique to install attachment fittings on pipelines such as thread-o-lets, requiring the use of E-7018, since the weld joint for fittings is a full penetration single bevel?Yes.Paragraph 3.3.2.b requires requalification.if the direction of welding changes from vertical uphill to vertical downhill or vice versa.Also, paragraph 3.3.2.c requires requalification.
if the filler metal classification is changed from Group 1 or 2 to Group 3 or from Group 3 to Group 1 or 2.110418th1104-I-0130-97After completion of the multiple qualification tests prescribed in section 3.3.2 using E-6010 and/or E-7010 electrodes in the downhill progression, and electing not to certify on a full size branch test again, is the only other option for a welder to be qualified for welding fittings on a pipeline using E-6010 for the root and E-7018 for the fill and cover passes are those outlined in ASME Section Ix, Boiler & Pressure Vessel Code, QW 452?No.The welder could be qualified under 3.2 "Single 3 refers to API RP 1107, Third Edition April 1991.
Section 3.1 allows for a welder to perform maintenance welding after successfully completing the requirements of API Std 1104 3.1 to 3.6 or API RP 1107 3.2 to 3.5.Is a welder qualified to install sleeves using E-7018 if the welder test on a Butt and Branch using E-7018?We assume that by "---on a butt and branch---" you mean the butt weld and branch described in paragraph 3.3.1 of API 1104 and to the branch described in paragraph 3.2 of API 1107.
With this assumption the answer to your question is yes.However, to install sleeves the welder does not need to make a butt weld qualification test.The welder can make a single qualification test as described in the second paragraph of 3.2.1 of ASPI 4 & 5 refer to API 1104, 18th - May 1994 and API RP 1107, Third Edition, April 1991.Provided a procedure was qualified and a welder was tested on the 12-3/4" dia.butt weld and a 12-3/4 dia.full size branch test, per API Std.
3.3, using E-API Std.1104, Sec.3.3.2 for qualifications to weld in all positions, all wall thickness', joint designs, and fittings on all pipe diameters, including the installation of full encirclement sleeves as outlined in API RP 1107, Sec.3.1?Yes but the welder would only be qualified to weld using Group 1 or 2 electrodes downhill on the root pass and Group 3 electrodes uphill on the fill and cap passes.110418th1104-I-0130-97DOT CFR 192, Sec.192.229(C) states that welders are required to re-certify after 6 months unless proof of welding using the process for which they are certified under is produced.DOT 195, Sec.195.222 does not address a specific qualification term limit.Both DOT sections 192-Transportation of Natural Gas and DOT Section 195-The Transportation of Hazardous Liquids by Pipeline, reference API Std.1104 and ASME Sec.
IX for welder qualification testing.
ASME B31.3 (1990 Edition), Sec.434.8.3 references API Std 1104 and/or ASME Sec.
IX for welder certification.ASME B31.4 (1992 Edition), Sec.
328.2 references only ASME Sec.
IX for certification testing.ASME Boiler & Pressure Vessel Code Sec.IX, QW-322 does address six months without welding requiring API RP 1107, Sec.
3.6 stipulate a time limit for qualification of welders?The subject of a time limit for the qualification of welders has always been left to the codes and user companies.However, this subject will be presented to the API 1104 Subcommittee On Welder Qualification for review.110418th1104-I-0507-97Does a specific procedure for the branch weld in a multiple qualification test of welders need to be in place when doing the multiple qualification?Yes, a welder must use a qualified welding procedure when qualifying.See the first paragraph of Paragraph 3.3.1, "For multiple qualification, a welder shall successfully complete the two test welds described below, using qualified procedures."
We point out that the welder who successfully makes the procedure test weld is also branch connection diameter considered an essential variable when qualifying welding procedures for fillet welds on branch connections? Is it correct to assume that header diameter in a branch connection weld is NOT an essential variable?Diameter is not an essential variable in the qualification of a welding procedure as it is not listed in Paragraph 2.4.2.However, Paragraph 188.8.131.52 requires that the company establish its own diameter range for which the procedure is applicable.This range must then be recorded in the procedure specification.Having done this, pipe with diameters that were outside the selected range can be welded without requalifying the welding procedure.However, the procedure specification covering that weld must be changed to include the new diameter range for which the procedure is the standard intend that any elongated porosity indication in the root pass should be considered to be hollow bead?Yes.110419th 9.3.91104-I-0106-00If so, does the standard intend that the definition of linear indication (length more than 3 times the width as in MT and PT) be applied to porosity indications in radiographic applications?
At the moment, we have a project (.250" wall pipe) in which a proe of porosity 1/16" wide and 5/32" long is deemed rejectable because it does not meet the linear indication criteria, and is considered a single pore rather than hollow bead.
If the same indication was over 3/16" long, it is considered hollow bead and is acceptable.
In other words, the shorter indication is rejectable and the longer indication is acceptable.
This interpretation is causing some the entire procedure qualification test rejected and thus the welding procedure not qualified?The welding procedure is not qualified because all of the test specimens shown in Table 2 and figure 3 have not been successfully tested.110419th6.11104-I-0121-00.