API STANDARD 1104 (ACCEPTANCE CRITERIA) USMAN RASHID

Table 1 FILL
Excessive cap Height Maximum 1.6 mm
Inadequate weld width Approx. 3mm wider than Groove
GROUP
Incomplete fill Grove(Underfill) At no point shall be crown fall below the outside
surface of the pipe 1
Slag Inclusions (Dia > 2.375'' ) For ESI L=50 mm ,W=1.6 mm max
ESI (Elongated slag inclusion) Aggregate L= 50 mm in 300 mm weld Length 2
ISI (Isolated Slag Inclusion) For ISI max L = 13mm in 300mm welds length & 3
W=3 mm maximum.
Max aggregate length of ESI or ISI 8% of weld Length 4a
Undercut If 0.4 mm>Depth>0.8 mm,Acceptable (50 mm in 300 mm)
If depth <0.4 mm , all Acceptable
Depth > 0.8 mm, Reject
Porosity IP max of 3 mm. Size of IP exceeds 25% of the thinner
IP (Individual porosity) nominal wall thickness joined.
CP (Cluster porosity) CP Max Dia/L = 13 mm. An IP with in a CP is 2 mm Max.
HB (Hollow Bead Porosity) Max. L =13 mm,Aggregate L=50mm in 300mm weld length 5b
Individual indication of HB,Max. L=6mm and separated by
less than 50 mm,Aggregate Length of all indications of HB
Exceeds 8% of the weld.
Cracks Not permitted (unless crater cracks, L= 4 mm Max) 6
Incomplete Fusion Max. L= 25 mm, Aggregate Length Max. 8% of weld length 7
in any weld less than 300 mm weld length.
Arc strikes Maximum W= 7.9 mm, L= 7.9 mm, Depth= 1.5 mm 8
Mechanical Damage Refer to higher authority & refer comments 9
Longitudinal seams Refer o higher authority & refer comments
ROOT----ROOT----ROOT
Misalignment Max. of 3 mm for pipes of same Thickness
Excessive Penetration Refer to Higher Authority & refer comments
Lack of Root Penetration Without Hi-Lo, Max. L= 25 mm , Aggregate L= 25 mm in
300 mm weld length, Aggregate L= 8% of weld length in
any weld less than 300 mm weld length.
With Hi-Lo, Max. L=50 mm,Aggregate Length of 75 mm in
300 mm weld length.
Root Concavity Any length is Acceptable providing the sensitivity of the
radiographic images does not exceed that of the thinnest
adjacent parent metal.
Burn Through Max. Dimension of BT is 6 mm,Reject if exceeds thinner
(Pipe Dia > 2.375 '' ) wall Thk. The sum of the Max. dimensions of the separate
burn through 13 mm in any 300 mm weld Length
able 1 FILLER METAL GROUPS
AWS
Electrode
AWS classification
Fluxc
Specification Electrode Classification
A 5.1 E 6010, E 6011 Note:
A 5.5 E 7010, E 7011 Other electrodes,filler metals
A 5.5 E 8010, E 8011, E 9010 and fluxes may be used but
A 5.1 / A 5.5 E 7015, E 7016, E 7018 require separate procedure
A 5.5 E 8015, E 8016, E 8018, E 9018 qualification.
A 5.17 El 8 P6XZ a
, any combination of flux &
El 8k F6X0 electrode combination in
El 12 F6X2 group 4 may be used to qualify
EM 5k F7XZ a procedure.
EM 12K F7X0 b, Shielding gas can be used
EM 13K F7X2 with the electrodes in Group 5.
EM 15K c
, In the flux designation,th X
A 5.18 ER 70S-2 Can be either an A or P for as
A 5.18 ER 70S-6 welded or PWH treatd.
A 5.28 ER 80S-D2 d
, For root pass welding only.
A 5.28 ER90s-G
A 5.2 RG 60, RG 65
A 5.20 E61T-GSd
E71T-GSd
A 5.29 E 71T8-K6
A 5.29 E 91T8-G
 Shortcuts of API 1104 Usman Rashid

All filler metals shall conform to one of following specifications:

a ) AWS A 5.1
b ) AWS A 5.2
c ) AWS A 5.5
d ) AWS A 5.17
e ) AWS A 5.18
f ) AWS A 5.19
g ) AWS A 5.20
h ) AWS A 5.28
i ) AWS A 5.29

All Materials shall be grouped as follows for procedure developing :

a) Min.Yield Strength ≤ 42,000 Psi (290 Mpa)
b) 42,000 Psi (290 Mpa) < Min.Yield Strength ≤ 65,000 Psi (448 Mpa)
c) Min.Yield Strength > 65,000 Psi (448 Mpa)

Essential Variables for Welder's / Operators:

a ) A change from on welding process to another Process or Combination of processes.
b) A change in Welding Progression Uphill direction to Downhill or Vice versa.
c) A change of filler metal classification from Group 1 or 2 to Group 3 or Vice versa .
d) A change from one outside diameter Group to another, These groups are as follows :
OD ≤ 2.4"
2.4" < OD ≤ 12.75"
OD > 12.75"
e) A change from one wall thickness group to another, These groups are as follows:
Thk ≤ 4.8 mm
4.8 mm < Thk ≤ 19.1 mm
Thk > 19.1 mm

f) A change in Position i.e. Rolled to Fixed

g) A change in joint design from V groove to U groove,Backing to without backing

Essential Variables for Welding procedure specification (WPS) :

a) Welding Process, A change in welding process established in the procedure specification
constitutes essential variable.
b) Base Material, A change in groups for base materials.
c) Joint design, A major change in joint design (i.e. V to U groove).
d) Position, A change in Roll position to fixed position of pipe constitutes essential variable.
e) Wall Thickness, A change in one wall thickness group to another group.
f) Filler metal, A change in filler metal groups & A change in AWS classification of the filler metal
for welding of pipe materials having Min. Yield Strength ≥ 65,000 Psi.
g) Electrical Characteristics, A change from DCEP to DCEN or vice versa & A change from
 DC to AC or vice versa.
h) Time between passes, An increase in time between completion of the root bead and start
of the next bead constitutes an essential variable.
i) Shielding Gas & Flow rate, A change from shielding gas to an other or from a one mixture of
gases to another. A major increase or decrease in the range of flow rates for the shielding
also constitutes an essential variable.
j) Shielding Flux, Changes in Shielding flux constitutes an essential variable.
k) Travel Speed, A change in Travel speed range constitutes an essential variable.
l) Preheat, A decrease in specified Min.Preheat Temperature constitutes an essential variable.
m) PWHT, The addition of PWHT or change in specified PWHT temperature.