C7 Code and Standard

Fabrication and Joining Technology Unikl Mfi UNIVERSITY KUALA LUMPUR Fabrication and Joining Technology Study Guide Chapter 7: Code and Standard Course Code: FWB 36103 Welding Inspection And Technology Prepared by: Mohd Kamarul Nizam Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and Joining Technology Unikl Mfi Contents 7.1 Introduction 7.2 Contetnts in API 1104, 19th edition 7.3 Section - General 7.4 Section – Reference Publication 7.5 Section - Definition of Terms 7.6 Section – Specification 7.7 Section - Qualification of Welding Procedures for Welds Containing Filler Metal Additives 7.8 Section - Qualification of Welders 7.9 Section - Design and Preparation of a Joint for Production Welding 7.10 Section – Inspection and Testing For Production Welds 7.11 Section - Acceptance Standards For Nondestructive Testing 7.12 Section 10 – Repair and Removal of Defects 7.13 Section 11 – Procedures for Non Destructive Testing 7.14 Section 12 – Automatic Welding 7.15 Section 13 – Automatic Welding Without Filler Metal Additions 7.2 Acceptance Standard for NDT (API 1104, 1999 Section 9), page 21 Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and Joining Technology Unikl Mfi 7.1 Introduction The materials are of little use if we cannot, by use of an effective QA system trace them from specification and purchase order to final documentation package handed over to the Client All materials arriving on site should be inspected for: •Size / dimensions •Condition •Type / specification In addition other elements may need to be considered depending on the materials form or shape There are a number of different types of standards that are generally written by consensus standards writing bodies These bodies are made up of volunteers who are experts in the field and represent all facets of the industry The standards are written and presented for public review and vote so that they truly become the best consensus documents with wide expertise These standards fall into major categories: Codes are generally associated with a process and they spell out MANDATORY use of materials or actions Specifications likewise are mandatory but they are generally associated with a product Recommended practices and guides are documents offered as an aid to the practitioner to help in manufacturing Classification and methods provide lists of established practices or products Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and Joining Technology Unikl Mfi 7.2 Contents in API 1104, 19th Edition 1999 API standards are published to facilitate the broad availability of proven, sound engineering and operating practices These standards are not intended to obviate the need for applying sound engineering judgment regarding when and where these standards should be utilized API 1104 contains 13 sections and two appendices: General References Publication Definition Of Terms Specifications Qualification Of Welding Procedures For Welds Containing Filler-Metal Additives Qualification Of Welders Design And Preparation Of A Joint For Production Welding Inspection And Testing Of Production Welds Acceptance Standards For Nondestructive Testing 10 Repair And Removal Of Defects 11 Procedures For Nondestructive Testing 12 Automatic Welding 13 Automatic Welding Without Filler-Metal Additions Appendix A Alternative Acceptance Standards for Girth Welds Appendix B In-Service Welding API 1104 Welding of Pipelines and Related Facilities This standard covers the gas and arc welding of butt, fillet, and socket welds in carbon and low-alloy steel piping used in the compression, pumping, and transmission of crude petroleum, petroleum products, fuel gases, carbon dioxide, and nitrogen, and where applicable, covers welding on distribution systems It applies to both new construction and in-service welding The welding may be done by a shielded metal-arc welding, submerged arc welding, gas tungsten-arc welding, gas metal-arc welding, flux-cored arc welding, plasma arc welding, oxyacetylene welding, or flash butt welding process or by a combination of these processes using a manual, semiautomatic, or automatic welding technique or a combination of these techniques, The welds may be produced by position or roll welding or by a combination of position and roll welding This standard also covers the procedures for radiographic, magnetic particle, liquid penetrant, and ultrasonic testing as well as the acceptance standards to be applied to production welds tested to destruction or inspected by radiographic, magnetic particle, liquid penetrant, ultrasonic, and visual testing methods Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and Joining Technology Unikl Mfi 7.3 Section - General This standard covers the gas and arc welding of butt, fillet, and socket welds in carbon and low-alloy steel piping used in the compression, pumping, and transmission of crude petroleum, petroleum products, fuel gases, carbon dioxide, and nitrogen and, where applicable, covers welding on distribution systems It applies to both new construction and in-service welding The welding may be done by a shielded metalarc welding, submerged arc welding, gas tungsten-arc welding, gas metal-arc welding, flux-cored arc welding, plasma arc welding, oxyacetylene welding, or flash butt welding process or by a combination of these processes using a manual, semiautomatic, or automatic welding technique or a combination of these techniques This standard also covers the procedures for radiographic, magnetic particle, liquid penetrant, and ultra sonic testing as well as the acceptance standards to be applied to production welds tested to destruction or inspected by radiographic, magnetic particle, liquid penetrant, ultrasonic, and visual testing methods Processes other than those described above will be considered for inclusion in this standard Persons who wish to have other processes included shall submit, as a minimum, the following information for the committee's consideration: a A description of the welding process b A proposal on the essential variables c A welding procedure specification d Weld inspection methods e Types of weld imperfections and their proposed acceptance limits f Repair procedures It is intended that all work performed in accordance with this standard shall meet or exceed the requirements of this standard Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and Joining Technology Unikl Mfi 7.4 Section - References Publication Code – A body of laws arranged systematically for easy reference and use Because a code has a legal status, it is definition mandatory, and use words such as shall, will, and must to express certain conditions and requirements, and to verify that those requirements are being met Examples of codes includes AWS D1.1, D1.5 Standard – Is establish for use as a rule or basis of comparing in measuring quality, quantity, content, relative value Examples AWS A30, Standard Welding Terms and Definition Specification – Is detailed description of the parts of a whole A statement of particulars as to actual or required size, quality, performance, terms Thus, a specification describes all technical information for a material, product, system or service and indicates hot to determine that the requirements have been met Examples AWS Filler Metal Specification A5.1 through A5.32 Recommend Practice - Is non mandatory description of generally accepted industrial methods and technique One of the most common examples is Recommended Practice No SNT-TC-1A, ASNT’s guideline to personnel qualification and certification in non-destructive examination Guide – Provides information on proven methods to accomplish certain tasks It is not mandatory but should reflect best practices Examples AWS B1.11, Guide for the Visual Examination of Welds Quality – Is measureable conformance to specification To establish product quality, purchasers invoke or mandate certain codes, standards and specifications that state the requirements to which the product must conform Quality professional must be able to read, understand and apply the provision of the governing documents cited in a contract, job specification or purchase order Code Provision – Is the specific text contained within a numbered section or subsection of a code Identify the key term or phrase that describes the issue or requirements of interest, and them locate the code provision that best addresses the issue Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and Joining Technology Unikl Mfi 7.5 Section - Definition of Terms The definition of welding terms used in this API 1101 standard are as defined in AWS A3.0, Standard Welding Terms and Definitions, with additions and modifications 7.6 Section – Specification This section calls for good judgement, sound engineering, suitable operating practices and attention to s afety A welding equipment, both gas and arc, shall be of a size and type suitable for the work and shall be maintained in a condition that ensures acceptable welds, continuity of operation and safety of person nel Arc welding equipment shall be operated within the amperage and voltage ranges given in the qua lified welding procedure Gas welding equipment shall be operated with the flame characteristics and ti p sizes given in the qualified welding procedure Equipment that does not meet these requirements shall be repaired or replaced 7.7 Section - Qualification of Welding Procedures for Welds Containing Filler Metal Additives A welding procedure is an activity undertaken according to a set of specific instructions provided in a welding procedure specification Before production welding is started, a detailed procedure specificatio n shall be established and qualified to demonstrate that welds with suitable mechanical properties (such as strength, ductility, and hardness) and soundness can be made by the procedure The quality of the we ld shall be determined by destructive test 7.8 Section - Qualification of Welders Welders must pass a qualification test to show that they can use a given welding procedure The test should employ the same manipulative techniques that welders will use in production The welder who qualifies the PQR is also qualified as long as the welder qualification requirements detailed in API 1101 Section are met Before starting the qualification tests, the welder shall be allowed reasonable time to adjust the welding equipment to be used The welder shall use the same welding technique and proceed with the same speed he will use if he passes the test and is permitted to production welding The qualification of welders shall be conducted in the presence of a company representative Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and Joining Technology Unikl Mfi 7.9 Section - Design and Preparation of a Joint for Production Welding The purpose of this section is to establish requirements for production welding and fabrication It requires constant attention to the specific of the welding procedure which is why it must be performed only by welders who have qualified for that procedure Welders who have been qualified for that procedure can perform welding on production weldments 7.10 Section – Inspection and Testing For Production Welds The company may dictate what kind of inspection will occur, when, how often, and may require that inspector demonstrate the effectiveness of the inspection procedure being used and their ability to use those procedure The company must keep detailed records of inspection and the certification of the personnel conducting them 7.11 Section - Acceptance Standards For Nondestructive Testing NDT testing does not hurt the serviceability or function of a part When performing a nondestructive examination, the inspector may find imperfections or discontinuities which may not require rejection of the part The acceptance standards presented in this section apply to discontinuities located by radiographic, magnetic particle, liquid penetrant, and ultrasonic test methods They may also be applied to visual inspection Nondestructive testing shall not be used to select welds that are subjected to destructive testing in accordance To find discontinuities for evaluation, the inspector must understand how they present themselves using the inspection method 7.12 Section 10 – Repair and Removal of Defects The company must authorize repair of defects in the root and filler beads, but need not authorize repair cover pass defects Two conditions require a qualified repair welding procedure: when the repair employs a welding process different from that of the original weld, and when a previously repaired area is repaired again Once a weld is repaired, it must be inspected in the same manner as the original weld and meet the requirement of API 1101 section Deciding whether to have just the repaired area or the entire weld inspected is up to the company Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and Joining Technology Unikl Mfi 7.13 Section 11 – Procedures for Non Destructive Testing Some of the technologies involved in nondestructive testing of welds especially radiography and ultrasound They have similar applicability to welding Just as welding and destructive testing require the writing of qualified procedures A detailed procedure for the production of images shall be established and recorded Radiographic film produced by the use of this procedure shall have the density, clarity, and contrast required by this standard Images produced by other systems shall have the requisite sensitivity to define clearly the essential hole or wire diameter of the proper penetrameter 7.14 Section 12 – Automatic Welding Welding procedures for a given welding process vary with the level of automation involved The process involved SAW, GMAW, GTAW, flux core and plasma arc These procedures shall be adhered to except where a change is specifically authorized by the company 7.15 Section 13 – Automatic Welding Without Filler Metal Additions This section discuss about Automatic welding without filler-metal additions shall be done using the flash butt welding process These procedures shall be adhered to except where a change is specifically authorized by the company 7.2 Acceptance Standard for NDT (API 1104, 1999 Section 9), page 21 9.1 General The acceptance standards presented in this section apply to imperfections located by radiographic, magnetic particle, liquid penetrant, and ultrasonic test methods They may also be applied to visual inspection 9.2 Rights of Rejection All nondestructive test methods are limited in the information that can be derived from the indications they produce The company may therefore reject any weld that appears to meet these acceptance standards if, in its opinion, the depth of an imperfection may be detrimental to the weld Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and Joining Technology Unikl Mfi 9.3 RADIOGRAPHIC TESTING All imperfections and densities referred to 9.3.1 through 9.3.13 based on negative images Radiographic test can identify the following defects: 9.3.1 Inadequate Penetration Without High-Low 9.3.2 Inadequate Penetration Due to High-Low 9.3.3 Inadequate Cross Penetration 9.3.4 Incomplete Fusion 9.3.5 Incomplete Fusion Due to Cold Lap 9.3.6 Internal Concavity 9.3.7 Burn-Through 9.3.8 Slag Inclusions 9.3.9 Porosity 9.3.10 Cracks 9.3.11 Undercutting 9.3.12 Accumulation of Imperfections 9.3.13 Pipe or Fitting Imperfections 9.4 MAGNETIC PARTICLE TESTING 9.4.1 Classification of Indications 9.4.1.1 Indications produced by magnetic particle testing are not necessarily imperfections Magnetic and metallurgical variations may produce indications that are similar to those produced by imperfections but that are not relevant to acceptability 9.5 LIQUID PENETRANT TESTING 9.5.1 Classification of Indications 9.5.1.1 Indications produced by liquid penetrant testing are not necessarily imperfections Machining marks, scratches, and surface conditions may produce indications that are similar to those produced by imperfections but that are not relevant to acceptability 9.6 ULTRASONIC TESTING 9.6.1 Classification of Indications Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : 10 Fabrication and Joining Technology Unikl Mfi Section - Acceptance Standard for NDT In accordance to API 1104, the acceptance standards presented in this section apply to imperfections located by radiographic, magnetic particle, liquid penetrant, and ultrasonic test methods They may also be applied to visual inspection a Listed the NDT testing method of acceptable standard for imperfections Described how those methods encountering an imperfection in weld material b Define the terms “Imperfections” as stated in Section 9.1 c How does the inspector determine the disposition of particular imperfections? d Describe how the Acceptance Standards in Section applies to imperfections detected by visual inspection In accordance to API 1104, an Acceptance Standard for Radiographic Testing (RT) are based on negative images a Describe the radiographic test method and how it is used to inspect weld imperfections b An Inadequate Penetration without High-low (IP) and, an Acceptance Standard for Inadequate Penetration Due to High-low (IPD) are joint root conditions where the weld metal does not extend entirely through the thickness of a groove weld joint i What is the causes of Inadequate Penetration without High-low (IP)? ii How does radiographic image appear for this imperfections? iii What is the imperfections condition of IP and IPD of groove weld joint? c An Acceptance Standard for Inadequate Cross Penetration (ICP) shall be considered as a defect when the length of an individual indication of ICP exceeds 50mm i How does Inadequate cross penetration occurs between the weld joint? ii What is the causes of Inadequate Penetration without High-low (IP)? iii How does radiographic image appear for this imperfections? d Incomplete Fusion (IF) is a discontinuity and surface imperfection between the weld metal and the base metal that is open to the surface i How Incomplete Fusion does occurs between the weld metal and weld beads? ii What is the causes of Incomplete Fusion (IF)? Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : 24 Fabrication and Joining Technology Unikl Mfi iii How does radiographic image appear for this imperfections? iv How can a notch cause incomplete fusion? e In accordance to API 1104, Incomplete fusion is defined as a surface imperfection between the weld metal and the base material that is open to the surface i When they should be considered as a defect? ii Sketch the example of Incomplete Fusion at Root of Bead f Internal Concavity (IC) is acceptable, as long as the density of the radiograph negative image showing internal concavity does not exceed of the thinnest adjacent base metal i How Incomplete Fusion does occurs between the weld root and weld surface? ii What is the causes of Internal Concavity (IC)? iii How does radiographic image appear for this imperfections? g Burn-Through (BT) is a characterized by visible root reinforcement in a joint welded from one side or a hole in the weld bead where excessive penetration has caused the weld puddle to be blown into the pipe i How Burn-Through (BT) collapse in root area of the weldment? ii What is the causes of Burn-Through (BT)? iii How does radiographic image appear for this imperfections? h API 1104 breaks Slag Inclusions (SI) into two main groups Acceptance criteria for slag inclusion depend on the outside diameter of the pipe i What are Slag Inclusions (SI)? ii Names two types of Slag Inclusions (SI) iii What is the causes of Slag Inclusions (SI)? iv How does radiographic image appear for this imperfections? v How can slag inclusion be prevented in multiple pass welds? i Porosity is defined as gas trapped by solidifying weld metal before the gas has a chance to rise to the surface of the molten puddle and escape It takes many shapes on a radiograph Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : 25 ... ultrasonic, and visual testing methods Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and Joining Technology Unikl Mfi 7.3 Section - General This standard. .. Additions 7.2 Acceptance Standard for NDT (API 1104, 1999 Section 9), page 21 Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and Joining Technology... acceptance standards if, in its opinion, the depth of an imperfection may be detrimental to the weld Welding Inspection and Technology Code: FWB 36103 Chapter 7: Code and Standard Page : Fabrication and