AWS API-M-2017 Study Guide for API Standard 1104 Welding of Pipelines and Related Facilities (21st Edition).pdf

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1、Seminar CWI Study Guide: Twenty-First Edition STUDY GUIDE for API Standard 1104: Welding of Pipelines and Related Facilities 21 stEditionDISCLAIMER The American Welding Society, Inc. assumes no responsibility for the information contained in this publication. An independent, substantiating investiga

2、tion should be made prior to reliance on or use of such information. International Standard Book Number: American Welding Society 8669 NW 36th Street, #130, Miami, Florida 33166-6672 2017 by American Welding Society All rights reserved Printed in the United States of America Photocopy Rights. No por

3、tion of this document may be reproduced, stored in a retrieval system, or transmitted in any form, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright owner. Authorization to photocopy items for internal, personal, or educational classro

4、om use only or the internal, personal, or educational classroom use only of specific clients is granted by the Ameri- can Welding Society provided that the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400; .Study Guide for API Standard

5、1104 Welding of Pipelines and Related Facilities TWENTY-FIRST EDITION Published by American Welding Society Education Department Abstract This study guide contains information on the use of API Standard 1104, Twenty-First Edition, which will assist the student in learning how to use the standard as

6、well as in preparing for code-related examinations. Material is provided for each of the 13 sections of the standard and Annexes A and B. Exercise questions and answers are provided for each section and annex, and additional practice tests are included at the end. American Welding Society EDUCATIONv

7、 Study Guide for API Standard 1104, Twenty-First Edition Foreword AWS Education Services has published this Study Guide for API 1104 to assist quality professionalsinspectors and supervisorsand quality-conscious engineers and managers in reading, understanding, and learning to ap- ply the American P

8、etroleum Institutes (API) Standard 1104, Welding of Pipelines and Related Facilities, Twen- ty-First Edition. This Study Guide was written specifically for the 21st Edition with Errata 4 and Addendum 2. For other errata or addenda, page numbers may be different. The API Standard 1104 applies to the

9、welding of piping used in the compression, pumping, and transmission of petroleum products, fuel gases, carbon dioxide, and nitrogen. The standards purpose is to present methods for the production and inspection of high-quality welds through the use of qualified personnel using approved pro- cedures

10、, materials, and equipment. It applies to new construction and in-service welding and is voluntary. This API 1104 Study Guide consists of an introduction, 15 sections, each covering the corresponding section or annex of the standard along with exercise questions for each section, and several groups

11、of practice questions with an answer key. Answering the practice questions serves as a valuable review of the section contents. These questions also illus- trate the types of questions youre likely to encounter on the AWS CWI exam. In addition to explanations of each section of API 1104, in some cas

12、es, this Study Guide also provides a com- mentary or examples to further explain the provision. As you read this book, open the standard to the corresponding page. Remembering excerpts from the standard is neither necessary nor desirable. Y ou need not memorize the stan- dard; just learn how to use

13、it. The American Welding Society appreciates feedback from participants in its education programs. Please send comments or questions to: American Welding Society Education Department, 2nd Floor 8669 NW 36th Street #130 Miami, Florida 33166-6672 or contact the AWS Education Services Department by ema

14、il at aws.seminarsaws.org. Additional information on AWS products and services may be found on our website at www.aws.org. vivii Study Guide Table of Contents Foreword to the Study Guide for API Standard 1104 v Introduction: How to use API 1104 . I-1 Definition of Documents . I-2 Less Than or Greate

15、r Than . I-2 Other Definitions I-3 The Meaning of Quality . I-3 Finding Provisions I-4 Reference Exercise I-5 API 1104 Contents I-5 Section 1 Scope .1-1 Section 2 Normative References .2-1 Section 3 Terms, Definitions, Acronyms, and Abbreviations .3-1 Section 4 Specifications .4-14.1 Equipment .4-2

16、4.2 Materials 4-2 Section 5 Qualification of Welding Procedures with Filler Metal Additions .5-15.1 Procedure Qualification .5-2 5.2 Record 5-2 5.3 Welding Procedure Specification 5-2 5.4 Essential Variables 5-2 5.5 Welding of Test JointsButt Welds .5-7 5.6 Testing of Welded JointsButt Welds .5-7 5.

17、7 Welding of Test JointsFillet Welds 5-9 5.8 Testing of Welded JointsFillet Welds 5-9 Section 6 Qualification of Welders .6-16.1 General .6-2 6.2 Single Qualification 6-2 6.3 Multiple Qualification 6-3 6.4 Visual Examination 6-4 6.5 Destructive Testing .6-4 6.6 Nondestructive Testing (NDT)Butt Welds

18、 Only 6-5 6.7 Retesting 6-5 6.8 Records .6-5viii Section 7 Design and Preparation of a Joint for Production Welding 7-17.1 General .7-2 7.2 Alignment 7-2 7.3 Use of Lineup Clamp for Butt Welds .7-2 7.4 Bevel .7-2 7.5 Weather Conditions .7-2 7.6 Clearance .7-2 7.7 Cleaning Between Beads 7-3 7.8 Posit

19、ion Welding .7-3 7.9 Roll Welding 7-3 7.10 Identification of Welds .7-3 7.11 Preheat and PWHT 7-3 Section 8 Inspection and Testing of Production Welds.8-1 8.1 Rights of Inspection8-2 8.2 Methods of Inspection .8-2 8.3 Qualification of Inspection Personnel .8-2 8.4 Certification of NDT Personnel 8-2

20、Section 9 Acceptance Standards for NDT .9-19.1 General .9-2 9.2 Rights of Rejection .9-2 9.3 Radiographic Testing .9-2 9.4 Magnetic Particle Testing 9-4 9.5 Liquid Penetrant Testing 9-4 9.6 Ultrasonic Testing .9-4 9.7 Visual Acceptance Standards for Undercutting 9-5 Section 10 Repair and Removal of

21、Weld Defects .10-110.1 General .10-2 10.2 Authorization for Repair .10-2 10.3 Repair Procedure 10-2 10.4 Repair Welder Qualification .10-3 10.5 Supervision 10-4 10.6 Acceptance Criteria 10-4 Section 11 Procedures for Nondestructive Testing (NDT) .11-111.1 Radiographic Test Methods 11-2 11.2 Magnetic

22、 Particle Test Method .11-3 11.3 Liquid Penetrant Test Method 11-4 11.4 Ultrasonic Test Methods .11-4ix Section 12 Mechanized Welding with Filler Metal Additions 12-112.1 Acceptable Processes 12-2 12.2 Procedure Qualification .12-2 12.3 Record 12-2 12.4 Welding Procedure Specification12-2 12.5 Essen

23、tial Variables 12-3 12.6 Qualification of Welding Equipment and Operators .12-3 12.7 Records of Qualified Operators 12-4 12.8 Inspection and Testing of Production Welds 12-4 12.9 Acceptance Standards for NDT 12-4 12.10 Repair and Removal of Defects 12-4 12.11 Radiographic Testing .12-4 12.12 Ultraso

24、nic Testing 12-4 Section 13 Automatic Welding Without Filler Metal Additions 13-113.1 Acceptable Processes 13-2 13.2 Procedure Qualification .13-2 13.3 Record 13-2 13.4 Welding Procedure Specification13-2 13.5 Essential Variables 13-3 13.6 Qualification of Equipment and Operators 13-3 13.7 Records o

25、f Qualified Operators 13-3 13.8 Quality Assurance of Production Welds .13-3 13.9 Acceptance Standards for NDT 13-4 13.10 Repair and Removal of Defects 13-4 13.11 Radiographic Procedure 13-4 Annex A Alternative Acceptance Standards for Girth Welds . A-1A.1 General . A-2 A.2 Stress Analysis . A-2 A.3

26、Welding Procedure . A-2 A.4 Qualification of Welders A-3 A.5 Inspection and Acceptable Limits A-3 A.6 Record A-4 A.7 Repairs A-4 A.8 Nomenclature A-4 Annex B In-service Welding . B-1B.1 General . B-2 B.2 Qualification of In-service Welding Procedures . B-2 B.3 In-service Welder Qualification B-4 B.4

27、 Suggested In-service Welding Practices . B-5 B.5 Inspection and Testing of In-service Welds . B-5 B.6 Standards of Acceptability: NDT (Including Visual) . B-6 B.7 Repair and Removal of Defects . B-6x Practice Tests . T-1 Mini-Test 1 T-2 Mini-Test 2 T-6 Mini-Test 3 T-10 Mini-Test 4 T-14 Full-Length

28、Practice Test T-18 Answer Grids T-29 Answers to Chapter/Section Questions T-35 Answers to Mini-Tests . T-41 Answers to Full-Length Practice Test . T-46xixiiIntroduction How to Use API 1104 Study Guide for API 1104 (21 stEdition) Introduction I-2 INTRODUCTION: HOW TO USE API 1104 Definition of Docume

29、nts All codes, standards, and specifications are conceptually similar, but each has a specific application and purpose. API 1104 is a good example of the concept, so learning to use this standard will help you learn to use others as well. A CODE is a body of laws arranged systematically for easy ref

30、erence and use. Because a code has legal status, it is, by definition, mandatory, and it uses words such as shall, will, and must to express requirements and to verify that those requirements are being met. Examples of codes include the AWS D1.1 Structural Welding Code Steel, the AASHTO/AWS D1.5 Bri

31、dge Welding Code, and the ASME B31.1 Power Piping Code. A STANDARD is established for use as a rule or basis of comparison in measuring quality, quantity, content, relative value, etc. API Standard 1104, Welding of Pipelines and Related Facilities, is an example. So are the AWS A3.0, Standard Weldin

32、g Terms and Definitions and AWS QC1 Standard for AWS Certification of Welding Inspectors. A SPECIFICATION is a detailed description of the parts of a whole; a statement or enumeration of particulars, as to actual or required size, quality, performance, terms, etc. Thus, a specification describes all

33、 pertinent technical information for a material, product, system, or service, and indicates how to determine that the requirements have been met. Examples include the AWS Filler Metal Specifications A5.1 through A5.36. A RECOMMENDED PRACTICE is a description of generally accepted industrial methods

34、and techniques. One of the most common examples is ASNTs Recommended Practice No. SNT-TC-1A, ASNTs guideline to personnel qualification and certification in nondestructive examination. Less Than or Greater Than? In many codes and standards, including API 1104, the rules vary depending on the size of

35、 a part, the intended service, and the manufacturing requirements. Often these rules are differentiated symbolically. Most people know that = means “equal to” but the symbols for “less than” and “greater than” can cause confusion. Heres an easy way to keep them straight: “” is the symbol for “greate

36、r than” and it points to the right. Example: 9 5 indicates that nine is greater than five. “” is the symbol for “less than or equal to.” “” is the symbol for “greater than or equal to.”Introduction Seminar CWI Introduction I-3 Other Definitions Section 3 Terms, Definitions, Acronyms, and Abbreviatio

37、ns presents a list of welding terms and their defi- nitions that adds on to and, in some cases, supersedes those listed in AWS 3.0 Standard Welding Terms and Definitions. Many of the terms defined in Section 3 are specific to API 1104. The Meaning of Quality Quality is generally understood to mean m

38、easurable conformance to specifications. To establish product quality, purchasers invoke or mandate certain codes, standards, and/or specifications that state the requirements to which the product must conform. Thus, quality professionals must be able to read, understand, and apply the provisions of

39、 the governing documents cited in a contract, job specification or purchase order. For test-taking purposes, to find requirements in a code or standard more quickly, you should attach an index tab to the first page of each section and to significant tables and figures that you will use frequently. I

40、n addition, it may be helpful to briefly describe the contents of the section on that tab. API 1104 has 13 sections and two annexes that are included in the scope of the AWS CWI exam. See Study Guide Figure A below. 1 2 3 4 5 6 1 2 3 4 5 6 Scope Normative References Qualication of Welders Qualicatio

41、n of Welding Procedures Specications Terms & Denitions Figure A: Section ID Tabs Study Guide for API 1104 (21 stEdition) Introduction I-4 Many codes and standards make extensive use of notes, which may be footnotes in tables or figures or general notes incorporated into the text, to explain somethin

42、g or to cover special cases or particular circumstances. Every time you read the provisions of a code or standard, be thorough and pay close attention to any notes. Carefully review the tables and figures, being attentive to superscripts and their corresponding footnotes, which can modify the applic

43、ation of the information in the table or figure. In many cases, the answer to a given code or standard inquiry will either be modified by the footnote or contained completely within the footnote. If the question does not invoke the conditions of the footnote, the footnote does not apply. You will se

44、e three types of footnotes. They are: (a) Global or general footnotesThese appear in the title of a figure, list, or table and they influence all provisions from that figure, list, or table. Sometimes general footnotes are located in the footer of a table or figure and are labeled as “NOTE(S).” (b)

45、Regional footnotesThese appear in the column header or at the end of a row title in a table or at the top of a subsection and influence only that column or row of the table or that specific subsection of text. (c) Local or specific footnotesThese apply only to the specific item being footnoted. For

46、example, turn to page 15 in API 1104. Note the small superscript letters that follow certain filler metal Group Numbers in Table 1. Each superscript refers to a local footnote, which changes some aspect of the tables provisions for that specific filler metal in the table. As you work with a code or

47、standard, be aware of applicable Errata Sheets. Errata are published to correct printing errors. If any exist, mark the changes in the code or standard. Subsequent printings of that code or standard will usually incorporate those corrections. Typically, codes and standards are revised according to a

48、 regular schedule. API generally updates its standards every five years, though up to two additional years may be added to a review cycle. See the Foreword of API 1104 for information on ascertaining the status of the Twenty-First Edition. Finding Provisions Codes and standards typically use the mul

49、tiple decimal numbering system. See Study Guide Figure B below. The first “1” in “1.1.1.2.2” is the chapter or section in which the provision is found. The second “1” is the subsection within Section 1. However, for simplicity, in this Study Guide, any indented reference further than the second (subsection) number will be referred to simply as a “paragraph.” For instance, Section 5 is where rules for qualifying welding procedures using manual or semiautomatic welding processes are found. Subsection 5.4 lists the essential variables but “paragraph”