Mohamad Asrul, Mustapha

Unimas Institutional Repository

www.unimas.myGFC-206 – FUEL GAS PIPE WELDING Iwww.unimas.myOVERVIEW• INTRODUCTION – API 1104• WELDING EQUIPMENT AND MATERIAL• WELDING PROCEDURE• API 1104 ACCEPTANCE CRITERIA• WELDING TESTINGwww.unimas.myWHAT IS API 1104?• American Petroleum Institute• This standard covers the gas and arc welding of butt, fillet, andsocket welds in carbon and low-alloy steel piping used in thecompression, pumping, and transmission of crude petroleum,petroleum products, fuel gases, carbon dioxide, nitrogen, andwhere applicable, covers welding on distribution systems. It appliesto both new construction and in-service welding.www.unimas.myWELDING EQUIPMENT AND MATERIAL• Welding equipment, both gas and arc, shall be of a size and typesuitable for the work and shall be maintained in a condition thatensures acceptable welds, continuity of operation, and safety ofpersonnel. Arc welding equipment shall be operated within theamperage and voltage ranges given in the qualified weldingprocedure specification. Gas welding equipment shall be operatedwith the flame characteristics and tip sizes given in the qualifiedwelding procedure specification. Equipment that does not meetthese requirements shall be repaired or replaced.What determines the tip size for gas welding equipment?www.unimas.myWELDING EQUIPMENT AND MATERIALwww.unimas.myWELDING EQUIPMENT AND MATERIALwww.unimas.myWELDING EQUIPMENT AND MATERIAL• Filler metals and fluxes shall be stored and handled to avoiddamage to them and to the containers in which they are shipped.Filler metals and fluxes in opened containers shall be protected fromdeterioration, and filler metals that are coated shall be protectedfrom excessive changes in moisture. Filler metals and fluxes thatshow signs of damage or deterioration shall not be used.www.unimas.myWELDING EQUIPMENT AND MATERIAL• Shielding gases shall be kept in the containers in which they are supplied, andthe containers shall be stored away from extremes of temperature. Gases shallnot be field intermixed in their containers. Gases of questionable purity andthose in containers that show signs of damage shall not be used.www.unimas.myWELDING PROCEDURE• Developing a welding procedure specification (WPS).• Establishing a procedure qualification record (PQR) by identifying theessential variables of that WPS.• Implementing welder testing to verify that the welders are capable ofperforming the procedure.• API 1104 Section 5.1 also requires destructive testing to determine thequality of the welds, unless the company specifically authorizes a differentmethod.• API 1104 Section 5.2 requires the company to record the complete details ofeach qualified procedure, and to keep that record as long as the procedureis in use. The section provides sample forms for this purpose. Figure 1 is asample WPS. Figure 2 is a sample that can be used as a PQR, a WQTR, orboth.www.unimas.myWELDING PROCEDUREwww.unimas.myWELDING PROCEDUREwww.unimas.myWELDING PROCEDUREwww.unimas.myWELDING PROCEDURE• Filler metals and fluxes shall be stored and handled to avoiddamage to them and to the containers in which they are shipped.Filler metals and fluxes in opened containers shall be protected fromdeterioration, and filler metals that are coated shall be protectedfrom excessive changes in moisture. Filler metals and fluxes thatshow signs of damage or deterioration shall not be used.www.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsDefect Type7.2Not Exceeds 3.0 mmMisalignmentwww.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsDefect Type9.3.1.a9.3.1.bIndividual IP not exceeds 25 mmAggregate IP not exceeds 25 mm in 30 cm weld lengthIncomplete Penetration Without HI-LO (IP)www.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsImperfection Type9.3.2.a9.3.2.bIndividual IP not exceeds 50 mmAggregate IP not exceeds 75 mm in 30 cm weld lengthIncomplete Penetration With HI-LO (IP)www.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsImperfection Type9.3.4.a9.3.4.bIndividual IF not exceeds 25 mmAggregate IF not exceeds 25 mm in 30 cm weld lengthIncomplete Fusion (IF)www.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsImperfectionType9.3.5.a9.3.5.bIndividual CL not exceeds 50 mmAggregate CL not exceeds 50 mm in 30 cm weld lengthCold Lap (CL)www.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsImperfection Type9.3.6The density of the concave area shall not exceed the density of the adjacent of the base metal .And if the density is more the burn through acceptance limits should be applied.Internal Concavity (IC)www.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsImperfection Type9.3.7.a9.3.7.b9.3.7.cIndividual BT not exceeds 6 mmAggregate BT not exceeds 13 mm in 30 cm in weld lengthBurn Through (BT)www.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsImperfection Type9.3.8.a9.3.8.b9.3.8.c9.3.8.dIndividual elongated SI shall not exceed 50 mm in length and 1.6 mm in width.Aggregate  elongated  SI shall not exceed 50 mm in length in 30 cm weld length.Slag Inclusion (SI)www.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsImperfection Type9.3.9Individual pore size shall not exceed 3 mm Cluster porosity longest diameter shall not exceed 13 mm.Aggregate cluster porosity length shall not exceed 13 mm in 30 cm weld length.Porosity (P)www.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsImperfection Type9.3.9.4Individual HB shall not exceeds 13 mm length.Aggregate HB shall not exceeds 50 mm in 30 cm in weld length.Hollow Bead (HB)www.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsImperfection Type9.3.10Only star cracks and crater cracks are permitted with length shall not exceed 4 mm.Crackswww.unimas.myAPI 1104 ACCEPTANCE CRITERIARemarksAcceptance LimitsImperfection Type9.3.11Undercut length shall not exceed 50 mm in 30 cm weld length.Undercut (UC)www.unimas.myHOW ABOUT WELDING TESTING?• This standard also covers the procedures for radiographic,magnetic particle, liquid penetrant, and ultrasonic testing, aswell as the acceptance standards to be applied to production weldstested to destruction or inspected by radiographic, magnetic particle,liquid penetrant, ultrasonic, and visual testing methods.www.unimas.myNON-DESTRUCTIVE TEST - RADIOGRAPHIC  www.unimas.myNON-DESTRUCTIVE TEST – MAGNETIC PARTICLE  www.unimas.myNON-DESTRUCTIVE TEST – LIQUID PENETRANT  www.unimas.myNON-DESTRUCTIVE TEST – ULTRASONICwww.unimas.myTHANK YOU

Gas Fitter II

http://ir.unimas.my/id/eprint/37291/2/GFC-206.pdf

Gas Fitter II

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