API 1104, 22nd EDITION UNDERSTANDING WELDING AND
REPAIR PROCEDURES
Author: Sadhasivam Velu
INTRODUCTION:
The API 1104, 22nd edition is a comprehensive resource that provides valuable insights into
understanding welding and repair procedures. This edition specifically focuses on repair
procedures, offering detailed guidelines and recommendations for effective repairs in various
industries.
With an emphasis on safety and quality, this edition covers the latest techniques and industry
best practices for welding repair. It outlines step-by-step procedures for identifying,
evaluating, and executing repairs on different types of structures and equipment.
Key aspects of the API 1104, 22nd edition, include:
- Step-by-step procedures for identifying, evaluating, and executing repairs on different types
of structures and equipment
- Essential aspects of welding repair, including pre-welding preparations, material selection,
welding techniques, and post-welding inspections
- Practical solutions to address challenges faced during repairs
Whether you are a welding professional, inspector, engineer, or involved in the repair and
maintenance industry, this edition of API 1104 will equip you with the knowledge and
understanding necessary to carry out robust and reliable repair procedures.
API 1104 is a widely recognized welding standard used in the oil and gas industry. It
provides guidelines and specifications for the welding of pipelines and other related
structures. The American Petroleum Institute (API) periodically updates this standard to
ensure the highest level of safety and quality. In this article, we will discuss the key
differences between the API 1104 21st edition and the 22nd edition, focusing on welding and
repair welding procedures.
Features API 1104 21st Edition API 1104 22nd Edition
Publication
2013 on January 14, 2021
Year
The API 1104 21st edition was first
published in 1993 and has served as a The API 1104 22nd edition,
valuable resource for welding released in 2019, builds upon the
professionals for many years. It foundation set by its predecessor
covers welding procedures, while introducing several
Edition qualifications, inspection, and repair updates and enhancements.
of pipelines. This edition emphasizes These changes focus on
the importance of proper weld improving the safety and quality
design, joint preparation, and welder of welding procedures and repair
qualifications to ensure a strong and welding techniques.
durable weld.
Covers welding of pipelines and Scope expanded to include
Scope
related facilities fusion welding of titanium
Impact Testing Charpy V-notch testing required for Charpy V-notch testing required
Requirements certain situations for all welds
Heat Input No specific heat input control Includes recommended heat
Control requirements input control guidelines
Base Metal Base metals grouped by tensile Base metals grouped by material
Groupings strength,type and thickness type and thickness
Features API 1104 21st Edition API 1104 22nd Edition
Essential
55 essential variables listed 68 essential variables listed
Variables
Qualified for a specific welding
Welder Qualified for a specific welding
process, position, and thickness
Qualification process and position
range
Welding Qualified for a specific welding
Qualified for a specific welding
Procedure process, position, and thickness
process and position
Qualification range
Welding
No specific requirements for welding Requires welding inspector
Inspector
inspector certification
Qualification
Nondestructive
Radiographic testing acceptance Radiographic testing acceptance
Examination
criteria modified criteria modified
(NDE)
The 22nd edition addresses this
The 21st edition provided guidelines
issue by introducing limitations
for repair welding on pipelines, but it
Repair Welding on the number and size of
lacked specific limitations.
repairs allowed on a pipeline.
The 22nd edition introduces new
Branch The 21st edition provided guidelines requirements for branch
Connection but the requirements were not connections, including increased
provided in details. radiography and reinforcement
requirements.
API 1104 22nd Edition - Updates and Enhancements:
Key Differences Between the 21st and 22nd Editions:
Welding Procedure Qualification Record (WPQR):
In the 21st edition, the WPQR required thickness ranges and material types to be specified
separately. However, the 22nd edition combines these requirements into a single section,
simplifying the process for welders and ensuring consistency.
Limitations on Repair Welding:
Mechanical and Non-Destructive Testing:
The 22nd edition highlights the importance of mechanical and non-destructive testing in weld
quality assessment. It provides detailed guidelines on conducting these tests to ensure
compliance with industry standards.
Revision of Welding Variables:
The 22nd edition introduces revised welding variables for shielded metal arc welding
(SMAW) and gas metal arc welding (GMAW) processes. These variables refine the criteria
for prequalified welding procedures, resulting in improved weld quality.
Restrictions on Welding Filler Metals:
The 22nd edition imposes stricter restrictions on welding filler metals, emphasizing the use of
materials that meet specific requirements for strength and corrosion resistance. This ensures
the longevity and reliability of welded pipelines.
Guidelines for Repair Welding Procedure Qualification:
Unlike the 21st edition, the 22nd edition provides detailed guidelines for the qualification of
repair welding procedures. It outlines the necessary steps and requirements for certifying
repair welding procedures, ensuring the integrity of repaired pipelines.
Repair Welding:
API 1104, 22nd Edition provides requirements for repair welding on pipelines. Repair
welding procedures need to be qualified separately from the original welding procedures.
The repair welding procedures need to address the specific repair requirements, including the
type of defect or damage being repaired. The standard provides guidelines for assessing the
acceptability of repair welds, including specific criteria for dimensions, discontinuities, and
mechanical properties.
Nondestructive Examination (NDE):
The standard includes requirements for nondestructive examination techniques, such as
radiographic testing, ultrasonic testing, and visual inspection.
Acceptance criteria for NDE are provided to assess the quality and integrity of the welds.
The standard provides guidelines for the selection and application of NDE techniques.
ACCEPTANCE CRITERIA AS PER API 1104 (22nd Edition)
6.4 VISUAL EXAMINATION
For a qualification test weld to meet the requirements for visual examination, the weld shall
be free from cracks and inadequate penetration and shall present a neat workmanlike
appearance that is acceptable to the company.
For a butt weld, no burn-through (BT) shall be allowed. Branch connections shall not contain
any BT having a length more than ¼ in. (6 mm). The sum of the maximum dimensions of
separate unrepaired BTs in any continuous 12-in. (300-mm) length of branch connection
weld shall not exceed ½ in. (13 mm).
External undercut (and internal undercut, when practical) shall be evaluated to the
requirements of 9.7, and if any portion of the welder’s qualification weld exceeds the
undercut allowed by Table 8, the welder shall be disqualified.
Maximum Dimensions of Undercutting
Depth Length
> 1/32 in. (0.8 mm) or > 12.5 % of pipe wall Not acceptable
thickness, whichever is smaller
> 1/64 in. (0.4 mm) but = 1/32 in. (0.8 mm) 2 in. (50 mm) in a continuous 12-in. (300-
or > 6 % but ≤12.5 % of pipe wall thickness, mm) weld length or one-sixth the weld
whichever is smaller length, whichever is smaller
≤1/64 in. (0.4 mm) or ≤ 6 % of pipe wall Acceptable, regardless of length
thickness, whichever is smaller
TYPE
SL. NO. OF ACCEPTANCE LIMIT
IMPERFECTION
1.The length of an individual indication is accepted up to 1 inch (25 mm).
Inadequate
1. 2.The aggregate length of indications in any continuous 12 inches (300
Penetration
(Clause mm) length of Weld is accepted up to 1 inch (25 mm).
Without High-
-9.3.1) 3.The aggregate length of such indications is accepted up to 8% of the
Low
weld length in anywelds less than 12 inches (300 mm) in length.
1.The length of an individual indication is accepted up to 2 inches (50
2. Inadequate
mm).
(Clause Penetration due
2.The aggregate length of indications in any continuous 12 inches (300
-9.3.2) to High-Low
mm) length of weld is accepted up to 3 inches (75mm).
Inadequate 1.The length of an individual indication is accepted up to 2 inches (50
3.
Cross- mm).
(Clause Penetration 2.The aggregate length of indications in any continuous 12 inches (300
-9.3.3)
(ICP) mm) length of weld is accepted up to 2 inches (50 mm).
A discontinuity between weld metal and base metal that is open to the
surface.
4. Incomplete 1.The length of an individual indication is accepted up to 1 inch (25 mm).
(Clause Fusion 2.The aggregate length of indications in any continuous 12 inches
-9.3.4) (IF) (300 mm) length of weld is accepted up to 1 inch (25 mm).
3.The aggregate length of such indications of IF is accepted up to 8% of
the weld length in anyweld less than 12 inches (300 mm) in length.
1.The length of an individual IFD is accepted up to 2 inches (50 mm).
5. Incomplete 2.The aggregate length of indications of IFD in any continuous 12 inches
(Clause Fusion Due to (300 mm) length of weld is accepted up to 2 inches (50 mm).
-9.3.5) Cold Lap (IFD) 3.The aggregate length of indications of IFD is accepted up to 8% of the
weld length.
Any length of internal concavity acceptable, provided the density of the
6. radiographic image of the internal concavity does not exceed that the
(Clause
Internal
Concavity thinnest adjacent parent metal. For areas that exceeds the density of
-9.3.6)
thinnest adjacent parent material considered a defect.
7. BT shall be considered a defect when a portion of the area is thinner than
(Clause Burn Through the thinnest adjacent parent material.
-9.3.7)
Elongated slag inclusions (ESIs)—for example, continuous or broken
slag lines or wagon tracks—are found at the fusion zones.
Isolated slag inclusions (ISIs) are irregularly shaped and may be
located anywhere in the weld.
Pipe Diameter—2.375 in. (60.3 mm) or Greater
1.The length of an ESI indication is accepted up to 2 inches (50 mm).
2.Parallel ESI indications separated by approximately the width of the
root bead (wagon tracks) shall be considered a single indication unless the
width of either of them exceeds 1/32 inches (0.8 mm). In that event, they
shall be considered separate indications.
3.The aggregate length of ESI indications in any continuous 12 inches
(300 mm) length of weld is accepted up to 2 inches (50 mm).
4.The width of an ESI is accepted up to 1/16 inches (1.6mm)
5.The aggregate length of ISI indications in any continuous 12 inches
(300 mm) length of weld is accepted up to ½ inches (13 mm).
6.The width of an ISI indication is accepted up to 1/8 inches (3 mm)
8. 7.More than four ISI indications with the maximum width 1/8 inches (3
(Clause Slag Inclusion
-9.3.8) mm)
are present in any continuous 12 inches (300 mm) length of weld.
8.The aggregate length of ESI and ISI indications is accepted up to 8% of
the weld length.
Pipe Diameter—Less than 2.375 in. (60.3 mm)
1. The length of an ESI indication is accepted up three times the thinner
of the specified wall thicknesses joined.
2.Parallel ESI indications separated by approximately the width of the
root bead (wagon tracks) shall be considered a single indication unless the
width of either of them is accepted up 1/32 inches (0.8 mm). In that
event, they shall be considered separate indications.
3. The width of an ESI indication is accepted up 1/16 inches (1.6 mm).
4. The aggregate length of ISI indications is accepted up two times the
thinner of the specified wall thicknesses joined and the width is accepted
up to one-half the thinner of the specified wall thicknesses joined.
5. The aggregate length of ESI and ISI indications is accepted up 8 % of
the weld length.
Porosity is generally spherical but may be elongated or irregular in shape,
such as wormhole porosity, and when the size of the indication produced
by a pore is measured, the maximum dimension of the indication shall
apply to the criteria given in below.
Individual or Scattered Porosity
1.The size of an individual pore is accepted up to 1/8 inches (3 mm) in
diameter or 25 % of the specified wall thickness, whichever is less.
2.The size of an individual pore is accepted up to 25 % of the thinner of
9. the two specified wall thicknesses joined, but no more than 1/8 inches (3
(Clause Porosity mm) in diameter.
-9.3.9) 3.The distribution of scattered porosity exceeds the concentration
permitted by Figures.
Hollow Bead (HB) Porosity
1.The length of an individual indication of HB is accepted up to 1 inch
(25 mm).
2.The aggregate length of indications of HB in any continuous 12 inches
(300 mm) length of weld is accepted up to 2 inches (50 mm).
3.The aggregate length of all indications of HB exceeds 8 % of the weld
length.
1.The crack, of any size or location in the weld, is not a crater crack or
10. star crack.
(Clause Cracks
-9.3.10) 2.The crack is a crater crack or star crack with a length that is accepted up
to 5/32 inches (4 mm).
1.The aggregate length of indications of EU and IU, in any combination,
11. in any continuous 12 inches (300 mm) length of weld is accepted up to 2
(Clause Undercutting inches (50 mm).
-9.3.11) 2. The aggregate length of indications of EU and IU, in any combination,
is accepted up to one-sixth of the weld length.
1.The aggregate length of indications in any continuous 12 inches (300
12. Accumulation mm) length of weld is accepted up to 2 inches (50 mm).
(Clause of
-9.3.12) Imperfections 2.The aggregate length of indications is accepted up to 8 % of the weld
length.
13.
Imperfections in the base material and/or seam welds detected by
Base Material radiographic testing shall be reported to the company. The disposition of
(Clause
Imperfections
-9.3.13) these imperfections shall be as directed by the company.
CONCLUSION:
In conclusion, the API 1104, 22nd edition is a valuable resource for professionals seeking
insights into welding and repair procedures. With its deep focus on repair procedures, this
edition provides detailed guidelines and recommendations for efficient repairs across various
industries. The emphasis on safety and quality ensures the well-being of personnel and the
integrity of repaired structures and equipment. By addressing challenges and offering
practical solutions, the API 1104, 22nd edition equips professionals with the knowledge and
understanding necessary to carry out robust and reliable repair procedures. Whether one is a
welding professional, inspector, engineer, or involved in the repair and maintenance industry,
this edition serves as an essential reference for successful repair endeavours.
The API 1104, 22nd Edition provides indispensable guidance for repair welding procedures
in the petroleum industry, ensuring the restoration of the structural integrity, safety, and
functionality of welded components. Understanding the importance of repair welding,
following the specified procedures, and fulfilling the quality requirements outlined in API
1104 are essential for maintaining the highest standards of safety and reliability in the
petroleum industry.
Understanding the key differences between the API 1104 21st edition and the 22nd edition is
crucial for welding professionals operating in the oil and gas industry. The 22nd edition
incorporates important updates and enhancements that improve weld quality, repair
procedures, and overall pipeline integrity. By staying up-to-date with the latest edition of the
API 1104 standard, welders and inspectors can ensure compliance with industry best
practices, leading to safer and more efficient operations
REFERENCE AND ACKNOWLEGEMENTS
The author would like to thank everyone who helped with the creation of the guiding
material, whether it was by direct material contributions or reviewing. These below include,
but are not limited
1. API 1104 (22ND Edition July 2021) : Welding of Pipelines and Related Facilities.
2. www.api.org.
3. API Std 1104 Interpretations - Welding of Pipelines and Related Facilities, Last update:
July 2022.
