Madskills Certified Welding Services, LLC API 1104: 21st Edition Study Guide

The Basics

The Code portion (Part C) of the AWS CWI Exam, has 60 questions in 2 hours based solely out of the API
Standard 1104: 21st Edition. This exam is open-book; you must take your copy of API 1104 with you to
the exam. There will also be a PDF on the computer at the testing facility, but it is not searchable.

Your code book must be bound or secured in a binder. You cannot have any loose papers or sticky notes
in your book. You are not allowed to write anything in your book during the exam. However, you are
allowed to tab, highlight, underline and make all the notes you want in your book before the test.
PLEASE use the highlighter sparingly when just starting out! A very common mistake for beginners is to
over-highlight and - once the whole book is highlighted - the highlighting loses its purpose.

Madskills tips for highlighting in your book:

1. Use a light colored highlighter – dark colors can make it hard to read.
2. Do a spot check to make sure your highlighter is not bleeding through the page.
3. Only highlight specific words or phrases that are the core of that segment – do not highlight
whole sentences and never, ever, whole paragraphs.
4. Do not highlight headings that are already in bold print – it is redundant and distracting.
5. Pretend that every time you use the highlighter it costs $1. Too much highlighting can be
distracting and cost you on the test.

The Book

API 1104 is made up of 13 Sections and 3 Annexes. Exam questions may come from anywhere in the
book, including the Forward, Annexes, Tables, and Figures. The Table or Contents lists all the Sections in
order, followed by a list of every Figure, and, finally, a list of all the Tables. Remember that you can
make whatever notes in your book that you want, which means you can also star (*), highlight and add
notes to the Table of Contents.

Take a few minutes to read the Foreword. Make sure you understand the difference between “shall”,
“should”, and “may.” Possible answers on the exam may look identical, but with only one word different
(i.e. “should” instead of “shall”). You must pay attention to the specific wording and select the answer
that matches the code book verbatim.

Madskills Tip: You may want to underline “shall”, “should”, and “may” as you come across them
to make sure your brain registers the correct word. However, do not highlight these words as they are
not the core of the segment.

Now take a minute to familiarize yourself with the Table of Contents. The numbering system of a
technical document helps you identify when a new thought begins and how the thoughts are grouped.
Each time the number changes, a new thought is being discussed but still falls under the main idea of
the Section. For example: Everything that starts with the number 5 has to do with Qualifying Welding
Procedures, and everything that starts with 5.4 pertains to the Essential Variables for Qualifying Welding
Procedures.

Place a tab at the start of each Section. You may place your tabs across the top or down the side of the
book. Your tabs should be large enough to easily read the name of the Section and should not be easily

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removable. Once you’re happy with how your tabs are situated, tape them in place so that you can
easily and quickly open the book to the desired Section.

Madskills Tip: Place your first tab at Section 5. Sections 1 – 4 are relatively small and do not
contain much information related to the exam.

Section 1 – Scope

API 1104 can be used for gas or arc welding (SMAW, SAW, GTAW, GMAW, FCAW, PAW, OAW) of butt,
fillet or socket welds on carbon steel and low-alloy pipe. Welding can be done with manual, semi-
automatic, mechanized, or automatic processes. It also covers how to conduct NDT (RT, MT, PT, UT, and
VT) and the acceptance standards for each. Dimensions are given in U.S. Customary Units (i.e. 1/2 in., 12
in., etc.) with Metric Units in parenthesis (5 mm, 10 cm, etc.).

Madskills Tip: Since this code is written by the “American” Petroleum Institute, you will not have
to use Metric very often, but pay close attention when checking possible answers on the exam.

Section 2 – Normative References

This section simply lists every other standard or recommended practice that is referenced throughout
the book. Notice that there are notes in this Section. When you see ASNT ACCP 1 , the little “1” means
that Note 1 on the bottom of the page applies to ASNT ACCP. This is true throughout the entire book,
and all technical documents.

Madskills Tip: As you go through the book, you may want to ‘nick’ the little note numbers with
your highlighter to make sure that you don’t miss an important note which changes the answer (I.e.
ASNT ACCP 1). Do not highlight the whole thing or the whole note!

Section 3 – Terms, Definitions, Acronyms, and Abbreviations

API 1104 uses the AWS A3.0 Standard Welding Terms and Definitions with a few modifications and
additions. Those modifications and additions are listed in Section 3 along with all acronyms and
abbreviations used in the book.

Section 4 – Specifications

This section has the general guidelines for the equipment, materials, filler metals, fluxes and shielding
gases that can be used in accordance with API 1104. It’s important to note that the piping and filler
metals are not limited to those listed under 4.2. Other materials and filler metals can be used as long as
a welding procedure is qualified for their use.

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Section 5 – Qualification of Welding Procedures with Filler Metal Additions

A Welding Procedure Specification (WPS) is the ‘recipe’ for how to make a satisfactory weld. Before
production begins, sample pieces of pipe are welded together in accordance with a WPS and then
destructively tested to make sure that the weld has the necessary mechanical properties. Under 5.3.2,
there are 17 (5.3.2.1 through 5.3.2.17) things which must be recorded on a WPS form like the one
shown in Figure 1. The results of the destructive testing conducted on the procedure qualification test
must be documented on a form similar to Figure 2.

Essential variables are the aspects of the procedure qualification that cannot be changed on a WPS. If an
essential variable needs to be changed, a new WPS needs to be written, and a new procedure test
welded and destructively tested. The essential variables are the 14 things listed under 5.4.2 (5.4.2.1
through 5.4.2.14).

In a nut-shell, the essential variables for procedures using filler metals are:

1. Changing process
2. Changing SMYS from:
a. ≤ API 5L Grade X42
b. > API 5L Grade 42 to < API 5L Grade X65
c. Each separate grade ≥ API 5L X65
3. Changing joint design
4. Changing from fixed to rolled position or from rolled to fixed position
5. Changing wall thickness from:
a. < 0.188 in.
b. ≥ 0.188 in. through 0.750 in.
c. > 0.750 in.

Madskills Tip: When the book tells you to go see another part of the book, write the page
number next to the section so you can look it up faster (I.e. 5.4.2.5: Examples of suggested groupings
are shown in 6.2.2 e) PAGE 27 ).

6. Changing from any filler metal group number in Table 1 to any other group number (pay
attention to the notes and exceptions)
7. Changing current and/or polarity (DCEN/DCEP/AC)
8. Increasing the maximum time between finishing the root and starting the ‘hot pass’ (note that
decreasing the time is allowed)
9. Changing progression (uphill/downhill)
10. Changing shielding gas composition or changing the flow rate > 20%
11. Changing flux for SAW
12. Changing travel speed
13. Decreasing the minimum preheat (note that increasing preheat is allowed)
14. Adding or changing PWHT

Madskills Tip: The items listed in 5.3.1 only tells you what needs to be recorded on the WPS – it
doesn’t tell you what to record. The essential variables in 5.4.2 are where you get the ranges that are
allowed on the WPS (i.e. 5.3.2.5 says that the filler metal classification must be recorded on the WPS, but

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5.4.2.6 says that if qualified the procedure using an E6010 electrode the WPS is qualified for Group 1
filler metals: E6010, E6011, E7010, E7011). Make sure you are looking at the correct list per the question!

Once the procedure has been welded, it needs to be destructively tested. The type and number of tests
required is shown in Table 2 and the locations of the samples is shown in Figure 3 (again, pay attention
to the notes!). For pipe OD < 2.375 in., two test welds may be necessary to get the required test
specimens. Each different destructive test – Tensile, Nick Break, Root and Face Bend, Side Bend and
Fillet Weld Testing - has 3 subheadings: Preparation, Method, and Requirements and corresponding
Figures.

Tensile tests may use a standard specimen (Figure 4 a) or reduced section specimen (Figure 4 b). The
specimen shall be pulled apart and the ultimate tensile strength (UTS) calculated by dividing the
maximum load by the original cross-section of the specimen. If it breaks in the weld metal the UTS of the
specimen must be ≥ the specified minimum tensile strength (SMTS) of the base material. If the specimen
breaks in the base metal, it must have a UTS of at least 95% of the SMTS of the base metal.

Nick break specimen may be machined or torch cut. Then they are notched with a hacksaw in the middle
of the weld and broken in two. The exposed surface must show complete penetration and fusion.
Porosity cannot exceed 1/16 in., and the aggregate cannot exceed 2% of the surface area. Slag shall not
exceed 1/32 in. in depth or more than 1/8 in. or 1/2 the wall thickness in length.

Bend tests may be either root and face, or side. They may be machine or torch cut, and the edges need
to be smooth. Specimen are bent in a guided-bend test jig and bent in a U-shape. The convex surface of
the bend shall be inspected and accepted if no discontinuities exceed 1/8 in. or 1/2 the wall thickness.
Corner cracks that are not caused by obvious imperfection shall not be considered.

Fillet break tests shall be cut out and prepared as shown in Figures 10 and 11. The specimen shall be
broken and the exposed surface inspected. The specimen is acceptable if there is complete penetration
and fusion, no porosity greater than 1/16 in. and the aggregate does not exceed 2% of the surface area,
and slag inclusions do not exceed 1/32 in. in depth and 1/8 in. or 1/2 the wall thickness in length.

Madskills Tip: The Tables and Figures are simply in numerical order throughout the book (Table 5
is not in Section 5, it is just the 5th Table in the book). Remember that there is a list of all the Tables and
their page numbers in the Table of contents. This may help you get to the appropriate Table faster and
keep you from looking at the wrong Table. You can also add secondary tabs to your book marking Tables
and Figures that you find yourself using frequently.

Section 6 – Qualification of Welders

Now that we have our procedure in place, it’s time to qualify our welders. The welder who welded the
procedure test is automatically qualified in accordance with Section 6. All the other welders must follow
the WPS while making their test. Welders can qualify in two ways: single qualification or multiple
qualification.

For single qualification, the welder must make a butt weld between two pieces of pipe in either 1G, 2G,
5G or 6G position. The essential variables for welder qualification are listed in 6.2.2. These are the things
that, if changed, require the welder to take another test:

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1. Changing process
2. Changing progression (uphill/downhill)
3. Changing filler metal from a Group 1 or 2 in Table 1 to any group 3 through 9, or from any group
3 through 9 to a Group 1 or 2 (note that changing from a Group 1 to Group 2 or vice versa is
allowed)
4. Changing OD from:
a. < 2.375 in.
b. ≥ 2.375 in. through12.750 in.
c. > 12.750 in.
5. Changing wall thickness from (same as procedure qualification):
a. < 0.188 in.
b. ≥ 0.188 in. through 0.750 in.
c. > 0.750 in.
6. Changing from rolled to fixed position, or from 2G to 5G, or vice versa (6G qualifies the welder
for all positions)

Multiple qualification is a combination of two tests. The first test is a 6G butt weld and, for the second
test, the welder must lay-out, cut, fit, and weld a branch-on-pipe connection. Both tests must be on pipe
with an OD ≥ 6.625 in. and a wall thickness ≥ 0.250 in. These tests qualify the welder to weld in all
positions, on all wall thicknesses, joint designs, fittings, and OD’s ≤ the OD used in the tests.

If the multiple qualification tests are satisfactorily completed on pipe with an OD ≥ 12.750 in. the welder
is qualified to weld all positions, on all wall thicknesses, joint designs, fittings, and all OD’s. In that case,
the only essential variables are:

1. Changing process
2. Changing progression (uphill/downhill)
3. Changing filler metal from a Group 1 or 2 in Table 1 to any group 3 through 9, or from any group
3 through 9 to a Group 1 or 2 (note that changing from a Group 1 to Group 2 or vice versa is
allowed)

All welder qualification test must be visually inspected and meet the requirements of 6.4 and be
destructively tested in accordance with 6.5. Table 3 shows the type and number of destructive tests
required for welder qualification. If the company allows, RT or UT may be substituted for destructive
testing per 6.6. The requirements for NDE of a welder qualification test are found in Section 9.

Section 7 – Design and Preparation of a Joint for Production Welding

Now we can start welding! The general rules for production welding are as follows:

1. The pipe must be welded by qualified welders using qualified WPS’s, and the weld area must be
smooth and clean.
2. Misalignment (commonly called hi-lo) should not exceed 1/8 in.
3. Use of a line-up clamp must be specified in the WPS (5.3.2.11) and should not be removed until
equal segments of the root bead have been deposited.

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4. Bevels shall conform to the WPS and should be done by machine tool or oxygen cutting. Manual
cutting is only allowed with company authorization.
5. Moisture, blowing sand and high wind should be minimized.
6. If the pipe is being welded above ground, there should be at least 16 in. of clearance around the
pipe. If welding in the ditch, the bell hole shall be large enough for the welder to readily access
the joint.
7. All scale and slag shall be removed as well as heavy glass deposits when required by the
company.
8. For fixed position welding, the pipe shall be secured from moving. The completed surface can
have no underfill, reinforcement should not exceed 1/16 in., no two beads can start at the same
location, the width of the weld should be approximately 1/8 in. wider than the original groove,
and the whole weld shall be brushed and clean.
9. For roll welding, the pipe shall be supported to prevent sag. The completed surface can have no
underfill, reinforcement should not exceed 1/16 in., the width of the weld should be
approximately 1/8 in. wider than the original groove, and the whole weld must be brushed and
clean.
10. Welders shall identify their work in accordance with company requirements.
11. Preheat and PWHT must be specified on the WPS (5.3.2.13).

Madskills Tip: There’s a lot of “shall”, “should”, and “may” in this Section – pay attention!

Section 8 – Inspection and Testing of Production Welds

The company can inspect any weld, at any time, by either destructive or nondestructive testing. NDT
requirements fall under Section 9 or Annex A while destructive testing must meet the requirements of
6.5. Trepanning (cutting out a core sample of a weld and replacing it later) is not allowed.

Inspection workers have to be qualified and a record kept of their education, experience, training and/or
qualification exams.

NDT people have to be certified with a national program like ASNT SNT-TC-1A or ASNT ACCP. There are 3
levels of certification, but only Level II or III personnel are allowed to interpret test results. All levels
must be recertified and have a vision test at least every five years.

Madskills Tip: Qualification means simply whether or not you can do the job being asked.
Certification is the document proving you are indeed qualified for a job.

Section 9 – Acceptance Standards for NDT

This section covers the pass/fail requirements for RT, MT, PT, UT and VT. The company can reject a weld
even if NDT deems it acceptable.

RT is based on the density of the negative image developed on the film. Each discontinuity is listed
under 9.3 with its definitions and acceptance criteria: IP, IPD, ICP, IF, IFD, IC, BT (large and small

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diameter pipe), ESI and ISI (large and small diameter pipe), Porosity, Cracks, Accumulation of
Imperfections and Base Material Imperfections.

Madskills Tip: Weld length is the circumference of the pipe, calculated by diameter times pi
(3.14). So, to have at least 12 inches of weld length, the pipe must be at least 4 in. diameter. Making a
note of this ‘hack’ can help you avoid doing unnecessary math or getting an incorrect answer (i.e. When
determining the maximum allowable aggregate length of IP on a 3 in. pipe, only 9.3.1 c) would apply;
9.3.1 b) only applies to 4 in. diameter pipe and greater).

Indication found by MT may be misleading, so any indication ≤ 1/16 in. shall be considered nonrelevant.
Relevant indications are defects if they exceed the limits of 9.4.2.

PT also classifies nonrelevant indications as anything ≤ 1/16 in. The acceptance criteria for PT is found in
9.5.2.

UT classifies indications as Linear, Transverse, Volumetric, or Relevant. The acceptance standards are
listed under 9.6.2 for General, LS, LB, T, VC, VI, VR, Accumulation and Base Material Imperfections.

Indications found by VT have the same criteria as the other forms of NDT. In addition, the maximum
limit for undercutting is found in Table 4.

Madskills Tip: If the pipe wall thickness is ≥ 1/4 in., ignore the percentages and only compare the
physical undercut measurement to the fractions in Table 4. If the wall thickness is < 1/4 in., you will have
to disregard the fractions in Table 4 and calculate the percentage of the wall thickness to find the
acceptable length (i.e. If you physically measure undercut on a pipe with a 1/2 in. wall thickness to be
1/64 in. deep, ignore the percentages, and the physical undercut falls in the bottom row which makes it
acceptable, regardless of length).

Section 10 – Repair and Removal of Weld Defects

If NDT finds a discontinuity, it must be either repaired or cut out. Weld cracks can only be repaired if the
company allows, and the crack or aggregate length of cracks is < 8% of the weld length. A qualified
repair procedure is required if the repair will use a different process than originally used to make the
weld, for double repairs, back weld repairs, or whenever the company requires it. Grinding repairs have
to have a smooth contour and cannot violate the minimum wall thickness of the pipe.

When a repair procedure is required, it shall be qualified in accordance with 10.3. Table 5 provides the
type and number of destructive tests required to qualify a repair procedure. In addition to the essential
variables listed in 5.4.2, repair procedures also have the following essential variables:

1. Changing the location of the repair from:

a. Centerline to fusion line for partial thickness repairs
b. Centerline to fusion line for cover pass repairs
2. Changing repair type from:
a. Full thickness
b. Internal partial thickness
c. External partial thickness

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d. Cover pass
e. Back weld
3. Decreasing the minimum preheat temperature and adding or changing the interpass
temperature

The biggest difference between regular procedure qualification and repair procedure qualification is the
necessity for hardness testing. After preparing the specimens, but before conducting the hardness test,
each specimen shall be visually inspected in accordance with 10.3.7.2.2. Once the specimen passes VT, it
gets Vickers hardness tested at the locations shown in Figures 21 – 26.

If Charpy V-Notch (CVN) toughness testing is required by the company, the preparation and
requirements of 10.3.7.4.1 shall be followed.

When a repair procedure is required, a qualified repair welder is also required. Most of the
requirements are the same as Section 6 with the following additions:

1. Changing the type of repair except from full thickness to partial thickness
2. Changing filler metal group per Table 1
3. Increasing the depth of the repair by more than double
4. Changing the position except that overhead qualified all positions

All repairs shall be reexamined by the same means used to originally locate the defect. NDT must be
done over the whole repair area plus 10% or 2 in. on either side of the repaired area. The repair area
must meet the requirements of Section 9.

Section 11 – Procedures for Nondestructive Testing (NDT)

This section provides the requirements for Level III NDT technicians to create adequate procedures.
CWI’s do not make NDT procedures, but it is their responsibility to review and verify that the procedures
comply with API 1104.

RT procedures shall ensure that the film produced has the density, clarity, and contrast to evaluate the
weld. Images must be free of fog, use the appropriate Image Quality Indicators (IQI), and identification
system, proper techniques and setup, and acceptance standards. An RT procedure has to include at least
the following:

1. Source of radiation
2. Type and placement of screens
3. Type of film
4. Exposure geometry (SWE/SWV, DWE/SWV, DWE/DWV)
5. Exposure conditions
6. Processing
7. Materials
8. IQI’s
9. Heat shields

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Procedures for radiography using media other than film (such as Real Time Radiography) must include:

1. Source of radiation
2. Collection system
3. Processing system
4. Viewing system
5. Storage system
6. Exposure geometry (SWE/SWV, DWE/SWV, DWE/DWV)
7. Exposure conditions
8. Materials
9. IQI’s
10. Heat shields

11.1.3.1 dictates which exposure geometry must be used based on the placement of the source and the
diameter of the pipe. IQI must be ASTM E747 or ISO 19232-1. The placement and requirements are
detailed in Tables 8 and 9 along with 11.1.4 through 11.1.6.2. All images must be identifiable by using
lead numbers, letters, markers, etc. Film shall be stored in a clean, dry place where it won’t deteriorate.

The procedure for MT is detailed in ASTM E709.

The procedure for PT is detailed in ASTM E165.

Procedures for UT should be agreed on by both the company and the UT contractor before inspecting
production welds. When using UT on in-service welds, discontinuities in the parent metal and the
surface of the pipe may cause false indications. The UT procedure must include, at a minimum, these
details:

1. Type of welds
2. Material type
3. Surface preparation
4. Stage when UT will be performed
5. System and probes
6. Automatic or manual
7. Couplant
8. Technique
9. Reference standard(s)
10. Calibration requirements
11. Scanning level
12. Evaluation level
13. Results
14. Report

The UT contractor will have to demonstrate that the procedure and equipment are adequate before
inspecting production welds. The process for supporting this is detailed in 11.4.4. Manual UT shall use
two or three points on the screen to show that the equipment is sensitive enough to detect flaws in the
weld. Two of these points can be Distance Amplitude Correction (DAC) and Time Corrected Gain (TCG). If
a N10 notch on a calibration block does not show up as at least 80% of the screen height, it is not

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sensitive enough. For production welds, any indication over 50% of DAC/TCG is relevant and shall be
evaluated.

Section 12 – Mechanized Welding with Filler Metal Additions

Mechanized welding can be done with SAW, GMAW, GTAW, FCAW, PAW or a combination of processes.
The requirements for destructively testing a mechanized welding procedure are the same as Section 5.6
except that nick-breaks are not required. NDT follows Section 9. The 19 items listed under 12.4.2 must
be recorded on the WPS. The essential variables are listed in 12.5.2 as such:

1. Changing process
2. Changing SMYS from:
a. ≤ API 5L Grade X42
b. > API 5L Grade 42 to < API 5L Grade X65
c. Each separate grade ≥ API 5L X65
3. Changing joint design
4. Changing wall thickness
5. Changing OD
6. Changing from any filler metal group number in Table 1 to any other group number (pay
attention to the notes and exceptions)
7. Changing filler metal wire diameter
8. Increasing the maximum time between finishing the root and starting the ‘hot pass’ (note that
decreasing the time is allowed)
9. Changing progression (uphill/downhill)
10. Changing shielding gas composition or changing the flow rate
11. Changing flux for SAW
12. Changing travel speed
13. Decreasing the minimum preheat (note that increasing preheat is allowed)
14. Adding or changing PWHT
15. Changing electrical characteristics (DCEN/DCEP/AC)
16. Changing orifice diameter for PAW
17. Changing the method of cooling

Welding operators shall be tested with the same requirements as Section 6 except that nick break tests
are not required, and tensile tests cannot be replaced by nick-breaks. There are 10 essential variables
for qualifying welding operators:

1. Changing process
2. Changing progression (uphill/downhill)
3. Changing filler metal type (solid, flux core, etc.)
4. Changing OD from:
a. < 12.750 in.
b. ≥ 12.750 in.
5. Changing to a lighter wall thickness
6. Changing position except that fixed position qualifies rolled position

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Madskills Certified Welding Services, LLC API 1104: 21st Edition Study Guide

7. Changing bug manufacturer or model

8. Changing application or root bead (external/internal)
9. Changing joint design
10. If required by the company, changing from a specific portion of the weld to other portions of the
weld

Inspection of mechanized welds falls under Section 8, NDT acceptance under Section 9 (or Annex A at
the company’s option), repairs are made in accordance with Section 10, and NDT procedures in Section
11.

Section 13 – Automatic Welding without Filler Metal Additions

Flash-butt welding is an automatic welding process that does not use filler metal and it is the only
process recognized in Section 13. Procedures for flash-butt welding must be radiographed before they
are destructively tested. The locations of test specimens are shown in Figure 30 – 32, and the number
and type required is in Table 10. The preparation, method and requirements of the various destructive
tests mostly follows Section 5, but not entirely.

The essential variables for automatic welding are listed out in 13.5.2.

1. Changing pipe material

2. Changing wall thickness or OD
3. Changing pipe preparation dimensions
4. Changing position
5. Changing preheat
6. Changing voltage tolerances
7. Changing current tolerances
8. Changing axial speed tolerances
9. Changing the intervals of weld cycles
10. Changing upset stroke tolerances
11. Changing PWHT

Flash-butt welding operators must qualify along with the welding unit and have the same essential
variables as procedures.

A strip chart recorder (a special type of graph for recording time-sensitive information) shall be
monitored by the operator to verify the proper electrical and mechanical parameters of the weld. If any
of the parameters are violated, the weld shall be cut out.

All flash-butt welds shall undergo VT and RT after PWHT. Reinforcement shall not exceed 1/16 in. on the
ID or 1/8 in. on the OD. PWHT must exceed the Ac3 temperature (the temperature at which the metal
becomes completely austenitic) or it has to be heat treated again. An ISI cannot exceed 1/8 in., and the
aggregate length of ISI’s cannot exceed 1/2 in. in any 12 in. of weld length. Cracks and IF are always
considered defects regardless of size or location but may be repaired in accordance with Section 10.
Porosity is a defect and must be cut out.

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Annex A – Alternative Acceptance Standards for Girth Welds

This Section is far above our pay-grade as CWI’s, but it is part of the CWI exam. So, like it or not, you’ll
need to get familiar with it. At a very base level, Annex A provides a way for companies to circumvent
the acceptance criteria of Section 9 and use a more lax criteria. While regular acceptance criteria are
mainly based on the length of the discontinuity, Annex A considers height and length which usually
results in an increased tolerance for imperfections.

Madskills Tip: Read each paragraph in Annex A one at a time. At the end of each, ask yourself
what key words stand out as the core of the segment and highlight only those words. Try to boil the
paragraph down so that you can efficiently scan for key words during the exam and not get bogged
down reading paragraphs that have no bearing on the question.

The use of this annex relies on stress analysis and crack tip opening displacement (CTOD) toughness
testing to determine fitness for purpose (whether the pipeline will hold up to its intended service).
There are three options for determining the acceptance limits: Option 1, Option 2 and Option 3. In
ascending order, they are increasingly complex to use but offer a wider range of use. All three options
require destructive testing and analysis so it is impractical to use Annex A to save one weld from cut out.
A company would only opt to use Annex A for an entire project.

It is entirely up to the company whether to use Annex A or not. Annex A only applies to:

1. Girth welds on pipes of the same wall thickness

2. 100% NDE
3. No undermatching weld strength
4. Axial design stress no greater than the SMYS of the pipe
5. Axial design strain no greater than 0.5%
6. Regular pipeline welds (not valves, fittings, pumps of compressor stations)

An axial stress analysis must be done to determine what kind(s) of stress the pipe will undergo.
Obviously, the pipe is being stressed as it is lowered into the ditch, and the higher the pipe is lifted the
higher the stress is. Directional drilling and the friction of the dirt also cause stress on the pipe.

A cyclic stress analysis must be done to find the life cycle of the pipeline, based on how many cycles of
stress it will be subjected to. Things like hydro-testing, changing operating pressures, heating and
cooling, earthquakes, etc. decrease the life of the pipeline.

Madskills Tip: Don’t be scared! You will not have to perform these calculations during the exam.

The environment can also cause discontinuities to grow and reduce the life of the weld. CO2 and H2S are
extremely corrosive and high levels must be minimized by coating or cathodic protection if Annex A is to
be used.

Besides H2S, hydroxides, nitrates, or carbonates can also cause brittleness and stress corrosion cracking
(SCC). NACE MR0175 governs H2S and SCC.

The essential variables for procedures qualified in accordance with Annex A are:

1. Changing process
2. Changing the pipe:

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Madskills Certified Welding Services, LLC API 1104: 21st Edition Study Guide

a. Grade
b. Source or mill
c. Processing facility
d. Manufacturer
e. Manufacturing process
f. Chemistry
3. Changing joint design
4. Changing position
5. Changing wall thickness > 0.125 in.
6. Changing filler metal size, type, heat number or manufacturer
7. Increasing the maximum time between finishing the root and starting the ‘hot pass’ (note that
decreasing the time is allowed)
8. Changing progression (uphill/downhill)
9. Changing shielding gas composition or changing the flow rate > 10%
10. Changing flux for SAW
11. Changing current and/or polarity (DCEN/DCEP/AC)
12. Changing preheat temperature
13. Changing interpass temperature
14. Changing PWHT
15. Changing the OD > -0.025D or +0.5D
16. Changing heat input > 10%

The requirements for tensile testing in Annex A differ from Section 5 and are found in A.3.4.1. Also,
eighteen Charpy V-Notch (CVN) test specimens must be tested in accordance with A.3.4.2 and six (three
weld metal and three HAZ) CTOD fracture toughness testing shall be tested in accordance with A.3.4.3.

Welders are qualified using Section 6 or 12.6 for mechanized welding.

RT or UT can be used to find the height and length of discontinuities. Option 1 for acceptable
discontinuity size is based on the graph in Figure A.7 and A.8 which allows thinner discontinuities to be
longer. However, it is not acceptable for an imperfection to exceed 12/5% of the pipe circumference or
50% of the wall thickness.

Option 2 uses a failure assessment diagram (FAD) to consider elastic-plastic fractures. The FAD has three
components: a failure assessment curve (FAC), stress or load ratio and toughness ratio. The values from
the FAD are plugged into the equations in A.5.1.4.3 to find the acceptable size of discontinuities (but you
will not have to do that on the exam).

Option 3 is mostly used for offshore pipelines where cyclic loading is common. Using Option 3,
transverse planar imperfections are unacceptable. Also, lack of fusion on starts/stops cannot exceed 1/4
in. or 50% of the wall thickness. The limits for volumetric imperfections like slag and porosity are found
in Table A.4. Arc burns may be left unrepaired as long as their size does not exceed the limits of Table
A.5.

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Annex B – In-Service Welding

This Annex governs welding on ‘live lines’ – pipes with product flowing through them. The biggest
concerns when welding in-service pipelines are burn-through and hydrogen cracking.

Burn-through is unlikely on 1/4 in. wall thicknesses and greater. Special precautions like limiting heat
input should be taken when welding on thinner wall thicknesses.

Hydrogen cracking only occurs when there is hydrogen in the weld, the weld has a crack-susceptible
microstructure, and there is tensile stress acting on the weld all at the same time. Hydrogen cracking is
prevented if one or more of these conditions is eliminated (a tripod can’t stand on two legs). Using low-
hydrogen electrodes, a high enough heat input to counteract the contest flowing through the pipe,
preheating, and using a temper bead sequence like the one shown in Figure B.1 all help eliminate
hydrogen cracking.

In-service welding procedures are qualified the same as fillet welds in Section 5 except that the WPS
should include the following additions:

1. Carbon equivalent should be identified

2. Operating conditions should be identified
3. Heat input should be specified
4. Bead deposition sequence should be specified

The essential variables for Annex B are:

1. Increasing carbon equivalent (with exceptions)

2. Increasing the severity of operating conditions
3. Changing from a temper bead sequence to another deposition sequence

The test joint for In-Service welding procedure qualification and welder qualification is shown in Figure
B.2. A hose is connected to the test piece and water flows through the pipe as it is welded to simulate
the effect of product flowing through a live line. The number and type of tests are shown in Table B.1
and removed from the locations shown in Figures B.3 or B.4. In addition to tensile, nick and bend tests,
microsection tests are required for branch and sleeve welds.

Welders tested on pipe with an OD < 12.750 in. and qualified for all OD’s ≤ the diameter used on the
test. If the welder qualified on an OD ≥ 12.750 in., they are qualified for all diameters. The type and
number of destructive tests required for welder qualification is shown in Table B.2.

Welding on in-service pipelines can be dangerous. Welders should be aware of the safety concerns and
familiar with API 2201, Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries.
Clamps should be used on sleeve and saddle welds to minimize any gaps. Back-up bars should be used
on complete joint penetration longitudinal butt welds to prevent burning-through to the carrier pipe.
Figures B.7 through B.12 show suggested weld bead sequences.

NDT of in-service welds shall comply with Section 9. Inspection should be delayed to properly consider
the possibility of delayed hydrogen cracking.

Any repairs shall conform with Section 10.

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Annex C – Requests for Interpretation and Request for Revision to the Document

Questions about interpretations of revisions to API 1104 can be submitted to the American Petroleum at
the address listed in Annex C. The inquiry must state the purpose of the inquiry, the name, address, and
affiliation of the inquirer and enough information for the committee to understand the concern of the
inquirer. The inquiry may include a proposed reply.

Practice Questions

Questions on the actual exam will be randomized, but Madskills provides practice questions that go in
order with the API 1104. This helps the student to get the hang of how the book is laid out. As you read
each question, ask yourself the following questions:

1. What section should I find this in?

2. Should I find this information in the text, a table, or a figure?
3. What key words should I look for in the Table of Contents?

After a bit of practice, it should be obvious to you what section the answer will be in. You should also be
able to guess if the pertinent information will be in text, table, or figure. Then, when you look for the key
word or phrase in the Table of Contents, only look at the referenced locations in that section.

Madskills Tip: When you have a particularly hard question that takes ‘forever’ to find, make sure
you identify why it was so tricky. Were you looking for the wrong key words? Did you miss a footnote on
a table? Would a note in the Table of Contents helped you find the answer quicker?

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