API 1104

Defects
KGPIU
Acceptance
Aborahmah, Ala’a Criteria
 INTRODUCTION

• API 1104 IS THE PERFECT STANDARD TO LEARN ABOUT

WELDING
• INSPECTION AND TESTING OF PRODUCTION WELDS
• ACCEPTANCE STANDARDS FOR NONDESTRUCTIVE TESTING.
• REPAIR AND REMOVAL OF DEFECTS & MANY OTHER SUBJECTS…
 INTRODUCTION

What we are going to explain:

• Defect type
• causes
• Acceptance limits
• Reference
• picture
 MISALIGNMENT

Definition:
The alignment of abutting ends.
Causes:
Improper joint fit up
Acceptance criteria:
For pipe ends of the same nominal thickness, the offset
shall not exceed 1/8 in. (3 mm).
Reference:
API 1104 7.2
MISALIGNMENT
 Incomplete Penetration (IP)
Definition:
Inadequate penetration without high-low (IP) is defined as the
incomplete filling of the weld root.
Causes:
• Too small a root opening
• Too large a root face
• Excessive high low
• Travel speed too fast
• Welding current too low
• Electrode diameter too large
• Excessive arc length
 Incomplete Penetration (IP)

Acceptance Criteria
• The length of an individual indication of IP shall not exceed 1 in.
(25 mm).
• The aggregate length of indications of IP in any continuous12 in.
(300 mm) length of weld shall not exceed 1 in. (25 mm).
• The aggregate length of indications of IP shall not exceed 8% of
the weld length in any weld less than 12 in. (300 mm) in length.
Reference
API 1104 9.3.1 a / b / c
Incomplete Penetration (IP)
Incomplete Penetration (IP)
 Incomplete Fusion (IF)

Definition:
Incomplete fusion (IF) is defined as a surface imperfection
between the weld metal and the base material that is open to the
surface.
Causes:
• Improper electrode angle
• Travel speed too fast
• Welding current too low
• Faulty joint preparation
• Electrode diameter too large
 Incomplete Fusion (IF)

Acceptance Criteria:
• The length of an individual indication of IF shall not exceed 1 in.
(25 mm).
• The aggregate length of indications of IF in any continuous12 in.
(300 mm) length of weld shall not exceed 1 in. (25 mm).
• The aggregate length of indications of IF not shall exceed 8% of
the weld length in any weld less than 12 in. (300 mm) in length.
Reference:
API 1104 9.3.4 a / b / c
Incomplete Fusion (IF)
Incomplete Fusion (IF)
 Internal Concavity (IC)

Definition:
A bead that is properly fused to and completely penetrates the
pipe wall thickness along both sides of the bevel, but whose
center is somewhat below the inside surface of the pipe wall.
Causes:
• Incorrect electrode manipulation
• Welding current too high
• Excessive arc length
• Travel speed too fast
 Internal Concavity (IC)

Acceptance Criteria:
Any length of internal concavity is acceptable,
provided the density of the radiographic image of the
internal concavity does not exceed that of the thinnest
adjacent parent material. For areas that exceed the
density of the thinnest adjacent parent material, the
criteria for burn through are applicable.
Reference:
API 1104 9.3.6
Internal Concavity (IC)
Internal Concavity (IC)
 Burn Through (BT)

Definition:
A portion of the root bead where excessive
penetration has caused the weld puddle to be blown
into the pipe.
Causes:
• Excessive heat
• Fast traveling speed
 Burn Through (BT)

Acceptance Criteria:
For pipe with an outside diameter greater than or equal to 2.375 in. (60.3 mm):
• The maximum dimension shall not exceed 1/4 in. (6 mm) and the density in
any portion of the BTs image exceeds that of the thinnest adjacent parent
material.
• The maximum dimension shall not exceed the thinner of the nominal wall
thicknesses joined, and the density in any portion of the BTs image exceeds
that of the thinnest adjacent parent material.
• The sum of the maximum dimensions of separate BTs whose image density
for any portion of the BTs shall not exceed that of the thinnest adjacent
parent material and not exceeds 1/2 in. (13 mm) in any continuous 12 in.
(300 mm) length of weld or the total weld length, whichever is less.

Reference:
API 1104 9.3.7
Burn Through (BT)
 Slag Inclusion (SI)
Definition:
A nonmetallic solid entrapped in the weld metal or between the
weld metal and the parent material. Elongated slag inclusions
(ESIs) Isolated slag inclusions (ISIs)

Causes:
• Base Metal contaminated
• Wet, unclean electrodes
• Insufficient or damp shielding gas
• Excessive arc length
• Welding current too high
• Weld speed too fast
 Slag Inclusion (SI)

Acceptance Criteria:
For pipe with an outside diameter greater than or equal
to 2.375 in. (60.3 mm):
• The length of an ESI indication shall not exceed 2 in.
(50 mm).
• The aggregate length of ESI indications in any
continuous12 in. (300 mm) length of weld shall not
exceed 2 in. (50 mm).
• The width of an ESI indication shall not exceed 1/16 in.
(1.6 mm).
 Slag Inclusion (SI)

Acceptance Criteria:
• The aggregate length of ISI indications in any
continuous 12 in. (300 mm) length of weld shall not
exceed 1/2 in. (13 mm).
• The width of an ISI indication shall not exceed 1/8 in.
(3 mm).
Reference:
API 1104 9.3.8
Slag Inclusion (SI)
Slag Inclusion (SI)
Slag Inclusion (SI)
 Porosity (P)
Definition:
A gas trapped by solidifying weld metal before the gas has a
chance to rise to the surface of the molten puddle and escape.
scattered porosity (P), Cluster porosity (CP) and Hollow-bead
porosity (HB)
Causes:
• Insufficient interpass cleaning
• Unsteady travel speed
• Welding weave too wide
• Allowing slag to run ahead of the arc
• Using too large and electrode
 Porosity (P)

Acceptance Criteria:
Individual or scattered porosity (P):
• The size of an individual pore not exceeds 1/8 in. (3 mm).
• The size of an individual pore not exceeds 25% of the thinner of
the nominal wall thicknesses joined.
Cluster porosity (CP)
• The diameter of the cluster not exceeds 1/2 in. (13 mm).
• The aggregate length of CP in any continuous 12 in. (300mm)
length of weld not exceeds 1/2 in. (13 mm).
 Porosity (P)

Acceptance Criteria:
Hollow-bead porosity (HB)
• The length of an individual indication of HB shall not exceed 1/2
in.(13 mm).
• The aggregate length of indications of HB in any continuous12 in.
(300 mm) length of weld shall not exceed 2 in. (50 mm).
• It is a defect if the Individual indications of HB, each greater than
1/4 in.(6 mm) in length, are separated by less than 2 in. (50 mm).
• The aggregate length of all indications of HB shall not exceed 8%
of the weld length.
Reference:
API 1104 9.3.9
Porosity (P)
 Porosity (P)

• Cluster porosity (CP)

 Porosity (P)
• Root pass aligned Porosity
Porosity (P)
 Porosity (P)

• Surface Breaking Porosity

Porosity (P)
Porosity (P)
 Cracks

Definition:
The most critical discontinuity. this criticality comes
from the very sharp ends that has the tendency to
grow.
Causes:
• Stress is applied exceeding the tensile strength.
• Excessive joint restraint
• Incorrect pre-heat
• Incorrect filler metal
• Too fast a cooling rate
 Cracks

Acceptance Criteria:
Only crater or star crack is permitted with a length not exceeding
5/32 in (4 mm).
Reference:
API 1104 9.3.10
Cracks
Cracks
 Cracks

• Transverse Crack
 Cracks

• Longitudinal Crack
Cracks
 Undercut

Definition:
a groove melted into the parent material adjacent to the toe or
root of the weld and left unfilled by weld metal. Undercutting
adjacent to the cover pass (EU) or root pass (IU)

Causes:
• Improper welding technique
• Fast welding travel
• Heat is too high
• Electrode manipulating is incorrect
 Undercut

Acceptance criteria:
• The aggregate length of indications of EU and IU, in
any combination, in any continuous 12 in. (300 mm)
length of weld shall not exceed 2 in. (50 mm).
• The aggregate length of indications of EU and IU, in
any combination, shall not exceed one-sixth of the
weld length.
Reference:
API 1104 9.3.11
 Undercut

• Root Undercut (IU)

 Undercut

• Cap Undercut (EU)

Thank you for your attention