5 Qualification of Welding Procedures

with Filler Metal Additions

API 1104

5.4 Essential Variables

5.4.1 General
A welding procedure shall be reestablished as a new
welding procedure specification and shall be
completely requalified when any of the essential
variables listed in 5.4.2 are changed. Changes other
than those given in 5.4.2 may be made in the
procedure without the need for requalification,
provided the welding procedure specification is
revised to show the changes.

5.4.2 Changes Requiring Requalification

5.4.2.1 Welding Process or Method of Application

A change from the welding process or method of
application established in the welding procedure
specification (see 5.3.2.1) constitutes an essential
variable.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.2 Base Material

A change in base material constitutes an essential
variable. When welding materials of two separate material
groups, the procedure for the higher strength group shall
be used. For the purposes of this standard, all materials
shall be grouped as follows:
a) SMYS less than or equal to that of the material specified
as API 5L Grade X42;
b) SMYS greater than that of the material specified as API
5L Grade X42 but less than that of the material specified as
API 5L Grade X65;
c) for materials with a SMYS greater than or equal to that
of the material specified as API 5L Grade X65, each grade
shall receive a separate qualification test.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.2 Base Material

NOTE 1 The groupings specified in 5.4.2.2 do not imply that
base materials or filler metals of different analyses within a
group may be indiscriminately substituted for a material
that was used in the qualification test without consideration
of the compatibility of the base materials and filler metals
from the standpoint of metallurgical and mechanical
properties and requirements for preheat and PWHT.

NOTE 2 When base material with multiple grade markings is

being used, the company designates, before using the
material, the selected single grade to be used.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.3 Joint Design

A major change in joint design (e.g. from V
groove to U groove) constitutes an essential
variable. Minor changes in the angle of bevel or
the land of the welding groove are not essential
variables.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.4 Position
A change in position from roll to fixed, or
vice versa, constitutes an essential
variable.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.5 Wall Thickness

A change from one specified wall thickness range to
another constitutes an essential variable. Examples
of suggested groupings are shown in 6.2.2 e).

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6.2.2 d
...

wall thickness group to another. These groups are defined as follows:

1) specified pipe wall thickness less than 0.188 in. (4.8 mm),
2) specified pipe wall thickness from 0.188 in. (4.8 mm) through 0.750 in. (19.1 mm),
3) specified pipe wall thickness greater than 0.750 in. (19.1 mm).

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5.4 Essential Variables
5.4.2 Changes Requiring Requalification
5.4.2.6 Filler Metal

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5.4 Essential Variables
5.4.2 Changes Requiring Requalification
5.4.2.6 Filler Metal

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5.4 Essential Variables
5.4.2 Changes Requiring Requalification
5.4.2.6 Filler Metal

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.6 Filler Metal

The following changes in filler metal constitute essential

variables:
a) a change from one filler metal group to another (see
Table 1);

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API 1104

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5.4 Essential Variables
5.4.2 Changes Requiring Requalification

5.4.2.6 Filler Metal

b) for Groups 1 through 3 in Table 1, any change in

suffix designator except within the group
consisting of:
— no suffix designator,
— -1,
— A1,
— C1, C2, Ce,
— C1L, C2L, C3L,
— M,
— P1, or P2;
NOTE For example, a change in suffix designator from A1
to B3, or vice versa, constitutes an essential variable. A
change from A1 to C3, or vice versa, does not constitute
an essential variable.

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5.4 Essential Variables
5.4.2 Changes Requiring Requalification
5.4.2.6 Filler Metal

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5.4 Essential Variables
5.4.2 Changes Requiring Requalification

5.4.2.6 Filler Metal

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5.4 Essential Variables
5.4.2 Changes Requiring Requalification

5.4.2.6 Filler Metal

…

c) for any filler metals with a G suffix designator only,

a change in the manufacturer or trade name;
d) for materials with a SMYS greater than or equal to
that of the material specified as API 5L Grade X65, any
change in the AWS classification of the filler metal
(see 5.4.2.2).
NOTE Except as indicated items in b) and c) above,
changes in filler metal within filler metal groups may
be made within the material groups specified in
5.4.2.2, items a) and b).
The compatibility of the base material and the filler
metal should be considered from the standpoint of
mechanical properties.
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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.7 Electrical Characteristics

A change from direct current (DC) electrode positive
to DC electrode negative, or vice versa, or a change in
current from DC to alternating current (AC), or vice
versa, constitutes an essential variable.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.8 Time Between Passes

An increase in the maximum time between
completion of the root bead and the start of
the second bead constitutes
an essential variable.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.9 Direction of Welding

A change in the direction of welding from vertical
downhill to vertical uphill, or vice versa, constitutes an
essential variable.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.10 Shielding Gas and Flow Rate

A change from one shielding gas to another or
from one mixture of gases to another
constitutes an essential variable.
An increase or decrease in the range of flow
rates for the shielding gas greater than 20 % of
the nominal flow rate also constitutes an
essential variable.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.11 Shielding Flux

Refer to Table 1, Footnote a, for changes in
shielding flux that constitute essential
variables.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.12 Speed of Travel

A change in the range for speed of travel
constitutes an essential variable.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.13 Preheat
A decrease in the specified minimum preheat temperature constitutes an essential variable.

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5.4 Essential Variables

5.4.2 Changes Requiring Requalification

5.4.2.14 PWHT
The addition of PWHT or a change from the ranges or values specified in the procedure each
constitutes an essential variable.

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5.5 Welding of Test Joints—

Butt Welds
To weld the test joint for butt welds, two
pipe nipples shall be joined, following all
the details of the welding procedure
specification.

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5.6 Testing of Welded Joints—Butt Welds

5.6.1 Preparation
To test the butt-welded joint, test specimens shall be
cut from the joint at the locations shown in Figure 3.
…

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5.6 Testing of Welded Joints—Butt Welds

5.6.1 Preparation
…

The minimum number of test specimens and the tests

to which they shall be subjected are given in Table 2.
…

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5.6 Testing of Welded Joints—Butt Welds

5.6.1 Preparation
…

For pipe less than 2.375 in. (60.3 mm) in OD, two test
welds shall be performed to obtain the required number
of test specimens.

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5.6 Testing of Welded Joints—Butt Welds

5.6.1 Preparation
…

The specimens shall be air cooled to ambient

temperature prior to being tested.
The full-section specimen shall be tested in accordance
with 5.6.2.2 and shall meet the requirements of 5.6.2.3.

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5.6.2 Tensile Strength Test

5.6.2.1 Preparation
The full-thickness tensile strength test specimens shall be
either of the types shown in Figure 4.

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5.6.2 Tensile Strength Test

5.6.2.1 Preparation
…
a) The standard specimens shall be
prepared as shown in Figure 4 a). They
may be machine cut or oxygen cut, and
no other preparation is needed unless the
sides are notched or are not parallel. If
necessary, the specimens shall be
machined so that the sides are smooth
and parallel.

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5.6.2 Tensile Strength Test

5.6.2.1 Preparation
…
b) The reduced section specimens shall
be prepared as shown in Figure 4 b).
The weld reinforcement may be
removed.

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5.6.2 Tensile Strength Test

5.6.2.2 Method
The tensile strength test specimens shall be
broken under tensile load using equipment
capable of measuring the load at which failure
occurs. The tensile strength shall be computed by
dividing the maximum load at failure by the
smallest cross-sectional area of the specimen, as
measured before the load is applied.

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5.6.2.3 Requirements
The tensile strength of the weld, including the fusion zone of each specimen, shall be greater than or equal
to the specified minimum tensile strength (SMTS) of the pipe material but need not be greater than or equal
to the actual tensile strength of the material.

If the specimen breaks outside the weld and fusion zone (i.e. in the parent metal) at a tensile strength not
less than 95 % of that of the SMTS of the pipe material, the weld shall be accepted as meeting the
requirements.

If the specimen breaks in the weld or fusion zone and the observed strength is greater than or equal to the
SMTS of the pipe material and meets the soundness requirements of 5.6.3.3, the weld shall be accepted as
meeting the requirements.

If the specimen breaks in the weld and below the SMTS of the pipe material, the weld shall be set aside and
a new test weld shall be made.

If a specimen breaks outside of both the weld and the heat-affected zone (HAZ) at a tensile strength not less
than 95 % of that of the SMTS of the pipe material, that specimen shall be accepted as meeting the test
requirements.

Any specimen that fails due to improper specimen preparation or testing may be replaced and retested.
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5.6.3 Nick Break Test

5.6.3.1 Preparation
The nick break test specimens
(see Figure 5, top) shall be
approximately 9 in. (230 mm) long
and approximately 1 in. (25 mm)
wide and may be machine cut or
oxygen cut. They shall be notched
with a hacksaw on each side at
the center of the weld, and each
notch shall be approximately 1/8
in. (3 mm) deep and the edges
shall be smooth and parallel.

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5.6.3 Nick Break Test

5.6.3.1 Preparation
…
Nick break specimens prepared in this manner
from welds made with certain mechanized and
semiautomatic processes may fail through the
pipe instead of the weld.

When previous testing experience indicates

that failures through the pipe can be expected,
the external reinforcement may be notched to
a depth of not more than 1/16 in. (1.6 mm),
measured from the original weld surface

At the company’s option, nick break

specimens for qualification of a procedure
using a semiautomatic or mechanized welding
process may be macroetched prior to being
nicked.

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5.6.3 Nick Break Test

5.6.3.2 Method
The nick break specimens shall be broken through
the weld by any convenient method (i.e. pulling,
bending, or striking). This does not exclude other
testing methods. The exposed area of the fracture
shall be at least 3/4 in. (19 mm) wide.

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5.6.3 Nick Break Test
5.6.3.3 Requirements
The exposed surfaces of each nick break specimen shall show complete
penetration and fusion.
The greatest dimension of any gas pocket shall not exceed 1/16 in. (1.6 mm),
and the combined area of all gas pockets shall not exceed 2 % of the exposed
surface area.
Slag inclusions shall not be more than 1/32 in. (0.8 mm) in depth and shall not
be more than 1/8 in. (3 mm) or one-half the specified wall thickness in length,
whichever is smaller. There shall be at least 1/2 in. (13 mm) separation
between adjacent slag inclusions of any size.

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5.6.3 Nick Break Test

5.6.3.3 Requirements
…
The dimensions should be measured as
shown in Figure 6. Fisheyes, as defined in
AWS A3.0, are not cause for rejection.
For a test weld diameter greater than 12 3/4
in. (323.9 mm), if only one nick break
specimen fails, then the specimen may be
replaced by two additional nick break
specimens from locations near to the failed
specimen. If either of the replacement nick
break specimens fail, the weld is considered
unacceptable.

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5.6.4 Root and Face Bend Test
5.6.4.1 Preparation
The root and face bend test specimens (see Figure 7) shall be approximately 9 in. (230 mm) long and
approximately 1 in. (25 mm) wide, and their long edges shall be rounded. They may be machine cut or
oxygen cut. The cover and root bead reinforcements shall be removed flush with the surfaces of the
specimen. These surfaces shall be smooth, and any scratches that exist shall be light and transverse to the
weld. The specimen shall not be flattened prior to testing.

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5.6.4 Root and Face Bend Test

5.6.4.1 Preparation
…
5.6.4.2 Method
The root and face bend specimens shall be bent in
a guided-bend test jig similar to that shown in
Figure 8.
Each specimen shall be placed on the die with the
weld at midspan. Face bend specimens shall be
placed with the face of the weld toward the gap,
and root bend specimens shall be placed with the
root of the weld toward the gap.
The plunger shall be forced into the gap until the
curvature of the specimen is approximately U
shaped. Alternate best test fixtures with bend radii
equal to or less than the radius specified in Figure 8
may be used at the discretion of the company.

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5.6.4.3 Requirements

The bend test shall be considered acceptable if no

crack or other imperfection exceeding 1/8 in. (3 mm)
or one-half the specified wall thickness, whichever is
smaller, in any direction is present in the weld or
between the weld and the fusion zone after bending.

Cracks that originate on the outer radius of the bend

along the edges of the specimen during testing and
that are less than 1/4 in. (6 mm), measured in any
direction, shall not be considered unless obvious
imperfections are observed.

For test weld diameter greater than 12 3/4 in. (323.9

mm), if only one bend specimen fails, the specimen
may be replaced with two additional specimens from
locations adjacent to the failed specimen. If either of
the replacement bend test specimens fails, the weld
is considered unacceptable.

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5.6.5 Side Bend Test
5.6.5.1 Preparation
The side bend test specimens
(see Figure 9) shall be
approximately 9 in. (230 mm)
long and approximately 1/2 in.
(13 mm) wide, and their long
edges shall be rounded. They
shall be machine cut, or they
may be oxygen cut to
approximately a 3/4 in. (19
mm) width and then machined
or ground to the 1/2 in. (13
mm) width. The sides shall be
smooth and parallel. The
cover and root bead
reinforcements shall be
removed flush with the
surfaces of the specimen.

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5.6.5 Side Bend Test

…
5.6.5.2 Method
The side bend specimens shall be bent in a
guided bend test jig similar to that shown in
Figure 8. Each specimen shall be placed on
the die with the weld at midspan and with the
face of the weld perpendicular to the gap.
The plunger shall be forced into the gap until
the curvature of the specimen is
approximately U shaped. Alternate bend test
fixtures with bend radii equal to or less than
the radius specified in Figure 8 may be used
at the discretion of the company.

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5.6.5.3 Requirements
Each side bend specimen shall meet the
root and face bend test requirements
specified in 5.6.4.3. For test weld
diameter greater than 12 3/4 in. (323.9
mm), a single failed side bend specimen
may be replaced with two additional
specimens from locations adjacent to
the failed specimen. If either of the
replacement bend test specimens fails,
the weld is considered unacceptable.

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5.7 Welding of Test Joints—Fillet Welds
To weld the test joint for a fillet weld, a fillet weld shall be made to one of the configurations shown in
Figure 10, following all the details of the welding procedure specification.

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5.8 Testing of Welded Joints—Fillet Welds

5.8.1 Preparation
To test the fillet-welded joint, test specimens shall be cut from the joint at the
locations shown in Figure 10. At least four specimens shall be taken and
prepared as shown in Figure 11.
The specimens may be machine cut or oxygen cut. They should be at least 1
in. (25 mm) wide and long enough so that they can be broken in the weld. For
pipes less than 2.375 in. (60.3 mm) in OD, specimens shall be cut from the
same general location. It may be necessary to make two test welds to obtain
the required number of test specimens; two specimens shall be removed
from each of two test welds. The specimens shall be air cooled to ambient
temperature prior to testing.

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5.8 Testing of Welded Joints—Fillet Welds

5.8.2 Method
The fillet weld specimens shall be broken in the weld by any convenient method.

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5.8.3 Requirements
The exposed surfaces of each fillet weld specimen
shall show complete penetration and fusion, and

a) the greatest dimension of any gas pocket shall not

exceed 1/16 in. (1.6 mm);

b) the combined area of all gas pockets shall not

exceed 2 % of the exposed surface area;

c) slag inclusions shall not be more than 1/32 in. (0.8

mm) in depth and shall not be more than 1/8 in. (3
mm) or one half the specified wall thickness in
length, whichever is smaller; and

d) there shall be at least 1/2 in. (13 mm) separation

between adjacent slag inclusions. The dimensions
should be measured as shown in Figure 6.

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