Inspection of Oil Pipeline based on API 1104

Inspection of Oil Pipeline based on API 1104

The Inspection of Oil Pipelines Course based on API 1104 focuses on the principles and requirements outlined in the American Petroleum Institute (API) Standard 1104, which is the code for welding pipelines and related facilities in the oil and gas industry. This course provides participants with the skills and knowledge needed to inspect oil and gas pipeline welding, ensuring compliance with API 1104 standards throughout the welding and inspection process.

Overview of API 1104:

API 1104 is the internationally recognized standard for the welding of pipelines and related facilities. It establishes the guidelines for the fabrication, inspection, and testing of welding on pipelines used for the transportation of petroleum, natural gas, and other hydrocarbon products. The standard covers welding procedure qualification, welder qualifications, inspection criteria, and acceptance standards for weld quality.

Course Objectives:

• Understand the requirements of API 1104 for oil and gas pipeline welding.
• Gain knowledge about welding processes used in pipeline construction and the inspection methods required by API 1104.
• Learn how to conduct inspections to verify compliance with welding procedure specifications (WPS) and welder qualifications.
• Become familiar with destructive and non-destructive testing (NDT) methods used to inspect pipeline welds.
• Understand the acceptance criteria for pipeline welds, including visual inspection and other testing methods.
• Learn about documentation requirements for welding procedures, welder qualifications, and inspection records.

Key Topics Covered in the Course:

1- Introduction to API 1104 Standard

• Overview of the API 1104 code, its purpose, and its importance in pipeline construction and maintenance.
• Understanding the scope of the standard, including its application in the oil and gas pipeline industry for both onshore and offshore pipelines.
• Regulatory framework: How API 1104 integrates with government regulations and other industry standards such as ASME and CSA.

2- Welding Processes for Pipelines

• Understanding the key welding processes covered by API 1104, such as:
  • Shielded Metal Arc Welding (SMAW)
  • Gas Metal Arc Welding (GMAW)
  • Gas Tungsten Arc Welding (GTAW)
  • Submerged Arc Welding (SAW)
• Detailed explanation of pipeline welding techniques including manual, semi-automatic, and automatic welding.
• Key factors affecting weld quality, such as preheat temperature, interpass temperature, and welding speed.

3- Welding Procedure Specifications (WPS)

• Developing and qualifying a Welding Procedure Specification (WPS) according to API 1104.
• Procedure Qualification Records (PQR): Documentation of the testing results required to demonstrate that a welding procedure will produce sound welds.
• Reviewing the essential variables of a WPS, including base metal thickness, filler metals, welding positions, and welding techniques.

4- Welder Qualifications

• The process of welder qualification as per API 1104 requirements, which ensures that welders are capable of producing welds that meet the required quality standards.
• Understanding the testing procedures for qualifying welders, including visual inspection, bend testing, and other mechanical tests.
• Requalification of welders: When and how welders must be requalified, especially after a failed test or process changes.

5- Inspection of Pipeline Welds

• Visual inspection (VT): Inspecting the pipeline welds for surface defects such as cracks, porosity, undercut, and other discontinuities.
• In-process inspection: Monitoring the welding process to ensure compliance with WPS and maintaining weld quality during fabrication.
• Post-weld inspection: Final inspection of welds, including evaluating the root and final passes, ensuring proper fusion, and compliance with specified dimensions and tolerances.

6- Non-Destructive Testing (NDT) Methods for Pipelines

• API 1104 places a strong emphasis on non-destructive testing to ensure the structural integrity of pipeline welds. Key NDT methods covered in the course include:
  • Radiographic Testing (RT): Using X-rays or gamma rays to detect internal defects like lack of fusion, inclusions, or porosity in welds.
  • Ultrasonic Testing (UT): A method for detecting internal flaws using high-frequency sound waves, commonly used to assess the weld’s internal integrity.
  • Magnetic Particle Testing (MT): Detecting surface and near-surface defects in ferromagnetic materials by applying a magnetic field.
  • Liquid Penetrant Testing (PT): Used to identify surface-breaking defects in non-porous materials by applying a dye or penetrant to the weld surface.
  • Visual Testing (VT): The most basic form of weld inspection, ensuring that weld profiles meet the API 1104 standards.

7- Destructive Testing Methods

• API 1104 also outlines destructive testing methods for pipeline welds, particularly during the qualification of welding procedures and welder qualification:
  • Tensile Testing: Measuring the strength of the weld to ensure it meets the minimum required standards.
  • Bend Testing: Testing the ductility and toughness of the weld by bending it to a specified angle without cracking.
  • Nick Break Testing: Inspecting for internal flaws by fracturing the weld across the thickness.

8- Acceptance Criteria for Welds

• Weld quality standards: API 1104 provides detailed criteria for accepting or rejecting welds based on visual inspection and NDT results.
• Types of weld defects: Identifying common defects such as lack of fusion, incomplete penetration, cracks, undercut, porosity, and inclusions.
• Defect limits: Understanding the allowable defect sizes and limits set by API 1104 for various types of flaws.
• Repair of welds: Procedures for repairing defective welds and re-inspecting after repairs to ensure compliance with API 1104 standards.

9- Documentation and Record-Keeping

• Welding records: Maintaining records of all WPS, welder qualifications, and inspection results.
• Inspection reports: Properly documenting NDT results, including radiographs, ultrasonic data, and visual inspection findings.
• Quality control procedures: Ensuring that all welding and inspection activities are documented and meet regulatory and API 1104 requirements.

10 – Inspection During Pipeline Construction

• Pre-welding inspection: Ensuring that all materials, joints, and welding equipment meet the API 1104 requirements before welding begins.
• In-process inspection: Monitoring welding activities to verify that the WPS is followed, including checking welding parameters such as preheat and interpass temperatures.
• Post-welding inspection: Conducting final inspections on the completed welds to ensure they meet the acceptance criteria.

Target Audience:

• Welding Inspectors: Professionals involved in inspecting welds on oil and gas pipelines.
• Pipeline Engineers: Engineers responsible for overseeing the welding and construction of pipelines.
• NDT Technicians: Technicians performing non-destructive testing on pipeline welds.
• Quality Control Personnel: Individuals responsible for ensuring that welding and inspection activities comply with API 1104.
• Welding Supervisors: Supervisors overseeing welding operations in the oil and gas pipeline industry.

Certification:

Upon successful completion of the course, participants typically receive a certificate of completion. This certification demonstrates their competence in inspecting oil and gas pipeline welding as per API 1104. Certification is valuable for professionals involved in pipeline construction, ensuring that welds meet the required standards for safety and performance.