Pa ge |1

COMPETENCY - BASED LEARNING MATERIALS

Sector: METALS AND ENGINEERING SECTOR

Qualification:
SHIELDED METAL ARC WELDING (SMAW) NC II
Unit of Competency:
WELD CARBON STEEL PIPES USING SMAW
Module Title:
WELDING ON CARBON STEEL PIPES
Institution:

JACA SKILLS TRAINING AND ASSESSMENT

CENTER INC.
Brgy. Salawag Dasmariñas City, Cavite

JSTAC Date Developed: Document No.1

DECEMBER 2014

Shielded Metal Arc

Welding (SMAW) NC Developed by: Revision No.__
II JACA SKILLS
TRAINING
AND ASSESSMENT
CENTER INC.
 Pa ge |2

LIST OF COMPETENCIES

No. Unit of Competency Module Title Code

Weld Carbon Steel Plates Welding Carbon Steel Plates
1. MEE721306
using SMAW using SMAW
Weld Carbon Steel Pipes Using Welding Carbon Steel Pipes
2. MEE721306
SMAW Using SMAW

JSTAC Date Developed: Document No.1

DECEMBER 2014

Shielded Metal Arc

Welding (SMAW) NC Developed by: Revision No.__
II JACA SKILLS
TRAINING
AND ASSESSMENT
CENTER INC.
 Pa ge |3

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the module in Welding Carbon Steel Pipes Using SMAW . This
module contains training materials and activities for you to complete.

The unit of competency “Weld Carbon Steel Pipes Using SMAW” contains
knowledge, skills and attitudes required for Shielded Metal Arc Welding NC II. It
is one of the specialized modules at National Certificates Level (NC II).

You are required to go through a series of learning activities in order to

complete each learning outcome of the module. In each learning outcome are
Information Sheets and Resources Sheets (Reference Materials for further
reading to help you better understand the required activities). Follow these
activities on your own and answer the self-check at the end of each learning
outcome. You may remove a blank answer sheet at the end of each module (or get
one from your facilitator/trainer) to write your answers for each self-check. If you
have questions, don’t hesitate to ask you facilitator for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this
learner’s guide because you have:

 been working for some time

 already completed training in this area
If you can demonstrate to your trainer that you are competent in a particular
skill or skills, talk to him/her about having them formally recognized so you don’t
have to do the same training again. If you have a qualification or Certificate of
Competency from previous trainings, show it to your trainer. If the skills you
acquired are still current and relevant to the unit/s of competency they may
become part of the evidence you can present for RPL. If you are not sure about the
currency of your skills, discuss this with your trainer.

At the end of this module is a Learner’s Diary. Use this diary to record
important dates, jobs undertaken and other workplace events that will assist you
in providing further details to your trainer or assessor. A Record of Achievement
is also provided for your trainer to complete once you complete the module.

This module was prepared to help you achieve competency, in Welding Carbon
Steel Pipes Using SMAW. This will be the source of information for you to

JSTAC Date Developed: Document No.1

DECEMBER 2014

Shielded Metal Arc

Welding (SMAW) NC Developed by: Revision No.__
II JACA SKILLS
TRAINING
AND ASSESSMENT
CENTER INC.
 Pa ge |4

acquire knowledge and skills in this particular trade independently and at your
own pace, with minimum supervision or help from your instructor.

 Talk to your trainer and agree on how you will both organize the Training of
this unit. Read through the module carefully. It is divided into sections,
which cover all the skills, and knowledge you need to successfully complete
this module.

QUALIFICATION: SHIELDED METAL ARC WELDING NC II

UNIT OF COMPETENCY: Weld Carbon Steel Pipes Using SMAW

MODULE TITLE: Welding Carbon Steel Pipes Using SMAW

INTRODUCTION: This module covers the knowledge, skills and

proper attitude in groove welding on carbon steel
pipes in performing root pass, clean root pass, weld
subsequent/ filling passes, and perform capping.

NOMINAL DURATION: 80 HOURS

LEARNING OUTCOMES:

Upon completion of this module, the trainee/student must be able to:

1. Perform root pass
2. Clean root pass
3. Weld subsequent/filling pass
4. Perform capping

ASSESSMENT CRITERIA:

1. Root pass is performed in accordance with WPS and/or client

specifications.
2. Task is performed in accordance with company or industry requirement
and safety procedure.
3. Weld is visually checked for defects and repaired, as
4. required
5. Weld is visually acceptable in accordance with applicable codes and
standards
6. Root pass is cleaned and free from defects and discontinuities
7. Task is performed in accordance with approved WPS
8. Subsequent/ filling passes is performed in accordance with approved WPS

JSTAC Date Developed: Document No.1

DECEMBER 2014

Shielded Metal Arc

Welding (SMAW) NC Developed by: Revision No.__
II JACA SKILLS
TRAINING
AND ASSESSMENT
CENTER INC.
 9. Weld is visually checked for defects and repaired, as required
10. Weld is visually acceptable in accordance with applicable codes and
standards
11. Capping is performed in accordance with WPS and/or client specifications
12. Weld is visually checked for defects and repaired, as required
13. Weld is visually acceptable in accordance with applicable codes and
standards

PRE-REQUISITE:

BASIC AND COMMON COMPETENCIES

LEARNING OUTCOME #1: Perform root pass
Learning Contents: 1. Essentials of welding
2. Safe welding practices
3. Weld defects, causes and remedies
4. Welding Procedure and Specifications (WPS)
5. International welding codes and standards
6. Acceptable weld profiles
7. Welding technique and procedures

ASSESSMENT CRITERIA:

1. Root pass is performed in accordance with WPS and/or

client specifications.
2. Task is performed in accordance with company or
industry requirement and safety procedure.
3. Weld is visually checked for defects and repaired, as
required
4. Weld is visually acceptable in accordance with applicable codes
and standards

CONDITIONS:

Equipment

 AC-DC Welding Machine

 Welding Table
 Portable Grinder
 Portable Oven
 Welding Booth

Tools/Accessories

 Welding Mask
 Steel Brush
 Clear glass
 Chipping Hammer
 Dark glass

Supplies/Materials

 Electrodes
  Carbon steel plates
 Cutting grinding disc

Personal Protective Equipment

 Safety shoes
 Apron
 apron
 Leggings
 Safety goggles
 Gloves

Training Manuals

 Arc welding manuals

 Welding procedures specifications
 Welding standards

ASSESSMENT METHODS:

 Observation and interview

 Demonstration and interview
 Written test
 Portfolio
 LEARNING EXPERIENCES
Activities Special Instructions

1. Read Information Sheet 1.1 – 1 on the Read the information sheet

Essentials of welding . carefully
2. Answer Self – Check 1.1-1. Compare to answer key 1.1-1.
3. Read Information Sheet 1.1-2 on the Read the information sheet
Safe welding practices. carefully
4. Answer Self – Check 1.1-2. Compare to answer key 1.1-2.
5. Read Information Sheet 1.1-3 in Read the information sheet
identifying weld defects, causes and carefully
remedies
6. Answer Self – Check 1.1 -3. Compare to answer key 1.1-3.
7. Read Information Sheet 1.1 – 4 on Read the information sheet
Welding Procedures and Specifications carefully
(WPS).
8. Answer Self – Check 1.1 -4 (Written Compare to answer key 1.1-4.
Test)
9. Read Information Sheet 1.1-5 on Read the information sheet
International welding codes and standards. carefully
10. Answer Self – Check 1.1 -5 (Written Compare to answer key 1.1-5.
Test)
11. Read Information Sheet 1.1-6 on Read the information sheet
acceptable weld profiles. carefully
12. Answer Self – Check 1.1 -6 (Written Compare to answer key 1.1-6.
Test)
13. Guided by information sheet 1.1-7, Jot down observations.
observe the trainer as he demonstrates the
different welding techniques and
procedures correctly and properly.
14. Perform Job Sheets 1.1-7a-c on the Trainer evaluates performance
different welding techniques and and work outputs and makes
procedures. recommendations.
 INFORMATION SHEET No. 1.1-1

ESSENTIALS OF WELDING

After reading the Information Sheet, the trainee must be able

to determine the essentials of welding.

Weld quality and consistency can only be maintained with respect to the five
essentials. The five essentials of welding include the use of correct electrode size,
current, arc length or voltage, travel speed and electrode angles. All five must be
collectively and consistently maintain to successfully control the puddle and
produce a weld that is uniform in appearance, have consistent ripples, smooth
face contour, and no noticeable defect. Once the welder masters the ability to
consistently maintain the five essentials, the ability to control the puddle will
follow.

ELECTRODE SIZE

Choosing the correct electrode size involves many factors. If a smaller

recommended electrode is used, welding time and heat to the joint will increase. It
can result in increase costs, heat affected zone, cracking or distortion.
Larger electrode can cause melt – through and can be difficult to control in
out of position
joints. Poor appearance and possible defects can result. The welding procedure
designates the correct electrode size, generally based on metal type and thickness.
However, if no procedure or instruction is available the welder will have to choose
the correct electrode size.

CURRENT

The correct current setting is vital for maintaining consistency in weld

quality. If the current is too high, the electrode melts too fast, and the molten pool
is larger and irregular. If the current is too high when welding single vee -groove, it
might blow holes through the joint and cause large molten metal droplets to fall
out of the groove.
If the current is too low, there is not enough heat to melt the base metal. The
molten pool will be too small, piles up, and looks irregular. Poor penetration and
incomplete fusion in the joint can result.
TRAVEL SPEED

Incorrect travel is a common mistake. Sometimes travel speed is the only

condition a welder may need to change. Travelling too fast causes the puddle to
freeze too quickly. Because of this, impurities and gases can become entrapped,
making the bead face narrow with pointing ripple. Incomplete penetration due to
loss of the keyhole in root pass is possible.
Travelling too slow will cause the puddle to be large, with pile – up, and a
straight ripple pattern. For out of position welding, slow travel sped can cause the
puddle to drip out the joint.

ELECTRODE ANGLE
One of the most essentials is the use of the correct electrode angles. For fillet
and groove welds, correct electrode angles are vital for preventing undercut and
inadequate fill. When depositing a fillet weld the electrode should be held so that it
bisects the angle between the plates and is perpendicular to the line of the weld.
On groove weld, the technique is much the same; although varying slightly with
multiple pass welding.
There are two teams to specify electrode angles. These are travel angle and
work angles.
The travel angle applies to the position the electrode make with a reference
perpendicular to the axis of the weld in plane of the weld axis. It can be either a
drag angle or a push angle. A drag angle is when the electrode is pointing
backward, meaning the welder’s hand and electrode holder proceeds the puddle. A
push angle is when electrode is pointing just the opposite of the drag.
The work angle is the position the electrode makes with reference to the
surface of the plate on a plane perpendicular to the weld axis. On butt joints the
work angle is usually 90 degrees to the surface of the plate.
T o some degree, you can correct for an improper condition by varying the
essential variables. It is better though to have all conditions as correct as possible.

ARC LENGTH

Arc length is very important for weld puddle control. Correct arc length will
cause the deposit to be neat of even ripple and of good penetration.
Too long arc length will cause the deposit to coarse rippled and flatter than
normal with an increase in spatter. When welding a root pass in an open root vee
groove, the keyhole can grow too large and loose of weld control can result.

Too short an arc will cause deposited to be narrow, uneven and irregular
rippled and with poor fusion. The arc length reduces the voltage and increases the
amperage slightly but the electrode may stick to the work. When welding root
passes, too short an arc length often results n loss of the keyhole.
 SELF – CHECK 1.1-1

(Essentials of Welding)

TRUE OR FALSE

Direction: Read each statement below carefully. Write TRUE if the statement is
correct and FALSE if the statement is not correct.

______ 1. Using a larger electrode diameter can cause melt – through/ burn –

through.

______ 2. Travelling too fast will make the bead face narrow with pointing ripple.

______ 3. If the current is too low, the electrode melts too fast.

______ 4. Quality or sound weld is the result of correct current, constant voltage,

travel speed, electrode angle and correct electrode size.

______ 5. In fillet weld, electrode angle is not necessary for preventing undercut

and under fill.

 ANSWER KEY 1.1 – 1

Essentials of Welding

1. TRUE

2. TRUE

3. FALSE

4. TRUE

5. FALSE
 INFORMATION SHEET NO. 1.1 -2

Welding Personal Protective Equipment (PPE)

After reading the Information Sheet, the trainee must be able to identify the
different personal protective equipment and their uses.

The hazards in arc welding can endanger a welder’s life if he/she is not
wearing the proper protective clothing and equipment. Here are some information
on the suitable outfit that a welder must wear while welding:

WELDING SHIELD/HELMET

Welding shield/helmet is used to protect the face and eyes from the arc rays
(Infrared Rays, Ultra Violet Rays) and heat and spatter from the molten metal. The
arc is viewed through a filter which reduces the intensity of radiation but allows a
safe amount of light to pass for viewing the weld pool and end of the electrode.
The recommended minimum protective filter based on the welding current to
be used is shown in the table below:

Approximate Range
Of Welding Current Filter Lens Number

Up to 100 8
100 - 200 10
200 - 300 11
300 - 400 12
Over 400 13
LEATHER JACKET

Leather jacket is made of chrome leather and prevents the entry of sparks
between the welder’s clothes and body.

LEATHER APRON

Leather apron is made of chrome leather and provides a welder with

complete protection from sparks and hot metal from his/her chest to mid calf.
LEATHER GLOVES

Gloves are made of chrome leather and protect the welder’s hands from
heat, spatter, and radiation.

LEATHER SPATS

Spats are made of chrome leather and protect the feet from spatter.
SAFETY GLASSES

Safety clear glasses are used to protect the eyes when chipping slag and
grinding.

WELDERS CAP

Welders cap is used to protect welder’s head from spatters in out of

position welding or in confined spaces.
WELDERS LEATHER BOOTS

Welding Leather Boots is used to protect our feet from falling spatter,
sparks, and hot metals when welding overhead and confined spaces.

FACE SHIELD

Face Shield must also be worn where required to protect eyes. Welders must
wear safety glasses and chippers and grinders often use face shield in addition to
safety glasses.
 SELF – CHECK 1.1-2
Welding Personal Protective Equipment (PPE)

MULTIPLE CHOICE: Choose the correct answer and write the letter that
correspond to your choice on the answer sheet provided.

1. A safety gadget used to protect the face and eyes from the arc rays, heat and
spatter.
a. Welding gloves
b. Welding jacket
c. Safety shoes
d. Welding helmet/shield

2. The most serious danger from exposure to welding arc is,

a. X – rays
b. Beta – rays
c. Ultra Violet Rays
d. Sun rays

3. Protect the entry of falling hot slag and spatter.

a. Leggings
b. Welding gloves
c. Welding helmet
d. Clear glass

4. When welding at a current setting of 120 amperes, what is the recommended

filter lens number?
a. 8
b. 12
c. 10
d. 11

5. Safety gadget used to protect the eyes when chipping slag and grinding.
a. Safety glasses
b. Leather spats
c. Leggings
d. Welding gloves
 ANSWER KEY 1.1 – 2

Welding Personal Protective Equipment (PPE)

1. d

2. c

3. a

4. c

5. a
 INFORMATION SHEET 1.1 -3

Identifying Weld Defects, Causes and Remedies

After reading the Information Sheet, the trainee must be able to:
1. Identify the different welding defects and causes; and
2. Know the causes and remedies for these defects.

As previously explained, weld quality can only be attained by following the

five essentials, as preconditions for welding. Without due regard to these
essentials, defects will occur. The most common defects and corresponding causes
and preventions are discussed below.

A. POROSITY

CAUSES:

1. Short arc with exception of low hydrogen

2. Insufficient paddling
3. Impaired base metal
4. Poor Electrode
5. Improper Shield Coverage

REMEDIES:

1. Check Impurities in base metal

2. Allow sufficient paddling
3. Use proper current

B.POOR PENETRATION

CAUSES:

1. Speed too fast

2. Electrode too large
3. Current too low
4. Faulty penetration
REMEDIES:

1. Use enough current to obtain desired penetration- weld slowly

2. Select electrodes according to welding groove size
3. Leave proper gap at bottom of weld

C.WARPING

CAUSES:

1. Shrinkage of weld metal

2. Faulty clamping of parts
3. Faulty preparation
4. Over heating at joint

REMEDIES:

1. Peen joint edges before welding

2. Weld more rapidly
3. Avoid excessive space between parts
4. Pre-form parts before welding
5. Use proper sequence
6. Clamp or tack parts properly – back up to cool
7. Adopt a proper welding procedure
8. Use high speed, moderate penetration process

D.UNDERCUTING

CAUSES:

1. Faulty Electrode or poor manipulation

2. Faulty Electrode use
3. Correct to high

REMEDIES;

1. Use a uniform weave in butt welding

2. Avoid using an overly large electrode
3. Avoid excessive weaving
4. Use moderate current weld slowly
E. CRACK WELDS

CAUSES:

1. Wrong electrode
2. Weld and parts sizes unbalanced
3. Faulty welds
4. Faulty preparation
5. Rigid joint

REMEDIES:

1. Design structure to eliminate rigid joints

2 Heat parts before welding
3. Avoid welds in string beads
4. Keep ends free to move as long as possible
5. Make sound welds of good fusion
6 Adjust weld size to parts size
7. Allow joints a proper and uniform gap
8 Work with amperage as low as possible

F.POOR APPEARANCE

CAUSES:

1. Faulty electrode
2. over hang
3. Improper use of electrode
4. Wrong arc voltage and current

REMEDIES:

1. Use a proper welding technique

2. Avoid over heating
3. Use a uniform weave
4. Avoid overly high current
G.POOR FUSION

Lack of fusion, also called cold lapping or cold shuts

CAUSES:

1. Wrong speed
2. Current improperly adjusted
3. Faulty preparation
4. Improper electrode size

REMEDIES:

1. Adjust electrode to match joint

2. Weave must be sufficient to melt sides of joint
3. Select proper current and voltage
4. Keep weld metal from flowing away from plates

H. SPATTER

CAUSES:

1. Arc blow
2. Current too high
3. Arc too long
4. Faulty electrode

REMEDIES:

1. Clean parts in weld area

2. Adjust current
3. Adjust voltage
4. Pick suitable electrode
 SELF – CHECK 1.1-3

Identifying Weld Defects, Causes and Remedies

MULTIPLE CHOICE: Choose the correct answer and write the letter that
correspond to your choice on the answer sheet provided.

1. When electrode coating absorbs moisture, what will be the effect to the weld
bead?
a. poor penetration
b. porosities
c. excessive penetration
d. undercut

2. Incomplete sidewall fusion is normally found between

a. weld and base metal
b. HAZ and base metal
c. root joint
d. cover pass and filling pass

3. Welding distortion, warp and stresses are cause by

a. weaving technique
b. intermittent welding
c. high temperature heat
d. backstop welding

4. The most common cause of undercut in a weld is too

a. low a current
b. high an arc
c. short an arc
d. high a current

5. Which of the following weld defects DOES NOT have any tolerance for
acceptance?
a. crack
b. porosity
c. slag inclusion
d. undercut
 ANSWER KEY 1.1 –3
Identifying Weld Defects, Causes and Remedies

1. b

2. a

3. c

4. d

5. a
 INFORMATION SHEET 1.1 -4

Welding Procedure Specification (WPS)

After reading the Information Sheet, the trainee must be able to:
1. Identify welding procedure specification:
2. Interpret welding procedures specification.

A Welding Procedure Specification (WPS) is a formal document describing

welding procedures. The purpose of the document is to guide welders to the
accepted procedures so that repeatable and trusted welding techniques are used. A
WPS is developed for each material alloy and for each welding type used. Specific
codes and/or engineering societies are often the driving force behind the
development of a company's WPS. A WPS is supported by a Procedure
Qualification Record (PQR or WPQR). A PQR is a record of a test weld performed
and tested (more rigorously) to ensure that the procedure will produce a good weld.
Individual welders are certified with a qualification test documented in a
Welder Qualification Test Record (WQTR) that shows they have the understanding
and demonstrated ability to work within the specified WPS.

The following are definitions for WPS and PQR found in various codes and
standards:

According to the American Welding Society (AWS), a WPS provides in detail

the required welding variables for specific application to assure repeatability by
properly trained welders. The AWS defines welding PQR as a record of welding
variables used to produce an acceptable test weldment and the results of tests
conducted on the weldment to qualify a Welding Procedure Specification.

The American Society of Mechanical Engineers (ASME) similarly defines a

WPS as a written document that provides direction to the welder or welding
operator for making production welds in accordance with Code requirements.
ASME also defines welding PQR as a record of variables recorded during the
welding of the test coupon. The record also contains the test results of the tested
specimens.

In Europe, the European Committee for Standardization (CEN) has adopted

the ISO standards on welding procedure qualification (ISO 15607 to ISO 15614)
and on welder qualification (ISO 9606), with the exception of qualification for steel
welders, where a new version of the old European EN 287-1 standard still applies.
EN ISO 15706 defines a WPS as "A document that has been qualified by one of the
methods described in clause 6 and provides the required variables of the welding
procedure to ensure repeatability during production welding". The same standard
defines a Welding Procedure Qualification Record (WPQR) as "Record
comprising all necessary data needed for qualification of a preliminary welding
procedure specification ".In addition to the standard WPS qualification procedure
specified in ISO 15614, the ISO 156xx series of standards provides also for
alternative WPS approval methods. These include: Tested welding consumables
(ISO 15610), Previous welding experience (ISO 15611), Standard welding
procedure (ISO 15612) and Preproduction welding test (ISO 15613).

In the oil and gas pipeline sector, the American Petroleum Institute API 1104
standard is used almost exclusively worldwide. API 1104 accepts the definitions of
the American Welding Society code AWS A3.

Welding Procedure Specification:- (Example FORM)

Weld Procedure Number 30 P1 TIG 01 Issue A
Qualifying Welding Procedure (WPAR) WP T17/A

Method Of
Machine and
Preparation
Degrease
Manufacturer: National Fabs Ltd and Cleaning:
25 Lane End Parent Metal Grade 304L
Birkenshaw Specification: Stainless Steel
Leeds
Parent Metal
3 to 8mm Wall
Thickness
Location: Workshop
Pipe Outside
Welding 25 to 100mm
Manual TIG Diameter
Process:
Joint Type: Single Sided Butt Weld Welding Position: All Positions
Welding
Upwards
Progression:

Joint Design Welding Sequences

Welding Consumables Production Sequence:

Type, Designation Trade Name: BS 2901 Part 2 : 1. Clean weld and

308S92 25mm borders to
bright metal
Any Special Baking or Drying: No using approved
solvent.
Gas Flux: Argon 99.99% Purity 2. Position items to
be welded
ensuring good fit
Gas Flow Rate Shield: 8 – 12 LPM up and apply
Backing: 5 LPM purge
Tungsten Electrode Type / Size: 2 % Thoriated 2.4mm 3. Tach weld parts
Dia. together using
TIG, tacks to at
Details of Back Gouging / Gas Backing least 5mm min.
Backing: length
4. Deposit root run
Preheat Temperatures: 5°C Min using 1.2mm dia.
wire.
Interpass Temperature: 200°C Max 5. Inspect root run
internally
Post Weld Heat Treatment Not Required 6. Complete weld
using 1.6mm dia.
wire using
Time, temperature, method: stringer beads as
required.
7. 100 % Visual
Heating and Cooling Rates Inspection of
completed weld
SELF – CHECK 1.1 – 4
Welding Procedure Specification (WPS)

Test I – IDENTIFY THE FOLLOWING:

1. ASME

2. AWS

3. API 1104

4. ISO 15612

5. ISO 15613

Test II – ESSAY (5pts.)

1. What is WPS?
 ANSWER KEY 1.1 -4

Welding Procedure Specifications

Test I:

1. Welding Procedure Specification

2. American Welding Society

3. American Petroleum Institute 1104 - oil and gas pipeline sector

4. Tested welding consumables

5. Standard welding procedure

Test II

1. A Welding Procedure Specification (WPS) is a formal document describing

welding procedures. The purpose of the document is to guide welders to the

accepted procedures so that repeatable and trusted welding techniques are used.
 Information Sheet No. 1.1-5
International Welding Codes and Standard

After reading the Information Sheet, the trainee must be able to:

1. Identify international welding codes and standards; and

2. Interpret/apply international welding codes and standards.

Welder Qualifications

This information sheet is designed to give you a broad overview of the

specifications, codes and standards that are widely used in welded fabrication,
construction and maintenance work.

The begins with definition of codes, standards, specifications and related

terms. Another section deals with the advantages associated with the
standardization. In addition, the module identifies various agencies and societies
that sets codes and standards. The module then moves on to the identification and
study of specifications, codes and standards that govern welding in relation to:


structural steel,

boilers and pressure vessels,

piping systems,

pipelines and transmission system and

storage tanks

Before a welder can begin working on any job covered by a welding code or
specification be must become a certified under the code that applies. Many
different codes are in use today and it is exceeding important that the specific code
is referred to when taking qualifications test. In general the following type of work
is covered by codes pressure piping, high way and rail ways bridges, public
buildings tanks and containers that will hold flammable or explosive, materials
cross country pipe line aircraft ordinance.

Certification is obtained differently under the various codes certification

under one code will not necessarily qualify a welder under a different code. In most
cases certification for one employer will not allow the welder to work for another
employer .Also the welder uses a different process or if the procedure
adhere drastically re- certification is not required providing the work performed
meets the quality requirement. An exception is the air craft code which requires re-
qualification every six months.

Qualification test may be begin by responsible manufacturers or

contractors. On pressure vessel work the welding procedure must also be qualified
and this must be done before the welders can be qualified. Under these codes, this
is not necessary. To become qualified and the welder must make specified welds
using the required process, base metal ,thickness, electrode, type position and
joint design .Test specimen must be made according to standardize size sand
under observation of a qualified person .In most cases government specifications a
inspector must witness the making of welding specimen must be properly
identified prepared for testing. The most common test is the guided bead test,
however in some cases x-ray examinations, fracture test or in order test are
employed satisfactory completion of test specimen and providing that they meet
acceptability standards will qualify the welder for specific for the specific types of
welding. The welding that will be allowed again depends on the particular code. In
general however the range of thickness may be welded less difficult positions may
be employed and steels of fewer alloys are usually included.

Qualifications of welder is an extremely technical subject and cannot be

covered .It is recommended that the code be obtained and studied prior to taking
any test.

Terms Used In This Section:


Codes – documents that govern and guide welding and other activities.
Codes generally use the word shall to indicate the mandatory use of
certain types of materials, methods and procedures.

Standards – Documents that govern and guide welding and other
activities. Standards generally describe the requirements for materials,
process, products, systems or services rendered. Standards often
specify the procedures, methods, equipments and tests that determine
if standards requirements have been met. Standards can be in the
form of codes, specifications, classifications and guides.

Specifications – Are similar to codes excepts that specifications mainly
provide requirements for products rather than processes.
 Purpose:

The purpose of Codes, Standards and specifications is to secure that safe

and reliable products are produced and that those persons working around welded
structures and equipment are not exposed to undue danger or hazard to their
health.

Welding Specifications:

 G – GROOVE
 F – FILLET
PLATE

1 – FLAT POSITION


2 – HORIZONTAL POSITION
3 – VERTICAL POSTION

4 – OVER – HEAD POSITION

PIPE

1 – MOVABLE PIPE POSITION


2 – FIXED / MOVABLE VERTICAL PIPE POSITION
5 – FIXED HORIZONTAL PIPE POSITION

6 – FIXED 45 DEGREE PIPE POSITION

1. 2G – MEANS PIPE GROOVE, FIXED / MOVABLE VERTICAL PIPE POSITION

2. 5G - MEANS PIPE GROOVE, FIXED HORIZONTAL PIPE POSITION

3. 6G - MEANS PIPE GROOVE FIXED 45 DEGREE PIPE POSITION

 SELF – CHECK 1.1 – 5

International Welding Codes and Standard

MATCHING TYPE: Match column A to column B. Write only the letter on your
answer sheet.

Column A Column B

___ 1. Means Pipe Groove, A. 1F Plate

Fixed Horizontal Pipe Position
B. 6G Pipe
___ 2. Groove Weld Horizontal
Position Plate C. 2G Pipe

___ 3. Movable Pipe Position D. 1G Pipe

___ 4. Means Pipe Groove, Fixed E. 4G Plate

/ Movable Vertical Pipe Position
F. 2G Plate
___ 5. Means Pipe Groove Fixed 45
Degree Pipe Position G. 5G Pipe

___ 6. Groove Weld Over – Head

Position Plate

___ 7. Fillet Weld Flat Position Plate

 ANSWER KEY 1.1 – 5
International welding codes and standards

1. G

2. F

3. D

4. C

5. B

6. E

7. A
 Information Sheet no. 1.1 – 6
Weld Profiles

After reading the Information Sheet and viewing of Good and Bad welds
indicators video, the trainee must be able to:

1. Different Weld Profiles; and

3. Identify Good and Bad Welds.

Different Weld Profiles

A B C

A) Amperage correct (GOOD)

B) Amperage too low (BAD)
C) Amperage too high (BAD)
 Indicators of Good Weld Indicators of Bad Weld
1. Proper Current/ voltage/speed 1. Welding Current too high
2. Nice Convex 2. Arc too long/ voltage high
3. Straight line/ edge 3. Excessive filling up of weld
4. Smooth weld bead metal
5. Uniform weave/Ripples 4. over lapping bead
6. An efficient Weld 5. Bead very irregular
7. Excellent Weld 6. Irregular deposit
8. No Defects 7. Weld not properly
9. Good Penetration 8. Welding speed too fast
10. No Spatter 9. Welding speed too slow
10. Poor Penetration
11. Poor weld Appearance
12. No bead
13. War page metal
14. Distortion of metal
15. Warping of metal
16. Crack Welds
17. Weld Streets
18. Shrinkage metal
19. Poor internal fusion weld
20. Brittle Welds
21. Magnetic Blow
22. Pinholes
23. Cold laps
24. Concavity
 SELF – CHECK 1.1 – 6

Weld Profiles

MATCHING TYPE: Match indicators in column A to its results in column B.

Write only the letter on your answer sheet.

Column A Column B

____ 1. Voltage High A. Wet Electrode

B. Arc Length Too Long

____ 2. High Current
C. Spatter

____ 3. Arc Strike D. Low Current

_____ 4. Slag Inclusion E. Failure To Clean The

Weld

_____ 5. Porosity F. Improper Starting Of Arc

G. Undercut
_____ 6. Arc Blow

_____ 7. Poor Penetration

 ANSWER KEY 1.1 – 6
Weld Profiles

1. B

2. G

3. F

4. E

5. A

6. C

7. D
 Job Sheet No. 1.1.7a
Welding Technique and Procedure

Title: Perform Root Pass

Performance Objectives: Perform root pass in a multiple pass groove

weld in Flat position (1G)

Supplies and Materials: 2 pcs. Flat bar 10mmx60mmx150mm MS

2 pcs. Welding Electrode E6011/E6010 #3.2mm

Tools and Equipment: Welding Machine w/ complete accessories

Automatic cutting machine
Chipping hammer
Steel brush
Welding gloves
Welding jacket
Welding helmet
Steps:
1. Proceed to the Workstation at the SMAW Practical Work Area
2. Prepare the edge of the two(2) plates, with a bevel angle of 30
degrees and 2mm root face.
3. Wear suitable protective clothing to avoid burns and radiation
4. Set the welding machine;
Current setting:3.2mm, E6013: 90 – 120 amperes
5. Put the plates on the welding table in flat position and make sure that
the root gap is 3.2mm.
6. Position the plates;
Clamp the plates in the positioner in a flat position.
7. Position yourself comfortably with the electrode grip to the holder.
8. Strike the arc and hold the electrode at 90 degrees work angle and
75 – 80 degrees travel.
9. Maintain a short arc.
10. Move the electrode using a whipping motion and maintain a keyhole
Until you reach the other end of the plates.
11.Clean and check your work based on the Performance Criteria
Checklist.
12. After doing the task, present your work to your Trainer for evaluation.

Assessment Method:

Performance Test and Evaluation of finished output

Performance Criteria Checklist

Job Sheet 1.1-7

Welding Technique and Procedure

Trainees Name ______________________________ Date: _________

CRITERIA YES NO
Root pass is performed in accordance with WPS and/or
client specifications or as specified by welding codes and
standards on:

 concavity
 convexity
 undercut
 excess penetration
 lack of fusion
 cracks
 burn – through
Task is performed using PPE
Weld is visually checked for def ects and repaired, as
required
Weld is visually acceptable in accordance with applicable
codes and standards

______________________________ _____________________________

Trainer Date
 Terms and Definitions

1) base metal – the metal that is to be worked or welded

2) weld bead – a deposit of filler metal from a single welding pass
3) weld defect– an irregularity that spoils the weld appearance or
impairs the effectiveness of the weld or weldment by
causing weakness or failure
4) weld line – the junction of weld metal and the base metal, or
the junction of base metal parts when filler metal is not used
5) weldment – an assembly or structure whose component parts are joined
by welding
6) welding – joining two metals by applying heat to melt and fuse
them, with or without filler metal
7) welding electrode – the current-carrying rod used to strike an arc
← between rod and metal
9) welding rod – filler metal in the form of a rod or heavy wire
10)welding torch –a gas mixing and burning tool for the welding of metal
10) undercut – is a groove at the toe ( or at the root) of a weld run due on welding.
11) slag inclusion – these are caused by slag trapped in the weld metal.
11) incomplete penetration – failure of weldment to extend into the root of the
joint to provide full throat depth.
13) porosity – is entrapped gas cavities formed during solidification of the weld
14) cracks – are fractured that displace an opening or a split in the weld or
base metal.
15) Codes – documents that govern and guide welding and other activities. Codes
generally use the word shall to indicate the mandatory use of certain
types of materials, methods and procedures.
16) Standards – Documents that govern and guide welding and other
activities. Standards generally describe the requirements for
materials, process, products, systems or services rendered.
17) Specifications – Are similar to codes excepts that specifications mainly
provide requirements for products rather than processes.
18) Welding Procedure Specification (WPS) - is a formal document
describing welding procedures. The purpose of the document is to
guide welders to the accepted procedures so that repeatable
and trusted welding techniques are used.
19) welding helmet – is used to protect the face and eyes from the arc rays, heat
and spatter.
20) welding gloves – are made of chrome leather to protect welder’s hands
from heat spatter and radiation.