TVL – Industrial Arts

Shielded Metal Arc

Welding NC II
Groove Welding on Carbon Steel Pipes
A Group of welders, welding a carbon steel pipe using
SMAW welding process
1
 Table of Contents
Page no.
Cover page 1
Table of Contents 2

Groove Welding on Carbon Steel Pipes

Introduction 3
Module Content 3
Module Competency 3
Lesson 1: Pipe preparation and tack welding 4
Pre-test 1.1 4
Lesson Information 1.2 6
Lesson Activity 1.3 9
Post-test 1.4 10
Lesson 2: Groove Welding on Carbon Steel Pipe (1G) 11
Pre-test 2.1 11
Lesson Information 2.2 13
Lesson Activity 2.3 21
Post Test 2.4 21
Lesson 3: Groove Welding on Carbon Steel Pipe (2G) 22
Pretest 3.1 22
Lesson Information 3.2 24
Lesson Activity 3.3 29
Post-test 3.4 30
Lesson 4: Groove Welding on Carbon Steel Pipe (5G) 31
Pre-test 4.1 31
Lesson Information 4.2 33
Lesson Activity 4.3 41
Post-test 4.4 41
Lesson 5: Groove Welding on Carbon Steel Pipe (6G) 42
Pre-test 5.1 42
Lesson Information 5.2 44
Lesson Activity 5.3 50
Post-test 5.4 50
Lesson 6: Welding Quality 51
Pre-test 6.1 51
Lesson Information 6.2 53
Lesson Activity 6.3 58
Post-test 6.4 58
Lesson 7: Welding Inspection 59
Pre-test 7.1 59
Lesson Information 7.2 61
Lesson Activity 7.3 67
Post-test 7.4 67
Lesson 8: Welding Procedure Specification 68
Pre-test 8.1 68
Lesson Information 8.2 70
Lesson Activity 8.3 75
Post-test 8.4 75
Definition of Terms ---
Reference ---

2
Introduction

Every day countless miles of steel pipelines are installed worldwide for
varied civil and industrial purposes. They form networks comparable to a system
of road networks, which are definitely much more complex and carry liquids that
have become essential for all us. To comply with technical specifications and
fulfil the necessary safety requirements, dedicated materials and welding
processes, which have evolved with the sector, have been developed in recent
years. The main welding process used to install these pipelines is Shielded Metal
Arc Welding (SMAW) with coated electrode, which, thanks to its ease and
versatility, it is still the one most used today. It is more productive and less
expensive and favored process to weld pipes and it can reach positions of difficult
accessibility.

This module entitled “Groove Welding on Carbon Steel Pipes (SMAW) is one
of the learning outcomes of SMAW NC II under the track Technical Vocational
Livelihood strand Industrial Arts. It is a training program which comprises the
knowledge, skills and attitude of a welder. This module contains training
materials and activities related to the welding activities. This module will equip
you the fundamentals of welding and mechanics on how to weld on groove in 1G,
2G, 5G and 6G position, identify the groove joint details, Pipe preparation, tack
welding, and weld defects so that you can apply corrective actions to perform
groove welds and will serve as a vital tool for learning. In this module, you are
required to go through a series of learning activities to achieve the required
learning competency. This module provides lesson information and activities that
will help you deepen your understanding of the concepts and learning
competencies. Follow and answer the activities on your own. If you have
questions, do not hesitate to ask for assistance from your facilitator/teacher.

Remember the following instructions:

• Take your time reading and understanding the lesson.

• Write down points for clarification and discuss this with your teacher.
• Perform and answer all activities provided here in module.
• Answer all activities in a separate sheet of paper.
• Answer the Pretests before reading the lesson.
• Have a good time while learning with this module.

Module Competencies

After going through in module 1, you are expected to:

1. Identify the parameters for the pipe preparation and tack welding.

2. Understand the concept of Pipe preparation and groove welding.

3. Analyze the causes and remedies of pipe weld defects.

4. Perform groove welding on 1G, 2G, 5G and 6G welding position.

3
 LESSON 1: PIPE PREPARATION AND TACK WELDING
The scope of this chapter is to recommend a preparation and tacking procedure
for the construction of joint on sections of carbon steel pipe. A fine cut and well
grinded edge of the pipe lowers the possibility of weld defects.

Learning Competencies

By the end of this lesson, you are expected to:

1. Identify the parameters for the pipe preparation and tack welding.

2. Understand the concept of Pipe preparation and tack welding.

3. Perform tack welding theoretically prior to root pass procedures.

Pre-test 1.1

You must be eager to browse the content of the lesson. However, first, please let
us determine your prior knowledge by answering the pre-test to measure the
topics you have known so far.

Multiple choice. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

1. What should be the recommended bevel angle of a pipe prior to

welding?

a. 35-degree b. 90-degree c. 60-degree d. 15-degree

2. What term that is used when referring the angle that should be grinded
for pipe welding preparation?

a. V-groove b. Bevel angle c. Included angle d. Root angle

3. What is the main purpose of creating a bevel angle on pipe edges?

a. To clean the pipe and minimize rusts.

b. It is a space provided for root pass and hot pass.
c. For easy penetration of cap pass.
d. To lessen the time needed when depositing welds.

4. How should you prepare pipe edges prior to welding?

a. File the burrs then grind.

b. Grind the rough edges then use file to smoothen the edge.
c. Grind only the edges.
d. Use a Wheatstone to polish rough edge surfaces then grind afterwards.

5. In taking the clock face as reference, Where should you put the four
tack welds in a pipe?

4
a. 12 o’clock, 3 o’clock, 5 o’clock, 10 o’clock
b. 12 o’clock, 5, o’clock, 6 o’clock, 10 o’clock
c. 12 o’clock, 3 o’clock, 6 o’clock, 9 o’clock
d. 12 o’clock, 4 o’clock, 7 o’clock, 10 o’clock
6. What is the maximum misalignment for steel pipes?

a. Base on the size of the spacing wire. b. Base on the pipe thickness
c. 2.5mm d. 2.0mm

7. What is the common name of the electrode used for creating an

accurate root gap on pipes?

a. Spacing wire b. Rod c. Uncoated electrode d. Coated electrode

8. An E6010 electrode with a diameter of 3.2mm will be used for root pass
on a pipe that has 8mm thickness, what should be the recommended
distance of its root gap?

a. 8mm b. 2.5mm c. 2.3mm d. 3.2mm

9. What will be the cause of incorrect joint preparation?

a. Faulty tack welding b. Smooth tack welding

c. Good penetration in root pass d. Easy grinding on tack welds

10. What is the approximate thickness on tack welds in pipes?

a. 1.6mm
b. Base on the size of the electrode used for root pass
c. Base on the pipe’s thickness
d. 3.2mm

5
Lesson Information 1.2

Pipe preparation and tack welding

After cutting the pipe, grind the edges and create a beveled angle, at least
60degree angle (See in figure 1.1). Eliminate the burr caused by the grinding
operation. After grinding the pipe, clean the edge using files. The root gap and
root face for every joining pipe should be the same size as the diameter of the
electrode that should be use for the welding operations (See in figure 1.2).

Figure 1.1

Figure 1.2
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 The ampere should be adjusted according to the electrode used and speed
of travel. It varies in case-to-case basis and should not stick to the same amperes
when using different steel, welding machine or root face thickness.
In pipe alignment procedures, Rest one of the pipe sections on a flat surface
with the beveled edge facing upwards.
Peel-off an electrode’s coat, bend it and use it as basis for your pipe’s root
gap (See in figure 1.3). The Peeled-off electrode that is used as spacing tool for
your pipe is commonly called “Spacing wire”.
The first and second tack weld should be tacked beside the spacing wire
so that there is enough space to remove the spacing wire from the pipe (See in
figure 1.4).

Figure 1.3

Figure 1.4

In the case of uneven root gap, make a third tack where the gap is greatest,
in such a way that weld shrinkage will close it up. If the distance between the
edges on the most open side is too great to permit the third tack, first correct the
distances compressing the most open side. Place the third and fourth tacks at
right angles to the first and second (See figure 1.5).
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Figure 1.5
Place a spacing wire on the beveled edge then rest the second pipe section
on the spacing wire with the beveled edge facing downwards. Align the two
sections to form the desired beveling. In accordance with the API code, the
misalignment must not exceed about the same diameter of your spacing wire.
At this point start the tacking operation, laying a 12mm to 22mm long seam
(See figure 1.6).

Figure 1.6
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 The tack weld should penetrate the root in order to form an internal
projection and both edges of the bevel must be fused.
Grind the external surface of the tacks in such a way that the bead height
is approximately the size of the spacing wire to facilitate the start of the first bead
(See figure 1.7). To obtain a quality weld, correct joint preparation and accurate
tacking are necessary. Faulty tacking will cause defects in the succeeding weld
deposits.
Tack welds was simply done by just tapping your electrode to the
workpiece for a second until it penetrates to the root. A good tack weld should
not be too thick and it should be easy to remove in case there is a misalignment
to your pipe.

Figure 1.7

Lesson Activity 1.3

Direction. Read and reflect each statement carefully. Write your opinion in a
separate sheet of paper.
1. Pipe preparation and tack welding can be done as easy as pipe welding.

2. Tack welds is not necessarily thick.

3. Grinding pipe edges and tack weld during pipe preparation is a waste of time.

9
Post-test 1.4

Let us determine on how much you have learned from the lesson. Please refrain
yourself from browsing the lesson information while taking the Post-test so
that we could measure your performance accurately.

True or false. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

_____1. The main purpose of creating a bevel angle on pipe edges i s for easy
penetration.

_____2. The recommended bevel angle of a pipe prior to welding is 45-degree.

_____3. Bevel angle is the term used when referring the angle that should be
grinded for pipe preparation.

_____4. The right preparation procedure for pipe edges is to use whetstone.

_____5. Spacing rod is the common name of the electrode used for creating an
accurate root gap on pipes.

_____6. 3.2mm is the maximum misalignment for steel pipes.

_____7. In taking the clock face as reference, you should put the four tack welds
in 12 o’clock, 3 o’clock, 6 o’clock and 9 o’clock.

_____8. The approximate thickness on tack welds on pipes is base on the size
of the electrode used for root pass.

_____9. Faulty tack welding will be the effect of incorrect joint preparation.

_____10. An E6010 electrode with a diameter of 3.2mm will be used for root
pass of a pipe that has 8mm thickness, what should be the recommended
distance of its root gap?

10
 LESSON 2: GROOVE WELDING ON CARBON STEEL PIPE (1G)
The scope of this chapter is to recommend on how to perform groove welding on
carbon steel pipe in 1G welding position. The welding process shall include the
root pass, hot pass and cap pass process.

Learning Competencies

By the end of this lesson, you are expected to:

1. Identify the acceptable weld profile for 1G welding position.

2. Understand the concept of groove welding on carbon steel pipe in 1G welding

position.

3. Perform groove welding on carbon steel pipe in 1G welding position.

Pre-test 2.1

You must be eager to browse the content of the lesson. However, first, please let
us determine your prior knowledge by answering the pre-test to measure the
topics you have known so far.

Multiple choice. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

1. What is the maximum tilt angle of a rolled pipe in a 1G welding

position?

a. 5-degree b. 60-degree c. 10-degree d. 15-degree

2. What are the parameters of a pipe in 1G welding position?

a. The pipe is fix in a vertical position.

b. The pipe is fix in a horizontal position.
c. The pipe is rolled in a horizontal position and can be rotated.
d. The pipe is in a vertical position and can be rotated.

3. What weld pass should be done after the root pass?

a. Hot pass b. Cap pass c. Tack weld d. C-motion

4. How many tack welds should be performed to a pipe in a 1G welding

position?

a. One b. Two c. Three d. Four

5. What is the difference of a Stringer bead from Weave bead?

a. The stringer bead is done in a straight line and the weld is narrow.
b. The stringer bead has wider range of weld than weave beads.
c. The stringer bead forms an eight-figure pattern.
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d. The stringer requires higher amperes compare to weave beads.
6. What is the recommended diameter of the keyhole if your electrode is
3.2mm and the Pipe’s thickness is 12mm?

a. 1.6mm b. 3.2mm c. 12mm d. 3mm

7. When you tie-in a weld bead, how long the slag should be remove before
continuing the weld?

a. 25mm b. 3mm c. 40mm d. 15mm

8. What is the maximum allowable distance of the fill pass to the pipe’s surface?

a. Base on the electrode’s diameter.

b. 3.2mm
c. Base on the number of weld passes.
d. 1.6mm

9. According to the ASME standards, how long the total length of an

undercut should not exceed in each 152mm?

a. 50.8mm b. 60.9mm c. 3.2mm d. 50mm

10. What is the ideal electrode used for Cap pass in pipes?

a. E7011 b. E6013 c. E7018 d. E6010

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Lesson Information 2.2

1G groove welding position

The pipe on a 1G groove welding is rolled in a horizontal position. But not
tilted more than or less than 15-degree (See in figure 2.1). In addition, the pipe
can be rotated during welding. 1G pipe position is one of the most convenient
position among the four welding position in pipe groove welding. 1G position
enable the welder to rotate the pipe at will and not restricting the welder’s
movement unlike the 5G which is fixed and cannot be rotated.

Figure 2.1

There are three stages of weld deposit when joining two pipes. The first
stage is the Root pass. Second, is the Hot pass or commonly known as “Fill pass”.
And the third one is Cap pass. These three are performed on thick steel pipes to
achieve better weldment of the joint (See in figure 2.2).
The Root pass is the first weld deposit in your pipe. The Hot pass/ Fill pass
is welded just above the Root pass. And the Cap pass is deposited above the Hot
pass/ Fill pass where it could be seen visually after completing the weldment.
The Hot pass is literally the bead after the root bead. Hot pass is only a part of
the Fill pass.

Figure 2.2
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 Let us assume that you have already tacked weld the pipe and it is
prepared for the Root pass procedure and adjusted your welding machine to the
appropriate ampere. Make sure you have enough space to move when welding.
After carrying out the preparation and tacking, place the workpiece in a welding
positioner in 1G welding position (horizontal axis) (See in figure 2.3).
When performing uphill welding, start your weld from 6 o’clock to 12
o’clock and if downhill, start from 12 o’clock to 6 o’clock (See in figure 2.4). It is
also recommended to place the tack with the smallest root gap at 12 o’clock.

Figure 2.3 Figure 2.4

The uphill technique is more convenient to use compare to downhill. The

welder can also easily observe the direction of travel and the keyhole. In this case,
Uphill procedure will be used.
When welding Root pass, perform scratch or tap from the edge of the pipe
towards the tack weld when starting an arc (See in figure 2.5). Maintain the
workpiece free form arc strikes as much as possible.

Figure 2.5

14
 When the arc has been started, whip your electrode by moving ahead
about two electrode diameters then moving the electrode back about one
diameter. Like two-step forward, one step back technique. To start your weld,
make a U-motion or C-motion (See in figure 2.6). The number one will be the
starting point of the arc. Move your whip a bit slower at number two so that the
electrode is hot enough to fuse the joint. On the number three, start the C-motion
weave. The weld does not necessarily starts on where the tack weld was made.
The main purpose of the tack weld is only to temporarily hold the joint. Besides,
tack weld should not be thick. It should be thin as possible so that it could be
easily covered when the root pass is performed just above the tack weld.

Figure 2.6

Various weave techniques could be applied in Root pass. From Circular,

Zig-zag, U-motion, C-motion and other custom weave techniques. It is certain
that there are effective weave technique in various welding position. Moreover,
not all welds requires weave. There are circumstances where “Stringer bead” is
more efficient than the “Weave bead” (See in figure 2.7). Weave bead can cover a
wider range than the stringer bead in exchange, it is more difficult to accurately
fuse the joints and more likely to cause weld defects for welders that are not yet
seasoned in the trade. While stringer bead covers smaller range than the weave
bead, it is efficient on welding joints and has lesser chances of weld defects due
to its motion by just simply moving back and forth.

15
 Circular is one of the weave techniques that is effective when performing
welding on a 1G welding position. While the C-motion can be applied to almost
all welding position.

Figure 2.7

To carry out the Root bead start with the electrode at 3:30, at right angles
(See in figure 2.8) to both the pipe axis and the pipe surface (See in figure 2.9).
Start the arc at the root of the joint. Never weld on the edge of the tack or the
external pipe surface. Maintain an arc length the same diameter of the electrode
and swing from one edge to the other. And give enough time to pre-heat the edges
of the shoulder.

Figure 2.8

16
Figure 2.9

After two or three movements reduce the arc length to one electrode
diameter and form the “keyhole” crater. Then keep the arc on the edge of the
shoulders and advance. Use light up and down swinging movement. To
maintain a crater of the correct dimensions the movements must be rapid and
precise (See in figure 2.9.1).

Figure 2.9.1

When approaching a tack, reduce travel speed and slightly increase arc
length. If the crater tends to close, use a trailing angle (pulling) of 5-10-degree
and reduce feed speed. If instead it tends to widen, use a leading angle (pushing)
of 5-10-degreee and increase feed speed (See in figure 2.9.2).

17
Figure 2.9.2

If necessary interrupt the arc before the seam is finished, form a “keyhole”
by rapidly pushing the electrode point through the joint, and then completely
withdraw the electrode. In this way, complete penetration is assured at restart
(See in figure 2.9.3).

Figure 2.9.3

Remove the slag from the crater and from the last 25mm of seam. Restart
should be carried out starting on the weld approximately 20mm after the crater

18
and moving backwards with a slightly higher than normal arc length. Swing from
side-to-side on the crater to preheat the edge then reset the normal arc length
(See in figure 2.9.4).

Figure 2.9.4

Rotate the pipe after the quarter of the top bead has ended, remove the
slag then repeat the operation on the other quarters of the joint. The finished
bead should have a slightly convex surface and the height should not be more
than the diameter of the electrode (See in figure 2.9.5).
At this point, the filling and capping passes may be executed either continuing
with cellulosic or low-hydrogen electrodes.

Figure 2.9.5

For the Hot pass, use E7018 electrodes (low-hydrogen) or any cellulosic or
low hydrogen electrodes that has low penetration. Use a weave such as C motion,
zigzag or any weave that is efficient for 1G welding position. The travel speed and
dwell time determine the result. Too slow speed or an excessive dwell cause the
weld pool to be too wide and difficult to control, while too fast and short dwell
create lack of fusion on the previous seam with a very convex seam undercut
(See in figure 2.9.6).

19
 A correct joint filling reaches approximately the diameter of an electrode
from the pipe surface. If the penultimate bead does not reach this level, carry
out with another electrode using the same procedure. If the arc is interrupted
before the bead is complete, remove the crater slag, restart the arc starting on
the last bead in front of the crater then turn back until the crater is full and
resume normal travel. Finally remove the slag from the weld ends and carry out
the second half of the joint.

Figure 2.9.6
For the cap bead use the E7018 electrode again, using the same
techniques as the filling beads but with a wider swinging movements, pausing
on the joint edges. The overlap on the joint edges and thickness of the weld metal
must measure approximately the diameter of the electrode.
Welding current should be lower than that used in the root and is
determined by the pipe size. Depending on the width of the bevel welding is
carried out with Zigzag or C-motion weaving movements, pausing with the
electrode at the joint edges.
The acceptability criteria of ASME standards are as follows:

• Cracks: The weld must not present cracks.

• Penetration: The joint must show complete penetration.
• Fusion: The fusion between the base metal and filler metal must appear
complete.
• Slag inclusion: The cavities in the melted zone containing slag must not
exceed 3.2mm for each 152mm of weld.
• Gaseous inclusion: The section affected by porosity cannot be longer than
1.6mm and their total must not exceed the length of 3.2mm each 6.5 cubic
centimeters of weld surface.
• Undercut: It should not exceed a width of 0.8mm, a depth of 0.8mm and
their total length must not exceed 50.8mm in each 152mm of weld or 5%
of the wall thickness. If the weld is shorter.
• Weld metal: The surface and root reinforcements must not exceed the
indicated dimensions, must be smoothly merged with the surfaces of the
base metal and their edges must be free from undercuts.
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Lesson Activity 2.3
Direction. Read and reflect each statement carefully. Write your opinion in a
separate sheet of paper.
1. Pipe preparation and tack welding can be done as easy as pipe welding.

2. Tack welds is not necessarily thick.

3. Grinding pipe edges and tack weld during pipe preparation is a waste of time.

Post-test 2.4

Let us determine on how much you have learned from the lesson. Please refrain
yourself from browsing the lesson information while taking the Post-test so
that we could measure your performance accurately.

True or false. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

_____1. The maximum tilt angle of a rolled pipe in a 1G welding position is

20degree.

_____2. The pipe in a 1G welding position is fix in a horizontal position.

_____3. The Hot pass process is done before the fill pass.

_____4. The weld should be started at 3:30 position when welding on a 1G welding
position.

_____5. Weave beads has a wider range of weld than the stringer beads. And it is
commonly used for Cap pass.

_____6. The keyhole should not exceed the maximum diameter of the electrode
to avoid faulty or defective beads.

_____7. Tie-in is the term used when connecting a bead with a new weld bead.

_____8. The cracks, penetration and undercuts are few of the criteria that is
measured in the ASME standards to identify the weldment’s acceptability.

_____9. The E7018 electrode is a low-hydrogen type of electrode.

_____10. The E7018 electrodes is ideal for Fill pass and Cap pass.

21
 LESSON 3: GROOVE WELDING ON CARBON STEEL PIPE (2G)
The scope of this chapter is to recommend on how to perform groove welding on
carbon steel pipe in 2G welding position. This lesson focuses on techniques and
weld bead, unlike the last two lesson which aims to achieve the basics on pipe
welding.

Learning Competencies

By the end of this lesson, you are expected to:

1. Identify the acceptable weld profile for 2G welding position.

2. Understand the concept of groove welding on carbon steel pipe in 2G welding

position.

3. Perform groove welding on carbon steel pipe in 2G welding position.

Pre-test 3.1

You must be eager to browse the content of the lesson. However, first, please let
us determine your prior knowledge by answering the pre-test to measure the
topics you have known so far.

Multiple choice. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

1. What should be the welding position of a pipe that is fix in a vertical

axis?

a. 1G b. 2G c. 3G d. 5G

2. What is the recommend electrode used for Cap pass?

a. E6013 b. E7018 c. E6011 d. E7010

3. What should be the work angle for a 2G welding position?

a. 90-degree b. 360-degree c. 45-degree d. 60-degree

4. What should be the recommended electrode angle when performing root

pass on a 2G welding position?

a. 2-degree b. 7-degree c. 20-degree d. 45-degree

5. What is the distinct difference of the weaves that is performed in a 2G

welding position compare to the other welding position?

a. The weave should be wider.

b. There are pauses at the top points of the weave.
c. The work angle should be wider than 90-degree work angle.
d. The weave is formed in a single straight line.
22
6. What is the primary cause of too high amperage application in a weld
bead?

a. Narrow beads b. Large number of spatters

c. Shallow penetration d. Uneven beads

7. What is the effect of an electrode that is pushed too far into the joint?

a. Crack b. Slag inclusion c. Undercut d. Porosity

8. What is the maximum allowable distance of the fill pass to the pipe’s surface?

a. Base on the electrode’s diameter.

b. 3.2mm
c. Base on the number of weld passes.
d. 1.6mm

9. According to the ASME standards, how long the total length of a cavity
in the melted zone containing slag must not exceed each 152mm of weld.

a. 50.8mm b. 60.9mm c. 3.2mm d. 50mm

10. What part of the weld bead that joins the workpiece together?

a. Weld Face b. Weld root c. Weld toe d. Weld reinforcement

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Lesson Information 3.2

2G groove welding position

The 2G groove welding position is fix in a vertical axis (See in figure 3.1).
This type of joint and position is typically used on vessels.

Figure 3.1
Welding parameters:

• E6010/E6011 electrode for root pass with 90-110A.

• E7018 electrode for fill pass with 90-110A.
• E7018 electrode for cap pass with 110-150A.

Let us assume again that the pipe is already prepared for welding. Make a
root bead and E6010/E6011 electrode in a 90-degree work angle (See in figure
3.2).

Figure 3.2
24
 The electrode must be held horizontally with a trailing angle of 5-10degree.
Start the bead 50mm from the tack, form the “keyhole” crater and advance with
a slightly swinging movement (See in figure 3.3). Keep the electrode on the edges
of the shoulder. Weave in a W-motion, zigzag or any weave by pausing at the top
before continuing to swing back to the bottom (See in figure 3.4).

Figure 3.3

Figure 3.4

25
 If the crater tends to widen, increase the trailing angle from 5-10-degree.
If the electrode tip is pushed too far into the joint, undercuts form along the root
and excessive penetration and defects occur. If the electrode is not pushed deep
enough into the joint, insufficient penetration and undercuts on the beveled
surfaces of the preparation are obtained (See in figure 3.5).

Figure 3.5

If the arc is interrupted before the bead is complete, clean the crater and
restart until the crater is filled. The second or hot pass will be carried out with
an E7018 electrode. The electrode must be held horizontally with a trailing angle
of 5-10degree (See in figure 3.6).
Use a perpendicular W-motion again or any weave you prefer, with pauses
at the top to correctly fill the welding crater. Keep the arc as short as possible.
The bead must be flat or slightly convex with good fusion on the edges.

Figure 3.6
26
 The 2G welding is one of the most difficult to perform among the other
groove welding position. If the electrode’s control is rough, there has a high
tendency of creating deformed beads. To further understand the principles on
how to do it properly, consider the variables that affects the weld bead.

Parameters of welding:

• Length of arc: It affects the size of the bead

• Current setting: It affects the penetration and number of spatter build up
beside the weld beads.
• Angle of electrode: Too much angle difference deforms the bead and might
cause of incomplete fusion of the joint.
• Manipulation of electrode: It depends on the weaving or stringer technique
to achieve the desired bead result.
• Speed of travel: It measures the distance of bead gaps.
• Selection of electrode: It affects the viscosity of the weld pool, the
appropriate welding position and Amperage tolerance.

The bead forms vary for every changes of the welding parameters. It is not
constant but with practice and enough proficiency, identical correct form of
beads is achieved (See in figure 3.7).

Figure 3.7

27
 Weld bead compose of Root, Face, Toe and reinforcement. Fusion zone is
the fused part of the workpiece and the bead. The original surface of work
indicates the original shape of the workpiece before it was fused with the weld
bead. The root penetration is the penetrated part of the bead into the joint of the
workpiece. The Root or weld root is where the bottom underside of a weld crosses
the surface of the base metal. The Face of weld face is the weld that above your
weld bead. The weld toe or Toe is the weld that joins the workpiece together. The
Reinforcement or weld reinforcement is the thickness of the bead from the
workpiece surface to the Weld face (See in figure 3.8).

Figure 3.8
The cap pass should be made with E7018 electrodes. The work angle varies
with respect to the horizontal plane, from 5-degree above for the third bead, to
5-degree below for the fifth bead (See in figure 3.9).
A correct work angle assures good fusion on the joint edges. The beads
must overlap up to half of the previous one. Use the same swinging movement
described for the second bead. The finished joint must have a projecting machine
allowance of the same size of your electrode and the slightly convex surface must
not present undercuts.

28
Figure 3.9
The acceptability criteria of ASME standards For 2G welding position is
the same as the criteria from the 1G welding position and the other positions.
But it still vary depending on a company’s welding procedure specifications.

Lesson Activity 3.3

Direction. Read and reflect each statement carefully. Write your opinion in a
separate sheet of paper.
1. The 2G welding position is more difficult compare to 1G welding position
due to its fix position.

2. In the welding parameters, selection of electrode does not affect much the
weld beads.

3. The electrode angles for the whole part of Fill pass in 2G welding position
does not need to necessarily need to adjust change.

29
Post-test 3.4

Let us determine on how much you have learned from the lesson. Please refrain
yourself from browsing the lesson information while taking the Post-test so
that we could measure your performance accurately.

True or false. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

_____1. The 3G welding position of a pipe is fix in a vertical axis.

_____2. The E7011 is the recommend electrode used for Cap pass.

______3. The work angle for a 2G welding position is 90-degree.

______4. The fusion zone is the part of the weld bead where it joins the workpiece
together.

______5. The weaves for the 2G welding does not need to pause in any points.

______6. Too high amperage causes a large amount of spatters to the weld.

______7. The electrode angle is set to 90-degree when it welding on a 2G welding

position.

______8. The W-motion is one of the recommended weave used for Hot pass in a
2G welding position.

______9. Undercuts is commonly encounter when the arc is too short.

______10. Weld root is a part of the weld bead that joins the workpiece together.

30
 LESSON 4: GROOVE WELDING ON CARBON STEEL PIPE (5G)
The scope of this chapter is to recommend on how to perform groove welding on
carbon steel pipe in 5G welding position. This lesson will tackle the downhill
welding technique instead of uphill. This type of joint is commonly used to weld
a line of steel tubes used for the transportation of large amount of gas or liquids,
Molded bends, flanges, forged pieces, concentrated works in all diameters.

Learning Competencies

By the end of this lesson, you are expected to:

1. Identify the difference of Uphill welding technique from the downhill technique
in a 5G welding position.

2. Understand the concept of groove welding on carbon steel pipe in 5G welding

position.

3. Perform groove welding on carbon steel pipe in 5G welding position

(downhill).

Pre-test 4.1

You must be eager to browse the content of the lesson. However, first, please let
us determine your prior knowledge by answering the pre-test to measure the
topics you have known so far.

Multiple choice. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

1. What should be the welding position of a pipe that is fix in a horizontal

axis?

a. 1G b. 2G c. 3G d. 5G

2. What is the recommend angle of electrode when performing a downhill

weld in a 5G welding position?

a. 45-degree b. 4-degree c. 12-degree d. 10-degree

3. What is the common name of a dragging technique in welding?

a. Crater b. Keyhole c. Stringer d. Hidden

4. What should you do when blowholes form during welding?

a. Rapidly snap the electrode away from the weld

b. Slowly swing you’re weave
c. Increase the amperage
d. Increase the speed of travel during welding

31
5. When restarting a root bead, how many millimeters should be the
distance of the electrode from the crater?

a. 10mm b. 11mm c. 12mm d. 13mm

6. Where should be an electrode starts if the welding position is 5G

welding (downhill)?

a. 3 o’clock b. 6 o’clock c. 12 o’clock d. 9 o’clock

7. Where should be the electrode starts when you tie-in a weld in fill pass?

a. Right on the crater b. Before the crater

c. After the crater d. In the pipe’s surface

8. What should be the weaving technique used for downhill welding in fill
pass?

a. Stringer
b. C-motion
c. Zigzag
d. Tack weld

9. What should be the weaving technique used for downhill welding in cap
pass?

a. Stringer
b. C-motion
c. Zigzag
d. Tack weld

10. Where can you find the penultimate bead in a multi layered weld?

a. Below the Cap pass b. After the root pass

c. Above the Cap pass d. Before the root pass

32
Lesson Information 4.2

5G groove welding position (Downhill)

Again, let us assume the pipe preparation and tack weld is already carried
out. Use pliers or clamps to fix the workpiece in a horizontal position with the
tacks placed at 3, 6, 9 and 12 o’clock. It is recommended to place the tack with
the smallest root gap at 12 o’clock (See in figure 4.1).

Figure 4.1
Let us assume that you will be using a 3.2mm diameter electrode. Make
the root (stringer) bead with a 3.2mm and set the ampere to 120-160A. Start
with the electrode at 12 o’clock, with a trailing electrode angle of 1015-degree
and the electrode in the plane of the joint (See in figure 4.2).

Figure 4.2

Start the arc at the root of the joint but never the edge of the tack towards
the external surface of the pipe. Push the electrode into the joint and advance in
a regular manner (See in figure 4.3).

33
Figure 4.3
To better check the weld pool, it may be necessary to vary the trail angle
from 10-15-degree to 0-30-degree. Use the dragging or “hidden arc” technique.
Always keeping the electrode at the bottom point of the joint. A keyhole groove,
which follows the top of the electrode in its movement, is formed (See in figure
4.4).

Figure 4.4
If blowholes form, slightly swing the electrode from one side to the other.
If it is necessary to interrupt the arc before the run was ended, the tip of the
electrode must be rapidly snapped down (See in figure 4.5).

34
Figure 4.5

This prevents slag inclusion in the weld pool. Remove the slag from the
crater and from the last 25mm of the weld. The restart should be made starting
on the weld metal approximately 12 mm before the crater and moving towards it
with an arc length slightly above normal. Then push the electrode to the bottom
of the joint to fill the crater and continue welding in the normal manner (See in
figure 4.6).

35
Figure 4.6

The finish bead must form a 3.2mm thick weld reinforcement at the root.
When the first half of the bottom bead is completed, remove the slag then repeat
the process on the second half of the joint (See in figure 4.7).

Figure 4.7

For the hot pass, use E7010, E8010 or E9010 electrodes, depending on
the class of the steel to be welded.
Start with the electrode 12 o’clock, maintaining the same angles indicated
for the bottom bead, towards 6 o’clock (See in figure 4.8). Use a light up and
down movement to check the weld pool. Move the tip in the forward direction for
a length equal to the diameter of the electrode to allow the weld pool to solidify
slightly then move the tip back for a length equal to half of the diameter. At this
wait until the crater is full before moving onwards (See in figure 4.9).

36
Figure 4.9

Maintain an arc length equal to the electrode diameter. Do not increase

the arc length during movement. If the arc is interrupted before the bead is
complete, remove the slag from the crater, restart the arc starting on the bottom
bead, approximately 12mm in front of the second bead and move back up to the
crater (See in figure 4.9.1).

37
Figure 4.9.1

Make sure that you have filled the crater then restart welding as indicated
previously. Carry out the second half of the run with the same procedure. It
should be noted that “pulling” technique with which the root bead is laid causes
an incomplete fusion and slag inclusion or tramlines at the seam edges. Due to
the higher current used, the hot pass does not transfer much metal to the joint,
but its greater heat frees the slag and completes the fusion between the weld
edges and the base metal.
To carry out the fill pass, the starting position and trailing angles of the
electrode are the same as indicated for the root and hot passes. Use a swinging
movement, maintaining an arc length equal to the electrode diameter. Pause with
the tip of the electrode diameter. Pause with the tip of the electrode on the edge
of the previous bead. Move towards the opposite edge with descending by half
the electrode diameter (See in figure 4.9.2).

Figure 4.9.2
38
 If it is necessary to restart the arc, use the same procedure as indicated
for the second pass. After having welded the second half of the joint, completely
remove the slag (See in figure 4.9.3).

Figure 4.9.3
To fill the joint up to 3.2mm from the external pipe surface it may be
necessary to deposit additional passes on the whole circumference. These beads
should generally add a 3.2mm thick layer. Use the same techniques indicated
for the previous passes. Often, after having made all these layers, the joint is
thicker in the upper and lower zone than in the side zones of the pipe, making it
necessary to fill it evenly before making the cap. In this case, stripper beads are
laid with the same techniques illustrated previously (See in figure 4.9.4).

Figure 4.9.4

The technique used for the cap pass is the same as indicated for the
penultimate bead., but the swinging movement must be wider. Dwell with the tip of
the electrode on the edges of the previous bead. Use C-motion or any weave with
adequate arc length, travel speed and electrode slope (See in figure 4.9.5).

39
Figure 4.9.5

Advance at a speed that makes it possible to obtain an approximately

3.2mm thick reinforcement and an overlap at the edges (See in figure 4.9.6).

Figure 4.9.6
After having carried out the preparation and tacking, the workpiece is
marked for identification then welded in the 5G welding position as previously
indicated. A visual analysis of the weld is then carried out. The weld should more
or less look like a fish scale (See in figure 4.9.7).

40
Figure 4.9.7

Lesson Activity 4.3

Direction. Read and reflect each statement carefully. Write your opinion in a
separate sheet of paper.
1. The 5G welding can be done in downhill and uphill technique.

2. The Cap bead of a downhill and uphill has a big difference.

3. Electrodes used for pipe welding is based on the company’s standard

requirements.

Post-test 4.4

Let us determine on how much you have learned from the lesson. Please refrain
yourself from browsing the lesson information while taking the Post-test so
that we could measure your performance accurately.

True or false. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

_____1. The 5G welding position is fix in a vertical axis.

_____2. 5-10-degree is the recommend angle of electrode when performing a
downhill weld in a 5G welding position.
_____3. The common name of a dragging technique in downhill welding is called
keyhole.
_____4. The electrode should be snapped when blowholes form during welding.
_____5. When restarting a root bead, 12 millimeters should be the distance of
the electrode before the crater.
_____6. The electrode should start at 12 o’clock if the welding position is 5G
(downhill).
_____7. The downhill technique starts from 6 o’clock to 12 o’clock. _____8.
C-motion is the recommended weaving technique used for downhill welding
in fill pass.
_____8. C-motion is the recommended weaving technique used for downhill
welding in cap pass.
_____10. The penultimate bead in a part of the root bead.

41
 LESSON 5: GROOVE WELDING ON CARBON STEEL PIPE (6G)
The scope of this chapter is to recommend on how to perform groove welding on
carbon steel pipe in 6G welding position. This type of joint is used to weld bends
or elbows. The 6G welding position is typically applied on underground Pipelines
such as mines, power plants that goes from the ground to high mountains and
other structures where pipes are required to go downward or upwards. This
lesson also includes the nick break test for pipes.

Learning Competencies

By the end of this lesson, you are expected to:

1. Identify the qualification tests in 6G welding process.

2. Understand the concept of groove welding on carbon steel pipe in 6G welding

position.

3. Perform groove welding on carbon steel pipe in 6G welding position (downhill).

Pre-test 5.1

You must be eager to browse the content of the lesson. However, first, please let
us determine your prior knowledge by answering the pre-test to measure the
topics you have known so far.

Multiple choice. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

1. What should you call a pipe grove welding that is placed in 45-degree
axis?

a. 4G b. 5G c. 6G d. 6GR

2. Where should be the start of the electrode in 6G welding position

(Uphill)?

a. At 6:30 b. 6 o’clock c. 5 o’clock d. At 5:30

3. What should you do to prevent craters from widening?

a. Decrease the speed of travel.

b. Use a slight leading angle and/or increase travel speed.
c. Increase the amperage.
d. Use large swings and decrease the speed of travel.

4. What should be the recommended Ampere used for E7018 electrodes

during the cap pass process?

a. 90A b. 100A c. 120A d. 180A

42
5. In taking the clock face as reference, Where should you put the four
tack welds in a 6G pipe welding?

a. 3, 6, 9 and 12 o’clock b. 2, 5, 8 and 11 o’clock

c. 1, 5, 7 and 11 o’clock d. 1, 4, 8 and 11 o’clock

6. What should you call a mechanical test where the weld requires to be
stripped from the workpiece and bend samples to identify if it pass from
qualifications tests.

a. Nickle break test b. Radiographic test

c. Nick break test d. Dye penetrant test

7. How many strip sections must be marked for identification to evaluate

the weld acceptability of weld samples?

a. 4 b. 5 c. 6 d. 7

8. What is the minimum depth of slag inclusion for it to pass in weld

qualification test?

a. 0.8mm b. 2.5mm c. 0.3mm d. 3.2mm

9. What is the recommended work angle for 6G groove welding?

a. 6-degree b. 11-degree c. 15-degree d. 45-degree

10. What welding position should be used to weld on the center of an

elbow pipe that point upwards?

a. 6G b. 5G c. 4G d. 2G

43
Lesson Information 5.2

6G groove welding position (Uphill)

After having carried out the preparation and tacking, fix the piece in the
6G position (axis 45-degree to the horizontal plane) the tack must be placed at
2. 5. 8 and 11 o’clock (See in figure 5.1). Place the tack where there is the smallest
rot gap at 5 o’clock.

Figure 5.1

Then carry out the root bead with E6010/E6011 electrodes of 3.2mm
diameter. Start with the electrode at 6:30. With the electrode in the plane of the
joint and at right angles to the direction of travel. The bottom bead should
penetrate inside the pipe not more than 3.2mm.
Use a light swinging movement. The tip of the electrode should be kept on the
edges of the shoulder but without exerting pressure on them (See in figure 5.2).
If the crater tends to close, use a slight trailing angle and/or reduce travel speed.
If the crater tends to widen, use a slight leading angle and/or increase travel
speed (See in figure 5.3).

Figure 5.2

44
Figure 5.3
The arc interruption and reinsertion procedures are similar to those
described in previous lessons. Execute both halves of bead and remove the slag
before laying the second bead.
The filling pass should be carried out starting the arc at 6:30 and
stabilizing it at 6 o’clock on a fairly reduced width. Use E7018 electrodes of
2.5mm diameter. The filling pass should reach approximately 1.6mm from the
external surface of the pipe (See in figure 5.4).

45
Figure 5.4
Then carry out the capping passes with E7018 electrodes of 3.2mm
diameter, using 120-150A current (See in figure 5.5). But adjust the current as
you see fit.

46
Figure 5.5

The electrode angles of are the same as those used for filling. Take note
the number of beads for each layer (See in figure 5.6).
.

Figure 5.6

To pass the qualification test in a welding process in the 6G position which

covers all the others, some mechanical tests must be performed on a sample (See
in figure 5.7). For this purpose prepare and tack a piece as described in lesson
1.
47
Figure 5.7
Carry out the welding as described in this lesson. Take care to remove the
largest irregularities using a grinder with flexible disk and fine grain before laying
the second bead and make visual check. From the welded piece will be obtained
six sections which must be previously marked for identification by the operator.
Proceed with pipe cutting to obtain six strips of a width of 25mm (See in figure
5.8).

Figure 5.8
The coupons for the bend tests must be ground on both surfaces of the
weld to the thickness of the pipe wall, but without notching the base metal.
Using a jig, bend the strips over a mandrel 3 times the pipe thickness, one with
the root on the outside and one the opposite way (See in figure 5.9).
48
Figure 5.9

The acceptability standard is satisfied if no cracks or other defects of over

3.2mm or half the wall thickness, if this is lower, appear after bending in the
weld seam or fusion zone in each direction. No cracks starting from the edge of
the samples, if smaller than 6.4mm measured in each direction, should be taken
into consideration, unless accompanied by other defects.
To carry out the nick break tests, a notch is made in the center of the weld
with the 3.2mm deep saw cut on all sides of the sample (See in figure 5.9.1). The
internal and external reinforcement must not be removed.

Figure 5.9.1

The samples may be broken under tension with a special machine, or by

striking their center with a hammer after having supported their ends, or striking
one end of them after having fixed the other. The acceptability standard is
satisfied when the exposed surfaces of each sample show complete penetration
and fusion. The maximum size of porosity areas must not exceed 1.6mm and the
49
total porosity areas must not exceed 2% of the examined surfaces. Slag inclusion
must not exceed 0.8mm in depth, 3.2mm in length or half the wall surface if this
is smaller. Furthermore, there must be at least 12mm of sound metal between
one inclusion and the other.

Lesson Activity 5.3

Direction. Read and reflect each statement carefully. Write your opinion in a
separate sheet of paper.
1. The 6G welding can be done with any weaving technique.

2. The nick break test is not necessary to check the weld qualifications.

3. Why a notch is made to your weld in nick break test?

Post-test 5.4

Let us determine on how much you have learned from the lesson. Please refrain
yourself from browsing the lesson information while taking the Post-test so
that we could measure your performance accurately.

True or false. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

_____1. The 6G welding position is placed in a 45-degree axis.

_____2. In 6G welding position (Uphill), electrodes start at 6 o’clock. _____3.
Decreasing the speed of travel prevent craters from widening. _____4. The
recommended Ampere used for E7018 electrodes during the cap pass
process is about 130A.
_____5. In taking the clock face as reference, 3,6,9 and 12 o’clock should be the
location of four tack welds in a 6G groove welding position. _____6. The nick
break test is done by bending the strip samples.
_____7. How many strip sections must be marked for identification to evaluate
the weld acceptability of weld samples.
_____8. There is no minimum depth of slag inclusion for it to pass in weld
qualification test.
_____9. The recommended work angle for 6G groove welding is 45-degree.
_____10. The welding position used to weld on the center of an elbow pipe that
point upwards is placed in 4G welding position.

50
 LESSON 6: WELDING QUALITY

The scope of this chapter is to recommend on how to perform a quality weld

in your pipes and remedies of weld defects. Weld defects are unavoidable,
especially in SMAW welding process due to the nature of electrode used for
the work and other variables. Weld is not necessarily perfect, weld defects can
be tolerated but cracks is unacceptable.

Learning Competencies

By the end of this lesson, you are expected to:

1. Identify Pipe weld defects.

2. Understand the concept of Quality Weld.
3. Perform remedies of various Pipe Weld Defects.

Pre-test 6.1

You must be eager to browse the content of the lesson. However, first, please
let us determine your prior knowledge by answering the pre-test to measure
the topics you have known so far.

Multiple choice. Read and analyze the statements carefully. Write your
answers on a separate sheet of paper or in your notebook.

1. What should be the remedy for the slag inclusion weld defects?

a. Thorough cleaning of the second bead.

b. Check the good state of maintenance of coverages for protection from the wind.
c. Check bevel, check welding parameters and pipe rotation.
d. Use proper insulated welding equipment.

2. What should be the remedy for the lack of penetration weld defects?

a. Thorough cleaning of the second bead.

b. Good preparation of the joint before executing the finishing bead
c. Check bevel, check welding parameters and pipe rotation.
d. Use proper insulated welding equipment.

3. What should be the remedy for the porosity weld defects?

a. Thorough cleaning of the second bead.

b. Good preparation of the joint before executing the finishing bead
c. Check bevel, check welding parameters and pipe rotation.
d. Check the good state of maintenance of coverages for protection from the wind.

4. What should be the remedy for spatter weld defects?

a. Thorough cleaning of the second bead.

b. Good preparation of the joint before executing the finishing bead
c. Check bevel, check welding parameters and pipe rotation.
d. Use proper insulated welding equipment and welding practices.

51
5. What should you call a crack within the weld metal perpendicular to
the direction of travel?

a. Transverse c. HAZ
b. Centerline d. underbead

6. What should you call a crack that is separated in the center of a given
weld bead?

a. Transverse c. HAZ
b. Centerline d. Underbead

7. What weld defect that is roughly spherical particles of molten weld

metal that solidify on the base metal outside the weld joint?

a. Spatter c. Slag inclusion

b. Arc Strikes d. Lack of penetration

8. What weld defect that is found only in the mixed (electrode+wire)

technique, it presents itself in the slab as an elongated, cracked inclusion
of a certain thickness, usually positioned on one side of the bevel?

a. Spatter c. Slag inclusion

b. Arc Strikes d. Lack of penetration

9.What are the unique limitations of shielded metal arc welding?

a. 1. There must be a sufficient level of hydrogen.

2. There must be a sufficient sensitive material involved.
3. There must be a sufficiently high level of residual or applied stress.

b. 1. There must be a sufficient level of argon.

2. There must be a sufficient sensitive gas involved.
3. There must be a sufficiently high level of residual or applied stress.

c. 1. Arc length related discontinuities.

2. Start-stop related discontinuities.
3. Coating moisture related problems.

d. 1. Weld cracks
2. Cold cracks
3. Hot cracks

10. The coatings of _____ electrodes are sensitive to moisture pick-up.

a. SMAW b. GMAW c. SAW d. GTAW

52
Lesson Information 6.2

Welding Quality
A weld must be of an appropriate quality to ensure that it will satisfactorily
perform its function over its intended lifetime. A quality weld is one that meets
applicable requirements for a specific project.
All welds contain discontinuities, which are defined as an interruption in the
typical structure of the material. A defect is defined as a discontinuity that is
unacceptable with respect to the applicable standard or specification.
Welds are not required to be perfect; most welds contain some discontinuities. It
is imperative that the applicable standards establish the level of acceptability of these
discontinuities in order to ensure both dependable and economical structures.
Acceptable weld quality in some cases, would be less rigorous than what would be
normally produced by a qualified welder.

The Shielded Metal Arc welding (SMAW) process

The unique limitations of shielded metal arc welding fall into three categories. 1.
Arc length related discontinuities. 2. Start-stop related discontinuities. And 3. Coating
moisture related problems. In SMAW, the operator controls arc length. Excessively
short arc lengths can lead to arc outages, where the electrode becomes stuck to the
work. When the electrode is mechanically broken off the joint, the area where the short
has occurred needs to be carefully cleaned, usually ground to ensure conditions that
will be conductive to good fusion by subsequent welding. The electrode is usually
discarded since a portion of the coating typically breaks off of the electrode when it is
removed from work. Excessively long arc lengths will generate porosity, undercut and
excessive spatter. Because of finite length of the SMAW electrodes, an increased
number of starts and stops is necessitated. During arc initiation with SMAW, starting
porosity may result during the short time after the arc is initiated and before adequate
shielding is established. Where the arc is terminated, under-filled weld craters can lead
to crater cracking. The coatings of SMAW electrodes are sensitive to moisture pick-up.
Improper care of low hydrogen SMAW electrodes can lead to hydrogen assisted cracking
such as underbead cracking or transverse cracking.

Weld Cracking
Several types of discontinuities may occur in welds or heat affected
zones. Welds may contain porosity, slag inclusions or cracks. Cracks are by
far the most detrimental. Whereas there are acceptable limits for slag
inclusions and porosity in welds, cracks are never acceptable. Cracks in the
vicinity of a weld indicate that one or more problems exist that must be
addressed.
Cracking is distinguished as a weld failure. Welds may fail due to over-
load, under design or fatigue. The cracking is the result of solidification,
cooling and the stress that develop due to weld shrinkage. Weld cracking
occurs close to the time of fabrication. Hot cracks are those that occur at
elevated temperatures and area usually solidification related. Cold cracks are
those that occur after the weld metal has cooled to room temperature. Neither
is the result of service load.
Most forms of cracking result from the shrinkage strains that occur as
the weld metal cools. If the contraction is restricted, the strains will induce
residual stresses that cause cracking. Large weld sizes and deep penetrating
procedures increase the shrinkage strains. The stresses induced by these
strains will increase when higher strength filler metals and base materials are
involved.

Centerline cracking
53
It is characterized as a separation in the center of a given weld bead. If the
weld bead happens to be in the center of the joint, as is always the case on a
single pass weld, centerline cracks will be in the center of the joint. See Figure
6.1.

Figure 6.1

When centerline cracking is induced, several solutions may be executed.

Since the contaminant usually comes from the base metal, the first
consideration is to limit the amount of contaminant pick-up from the base
metal. This may be done by limiting penetration of the welding process. In
some cases, a joint redesign may be desirable. This can be can be done by
using lower welding current.

Heat affected zone (HAZ) cracking

It is characterized by separation that occurs immediately adjacent to the
weld bead. Although it is related to the welding process, the crack occurs In
the base metal, not in the weld deposit. This type of cracking is also known as
“underbead cracking”, “toe cracking” or “delayed cracking”. Because this
crack occurs after the steel has cooled below approximately 400 degrees
Fahrenheit, it can be called “cold cracking”. See Figure 6.2

Figure 6.2

Three conditions must be present simultaneously for heat affected zone

cracking to occur.

1. There must be a sufficient level of hydrogen.

2. There must be a sufficient sensitive material involved.
3. There must be a sufficiently high level of residual or applied stress.

Adequate reduction or elimination of one of the three variables will

generally eliminate heat affected zone cracking.
Hydrogen can enter into weld pool from a variety of sources. Moisture
and organic compounds are the primary sources pf hydrogen. It may be
present on the steel, the electrode, shielding materials and it is present in the
atmosphere. To limit the hydrogen content in deposited welds, welding

54
consumables must be properly maintained and welding must be performed
on surfaces that are clean and dry.
Conditions that encourage the development of crack sensitive
microstructures include high cooling rates and higher hardenability levels in
the steel. The most effective way to reduce the cooling rate is by raising the
temperature of the surrounding steel through preheat. This reduces the
temperature gradient, slow cooling rates and limiting the formation of
sensitive microstructures.
With time, hydrogen diffuses from weld deposits. Sufficient diffusion to
avoid cracking normally takes place in a few weeks, although it tales many
months depending on the specific application. The concentrations of
hydrogen near the time of welding are always the greatest and if hydrogen
induced cracking is to occur, it will generally occur within a few days of
fabrication. However, it may take longer for the crack to grow sufficient size to
be detected.
Post heat treatment is generally involves the heating of the weld to a
temperature of 400-450 degrees Fahrenheit. Hydrogen diffuses at the rate of
approximately 1 inch per hour. In order for post operations to be effective,
they must be applied before the weldment is allowed to cool to room
temperature. In some instances, metals which are less than an inch thick
requires less time of heating period.

Transverse cracking
It is also called cross cracking, and characterized as a crack within the
weld metal perpendicular to the direction of travel. See Figure 6.3. this is the
least frequently encountered type of cracking, and is generally associated with
the weld metal that is higher in strength, significantly overmatching the base
metal.
As the weld bead shrinks longitudinally, the surrounding base metal
resists this force by going into compression. The high strength of the
surrounding steel in compression restricts the required shrinkage of the weld
metal. Due to the restraint of the surrounding base metal, the weld metal
develops longitudinal stresses which may facilitate cracking in the transverse
direction.

Figure 6.3

Preheat may be applied to alleviate transverse cracking. The preheat will

assist in diffusing hydrogen. As preheat is applied, it will additionally expand
the length of the weld joint, allowing the weld metal and the joint to contract
simultaneously and reducing the applied stress to the shrinkage weld.

PIPE WELD DEFECTS AND REMEDIES

Hollow bead
The x-ray shows how a hollow channel inside the first bead may be
caused by the presence of dirt inside the pipe, by inaccurate grinding of the

55
internal wall of the pipe near the bevel, by bad weather conditions which make
water or steam reach the weld while the first bead is being carried out or by
incorrect welding parameters (too much current, too much gas).

Remedies:
Check internal cleaning of the pipe, all the circumference, by means of manual grinding
(brushing is not sufficient) for a section of at least 2 cm from the bevel.
In bad weather conditions, manual cleaning with cloths of the internal wall of both the
pipes to be joined even before carrying out the first bead and before the overhead section
(6:00) as it is that most likely to convey water or steam.
Periodic check of welding parameters

Lack of penetration
This presents itself as an interruption, perhaps of considerable length or with
sections of the inside weld seam, which should instead be uniform after the first bead.
In pipes with a sufficiently large diameter to permit internal accessibility it is visible to
the naked eye and, in some cases, the intact bevel is visible (a welding process for
instantaneous repair of the fault from the inside) is recommended. It may be caused by
incorrect geometrical dimensions of the bevel, incorrect welding parameters, bad fit up
(excessive misalignments) or poor operator skill.

Remedies:
Check bevel, check welding parameters, pipe rotation (always compatible with the
position of the longitudinal welds which must be spaced a certain length) or application
of shims on the internal clamp expanders to reduce misalignments.
We will not dwell on the skill of the operators; the most expert should be chosen and
reserved for the first bead (a delay in execution stops the whole “welding train”).

Lack of fusion
The main defect of wire processes. In x-ray it appears as a continuous or short
dashed line on one or both sides of the joint; by assessing its position as regards the
first bead (whiter seam at the centre of the film), you can assume its depth.
The main causes are: incorrect bevel dimensions, incorrect welding parameters or
operator negligence.

Remedies:
Constant check of all process geometrical and functional parameters and informed
operators. A second case exists. Less common than the lack of fusion called INTERPASS,
caused by the dropping of the weld pool in the vertical section of the pipe (2:00-5:00)
due to incorrect welding parameters; it appears in the xray as a darker veil between
two successive beads.

Porosity
In a coated electrode process, the weld pool is protected from external oxidation
by combustion of the coating, but in a wire process it is protected by a protective gas,
introduced into the arc zone by a torch; the lack of gas causes porosity.

Remedies:
Check the good state of maintenance of coverages for protection from the wind, check
the good state of maintenance of sleeves, connections, gas diffusers and, more as
recommendation than a technical remedy, substitute gas cylinders before finishing it
completely.

Slag inclusion
Defect found only in the mixed (electrode+wire) technique, it presents itself in the
slab as an elongated, cracked inclusion of a certain thickness, usually positioned on

56
one side of the bevel. It is caused by bad slag cleaning in the second bead, which
remains imprisoned and does not melt in the successive bead.
A sporadic case, mentioned for comprehensiveness, is slag inclusion due to its
entrapment in the hollow created between the second bead and the bevel wall if this,
in the section at 30°, has not been completely filled. To be more clear, if you start to
weld with wire before filling the bevel section at 30° with the electrode, this could cause
defects (even lack of fusion).

Remedies:
Thorough cleaning of the second bead

Undercut/ Overlap
These cannot be considered real welding defects which cause joint seal problems,
but are “to be repaired” due to the possibility of the start of corrosion or fatigue failure
(cuts) or to facilitate subsequent operations of coating and installation (excess weld
material)

Remedies:
Good preparation of the joint before executing the finishing bead: the underlying bead
must be uniform, perfectly clean and leave 1mm from the pipe surface to permit the
voluminous pool of the last bead to rest smoothly and create a 1-1.5mm seam for the
widest part of the joint.
At the end of the “welding train”, it is advisable to provide a tractor, even of small size
for the manual repair of defects on the external bead.

Arc strikes
It consists of small, localized regions of metals that have been melted by the
inadvertent arcing between electrically charged elements of the welding circuit and the
base metal. Welding arcs that are not initiated in the joint leave behind these arc strikes.
SMAW is especially susceptible to creating arc strikes since the electrode holder is
electrically hot when not welding.

Remedies:
Use proper insulated welding equipment and proper welding practices minimize arc
strikes. Grinding away affected metal is an effective way of eliminating any potential
harm from arc strikes.

Spatter
It is a roughly spherical particles of molten weld metal that solidify on the base
metal outside the weld joint. It is generally considered to be harmful to the performance
of welded connections, although excessive spatter may inhibit proper ultrasonic
inspection and may be aesthetically unacceptable for exposed steel applications.

Remedies:
Excessive spatter is an indication of less than optimum welding conditions and
suggests that the welding consumables or welding procedures may need to be adjusted.

57
Lesson Activity 6.3

Direction. Read and reflect each statement carefully. Write your opinion in a
separate sheet of paper.
1. What weld defect is most difficult to repair?
2. What should be the bases to ensure a Quality Weld?.
3. What is the best remedy of arc strikes?

Post-test 6.4

Let us determine on how much you have learned from the lesson. Please
refrain yourself from browsing the lesson information while taking the Post-
test so that we could measure your performance accurately.

True or false. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

_____1. A defect is defined as a discontinuity that is unacceptable with respect

to the applicable standard or specification.
_____2. In SMAW, the operator controls arc length. Excessively short arc
lengths can lead to arc outages, where the electrode becomes stuck to the
work.
_____3. Excessively long arc lengths will generate porosity, undercut and
excessive spatter.
_____4 Improper care of low hydrogen SMAW electrodes can lead to hydrogen
assisted cracking such as underbead cracking or transverse cracking.
_____5. HAZ cracking occurs In the base metal, not in the weld deposit.
_____6. Centerline cracking is also called cross cracking
_____7. Arc strikes is a roughly spherical particles of molten weld metal that
solidify on the base metal outside the weld joint.
_____8. Slag inclusion is caused by bad slag cleaning in the second bead,
which remains imprisoned and does not melt in the successive bead.
_____9. Preheat may be applied to alleviate transverse cracking.
_____10. Transverse cracking is characterized by separation that occurs
immediately adjacent to the weld bead.

58
 LESSON 7: WELDING INSPECTION

The scope of this chapter covers the topics relating to Non-destructible tests
and destructible tests on weldment. There are a lot of tests out there to test
weld quality, this module shall be introducing some of the commonly known
tests.

Learning Competencies

By the end of this lesson, you are expected to:

1. Identify the difference of Non-Destructible test from Destructible Test.

2. Understand the concept of Welding Inspection.
3. Perform Visual inspection and properly pinpoint its defects.

Pre-test 7.1

You must be eager to browse the content of the lesson. However, first, please
let us determine your prior knowledge by answering the pre-test to measure
the topics you have known so far.

Multiple choice. Read and analyze the statements carefully. Write your
answers on a separate sheet of paper or in your notebook.

1. What test is by far the most powerful visual inspection method

available Because of its relative simplicity?

a. Visual inspection Test

b. Liquid penetrant test
c. Magnetic particle inspection
d. Radiographic inspection

2. What Non-destructible test that involves the application of liquid

which by a capillary action is drawn into a surface breaking discontinuity,
such as crack or porosity?

a. Visual inspection Test

b. Liquid penetrant test
c. Magnetic particle inspection
d. Radiographic inspection

3. What Non-destructible test that utilizes change in magnetic flux that

occurs when a magnetic field is present in the vicinity of a discontinuity?

a. Ultrasonic inspection
b. Liquid penetrant test
c. Magnetic particle inspection
d. Radiographic inspection

4. What Non-destructible test relies on the transmission of high

frequency sound waves through materials?
a. Ultrasonic inspection
59
b. Liquid penetrant test
c. Magnetic particle inspection
d. Radiographic inspection

5. What destructible test that involves breaking a sample fillet weld that
is welded on one side only.

a. Macro etch test c. Guided bend test

b. Transverse tension test d. fillet weld break test

6. What destructible test method in which a specimen is bent to a

specified bend radius?

a. Macro etch test c. Guided bend test

b. Transverse tension test d. fillet weld break test

7. What destructible method of testing typically involves the removal of

small samples of the welded joint and polished across their cross-section
and then etched using some type of mild acid mixture?

a. Macro etch test c. Guided bend test

b. Transverse tension test d. fillet weld break test

8. What is the advantage of a Non-destructible test over the Destructible

test?

a. Test can be done in laboratory c. Cost effective and repeatable

b. The test is more accurate d. Test requires sophisticated equipment

9. Which test uses X-rays or gamma rays that are passed through the weld and
expose a photographic film on the opposite side of the joint?

a. Ultrasonic inspection
b. Liquid penetrant test
c. Magnetic particle inspection
d. Radiographic inspection

10. Which one of the tests below is a Non-destructible test?

a. Macro etch test c. Liquid penetrant test

b. Transverse tension test d. fillet weld break test

60
Lesson Information 7.2

Welding Inspection
Weld quality is directly tied to the code or specification under which the work is
being performed. Welds are acceptable when they conform to all the requirements in a
given specification or code. Inspection can be done in a workshop or in a laboratory.
An error in welding process may damage weld metals significantly resulting in the loss
of strength, durability and failure of the structure. Welding test methods are assurance
that products are secure for the intended use.

Two types of Welding tests

1. Destructive test
2. Non-destructive test

Destructive test
Destructive weld testing involves the physical destruction of the completed weld
in order to evaluate its characteristics. This method of testing is used frequently for a
number of applications. Some of these applications include welding procedure
qualification and welder performance qualification testing, sampling inspection of
production welds, research inspection, and failure analysis work. A number of
destructive weld testing methods are used to determine weld integrity or
performance. Typically they involve sectioning and/or breaking the welded component
and evaluating various mechanical and/or physical characteristics.

Types of Destructive tests

Macro Etch Test – This method of testing typically involves the removal of small
samples of the welded joint. These samples are polished across their cross-section
and then etched using some type of mild acid mixture, dependent on the base material
used. The acid etch provides a clear visual appearance of the internal structure of the
weld. Particular interest is often shown at the fusion line, this being the transition
between the weld and the base material. Such items as depth of penetration, lack of
fusion, inadequate root penetration, internal porosity, cracking and inclusions can be
detected during inspection of the etched sample. This type of inspection is obviously
a snapshot of the overall weld length quality when used for sampling inspection of
production welds. This type of testing is often used extremely successfully to
pinpoint welding problems such as crack initiation, when used for failure analyses. See
figure 7.1 as reference how clear the material after etching.

figure 7.1
61
Fillet Weld Break Test – This type of testing involves breaking a sample fillet weld that
is welded on one side only. The sample has load applied to its unwelded side,
transverse to the weld and directed to its unwelded side (typically in a press). The load
is increased until the weld has failed. The failed sample is then inspected to establish
the presence and extent of any welding discontinuities. This test will provide a good
indication as to the extent of discontinuities within the entire length of weld tested
(normally 6 to 12 inches) rather that a cross-sectional snapspot like the macro etch
test. This type of weld inspection can detect such items as lack of fusion, internal
porosity and slag inclusions. This testing method is often used in conjunction with the
macro etch test. These two testing methods complement each other by providing
information on similar characteristics in different detail and in different ways. See
Figure 7.2 shows the direction of force.

figure 7.2

Transverse Tension Test – Since a large proportion of design is based on tensile

properties of the welded joint, it is important that the tensile properties of the base
metal, the weld metal, the bond between the base and the weld, and the heat-affected
zone conform to the design requirements. Tensile strength of the welded joint is
obtained by pulling specimens to failure. Tensile strength is determined by dividing
the maximum load required during testing by the cross-sectional area. The result will
be in units of tension per cross-sectional area. This test is nearly always required as
part of the mechanical testing when qualifying welding procedure specifications for
groove welds. See Figure 7.3 shows the specimens taken.

Figure 7.3
62
Guided Bend Test – This is a test method in which a specimen is bent to a specified
bend radius. Various types of bend tests are used to evaluate the ductility and
soundness of welded joints. Guided bend tests are usually taken transverse to the weld
axis and may be bent in plunger type test machines or in wrap-around bend test
jigs. Face bend tests are made with the weld face in tension, and root bend tests are
made with the weld root in tension. When bend testing thick plates, side bend test
specimens are usually cut from the welded joint and bent with the weld cross section
in tension. The guided bend test is most commonly used in welding procedure and
welder performance qualification tests. This type of testing is particularly good at
finding liner fusion defects, which will often open up in the plate surface during the
testing procedure. See Figure 7.4 shows how the bend test is done.

Figure 7.4

Non-Destructive test
It is a testing and analysis technique used by industry to evaluate the properties
of a material, component, structure or system for characteristic differences or welding
defects and discontinuities without causing damage to the original part. NDT also
known as non-destructive examination (NDE), non-destructive inspection (NDI) and
non-destructive evaluation (NDE).
Non-destructive testing is also a very accurate way of inspection since the tests
are repeatable and a number of tests can be used together to correlate results.
These testing methods are also economical. Unlike destructive testing, NDT is cost
effective as it can prevent the need to replace an item before malfunction occurs without
destroying the piece itself.
This testing technique also offers operators peace of mind, knowing that
equipment is functioning as it should, preventing future accidents and determining any
measures that can be taken for life extension.
It is also useful for testing of welds and verification of welding procedures to
ensure that a welding process has been completed to the correct specification within
the bounds of quality control, for example to make sure that the base metal has reached
the correct temperature, cooled at the specific rate and that compatible materials have
been used to prevent welding defects.

Types of Non-destructive tests

Visual inspection Test (VT) – It is by far the most powerful visual inspection method
available. Because of its relative simplicity. It is the only inspection method that can
actually increase the quality of fabrication and reduce generation of welding defects.

63
Visual inspection begins long before an arc is struck. Materials that are to be welded
must be examined for quality, type, size, cleanliness and free from defects. The pieces
to be joined should be checked for straightness, flatness and dimensions. Alignment
and fit-up of parts should be examined. Joint preparation should be verified. All of
these activities should precede any welding that will be performed.
During welding, visual inspection includes verification that the procedures used are in
compliance with the welding procedure specification (WPS). Upon completion of the
weld bead, the individual weld passes are inspected for signs of porosity, slag inclusion
and any weld cracks. Bead size, shape and sequence can be observed.
Some lightning is imperative for effective visual inspection. Magnifying glasses, gauges
and workmanship samples all aid on visual inspection. See Figure 7.5 are the tools
used for visual inspection.

Figure 7.5

Liquid penetrant test (PT) – It involves the application of liquid which by a capillary
action is drawn into a surface breaking discontinuity, such as crack or porosity. When
the excess residual dye is carefully removed from the surface, a developer is applied,
which will absorb the penetrant that is contained within the discontinuity. This results
in a stain in the developer showing that a discontinuity is present.
Dye penetrant testing is limited to surface discontinuities. It has no ability to
read subsurface discontinuities, but it is highly effective identifying the surface
discontinuities that nay be overlooked or be too small to detect with visual inspection.
See Figure 7.6 applied penetrant to the pipe to reveal surface defects.

Figure 7.6
64
Magnetic particle inspection (MT) – Utilizes change in magnetic flux that occurs
when a magnetic field is present in the vicinity of a discontinuity. This change in
magnetic flux density will show up as a different pattern when magnetic powders are
applied to the surface of a certain part The process is effective in locating
discontinuities that are on the surface and slightly subsurface. For steel structures,
magnetic particle inspection is more effective than dye penetrant inspection and hence,
is preferred for most applications. It can reveal cracks very near the surface, slag
inclusion and porosity.
The magnetic field is created in the material to be inspected in one of two ways.
Current is either directly passed through the material or a magnetic field is induced
through coil on a yoke. With the first method, electrical current is passed through two
prods that are placed in contact with the surface. When the prods are initially placed
on the material, no current is applied. After intimate contact is assured, current is
passed through. Small arcs may occur between the prods and the base material
resulting in an arc strike, which may create a localized brittle zone.
The second method of magnetic field generation is through induction. In what is
known as the yoke method. An electrical coil is wrapped around a core, often with
articulated ends. Electrical current is passed through the coil, creating a magnetic field
in the core. When the ends of the yoke are placed in contact with the part being
inspected, the magnetic field is induced into the part. Since current is not passed into
the part, the potential for arc strikes is eliminated. See Figure 7.7 as reference how MT
is applied into a pipe to detect surface defects.
Magnetic particle inspection is most effective when the region is inspected twice:
once with field located parallel to, and once with the field perpendicular to the weld
axis. While MT can reveal some subsurface discontinuities, it is best used to enhance
visual inspection. Another use of MT is for the inspection of intermediate passes on
large groove welds, particularly in crack sensitive situations.

Figure 7.7

Radiographic inspection (RT) – Uses X-rays or gamma rays that are passed through
the weld and expose a photographic film on the opposite side of the joint. X-rays are
produced by high voltage generators, while gamma rays are produced by atomic
disintegration of radioactive isotopes. Whenever radiography is used, precaution must
be taken to protect workers from exposure to excessive radiation.
Radiographic testing is most effective detecting volumetric discontinuities: slag
and porosity. When cracks are oriented perpendicular to the direction of the radiation
source, they may be missed with the RT method.
It has the advantage of generating a permanent record for future reference. It is
best suited for inspection of complete joint penetration groove welds in butt joints. It is
not particularly suitable for inspection of partial joint penetration groove welds or fillet

65
welds. When applied to tee and corner joints, the geometric constraints of the
applications make RT inspection difficult and interpretation of the result is highly
debatable. See Figure 7.8 for pictures of RT x-ray results.

Figure 7.8

Ultrasonic inspection (UT) – Relies on the transmission of high frequency sound waves
through materials. Solid, discontinuity-free materials will transmit the sound
throughout a part in an interrupted fashion. A receiver “hears” the sound reflected off
of the back surface of the part being inspected. If a discontinuity is contained between
the transmitter and the back side of the part, an intermediate signal will be sent to the
receiver indicating the presence of this discontinuity. The pulses are displayed on a
screen The magnitude of the signal received from the discontinuity is proportional to
the amount of reflected sound. It is a sophisticated device that is very effective in
spotting even small discontinuities.
UT is most sensitive to planar discontinuities, such as cracks, laminations and non-
fusion perpendicular to the direction of the sound transmission. Under some conditions,
informly cylindrical or spherical discontinuities can be overlooked with UT. See Figure
7.9 for actual application of UT.

Figure 7.9
66
Lesson Activity 7.3
Direction. Read and reflect each statement carefully. Write your opinion in a
separate sheet of paper.
1. What are the advantages of NDT over DT?
2. Why are destructible test is dangerous?
3. What test can be done in a shop or in a site?

Post-test 7.4

Let us determine on how much you have learned from the lesson. Please
refrain yourself from browsing the lesson information while taking the Post-
test so that we could measure your performance accurately.

True or false. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

_____1. Ultrasonic inspection (UT) Relies on the transmission of high

frequency sound waves through materials.
_____2. Radiographic inspection (RT) Uses X-rays or gamma rays that are
passed through the weld and expose a photographic film on the opposite side
of the joint.
_____3. Magnetic particle inspection (MT) Utilizes change in magnetic flux that
occurs when a magnetic field is present in the vicinity of a discontinuity.
_____4. Radiographic inspection (RT) involves the application of liquid which
by a capillary action is drawn into a surface breaking discontinuity, such as
crack or porosity.
_____5. Visual inspection test (VT) is by far the most powerful visual inspection
method available. Because of its relative simplicity.
_____6. Destructive testing is a very accurate way of inspection since the tests are
repeatable and a number of tests can be used together to correlate results.
_____7. Transverse bend test is a test method in which a specimen is bent to
a specified bend radius.
_____8. Fillet weld break test involves breaking a sample fillet weld that is
welded on one side only.
_____9. Non-destructive weld testing involves the physical destruction of the
completed weld in order to evaluate its characteristics.
_____10. Macro etch testing typically involves the removal of small samples of
the welded joint.

67
 LESSON 8: WELDING PROCEDURE SPECIFICATION

The scope of this chapter covers the topics of the Welding procedure
specification, the basis of its standards, specification that can be found in
WPS. This topic aims to let the learners understand how was the WPS was
made and read its complex specifications.

Learning Competencies

By the end of this lesson, you are expected to:

1. Identify the welding codes used in WPS.
2. Understand the structure of Welding Procedure Specification.
3. Comprehend the Welding Procedure Specification.

Pre-test 8.1

You must be eager to browse the content of the lesson. However, first, please
let us determine your prior knowledge by answering the pre-test to measure
the topics you have known so far.

Multiple choice. Read and analyze the statements carefully. Write your
answers on a separate sheet of paper or in your notebook.

1. What part of the WPS wherein this the form, the company’s name,
revision number, date created and welding procedure are found?

a. General information
b. Material
c. Technical/ Electrical characteristics
d. Joint/ Position Design

2. Which part of WPS that compose of base metals, filler metals, shielding
and post weld heat treatment related details?

a. General information
b. Material
c. Technical/ Electrical characteristics
d. Joint/ Position Design

3. Which part of WPS where Drawing related to the joint/position is also

shown in the section for better understanding or visual reference of the
welder?

a. General information
b. Material
c. Technical/ Electrical characteristics
d. Joint/ Position Design

4. What is the welding code for the welding of pipelines and related
facilities?

a. API 1104 c. ASME BPVC section V

68
b. API 1169 d. AWS D10.1

5. What is the welding code for the non-destructive examination?

a. API 1104 c. ASME BPVC section V

b. API 1169 d. AWS D10.12
6. What is the welding code for the welding guidance on the measurement
of preheating temperature, interpass temperature and preheat
maintenance temperature?

a. ISO13916 c. ASME BPVC section V

b. API 1169 d. AWS D10.12

7. What is the welding code for the basic inspection requirements for new
pipeline?

a. ISO13916 c. ASME BPVC section V

b. API 1169 d. AWS D10.12

8. What is the welding code for the pipe welding (mild steel)?

a. ISO13916 c. ASME BPVC section V

b. API 1169 d. AWS D10.12

9. What is the abbreviation of API welding standards?

a. American Petroleum Institute

b. African Petroleum Institute
c. American Petrol Institute
d. American Petrol Institution

10. What is the abbreviation of AWS welding standards?

a. American Welding Society

b. African Welding Society
c. American Welding Social Guild
d. American Welding Group

69
Lesson Information 8.2

Welding Procedure Specification

It is a document that serves as a guide for the effective creation of a weld that
meets all applicable code requirements and production standards. WPS are made for a
specific purpose and for a specific company by following the recognized codes and
standards such as the American Society of Mechanical Engineers (ASME) Codes,
American Welding Society (AWS) Standards, American petroleum institute (API)
Standards, British Standard (BS) Standards, International Organization for
Standardization (ISO) Standards, European Union (CEN) Standard and others. The
AWS publishes many documents addressing the use and quality control of welding.
These documents include such general subjects as Welding Definitions and Symbols,
Classification of Filler Metals, Qualification and Testing, Welding Processes, Welding
Applications, and Safety. The ASME covers all aspect of design and manufacture of
boilers and Pressure vessels. ASME also produces the Code for Pressure Piping, which
consists of seven sections. Each section prescribes the minimum requirements for the
design, materials, fabrication, erection, testing and inspection of a particular type of
piping system. The API is one of the most successful programs and was existed before
the other codes was published. Its first standard started in 1924. It maintains over 500
standards covering the oil and gas field. The BS is the national standards used by the
United Kingdom. The ISO has developed over 18500 standards and over1100 new
standards are published every year. The CEN has issued massive standards covering
welding processes which unified and replaced former national standards. After Vienna
Agreement with ISO, CEN has replaced most of them with equivalent ISO standards
(EN ISO series).
There are many publications and iterations of standards that are being develop
and publicized every year for standardization. Below are some of the codes and
descriptions that are being used today

CODE DESCRIPTION

ASME BPVC
Rules for Construction of Power Boilers
Section I

ASME BPVC
Part C: Specifications for Welding Rods, Electrodes and Filler Metals.[a]
Section II

ASME BPVC Rules for Constructions of Nuclear Facility Components-Subsection NCA-General

Section III Requirements for Division 1 and Division 2

ASME BPVC
Rules for Construction of Heating Boilers
Section IV

ASME BPVC
Nondestructive Examination
Section V

ASME BPVC
Rules for Construction of Pressure Vessels Division 1 and Division 2
Section VIII

70
ASME BPVC
Welding and Brazing Qualifications
Section IX

AWS A3.0 Standard welding terms and definitions

AWS A5.1 Specification for carbon steel electrodes for shielded metal arc welding

AWS A5.18 Specification for carbon steel electrodes and rods for gas shielded arc welding

AWS B1.10 Guide for the nondestructive examination of welds

AWS B2.1 Specification for Welding Procedure and Performance Qualification

AWS D1.1 Structural welding (steel)

AWS D1.2 Structural welding (aluminum)

AWS D1.3 Structural welding (sheet steel)

AWS D10.11 Root pass welding for pipe

AWS D10.12 Pipe welding (mild steel)

API RP 577 Welding Inspection and Metallurgy

API RP 582 Welding Guidelines for the Chemical, Oil, and Gas Industries

API 1104 Welding of pipelines and related facilities

API 1169 Basic Inspection Requirements for New Pipeline Construction

BS 4515-2 Specification for welding of steel pipelines on land and offshore. Duplex stainless steel pipelines

Structural use of steel and aluminium. Recommendations for the execution of steel bridges to
PD 6705-2
BS EN 1090-2

Structural use of steel and aluminium. Recommendations for the execution of aluminium
PD 6705-3
structures to BS EN 1090-3

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ISO/TR 20172 Welding — Grouping systems for materials — European materials

ISO/TR 20173 Welding — Grouping systems for materials — American materials

ISO/TR 20174 Welding — Grouping systems for materials — Japanese materials

ISO 13847 Petroleum and natural gas industries -pipeline transportation system - Welding of pipelines

Welding - Guidance on the measurement of preheating temperature, interpass temperature and

ISO 13916
preheat maintenance temperature

ISO 13918 Welding - Studs and ceramic ferrules for arc stud welding

Execution of steel structures and aluminium structures - Part 1: Requirements for conformity
EN 1090-1
assessment of structural components

Execution of steel structures and aluminium structures - Part 2: Technical requirements for steel
EN 1090-2
structures

Execution of steel structures and aluminium structures - Part 3: Technical requirements for
EN 1090-3
aluminium structures

Parts of Welding Procedure Specification

General Information
In this part of the form, the company’s name, revision number, date created,
welding procedure that should be used (SMAW, GTAW or any other welding process),
type of work if its either manual, machine, automatic, or seme-automatic, the name of
person who authorized the WPS, some memo if it is necessary and supporting
Procedure Qualification Record (PQR).

Materials
It compose of base metals, filler metals, shielding and postweld heat treatment
related details. This section is all about the materials that should be used prior in
welding. There are some details that were marked N/A because specific materials or
details is not specified.
Base metals indicate the material specification (the code of the steel that will be
used for the work), type or grade of the base metal. The thickness of groove, fillet and
the pipe diameter.
Filler metals consists of welding codes such as AWS, ASME or any other code
depending on the code they were using. Standard number of filler or electrode were
written here to indicate the specific material that should be used for the work.
Shielding is also specified here if it is available or must be done for the work. If it is not,
details regarding the shielding were labelled N/A. Shielding specific details contains the
Flux, Flux class, Gas, Composition, Flow rate and Gas cup size.

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Postweld heat treatment contains the details regarding the temperature and time
duration of the heat treatment after the welding. It also shows here if post heat
treatment is required or not.

Joint/Position Design
The joint and position details are inserted here. The type of joint such as butt,
corner, T-joint, lap joint or edge joint, indication if it should be single weld or double
weld, if backing is required or not for the weld, the type of backing material (type of
steel or such), root opening size, root face dimension if necessary, the groove angle,
radius if specified, Back gouging if it should be done and the method.
The position of the groove or fillet. If it is flat, vertical, horizontal or overhead. The
vertical progression if it should be performed downwards or upwards.
Drawing related to the joint/position is also shown in this section for better
understanding or visual reference of the welder. In Weld joint parameters it shows joint
design fillet, groove or combined. Joint dimension such as; thickness, root opening,
root face, angle opening, radius and length, Number of passes and layers, and weld
symbols necessary for the design. In some cases, memo were also inserted for reference.

Technical/Electrical Characteristics
It specifies the electrical characteristics like the transfer mode such as the short-
coming, globular and spray(for GMAW). The type of current such as the AC, DCEP,
DCEN and pulse. The type and size of the tungsten if it should be used.
Preheat details, such as the preheat and interpass temperature per minute and its
maximum temperature. In some instances, specific heat for specific sizes of metal are
also included.
The details regarding the technique should be used indicates whether to use a
stringer, weave or both in welding, indicates whether it should be performed in a single
or multi pass per side, no. of electrodes that should be consumed per pass, electrode
spacing details regarding its longitudinal, lateral and angle specifics and interpass
cleaning method like wire wheel and grinding.

Welding procedure
Here is the specific procedure that should be done in each layer, the welding
process should be used, electrode that should be applied, diameter of the electrode,
current type of the welding process, Amperes used for the work, the travel speed,
measured in (inch per minute)
And some other specifics.

Stages of Welding Procedure Specifications

Before any welding or start of constructing any welding related structures, a WPS
should be made or must be presently available for the basis of construction or metal
works. Developing WPS has many stages before it is distributed. Careful planning and
testing of the WPS are one of common practices to avoid costly unnecessary expenses
or failure of the structure in the welding inspection.

Stages
1. Identify the welding process
2. Identify the variables
3. Prepare sWPS
4. Prepare test coupons
5. Test coupons subjected to DT/NDT tests
6. Finalize the sWPS
7. Prepare Procedure Qualification Record (PQR)
8. Prepare WPS
9. Approval of WPS

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See Figure 8.1 and 8.2 for reference of the welding procedure specification. It may vary
from various WPS developers but the codes and standards used are the same.

Figure 8.1

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Figure 8.2

Lesson Activity 8.3

Direction. Read and reflect each statement carefully. Write your opinion in a
separate sheet of paper.

1. Is the WPS important?

2. AWS codes are necessary to produce quality pipe welding works.
3. WPS is not accurately followed in actual application.

Post-test 8.4

Let us determine on how much you have learned from the lesson. Please
refrain yourself from browsing the lesson information while taking the Post-
test so that we could measure your performance accurately.

True or false. Read and analyze the statements carefully. Write your answers
on a separate sheet of paper or in your notebook.

_____1. Welding procedure specifies the procedure that should be done in

each layer, the welding process should be used, electrode that should be
applied, diameter of the electrode and the current type of the welding process.
_____2. The AWS D10.11 contains the guideline on Root pass welding for pipes.
_____3. API 1169 is the welding code for the welding of pipelines and related
facilities
_____4. Finalizing WPS is the 9th and final part of the stage in developing WPS.
_____5. PD 6705-3 is the welding code for welding and brazing qualifications
_____6. The BS standards stands for Britain standards
_____7. ASME BPVC section IV contains the rules for constructing of heating
boilers.
_____8. AWS B1.10 compose of guide for the non-destructive examination of
welds.
_____9. AWS A5.1 contains the specification for welding procedure and
performance qualifications.
_____10. AWS A5.1 is the Specification for carbon steel electrodes for SMAW.
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Note:

This module is currently under development, Reference, Signature of Authorize

personnel or any related groups and other necessary details are currently unavailable.

This is the 7th version of the module, some illustration that was presented is subject to
change to avoid plagiarism.

The planned next module after this is FILLET WELDING IN CARBON STEEL PIPES. The
target accomplish date is at the end of the year 2022.

Please update the developer of this module for correction and updates. The absence of
Actual Performance activities is intentionally not included. Besides, We do not have
face-to-face classes yet.

Mvillamil,

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