Welding Instruction Manual For Local 597 Pipe Fitters Training Center Apprentice Welding Program Pipe Fitters Training Center Local Union 597 Chicago 10850 West 187th Street Mokena, IL 60448 Edition No. 1, Revision No. 2, March 29, 2013 Issued June 1, 2012 Manual Number 1 1
Table of Contents General A. Statement of Policy and Authority B. Organization Chart C. Terms & Abbreviations Section 1.0 Arc Initiation & Maintaining the Arc (SMAW) Section 2.0 Plate Welding (SMAW) Section 3.0 Pipe Welding: 1G 6 Sch 80 (SMAW) Section 4.0 Pipe Welding: Position Welds 6 Sch 80 (SMAW) Section 5.0 Pipe Welding: Position Welds 2 XXH (SMAW) Section 6.0 Introduction to GTAW Section 7.0 Pipe Welding: 1G 4 STD (GTAW) Section 8.0 Pipe Welding: Position Welds 4 STD (GTAW) Section 9.0 Pipe Welding: Position Welds 2 Sch 80 (GTAW) Section 10.0 Introduction to Stainless Steel (GTAW) Section 11.0 Introduction to Inconel (GTAW) Section 12.0 Introduction to Chromium (GTAW & SMAW) Section 13.0 Introduction to GMAW & FCAW Processes Section 14.0 Introduction to Stainless Steel & Inconel Covered Electrodes (SMAW) Section 15.0 Supplementary Documents Section 16.0 Errata/Addendum with Revision No. 2, March 29, 2013 2
A. Statement of Policy and Authority This Welding Instruction Manual has been established to assure compliance with the applicable training procedures and techniques that shall be taught by all welding staff personnel. This Welding Instruction Manual is intended to be used in the training of all apprentices and journeymen while being instructed at the Training Center. The responsibility and authority for implementation of this system has been assigned to David Hintz, Welding Coordinator for Local 597. The Lead Instructor has been given the authority and organizational freedom to identify quality control and teaching technique problems and to initiate, recommend and provide solutions. Problems that cannot be resolved by the Lead Instructor shall be brought to the Welding Director for final resolution based on standard welding techniques, practices and issues in consultation with the Assistant Coordinator and also the Training Coordinator. Changes or revisions to the manual shall be reviewed with, and have concurrence of, the Welding Director, Assistant Training Coordinator and the Training Coordinator prior to implementation. Training Coordinator Signature Date Title 3
B. Organization Flow Chart: Pipe Fitters Training Center Local Union 597 Training Coordinator- John W. Leen Assistant Training Coordinator- Kevin Lakomiak Daily Operations Manager- Matt Majszak Welding Director- Dave Hintz Welding Staff (Full- Time): Glen Burch (Authorized) Calvin Gordon (Authorized) Rick Hobson (Authorized Monte Kimes (Authorized) Mike Pelegrino (Authorized) Marc Randulich (Authorized) Jon Walker (Authorized) Welding Staff Mokena (Part- Time): Bob Borgia Rob Carhart Jim Cebulski Dan Neary Joe Esposito Tyler Johnson Paul Kadlec Pete Larou Vince Macaluso Kevin Potter Jonathan Neu Joe Newren Dean Rapp Aaron Rose Esteban Senesias Ted Slattery Randy Smith Kyle White Joel Zacarias Dorjan Zoni Welding Staff Volo (Part- Time) Dave Barthelt Richard Hering Arlan Nathan Franz Quidayan Andrew Schlabowske Edward Whalen 4
C. Terms & Abbreviations: ANSI American National Standards, Institute, Inc. ASME American Society of Mechanical Engineers CODE ASME Boiler and Pressure Vessel Section IX API- 1104 GMAW Gas Metal Arc Welding GMAW- S Gas Metal Arc Welding Short Arc GTAW Gas Tungsten Arc Welding (TIG) MTR Material Test Reports or certificates of compliance as applicable NDE Non- Destructive Examination PQR Procedure Qualification Record SMAW Shielded Metal Arc Welding WTS Welding Test Specifications Glossary of Terms TBD if needed 5
Section 1 - Arc Initiation & Maintaining the Arc 1.1 Two Methods tap or scratch 1.2 Start with 1/8 E6010 Set amps at 100 Lower amps as they become more comfortable Continue to lower amperage until it becomes more difficult (40 amps) 1.3 As the student becomes proficient with striking the arc have them run short beads about 2-3 inches Teaching Topics: Stress the importance of amperage and its effect on welding (see attached Six Basic Fundamentals for SMAW ) Electrode angle, travel speed and arc length shall be demonstrated by the welding instructor Note: All students will be shown a Welding Safety Power Point and an Introduction to Welding Power Point prior to starting any hands- on welding. 1st year apprentices will not be allowed to weld prior to their first assigned school day. All students will be given a copy of the Weld Shop Rules & Regulations. This hand- out will be presented to them and once understood by all they will sign- off for compliance. Dismissal from the Weld Shop shall be enforced for any infraction. All welding staff personnel have the authority to address any safety violation. All Power Points, hand- outs, or any other documents that are being used for the Welding Program will be provided and found in the Section Supplementary Documents. 6
Section 1 Padding Plate (E6010-1/8 ) [Running Stringers] 1.4 Whipping technique to be demonstrated on 6 scrap pipe Maximum whip length will be 5/32-3/16 Allow weld puddle to widen to 1.5 to 2 times the electrode diameter (amperage will vary per machine, range shall be 75-125) Direction of travel will be toward the dominant hand (Right handed left to right, Left handed right to left) The use of the drag technique shall not be demonstrated for the E6010 electrode. The instructor should watch and stop long whipping. Demonstrate arc length and the differences between a short and long arc. Show variances in travel speed and electrode angles and their effects on the weld bead. References to this exercise can be found in Chapter 10 of the UA Oxy- Fuel Cutting & Welding and SMAW Book that each apprentice has received during their Orientation. Refer to Exercise 3, page 191. Apprentice shall show proficiency throughout weldment prior to moving on to the next exercise. The instructor shall evaluate the width, build- up and voids in between deposited weld metal. There shall be no undercutting, excessive spatter or poor appearance to the weld bead. Bead overlap and tie- ins to adjacent bead shall be uniform, leaving no hills or valleys (lack of fusion). 7
Section 1 Padding Plates (E7018-1/8 ) [Running Stringers] 1.5 Proper arc initiation using Low- Hydrogen Electrodes No long arcing Start ¼ to ½ ahead of starting point and come back Immediately after establishing the arc, lift the electrode up a short distance from the work and holding it there for a second or two, allow a few drops of molten steel to fall from the tip of the electrode. The arc will bring the tip of the electrode up to operating temperature quickly, enabling the core wire to burn up inside the flux coating and initiate the gassing effect of the flux. Then, when the electrode is lowered to the work, the weld will be properly shielded, and porosity will be minimized. Demonstrate amperage changes, travel speed and electrode angles. Allow to the student to see the differences in the weld bead. Show possible weld bead discontinuities on their weldments. References to this exercise can be found in Exercise 6, page 196 & Exercise 7, page 197-201. Apprentice shall show proficiency throughout weldment prior to moving on to the next exercise. The instructor shall evaluate the width, build- up and voids in between deposited weld metal. There shall be no undercutting, excessive spatter or poor appearance to the weld bead. Bead overlap and tie- ins to adjacent bead shall be uniform, leaving no hills or valleys (lack of fusion). 8
Section 2 Plate Welding (SMAW) 2.1 2F Horizontal T- joint (2 x10 x3/8 plate) Joint Set- up will demonstrated by instructor o Use 3/32 gap rod to simulate open root on pipe Each pass will be demonstrated by instructor o E6010 1/8 for the root (1) pass o E7018 3/32 for the hot (1) pass o E7018 3/32 for the fill (2) passes o E7018 3/32 for the cap (3) passes Maximum whipping motion is 5/32-3/16 for the root Hot pass shall be demonstrated with either a weave technique or stringer, no figure 8 s or elongated J- hook weave Fill pass shall be demonstrated with a stringer technique or slight oscillation Cap pass shall be demonstrated with a stringer technique or slight oscillation Instructor needs to stress MAXIMUM whipping motion is 5/32 3/16 for the E6010 1/8 root technique. The Introduction to Welding presentation will provide a descriptive procedure for 2F and also 3F plate welding. The instructor will be able to view this presentation in Section 15 Supplementary Documents. In the UA SMAW book Exercise 10, Step 3, page 205 depicts a whipping diagram. The use of the I- Pad for acceptance of welds starts at this step. End Prep will always be accepted on plate. The Tack- up/fit- up will either be acceptable or rejectable based on the sample being aligned and with a proper gap. The inspection for the welding of the root through the cap will follow the columns on the I- Pad. The root pass shall not exhibit any undercutting or lack of fusion between the plates or the weld deposit in front or behind it (skips or voids). Please review the Acceptable and Unacceptable Fillet Weld Profiles hand- out found in Section 15 of this manual. In the event of an acceptable weldment on a Saturday (Tack- up to cap), the instructor shall have two full- time (CWI & ATR) instructors evaluate the weld based on the 1st Year Welding Criteria specification. At no time should anyone else measure, or say it looks good to me, only to have the sample rejected creating a confrontational situation. Once the sample is accepted then the student will move on to the next requirement. If the acceptable sample is done on a week night then it will be evaluated by the Night Time Inspector (full- time [CWI & ATR] instructor). NOTE: The Cap shall be accepted on the I- Pad only by full- time (CWI & ATR) instructors. 9
Section 2 Plate Welding (SMAW) 2.2 3F Vertical- Up T- Joint (2 x10 x3/8 plate) Each pass will be demonstrated by the instructor o E6010 1/8 for the root (1) pass o E7018 3/32 for the hot (1) pass o E7018 3/32 for the fill (1) pass o E7018 3/32 for the cap (1) pass Enforce maximum whipping length 5/32 to 3/16 for root pass o Watch student for pausing at the keyhole (holding too long or holding too little) o No drag technique for root pass Hot pass weave technique, forward progression uphill o Pause at the side just long enough to cover the entire root pass o Must fuse into the plates Fill pass weave technique past edge of the hot pass Cap pass weave technique past edge of the fill pass Pausing and the speed across the center of the weld, show excessive convexity and review the acceptable weld profile with the student. The use of the I- Pad for acceptance of welds continues for the remainder of the apprentice welding program. End Prep will always be accepted on plate. The Tack- up/fit- up will either be acceptable or rejectable based on the sample being aligned and with a proper gap. The inspection for the welding of the root through the cap will follow the columns on the I- Pad. The root pass shall not exhibit any undercutting or lack of fusion between the plates or the weld deposit in front or behind it (skips or voids). Please review the Acceptable and Unacceptable Fillet Weld Profiles hand- out found in Section 15 of this manual. In the event of an acceptable weldment on a Saturday (Tack- up to cap), the instructor shall have two full- time (CWI & ATR) instructors evaluate the weld based on the 1st Year Welding Criteria specification. At no time should anyone else measure, or say it looks good to me, only to have the sample rejected creating a confrontational situation. Once the sample is accepted then the student will move on to the next requirement. If the acceptable sample is done on a week night then it will be evaluated by the Night Time Inspector (full- time [CWI & ATR] instructor). NOTE: The Cap shall be accepted on the I- Pad only by full- time (CWI & ATR) instructor. 10
Section 3 - Pipe Welding: 1G 6 Sch 80 (SMAW) 3.1 End Prep Removal of dross from ID of pipe Removal of scale on flame cut bevel without damaging the outer edge (file or grinder) Shall be demonstrated by the instructor with a 9 grinder (all instructors shall demonstrate safe working habits) o Whole disc completely flat on pipe to create land o Portion of disc resting on pipe to create land o Remove burrs on ID of pipe prior to checking the land size Land size shall be 1/8 o Use a 1/8 welding rod to identify the correct land size o Must conform to 1/8 prior to moving to next step o Use file to fine tune the land 3.2 Tack- Up/Fit- Up Place 1st pipe coupon in the 2G position in pipe fixture Use 1/8 welding rod to create 1/8 gap on 1st coupon Place 2nd pipe coupon on top of 1st coupon Maintain a 1/8 gap all around the joint Use 1/8 E6010 to start tacking, explain that this step not only secures the pipe joint, but also allows the student to set the amperage based on key hole size (4) equally spaced tacks are mandatory o Tack length shall be ½ o Fully penetrated, whether they are tying- in or burning through Teaching Topics: Each step shall be demonstrated in groups, then individually to personalize instruction. Stress good work and travel angles while tacking. Key hole size shall be no larger than 3/16. The maximum misalignment allowed is 1/16. All four tacks shall show complete penetration and the gap shall not have any tight nor wide areas. Failure to do so will result in two outcomes, they are: either the student will have to cut it apart until it is correct, or the student will be allowed to continue but will fail the Tack- Up/Fit- Up hold point. If the sample is rejected at this time the sample will fail no matter what the other passes look like. 11
Section 3 - Pipe Welding: 1G 6 Sch 80 (SMAW) 3.3 Grinding Tacks (feathering tacks) Heavy end of tack should be feathered edged without ruining the bevel or the land prior to the tacks Key hole of tack shall also be feathered Care shall be taken with the grinding disc to only make contact with the tack area Grind one tack at a time if consuming tacks Allowed to grind all four tacks at once if tying into tacks Care should be taken not to over grind, as this may cause the tacks to break and the joint to close up. Refer to Exercise 23, Step 6 for a descriptive drawing of the feathered tacks. Watch student while they grind and correct any bad techniques. Encourage them to purchase a 4 grinder with various sized discs for cutting and grinding. This is not a hold point or inspection point, just informative. 12
Section 3 - Pipe Welding: 1G 6 Sch 80 (SMAW) 3.4 Root Pass Only two (2) techniques will be demonstrated and taught o Whip o Circle No Drag technique will demonstrated or taught for the root pass E6010 1/8 (Amperage Range: 75 125 DCEP) o Initiate the arc in the work area (bevels) and long arcing the rod is required prior to depositing metal o Proceed forward into keyhole Electrode Angle o Plus or minus 5 to 10, push to drag angle, from center line of pipe o Keep electrode perpendicular in the bevels to help avoid key holing of only one side Key hole o Using an 1/8 electrode, the key hole size should be between 5/32 and 3/16 o Demonstrate welding the key hole o Amps and travel will be dictated by the key hole size Penetration o Minimum acceptance criteria flush with the ID o Maximum acceptance criteria 1/8 past the ID Grinding on the Root pass o Light grinding is recommended (making it all shine ) may cause a possible burn- through on the hot pass. If this type of grinding is necessary, then this would indicate problems with the student s welding technique and further instruction should follow. The root pass shall be free from excessive penetration, lack of penetration, lack of fusion between deposited weld ripples (voids/holes/under flushed craters) and undercut. Poor tie- ins and double roots shall be rejected or repaired. The student shall be allowed one (1) attempt at a repair and visually inspected prior to starting the hot pass. The student should gain some proficiency with welding the roots prior to attempting any repairs. The instructor must limit the repair time to a minimum as this is counterproductive to the students progress. Use of a hammer and chisel to remove excessive penetration will never be allowed. The student will not be allowed to fix a root from the inside, all root repairs are from the outside only for all sizes, diameters and processes while at the Training Center. 13
Section 3 - Pipe Welding: 1G 6 Sch 80 (SMAW) 3.5 Hot Pass E7018 3/32 (Amperage Range: 70 100 DCEP) o Initiate the arc in the work area o No long arcing, will cause porosity o Demonstrate starting ¼ to ½ ahead of starting point and come back When tying into a stopping point, come back into half of the crater and continue Width/Height o Weld the edges of the root pass to the bevels by weaving side to side with a forward progression o Hold the electrode at these points long enough to allow the arc force to dig into the bevels and tie- in One Pass for the Hot o Reiterate to student that this is the same as the 3F plate technique Grinding the root pass very deep and narrow will create problems for student on their hot pass; demonstrate good grinding techniques that will maintain the original bevel faces and opening without over grinding. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the hot pass. Arc striking on the OD of the pipe within 2 of either side of the joint will not be tolerated. If the arc strike occurred while tacking the student should explain this to the instructor while it is being inspected during the tack- up hold point. 14
Section 3 - Pipe Welding: 1G 6 Sch 80 (SMAW) 3.6 Fill Pass E7018 1/8 (Amperage Range: 115 165) o Arc initiation and tie- ins are the same as the hot pass o Stagger starts/stops to eliminate heavy spots and to avoid clusters of porosity The weld metal shall be 1/32 to 1/16 below flush with the outside surface. The weld metal should be level, without excessive convexity and concavity. If a grinder is needed to fix these problems the welder s technique should be addressed. The welder must evaluate each pass to assure they are within tolerances. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the fill pass. This criterion is for all positions: 2G, 5G, 6G and the 1G, including but not limited to all 6 and 2 pipe. 15
Section 3 - Pipe Welding: 1G 6 Sch 80 (SMAW) 3.7 Cap Pass 1/8 E7018 (Amperage Range: 115 165) Placement of half the electrode diameter over the edge of the bevels is recommended Weld reinforcement shall be flush (minimum) to 1/8 (maximum) above the outside surface. The weld shall not exceed 1/8 on either side of the joint (per the UA). Undercut is allowed up to 1/32 deep. Undercut indicates that the welder is depositing metal incorrectly. Repairs are allowed on the cap. The repairs must be 2-3 in length and must be re- welded (for all diameters of pipe). Note: 2G or 6G: three (3) stringer beads are required for 6 and the 2 (bottom, middle & top). (3) Acceptable samples shall be required prior to testing. One full- time welding instructor shall be required to accept or reject the final, overall weld on all samples throughout the student s welding career at the Training Center, except for the samples being submitted to Mr. Hintz prior to a UA test, then two instructors shall be required to accept it. The proper paperwork shall be filled out and submitted to Mr. Hintz for his approval. 16
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 2G 6 Sch 80 4.1 End Prep Refer to Section 3.1 of this manual 4.2 Tack- up/fit- up Refer to Section 3.1 of this manual Teaching Topics: All students will be given a demonstration on each new position. Most students progress quickly with the 2G. Reiterate that this is the same joint as their (7) pass 2F T- joint. This is a Hold Point ; do not allow the student to bypass any step. The maximum misalignment allowed is 1/16. All four tacks shall show complete penetration and the gap shall not have any tight nor wide areas. Failure to do so will result in two outcomes, they are: either the student will have to cut it apart until it is correct, or the student will be allowed to continue but will fail the Tack- Up/Fit- Up hold point. If the sample is rejected at this time the sample will fail no matter what the other passes look like. 17
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 2G 6 Sch 80 4.3 Grinding Tacks (feathering tacks) Refer to Section 3.3 of this manual The student shall be allowed to rotate the coupon in the fixture, rather than walk around it. This is a safety concern. Some students have wrapped their cords or cables around their legs and tripped. They will not be allowed to remove or flip the coupon once they start the root pass. All grinding will be done in place. The fixture shall not be allowed to change elevation (must stay at one height until complete). In order to inspect tacks or the root pass please show the student how to change from a 2G to a 5G to check the root. 18
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 2G 6 Sch 80 4.4 Root Pass Whipping technique or circle technique shall be taught E6010 1/8 (Amperage Range: 75 125 DCEP) The key hole is to be 5/32-3/16 maximum Penetration o Minimum acceptance criteria flush with the ID o Maximum acceptance criteria 1/8 past the ID Grinding on the Root pass o Light grinding is recommended (making it all shine ) may cause a possible burn- through on the hot pass. If this type of grinding is necessary, then this would indicate problems with the student s welding technique and further instruction should follow. The root pass shall be free from excessive penetration, lack of penetration, lack of fusion between deposited weld ripples (voids/holes/under flushed craters) and undercut. Poor tie- ins and double roots shall be rejected or repaired. The student shall be allowed one (1) attempt at a repair and visually inspected prior to starting the hot pass. The student should gain some proficiency with welding the roots prior to attempting any repairs. The instructor must limit the repair time to a minimum as this is counterproductive to the students progress. 19
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 2G 6 Sch 80 4.5 Hot Pass E7018 3/32 (Amperage Range 70-100 DCEP) Single pass Technique o Stringer (drag) o Weave/oscillate This is the same technique that was demonstrated on the 2F plate o lllll, lllll, wwwww, No excessive motions, try to limit the amount of weld deposit. Over filling will not allow the fill passes to go in properly, causing the student to grind off welds. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the hot pass. 20
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 2G 6 Sch 80 4.6 Fill Pass (2) stringers are required 1/8 E7018 will be used Equal sized passes This is the same as the 2F T- joint Overfilling the joint and then grinding out the top or bottom 1/3 rd of every pass shall not be demonstrated. Removal of slag or etching lines to see the joint shall be allowed, but not excessive, limit the practice to about 1/32. The weld metal shall be 1/32 to 1/16 below flush with the outside surface. The weld metal should be level, without excessive convexity and concavity. If a grinder is needed to fix these problems the welder s technique should be addressed. The welder must evaluate each pass to assure they are within tolerances. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the fill pass. 21
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 2G 6 Sch 80 4.7 Cap Pass 1/8 E7018 (3) stringers are required Equally sized passes Grinding shall be limited to skimming starts/stops, in order to check for porosity. Refer to Ch. 12 in the UA SMAW book for more details in regards to grinding. Weld reinforcement shall be flush (minimum) to 1/8 (maximum) above the outside surface. The weld shall not exceed 1/16 on either side of the joint (per the UA). Undercut is allowed up to 1/32 deep. Undercut indicates that the welder is depositing metal incorrectly. Repairs are allowed on the cap. The repairs must be 2-3 in length and must be re- welded (for all diameters of pipe). Note: (2) Acceptable samples shall be required prior to advancing to the 5G position 22
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 5G 6 Sch 80 4.1a End Prep Refer to Section 3.1 of this manual 4.2a Tack- up/fit- up Refer to Section 3.1 of this manual This step is a Hold Point for the student All students will be given a demonstration on each new position. This joint is the same as the 1G, except the student is the one rolling. Relate this to the 3F T- joint. No rotating to grind or change in height, once it is set in the fixture the student will mark the top and the coupon shall stay in a fixed position. The maximum misalignment allowed is 1/16. All four tacks shall show complete penetration and the gap shall not have any tight nor wide areas. Failure to do so will result in two outcomes, they are: either the student will have to cut it apart until it is correct, or the student will be allowed to continue but will fail the Tack- Up/Fit- Up hold point. If the sample is rejected at this time the sample will fail no matter what the other passes look like. Notes: The welding progression is uphill. Welding shall start approximately at the 6 o clock position, and then proceed to either 9 o clock or 3 o clock with the uphill progression. Downhill/Opposite direction shall be 1/2 maximum off of center. See letter that pertains to this topic in Section 15. 23
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 5G 6 Sch 80 4.3a Grinding Tacks (feathering tacks) Refer to Section 3.3 of this manual The student will not be allowed to remove or flip the coupon once they start the root pass. All grinding will be done in place. The fixture shall not be allowed to change elevation (must stay at one height until complete). 24
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 5G 6 Sch 80 4.4a Root Pass 1/8 E6010 (Amperage Range: 75 125 DCEP) The keyhole is to be 5/32-3/16 maximum, using the same techniques stated earlier o Whipping o Circle Penetration o Minimum acceptance criteria flush with the ID o Maximum acceptance criteria 1/8 past the ID Grinding on the Root pass o Light grinding is recommended, remove humps and create an area that will enable proper welding technique on the hot pass. Stress the importance of maintaining the original bevel shape. Suggest that the student weld out on the bottom of the joint to familiarize themselves with this new position. The root pass shall be free from excessive penetration, lack of penetration, lack of fusion between deposited weld ripples (voids/holes/under flushed craters) and undercut. Poor tie- ins and double roots shall be rejected or repaired. The student shall be allowed one (1) attempt at a repair and visually inspected prior to starting the hot pass. The student should gain some proficiency with welding the root pass prior to attempting any repairs. The instructor must limit the repair time to a minimum as this is counterproductive to the students progress. 25
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 5G 6 Sch 80 4.5a Hot Pass E7018 3/32 (Amperage Range 70 100 DECP) Single pass Weave technique o Wide enough to cover the root pass o This should not fill out the remainder of the joint No excessive motions, try to limit the amount of weld deposit. Over filling will not allow the fill passes to go in properly, causing the student to grind off welds. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the hot pass. 26
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 5G 6 Sch 80 4.6a Fill Pass 1/8 E7018 (Amperage Range: 110 150 DCEP) Weave technique, going wide enough to cover the hot pass Single pass Overfilling the joint and then grinding out the weld pass shall not be demonstrated. The weld metal shall be 1/32 to 1/16 below flush with the outside surface. The weld metal should be level, without excessive convexity and concavity. If a grinder is needed to fix these problems the welder s technique should be addressed. The welder must evaluate each pass to assure they are within tolerances. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the fill pass. 27
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 5G 6 Sch 80 4.7a Cap Pass 1/8 E7018 shall be used (Amperage Range: 110-150 DCEP) Single pass, no split caps Grinding shall be limited to skimming starts/stops, in order to check for porosity. Refer to Ch. 12 in the UA SMAW book for more details in regards to grinding. Weld reinforcement shall be flush (minimum) to 1/8 (maximum) above the outside surface. The weld shall not exceed 1/16 on either side of the joint (per the UA). Undercut is allowed up to 1/32 deep. Undercut indicates that the welder is depositing metal incorrectly. Repairs are allowed on the cap. The repairs must be 2-3 in length and must be re- welded (for all diameters of pipe and processes). Remind the students that the weld shall be left in the as welded condition; filing or grinding on the finished product shall be cause for rejection, just like a UA test. Note: (2) Acceptable samples shall be required prior to advancing to the 6G position 28
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 6G 6 Sch 80 4.1b End Prep Refer to Section 3.1 of this manual 4.2b Tack- up/fit- up Refer to Section 3.1 of this manual This step is a Hold Point for the student All students will be given a demonstration on each new position. This joint is the same as the 2F plate and also the 2G, except it is now on a 45 angle. No rotating to grind or change in height, once it is set in the fixture the student will mark the top and the coupon shall stay in a fixed position. The maximum misalignment allowed is 1/16. All four tacks shall show complete penetration and the gap shall not have any tight nor wide areas. Failure to do so will result in two outcomes, they are: either the student will have to cut it apart until it is correct, or the student will be allowed to continue but will fail the Tack- Up/Fit- Up hold point. If the sample is rejected at this time the sample will fail no matter what the other passes look like. Notes: The welding progression is uphill. Welding shall start approximately at the 6 o clock position, and then proceed to either 9 o clock or 3 o clock with the uphill progression. Downhill/Opposite direction shall be 1/2 maximum off of center. See letter that pertains to this topic in Section 15. 29
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 6G 6 Sch 80 4.3b Grinding Tacks (feathering tacks) Refer to Section 3.3 of this manual The student will not be allowed to remove or flip the coupon once they start the root pass. All grinding will be done in place. The fixture shall not be allowed to change elevation (must stay at one height until complete). 30
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 6G 6 Sch 80 4.4b Root Pass 1/8 E6010 (Amperage Range: 75 125 DCEP) The keyhole is to be 5/32-3/16 maximum, using the same techniques stated earlier o Whipping o Circle Penetration o Minimum acceptance criteria flush with the ID o Maximum acceptance criteria 1/8 past the ID Grinding on the Root pass o Light grinding is recommended, remove humps and create an area that will enable proper welding technique on the hot pass. Stress the importance of maintaining the original bevel shape. Suggest that the student weld out on the bottom of the joint to familiarize themselves with this new position. Body and head placement are crucial in achieving a sound weld. Offer a different approach, such as kneeling as opposed to standing. The root pass shall be free from excessive penetration, lack of penetration, lack of fusion between deposited weld ripples (voids/holes/under flushed craters) and undercut. Poor tie- ins and double roots shall be rejected or repaired. The student shall be allowed one (1) attempt at a repair and visually inspected prior to starting the hot pass. The student should gain some proficiency with welding the root pass prior to attempting any repairs. The instructor must limit the repair time to a minimum as this is counterproductive to the students progress. 31
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 6G 6 Sch 80 4.5b Hot Pass E7018 3/32 (Amperage Range 70 100 DECP) Single pass Weave technique o Wide enough to cover the root pass o This should not fill out the remainder of the joint No excessive motions, try to limit the amount of weld deposit. Over filling will not allow the fill passes to go in properly, causing the student to grind off welds. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the hot pass. 32
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 6G 6 Sch 80 4.6b Fill Pass 1/8 E7018 (Amperage Range: 110 150 DCEP) (2) Stringers are required Equal sized passes Prohibit large weaves and the use of a grinder to open joint or to remove perfectly good weld metal Overfilling the joint and then grinding out the weld pass shall not be demonstrated. The weld metal shall be 1/32 to 1/16 below flush with the outside surface. The weld metal should be level, without excessive convexity and concavity. If a grinder is needed to fix these problems the welder s technique should be addressed. The welder must evaluate each pass to assure they are within tolerances. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the fill pass. Over filling the joint (past flush) as well as hills and valleys shall also be cause for rejection. 33
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW) 6G 6 Sch 80 4.7b Cap Pass 1/8 E7018 (Amperage Range 110-150 DCEP) (3) stringers are required Equally sized passes Grinding shall be limited to skimming starts/stops, in order to check for porosity. Refer to Ch. 12 in the UA SMAW book for more details in regards to grinding. Weld reinforcement shall be flush (minimum) to 1/8 (maximum) above the outside surface. The weld shall not exceed 1/16 on either side of the joint (per the UA). Undercut is allowed up to 1/32 deep. Undercut indicates that the welder is depositing metal incorrectly. Repairs are allowed on the cap. The repairs must be 2-3 in length and must be re- welded (for all diameters of pipe). Note: (2) Acceptable samples shall be required prior to advancing to the 2G position on 2 XXH 34
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 2G 2 XXH 5.1 End Prep Refer to Section 3.1 of this manual 5.2 Tack- up/fit- up Refer to Section 3.1 of this manual No bridge tacks, or droplets of metal will be allowed for tack- up. The student will be allowed to use a minimum of (3) tacks. The tacks shall be fully penetrated, no longer than 3/8 and placed at the 12, 3, 6, or 9 o clock areas. This is a Hold Point ; do not allow the student to bypass any step. The student will be allowed to rotate the coupon in the fixture rather than walk around it. The coupon will remain at one height through it s entirety. The coupon can be placed in the 5G position to check the root pass. Remind the student that all grinding will take place in the 2G position. 5.3 Grinding Tacks (feathering tacks) Refer to Section 3.3 of this manual 35
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 2G 2 XXH 5.4 Root Pass Whipping technique or circle technique shall be taught E6010 1/8 (Amperage Range: 75 125 DCEP) The key hole is to be 5/32-3/16 maximum Penetration o Minimum acceptance criteria flush with the ID o Maximum acceptance criteria 1/8 past the ID Grinding on the Root pass o Light grinding is recommended (making it all shine ) may cause a possible burn- through on the hot pass. If this type of grinding is necessary, then this would indicate problems with the student s welding technique and further instruction should follow. The root pass shall be free from excessive penetration, lack of penetration, lack of fusion between deposited weld ripples (voids/holes/under flushed craters) and undercut. Poor tie- ins and double roots shall be rejected or repaired. The student shall be allowed one (1) attempt at a repair and visually inspected prior to starting the hot pass. The student should gain some proficiency with welding the roots prior to attempting any repairs. The instructor must limit the repair time to a minimum as this is counterproductive to the students progress. 36
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 2G 2 XXH 5.5 Hot Pass E7018 3/32 (Amperage Range 70-100 DCEP) Single pass Technique o Stringer (drag) o Weave/oscillate This is the same technique that was demonstrated on the 2F plate o lllll, lllll, wwwww, No excessive motions, try to limit the amount of weld deposit. Over filling will not allow the fill passes to go in properly, causing the student to grind off welds. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the hot pass. 37
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 2G 2 XXH 5.6 Fill Pass (2) stringers are required 3/32 E7018 will be used Equal sized passes This is the same as the 2F T- joint Overfilling the joint and then grinding out the top or bottom 1/3 rd of every pass shall not be demonstrated. Removal of slag or etching lines to see the joint shall be allowed, but not excessive, limit the practice to about 1/32. The weld metal shall be 1/32 to 1/16 below flush with the outside surface. The weld metal should be level, without excessive convexity and concavity. If a grinder is needed to fix these problems the welder s technique should be addressed. The welder must evaluate each pass to assure they are within tolerances. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the fill pass. 38
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 2G 2 XXH 5.7 Cap Pass 3/32 E7018 (3) stringers are required Equally sized passes Grinding shall be limited to skimming starts/stops, in order to check for porosity. Refer to Ch. 12 in the UA SMAW book for more details in regards to grinding. Weld reinforcement shall be flush (minimum) to 1/8 (maximum) above the outside surface. The weld shall not exceed 1/16 on either side of the joint (per the UA). Undercut is allowed up to 1/32 deep. Undercut indicates that the welder is depositing metal incorrectly. Repairs are allowed on the cap. The repairs must be 2-3 in length and must be re- welded (for all diameters of pipe). Note: (2) Acceptable samples shall be required prior to advancing to the 5G position 39
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 5G 2 XXH 5.1a End Prep Refer to Section 3.1 of this manual 5.2a Tack- up/fit- up Refer to Section 3.1 of this manual This step is a Hold Point for the student All students will be given a demonstration on each new position. No rotating to grind or change in height, once it is set in the fixture the student will mark the top and the coupon shall stay in a fixed position. Students are allowed to use (3) or (4) tacks. The maximum misalignment allowed is 1/16. All tacks shall show complete penetration and the gap shall not have any tight nor wide areas. Failure to do so will result in two outcomes, they are: either the student will have to cut it apart until it is correct, or the student will be allowed to continue but will fail the Tack- Up/Fit- Up hold point. If the sample is rejected at this time the sample will fail no matter what the other passes look like. Notes: The welding progression is uphill. Welding shall start approximately at the 6 o clock position, and then proceed to either 9 o clock or 3 o clock with the uphill progression. Downhill/Opposite direction shall be 1/2 maximum off of center. See letter that pertains to this topic in Section 15. 5.3a Grinding Tacks (feathering tacks) Refer to Section 3.3 of this manual The student will not be allowed to remove or flip the coupon once they start the root pass. All grinding will be done in place. The fixture shall not be allowed to change elevation (must stay at one height until complete). 40
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 5G 2 XXH 5.4a Root Pass 1/8 E6010 (Amperage Range: 75 125 DCEP) The keyhole is to be 5/32-3/16 maximum, using the same techniques stated earlier o Whipping o Circle Penetration o Minimum acceptance criteria flush with the ID o Maximum acceptance criteria 1/8 past the ID Grinding on the Root pass o Light grinding is recommended, remove humps and create an area that will enable proper welding technique on the hot pass. Stress the importance of maintaining the original bevel shape. Suggest that the student adjust amperage to familiarize themselves with this new position during the welding of the root pass. Go back to the basics; remind them about the length of whipping motion. The student does not have to use one electrode to go from bottom to top. The student should stop welding as needed to maintain correct technique. The root pass shall be free from excessive penetration, lack of penetration, lack of fusion between deposited weld ripples (voids/holes/under flushed craters) and undercut. Poor tie- ins and double roots shall be rejected or repaired. The student shall be allowed one (1) attempt at a repair and visually inspected prior to starting the hot pass. The student should gain some proficiency with welding the root pass prior to attempting any repairs. The instructor must limit the repair time to a minimum as this is counterproductive to the students progress. 41
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 5G 2 XXH 5.5a Hot Pass E7018 3/32 (Amperage Range 70 100 DECP) Single pass Weave technique o Wide enough to cover the root pass o This should not fill out the remainder of the joint No excessive motions, try to limit the amount of weld deposit. Over filling will not allow the fill pass to go in properly, causing the student to grind off welds. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the hot pass. 42
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 5G 2 XXH 5.6a Fill Pass 3/32 E7018 Weave technique, going wide enough to cover the hot pass Single pass, due to the amount of grinding a student may need an extra fill pass to flush out joint, this is permissible Overfilling the joint and then grinding out the weld pass shall not be demonstrated. The weld metal shall be 1/32 to 1/16 below flush with the outside surface. The weld metal should be level, without excessive convexity and concavity. If a grinder is needed to fix these problems the welder s technique should be addressed. The welder must evaluate each pass to assure they are within tolerances. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the fill pass. 43
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 5G 2 XXH 5.7a Cap Pass 3/32 E7018 shall be used Single pass, no split caps Grinding shall be limited to skimming starts/stops, in order to check for porosity. Refer to Ch. 12 in the UA SMAW book for more details in regards to grinding. Weld reinforcement shall be flush (minimum) to 1/8 (maximum) above the outside surface. The weld shall not exceed 1/16 on either side of the joint (per the UA). Undercut is allowed up to 1/32 deep. Undercut indicates that the welder is depositing metal incorrectly. Repairs are allowed on the cap. The repairs must be 2-3 in length and must be re- welded (for all diameters of pipe and processes). Remind the students that the weld shall be left in the as welded condition; filing or grinding on the finished product shall be cause for rejection, just like a UA test. Note: (4) Acceptable samples shall be required prior to advancing to the 6G position 44
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 6G 2 XXH 5.1b End Prep Refer to Section 3.1 of this manual 5.2b Tack- up/fit- up Refer to Section 3.1 of this manual This step is a Hold Point for the student All students will be given a demonstration on each new position. This joint is the same as the 2F plate and also the 2G, except it is now on a 45 angle. No rotating to grind or change in height, once it is set in the fixture the student will mark the top and the coupon shall stay in a fixed position. The maximum misalignment allowed is 1/16. All tacks shall show complete penetration and the gap shall not have any tight nor wide areas. Failure to do so will result in two outcomes, they are: either the student will have to cut it apart until it is correct, or the student will be allowed to continue but will fail the Tack- Up/Fit- Up hold point. If the sample is rejected at this time the sample will fail no matter what the other passes look like. Notes: The welding progression is uphill. Welding shall start approximately at the 6 o clock position, and then proceed to either 9 o clock or 3 o clock with the uphill progression. Downhill/Opposite direction shall be 1/2 maximum off of center. See letter that pertains to this topic in Section 15. 45
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 6G 2 XXH 5.3b Grinding Tacks (feathering tacks) Refer to Section 3.3 of this manual The student will not be allowed to remove or flip the coupon once they start the root pass. All grinding will be done in place. The fixture shall not be allowed to change elevation (must stay at one height until complete). 46
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 6G 2 XXH 5.4b Root Pass 1/8 E6010 (Amperage Range: 75 125 DCEP) The keyhole is to be 5/32-3/16 maximum, using the same techniques stated earlier o Whipping o Circle Penetration o Minimum acceptance criteria flush with the ID o Maximum acceptance criteria 1/8 past the ID Grinding on the Root pass o Light grinding is recommended, remove humps and create an area that will enable proper welding technique on the hot pass. Stress the importance of maintaining the original bevel shape. Body and head placement are crucial in achieving a sound weld. Offer a different approach, such as kneeling as opposed to standing. The root pass shall be free from excessive penetration, lack of penetration, lack of fusion between deposited weld ripples (voids/holes/under flushed craters) and undercut. Poor tie- ins and double roots shall be rejected or repaired. The student shall be allowed one (1) attempt at a repair and visually inspected prior to starting the hot pass. The student should gain some proficiency with welding the root pass prior to attempting any repairs. The instructor must limit the repair time to a minimum as this is counterproductive to the students progress. 47
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 6G 2 XXH 5.5b Hot Pass E7018 3/32 (Amperage Range 70 100 DECP) Single pass Weave technique o Wide enough to cover the root pass o This should not fill out the remainder of the joint No excessive motions, try to limit the amount of weld deposit. Over filling will not allow the fill passes to go in properly, causing the student to grind off welds. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the hot pass. 48
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 6G 2 XXH 5.6b Fill Pass 3/32 E7018 (2) Stringers are required Equal sized passes Prohibit large weaves and the use of a grinder to open joint or to remove perfectly good weld metal Overfilling the joint and then grinding out the weld pass shall not be demonstrated. The weld metal shall be 1/32 to 1/16 below flush with the outside surface. The weld metal should be level, without excessive convexity and concavity. If a grinder is needed to fix these problems the welder s technique should be addressed. The welder must evaluate each pass to assure they are within tolerances. Undercutting, porosity, slag inclusions, lack of fusion, poor tie- ins and crowning or excessive convexity will be cause for rejection of the fill pass. Over filling the joint (past flush) as well as hills and valleys shall also be cause for rejection. 49
Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW) 6G 2 XXH 5.7b Cap Pass 3/32 E7018 (3) stringers are required Equally sized passes Grinding shall be limited to skimming starts/stops, in order to check for porosity. Refer to Ch. 12 in the UA SMAW book for more details in regards to grinding. Weld reinforcement shall be flush (minimum) to 1/8 (maximum) above the outside surface. The weld shall not exceed 1/16 on either side of the joint (per the UA). Undercut is allowed up to 1/32 deep. Undercut indicates that the welder is depositing metal incorrectly. Repairs are allowed on the cap. The repairs must be 2-3 in length and must be re- welded (for all diameters of pipe). All samples that are to be turned in for approval by Mr. Hintz shall be free from any repairs, whether it is the root pass or the cap pass. Checking of the root pass after the hot pass goes in shall not be allowed. The UA testing procedure does not accept this practice. Note: (4) Acceptable samples shall be required prior to testing. The 4 th sample shall be turned in for Mr. Hintz s approval before the student tests. A Request to Test form shall be generated and signed by two instructors, one of which will be a full- time, ATR and CWI. 50