CBLM

Republic of the Philippine
Technical Education and Skills Development

Authority
SURIGAO DEL NORTE COLLEGE OF AGRICULTURE AND
TECHNOLOGY
Magpayang, Mainit, Surigao Del Norte
Telefax No. (086)826-3765
01 Session plan
02 Competency Based learning Material ( CBLM )
03 Assessment Tool w/ Evidence w/ table of specification
04 Training Activity Matrix
05 Self Assessment Guide
06 Progress Chart
07 Achievement Chart
08 Session Evaluation Sheet
09 Third Party Certificate
10 Relevant Training Certificate
COMPETENCY BASED LEARNING MATERIAL

Sector : METALS AND ENGINEERING
Qualification Title : SHIELDED METAL ARC WELDING NC II
Unit of Competency : Weld Carbon Steel Pipes
Module Title : Performing Groove Welding on Carbon Steel Pipes
SNCAT
Surigao Del Norte College of Agriculture And Technology
Magpayang, Mainit, Surigao Del Norte
Date Developed: Doc. No.
CBLM on May 2014 Issued by:
Shielded Metal
Arc Welding SMAW NC Developed by: Surigao del Norte
II Engr. Gerson T. College of Agriculture
Welding Carbon Steel Estay and Technology Page i
Pipes Using SMAW
ACKNOWLEDGEMENTS
In the development of this CBLM, I would like to express my sincere
gratitude to my loving and understanding wife Germalyn T. Estay for their
continuous support of my research and writing of this CBLM.
I would like to show my sincere gratitude also and appreciation to Ms.

Lilian C. Garces and Mrs. Marife Pena. For their support, help and
encourage every time i need guidance and in time i can not understand
some of my task in every module. And I would like to give my warmest
thanks to my co-trainees especially Mrs. Maricel Salibungcogon and Mrs.
Liza Jumamoy for the sleepless nights we were working together before the
assessment and their always give me support and advice.
Special thanks to my lovely daughters Gerly and Gia Mae and also my
youngest baby Gerenyl for their unconditional support, emotionally and
patience show me during the training is greatly appreciated.

CBLM on Issued by:
Shielded Metal Arc May 2014
Welding SMAW NC II Surigao del Norte
Developed by: College of Agriculture
Welding Carbon Steel Engr. Gerson T. and Technology Page ii
Pipes Using SMAW Estay
Table of Contents
Title____________________________________________________________ i
Acknowledgement______________________________________________ ii
List of Competencies____________________________________________1
CBLM Instruction_______________________________________________2
Module Content_________________________________________________5
Learning Outcome No. 1 ________________________________________5
Learning Experiences ___________________________________________8
Safety Welding Practices____________________________________12
Self-check 1B.1-1 ____________________________________23
Answer Key 1B.1-1___________________________________ 24
Essentials in Welding_______________________________________25
Self-check 1B.1-1 ____________________________________39
Answer Key 1B.1-1___________________________________ 40
International Welding Codes and standards ________________ 41
Self-check 1B.1-1 ____________________________________47
Answer Key 1B.1-1___________________________________ 48
Acceptable weld profile _____________________________________49
Self-check 1B.1-1 ____________________________________59
Answer Key 1B.1-1___________________________________ 60
Weld defects, causes and remedies _________________________ 61
Self-check 1B.1-1 ____________________________________65
Answer Key 1B.1-1___________________________________ 66
Welding Procedure Specification (WPS) _______________________67
Self-check 1B.1-1 ____________________________________71
Answer Key 1B.1-1___________________________________ 72
Welding techniques and procedure _________________________ 73
Self-check 1B.1-1 ____________________________________78
Answer Key 1B.1-1___________________________________ 79
Procedures in welding carbon steel pipes
In horizontal position (2G) ___________________________________80
Self-check 1B.1-1 ____________________________________81
Answer Key 1B.1-1___________________________________ 82
Job sheet1B.1-8 ____________________________________ 83
Performance criteria checklist 1B.1-1 ________________ 88
In vertical position (5G) ____________________________________ 94
Self-check 1B.2-1 ____________________________________95
Answer Key 1B.2-1___________________________________ 96
Job sheet1B.2-1 ____________________________________ 97

CBLM on Issued by:
Welding Carbon Steel Engr. Gerson T. and Technology Page iii

Inclined 45˚ fix position (6G) ______________________________ 108
Self-check 1B.3-1 ____________________________________
109
Answer Key 1B.3-1___________________________________ 110
Job sheet1B.3-1 ____________________________________ 111
Terms and Definitions__________________________________________ 117
Bibliography____________________________________________________ 127

CBLM on Issued by:
Welding Carbon Steel Engr. Gerson T. and Technology Page iv
SHIELDED METAL ARC WELDING NC II
COMPETENCY-BASED LEARNING MATERIALS
List of Competencies
No. Unit of Competency Module Title Code
1A. Weld Carbon Steel Performing Groove

Plates Welding on Carbon Steel MEE721306A
Plates
1B. Weld carbon Steel Pipe Performing Groove

using SMAW Welding on Carbon MEE721306B
Steel Pipes

CBLM on Issued by:
Welding Carbon Steel Engr. Gerson T. and Technology Page 1
HOW TO USE THIS COMPETENCY-BASED LEARNING
MATERIAL
Welcome!
The unit of competency, “Weld Carbon Steel Pipes using SMAW”, is
one of the competencies of Shielded Metal Arc Welding NC II, a course which
comprises the knowledge, skills and attitudes required for a SMAW
TRAINEE to posses.
The module, Welding Carbon Steel Pipes using SMAW, contains

training materials and activities for you to complete. This will be the source
of information for you to acquire knowledge and skills in this particular
trade independently and at your own pace, with minimum supervision or
help from your instructor.
In this module, you are required to go through a series of learning

activities in order to complete each learning outcome. In each learning
outcome are Information Sheets, Self-Checks, Task Sheets. Follow and
perform the activities on your own. If you have questions, do not hesitate to
ask for assistance from your facilitator.
Remember to:
 Read information sheets and complete the self-checks. Suggested
references are included to supplement the materials provided in this
module.
 Perform the Job Sheets until you are confident that your outputs
conform to the Evaluation Criteria Checklist that follows the sheets.
 Submit outputs of the Task Sheets to your facilitator for evaluation
and recording in the Accomplishment Chart. Outputs shall serve as
your portfolio during the Institutional Competency Evaluation. When
you feel confident that you have had sufficient practice, ask your
trainer to evaluate you. The results of your assessment will be
recorded in your Progress Chart and Accomplishment Chart.
Recognition of Prior Learning (RPL)
You may already have some or most of the knowledge and skills
covered in this learner’s guide because you have:
 Been working for some time
 Already complete training in this area.
If you can demonstrate to your trainer that you are competent in a
particular skill or skills, talk to him/her about having them formally

CBLM on Issued by:
recognized so you don’t have to do the same training again. If you have a
qualification or Certificate of Competency from previous trainings, show it to
your trainer. If the skills you acquired are still current and relevant to the
unit/s of competency they may become part of the evidence you can present
for RPL. If you are not sure about the currency of your skills, discuss this
with your trainer.
This module was prepared to help you achieved the required

competency, in WELD CARBON STEEL PLATE AND PIPE. This will be the
source of information for you to acquire knowledge and skills in this
particular trade independently and at own pace, with minimum supervision
or help from your instructor.
 Talk to your trainer and agree on how you will both organize the
Training of this unit. Read through the module carefully. It is divided
into sections, which cover all the skills, and knowledge you need to
successfully complete this module.
 Work through all the information and complete the activities in each
section. Read information sheets and complete the self-check.
Suggested references are included to supplement the materials
provided in this module.
 Most probably your trainer will also be your supervisor or manager.

He/she is there to support you and show you the correct way to do
things.
 Your trainer will tell you about the important things you need to
consider when you are completing activities and it is important that
you listen and take notes.
 You will be given plenty of opportunity to ask questions and practice

on the job. Make sure you practice you new skills during regular work
shifts. This way you will improve both your speed and memory and
also your confidence.
 Talk to more experience workmates and ask for their guidance.
 Use the self-check questions at the end of each section to test your
own progress.

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 When you are ready, ask your trainer to watch you perform the
activities outlined in this module.
 As you work through the activities, ask for written feedback on your
progress. Your trainer keeps feedback/ pre-assessment reports for
this reason. When you have successfully completed each element, ask
your trainer to mark on the reports that you are ready for assessment.
 When you have completed this module (or several modules), and feel
confident that you have had sufficient practice, your trainer will
arrange an appointment with registered assessor to assess you. The
results of your assessment will be recorded in your competency
Achievement Record.

CBLM on Issued by:
QUALIFICATION : Shielded Metal Arc Welding NC II
UNIT OF COMPETENCY : Weld Carbon Steel Pipes
MODULE TITLE : Performing Groove Welding on Carbon Steel
Pipes
Introduction:
This module covers the skills, knowledge and attitudes required in
welding carbon steel pipes using SMAW process.
You need to complete this module by learning the theories and principles
closely coupled with practical activities to master the skills required. Desira
ble values and attitudes must also be taken into consideration.
This module consists of three learning outcomes. Each outcome contains
learning activities for both knowledge and skill, supported with information
sheets, self-checks and Job/Task Sheets gathered from different sources.
Upon completion of this module, you have to subject yourself for institu-
tional assessment to your instructor. You will be given a certificate or
achievement as a proof that you have met the standard requirement for this
module.
LEARNING OUTCOMES :
At the end of this module you must be able to:
 Identify the different theories and principles about SMAW welding

 Weld v-groove butt joint on carbon steel pipes in horizontal position
(2G)
 Weld v-groove butt joint on carbon steel pipes in vertical up position
(5G)
 Weld v-groove butt joint on carbon steel pipes inclined at 45º fix
position (6G)

CBLM on Issued by:
ASSESMENT CRITERIA
1. Root penetration not exceeding allowable tolerances specified by

welding codes and standards on:
 Concavity
 Convexity
 Undercut
 Excess penetration
 Lack Fusion
 Burn Through
 Cracks
2. Weld capping final pass not exceeding allowable tolerances specified

by welding codes and standard on:
 Height of Reinforcement
 Underhill
 Porosities
 Undercut
 Crack
 Cold Laps
 Uniformity of Bead ripples must be in accordance with welding
standard
 Stringer or layered beads deposited in accordance with welding
standard
3. Finish weldment visually acceptable in accordance with welding

standard for:
 Spatter
 Arc strike
 Slag
 Uniformity of beads

CBLM on Issued by:
Shielded Metal May 2014
Arc Welding SMAW NC Surigao del Norte
II Developed by: College of Agriculture
Engr. Gerson T. and Technology Page 6
Welding Carbon Steel Estay
Pipes Using SMAW
Introduction of learning outcome no 1
Accident and casualties resulted from carelessness and lack of

appreciation about safety. This learning outcome absolutely necessary to the
trainees because it covers working safely are the first essential should learn
even before he is taught how to operate welding machine and tools for
specific use with precautionary measure on safety which every one is
responsibility. The young man must always remember that safety is not only
his concern but everybody’s concern.
This learning outcome also give an overview about the essentials of

welding, techniques and procedure, acceptable weld profile and weld defects,
causes and remedies in which is necessary to the trainee to achieve quality
weld joint even critical or difficult to join, so that weld will meet the
international welding code standard requirements. The trainee may be
required to pass this learning outcome competent before proceeding to the
next learning outcome.

CBLM on Issued by:
QUALIFICATION : Shielded Metal Arc Welding NC II
Module Title : Performing groove welding on Carbon Steel
Pipes
Learning Outcome: #1: Weld v-groove butt joint on carbon steel pipes in
horizontal position (2G)
CONTENTS:
1. Welding Safety Practices
2. Five Essentials of Welding
3. International Welding Codes and Standards
4. Acceptable Weld Profile
5. Weld Defects Causes and Remedies
6. Welding Procedure Specification (WPS)
7. Welding Techniques Procedure
8. Procedures in weld carbon steel pipes in horizontal position (2G)
ASSESMENT CRITERIA;
1. Root penetration not exceeding allowable tolerances specified by welding

Codes/standards on:
 Concavity
 Convexity
 Undercut
 Excess penetration
 Lack of fusion
 Burn-through
 Cracks
2. Weld capping / final pass not exceeding allowable tolerance specified by

welding codes and standards on:
 Height of reinforcement
 Under fill
 Porosities
 Undercut
 Cracks
 Cold laps
 Uniformity of bead ripples must be in accordance with welding
standards
 Stringer or layered beads deposited in accordance with welding
standards
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4. Finish weld-ment visually acceptable in accordance with welding

standards for:
 Spatters
 Arc strikes
 Slag
 Uniformity of beads
CONDITIONS:
Trainees must be provided with the Following:
1. EUIPMENT:
 Welding Machine AC OR AC/DC
 Welding table or Jig
 Portable grinder
 Welding booth
 Portable oven
2. TOOLS AND ACCESSORIES;
 Welding mask
 Steel brush
 Clear glass
 Chipping hammer
 Dark glass
3. SUPPLIES/ MATERIALS;
 Electrodes
 Carbon Steel plates
 Cutting grinding disk
4. PERSONAL PROTECTIVE EUIPMENT;
 Safety shoes
 Apron
 Leggings
 Safety goggles
 Leather Gloves
5. TRAINING MATERIALS;
 Arc welding manuals
 Welding procedure specification WPS
 Welding standards
ASSESSMENT METHOD:
 Written test
 Demonstration with oral questioning
 Interview with oral questioning
CBLM on Issued by:
LEARNING EXPERIENCES
Learning outcomes No. 1
Weld V groove butt joint on carbon steel pipes in horizontal position 2G
Learning Activities Special Instructions

Read information sheet 1B.1-1 on If you feel you can identify the
Safety welding Practices hazardous area, the PPEs and its
uses and the handling of tools,
equipment and materials you can
now answer self check 1B.1-1
Answer Self-check 1B.1-1
Compare answers with answer key
1B.1-1
Read Information sheet 1B.1-2 on If you can feel you can already
Essentials of Welding explain the essentials of welding you
can now answer self check 1B.1-2
Answer self check 1B.1-2
Compare your answer to answer key
1B.1-2
Read information sheet 1B.1-3 on If you can feel you can already
International Welding Codes and identify and differentiate the source
Standards of international welding codes and
standard you can answer self check
1B.1-3
Refer/ Compare your answer to
answer key 1B.1-3
Read information sheet 1B.1-4 on If you can feel you can determined
Acceptable Weld Profiles and differentiate the acceptable and
unacceptable weld profile you ca now
answer self check AB.1-4

1B.1-4
Read information sheet 1B.1-5 on If you feel you can identify the
Weld Defects, Causes and different weld defects, their causes
Remedies and remedies you can answer self
Answer self check 1B.1-5 check 1B.1-5
1B.1-5
CBLM on Issued by:
II College of Agriculture
Developed by: and Technology Page 10
Welding Carbon Steel Engr. Gerson T.
Read information sheet 1B.1-6 on If you can feel you can explain the
Welding Procedure importance of WPS you now answer
Specification (WPS) self check 1B.1-6
Compare your answers to answer
key 1B.1-6
Read information sheet 1B.1-7 on If you feel you can identify the welding
Welding Techniques and techniques and procedures you can
Procedures answer self check 1B.1-7
Compare your answers to answer
key 1B.1-7
Read information sheet 1B.1-8 on Read information sheet 1B.1-8 and
Procedure in Welding carbon steel check yourself by answering the self-
pipes in horizontal position (2G) check 1B.1-8
If you feel you can identify the different
procedures and you are ready to
perform the task on welding carbon
steel pipes in horizontal position (2G)
you can now proceed to do task

Refer/Compare your answers to
answer key 1B.1-7
Perform job sheet 1B.1-8(2G)
Position
Check performance using
performance criteria checklist
1B.1-8
CBLM on
Shielded Metal May 2014 Issued by:
Arc Welding SMAW NC
II Developed by: Surigao del Norte
Engr. Gerson T. College of Agriculture
Welding Carbon Steel Estay and Technology Page 11
Pipes Using SMAW
INFORMATION SHEET 1B.1-1
Safety Welding Practices
LEARNING OBJECTIVES:
After reading this information Sheet, trainees must be able to:
1. Identify hazardous area

2. Explain safety welding practices
3. Identify the proper use of Personal Protective Equipment
WELDING SAFETY
SMAW welding, like other welding methods, can be a dangerous and

unhealthy practice if proper precautions are not taken. The process uses an
open electric arc, which presents a risk of burns which are prevented by
personal protective equipment in the form of heavy leather gloves and long
sleeve jackets. Additionally, the brightness of the weld area can lead to a
condition called arc eye, in which ultraviolet light causes inflammation of
the cornea and can burn the retinas of the eyes. Welding helmets with dark
face plates are worn to prevent this exposure, and in recent years, new
helmet models have been produced that feature a face plate that self-
darkness upon exposure to high amounts of UV light.
Have you ever heard the saying that some people are accident prone?
The important is that accidents just seem to follow individuals no matter
what they do. They just seem plagued with bad luck. Actually, there is no
such thing as being accident-prone. People have accidents simply because
they are careless, or indifferent to safety precautions.
Each year thousands of people suffer the pain of injury because they
failed to use good judgment in many ways, safety can be considered a habit
a kind of behavior. A habit is acquired; you are not born with it. It is a result
of reception-doing something over and over again until it becomes part of
you.
CBLM on Issued by:
IDENTIFY HAZARDOUS AREA
WARNING:
The outcome of childish tricks and pranks are often impossible to protect. Therefore,
practical jokes and general horseplay are no accepted behavior for the workplace.
All work places have their own special hazards and it is the employer’s
responsibility to provide and maintain a safe working environment. However,
when you enter a work area, you accept certain responsibilities. These
require you to familiarize yourself with the special safety considerations
which may apply and to observe all the agreed working practices for your
work area.
NOTE:
If you are unsure about the safety rules and working practices for your work
area, ask your supervisor.
In general, you share the responsibility for keeping the workplace clean and
tidy, which normally prevents most safety hazards from becoming a
problem. This is often termed Good Housekeeping.
GOOD HOUSEKEEPING
The following is a brief list of the common practices which lead to good
housekeeping:
 Keep your passageways, walkways, aisles and exits clear.
 Keep your work area clear and tidy and do not allow discarded or
waste material to accumulate
 Dispose of waste materials and chemicals in correct manner.
 Remove spillages of oils, greases, paints or other fluids promptly.
 Report any hazardous incidents to your supervisor immediately.
HAZARDS IN THE WORKPLACE

There are three primary types of hazards which all workshops can be
expected to be included:
 Fire
 Chemicals and dangerous materials
 Electricity
WARNING:
Before attempting to tackle any fire, be certain that you are not putting
yourself or your workmates at risk. Taking unnecessary risk to try to put
out is foolishness.
CBLM on Issued by:
ELECTRICITY
If you have the reason to doubt the safety or serviceability or any
electrical equipment or power leads, report it to your supervisor
immediately. Do not use or allow anyone else to use the equipment until
otherwise instructed by someone competent to make that decision.
WELDING SAFETY CHECKLIST
Hazard Severity Factors Precaution Summary

Electric shock Wetness Insulate welder from work piece and
can kill Welder in or work ground using dry insulation.
piece Rubber mat dry wood
Confined space Wear dry, hole-free gloves (Change
Electric holder and as necessary to keep dry)
cable insulation Do not touch electricity “hot” parts
or electrode with bare skin or wet
clothing
If wet area and welder cannot be
insulated from work piece with dry
insulation, use a semiautomatic,
constant voltage welder with voltage
reducing device
Keep electrode holder and cable
insulation in good condition
Fumes and Confined area Use ventilation or exhaust to keep

gases can be positioning of air breathing zone clear,
dangerous welder's head comfortable
Lack of ventilation Use helmet and positioning of the
Electrode types, head to minimize fume in breathing
manganese, chromic zone
etc. Read warnings on electrode
Base metals coating, container and material safety data
galvanize paint sheet for electrode
Provide additional ventilation/
exhaust where special ventilation
requirements exist
Use special care when welding in a
confined area
Do not weld unless ventilation is
adequate
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Welding sparks Containers which Do not weld on containers which

can cause fire have held have held combustible materials.
or explosion combustibles Check before welding
Flammable Remove flammable materials from
materials welding area or shield from sparks,
heat.
Keep a fire extinguisher in the
welding area
Wear fire retardant clothing and hot
use earplugs when welding overhead
Arc rays can Process: gas Select a filter lens which is

burn eyes and shielded arc are comfortable for you while welding
skin most severe Always use helmet/head shield
when welding
Provide non flammable shielding to
protect others
Wear clothing which protects skin
while welding
Confined space Metal enclosure Carefully evaluate adequacy of
Wetness ventilation especially where
Restricted entry electrode requires special ventilation
Heavier than air gas or where gas may displace breathing
Welder inside or on air
work piece If basic electric shock precaution
cannot be followed to insulate welder
from work and electrode, use
semiautomatic, constant voltage
equipment with cold electrode or
stick welder with voltage reducing
device
Provide welder helper and method of
welder retrieval from outside
enclosure
General work Cluttered area Keep cables, materials, tools neatly
area Indirect work organized
(welding ground Connect work cable as close as
connection) possible to area where welding is
Electrical equipment being performed. Do not allow
Engine driven alternate circuits through scaffold
equipment cables, hoist chains, ground leads
Gas cylinders

CBLM on Issued by:
Use only double insulated or

properly grounded equipment
Always disconnect power to
equipment before servicing
Use in only open, well ventilated
areas
Keep enclosure complete and guards
in place
Refuel with engine
Never touch cylinder with the
electrode
Never lift machine with cylinder
attached
Keep cylinder
SAFETY IN ARC WELDING- Arc welding includes shielded metal –arc, gas
shielded arc resistance welding. Only be indicated for these areas because
arc welding equipment varies considerably in size and type. Equipment may
range from small portable shielded metal-arc welder to highly mechanized
production spot or gas shielded arc welders. In each instance specific
manufacturers recommendations should follows.
Install welding equipment according to provisions of the National

Electric Code
1. Be sure a welding machine is equipped with a power disconnect
switch is conveniently located or near the machine so the power can
be shut off quickly.
2. Don't make repairs to welding equipment unless the power to the
machine is shut off. The high voltage used for arc welding machines
can inflict severe and fatal injuries.
3. Don't use welding machines without proper grounding. Stray current
may develop which can cause severe shock when grounded parts are
touched. Do not ground to pipelines carrying gases or flammable
liquids.
4. Don't use electrode holders with hose cable connections. Keep
connections tight all times. Avoid using electrode holders with
defective jaws or poor insulation.
5. Don't change the polarity switch when the machine is under a load,
wait until the machine idles and the circuit is open.

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6.
7.
8.
9.
10.
11.
6. Don't operate the range switch under load. The range switch which
provides the current setting should be operated only while the
machine is idling and the current is open. Switching the current while
the machine is under a load will cause an arc from between the
contact surfaces.
7. Don't overload welding cables or operate a machine with poor
connections. Operating with currents beyond the rated cable capacity
causes overheating. Poor connections may cause the cable to arc
when it touches metal grounded in the welding circuit.
8. Don't weld in damp areas and keep hands and clothing dry at all
times. Dampness on the body may cause an electric shock. Never
stand lie in puddles of water, on damp ground or against grounded
metal when welding without suitable insulation. Use a dry board or
rubber may to stand on.
9. Don't strike an arc if someone without proper eye protection is nearby.
Arc rays are harmful to the eyes and skin. If other persons must work
nearby. The welding area should be partitioned off with a fire-
retardant canvass curtain protect them from the arc welding flash.
10. Never pick up pieces of metal which have just been welded or heated.
11. Always wear protective eye goggles when chipping or grinding. A
small particle of slag or metal may cause a severe eye injury.
12. Don't weld on hollow casting unless they have been properly vented,
otherwise an explosion may occur.
13. Be sure press-type welding machine are effectively guarded.
14. Be sure suitable spark shields are used around equipment in flash
welding.
15. When welding is completed, turn off the machine that pulls the power
disconnected switch to hang the electrode holder in its designated
place.
CAUSES OF ACCIDENTS
An accident often has more than one cause. Accidents can be prevented
by removing their causes. Finding out what caused an accident is
important. It can help in planning how to prevent similar accidents.
There are two causes of accidents:
 Unsafe Acts
 Unsafe Conditions

CBLM on Issued by:
Arc Welding SMAW NC Developed by: Surigao del Norte
II Engr. Gerson T. College of Agriculture
Estay and Technology Page 17
Welding Carbon Steel
Pipes Using SMAW
The person who gets hurt does not always cause the accidents. However,
accidentally are caused by some person falling to act safely, or to correct an
unsafe condition such as;
 Using equipment without having received proper training in it is use.
 Using tools or equipment the wrong way.
 Not using the personal protective equipment, such as goggles, when
the job requires it.
 Fooling and playing about.
 Hurrying and taking dangerous short cuts through the workshops or
on the job.
 Distracting others from their work, or allowing yourself to be
distracted.
Consider these examples of unsafe conditions for the worker
Unsafe practices of welder

Personal Protective Equipments and its usages:
1. Apron or Jacket - use to protect your body and arm.
2. Welding shield helmet - is used to protect our face and eyes from the
arc rays and heat and the spatter from the molten metal.
3. Head shield mask - is more convenient to use because it allows both
hands free work.
4. Hand shield mask - allows only one hand free to work.
5. Gloves - is made of chrome leather and protects our hands from heat
spatter and radiations.
6. Goggles - use to protect your eyes from the spark and small objects.
7. Safety shoes - is made of leather use protect your foot in a sharpen
objects.
8. Respiratory mask - use to protect smoke and fumes of the welding.
9. Filter Lens - use to protect your eyes from the radiation arc.
10. Leggings - use to protect from the spark welds and sharp objects.
11. Hard hat - use to protect your head from pulling debris and hard
object.
12. Ear Phone ___ use to protect noise
PROTECTIVE EQUIPMENTS
Personal protective equipment (PPE) includes any device worn or
carried by an individual to protect against work place hazards, and
hazardous processes or environments such as exposure to chemical or
radiological hazards or mechanical irritants.
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Example of equipment and clothing are goggles, safety glasses, ear muffs,
ear plugs, hard hats, gloves, respirators, safety-toe footwear, welder’s Capes,
chemical aprons, fall- arresting harnesses, and personal flotation devices.
Protective clothing must be worn at all times when welding. The

heat created during arc welding arc welding creates flying molten sparks
and ultraviolet and infrared rays that can burn your skin and hurt your
eyes.
LEATHER GLOVES
Gloves protect the hands from burns

during welding.
The gloves should be made of thick

leather and have long cuffs to protect the
wrist sparks from falling into them.
LEATHER OR COTTON SLEEVES
Nonflammable material should be

Worn on the arms to protect from
burns due to sparks and intense heat.
BODY PROTECTION
Either a leather apron or coveralls

or work shirt made of a flame-retardant
material will protect the body during
arc welding.
All protective clothing should fit

Properly and be free of openings or rips
into which a spark might enter or intense
heat might penetrate.

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FOOT WEAR
Never wear open-toed shoes while

Working with hot metal or welding
apparatus.
Leather boots should be worn

while arc welding.
ARC WELDING HELMETS & SHIELDS
The brilliant light given off by the

electric arc produces invisible ultraviolet
and infrared rays which can severely burn
the eyes and skin.
NEVER LOOK AT THE ARC WITH

THE NAKED EYE. Helmets and shields are
equipped with special filtered lenses that
reducethe intensity of the light and pre-
prevent the ultraviolet and infrared rays
from reaching the eyes.
The welding helmet is designed specifically for the purpose of arc

welding. It fits on the head using a plastic adjustable headband. The helmet
leaves both hands free for working and positioning materials.
Many helmets have clear lenses under the filtered lenses that can be
used when chipping slag.
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PROTECTIVE LENSES
Welding lenses are not simply colored glass, but are special lenses
which screen out almost 100% of the infrared and ultraviolet rays.
These protective lenses come

in different shades, depending on the
type of welding you are doing.
Different types of welding use differ-
rent amounts of voltage and current
which determine the intensity of the
light and the amount of ultraviolet
and infrared rays produced.
 Spot welding requires the fewest amperes, and thus requires the least
amount of shading in the lens.
 Arc welding machines require from less than 30 to over 400 amperes.
Lens shades range from number 5 (which provides then least amount of
protection) to shade 14 (which provides the most protection).
1. Shade 5 is used for light spot welding.

2. Shades 6 and 7 are suitable for welding with up to 30 amperes.
3. Shade 8 is for welding with 30-75 amperes.
4. Shade 10 can be used when welding with 75-200 amperes.
5. Shade 12 is used when welding with 200-400 amperes.
6. Shade 14 is required when welding with over 400 amperes
GOGGLES
Goggles must be worn when chipping

slag if a shell lens is not provided in the
helmet. NEVER CHIP SLAG WITHOUT
PROTECTIVE EYEWEAR.

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Ear plug- use to protect our ear from noise area.
NOTE:
The eyecup or cover types of goggles are NOT to use as a substitute for
an arc-welding helmet.
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SELF-CHECK 1B.1-1
I. Multiple Choice:
Instruction: Choose the letter of the correct answer on your answer sheet.
1. To protect your ear from too much noise.

a. respirator b. ear plugs c. over all suit d. gloves
2. A device which is fitted over the face t remove contaminants from the
air being breath.
a. head shield b. ear plug c. respirator d. all of the above
3. To prevent eye injury due to splashing or air born chemicals and
materials.
a. leather apron b. safety shoes c. goggles d. all of the above
4. To protect from hot objects, flux and spatter.
a. gloves b. respirator c. over all suit d. safety shoes
5. To prevent flying object to your face and hair like flux or spatter.
a. welding mask b. ear plug c. welding gloves d. brush
II. Essay Type:
1. What is safety in welding practices?

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Answer Key 1B.1-1
I.
1. b
2. c
3. c
4. d
5. a
II.
SAFETY IN ARC WELDING – Arc welding includes shielded metal-arc,
gas shielded arc resistance welding. Only be indicated for these areas
because arc welding equipment varies considerably in size and type.
Equipment may range from small portable shielded metal-arc welder to
highly mechanized production spot or gas-shielded arc welders. In each
instance specific manufacturers recommendations should follows.
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THE ESSENTIALS OF WELDING
LEARNING OBJECTIVE:
After reading this Information Sheet, you must be able to identify the
Five Essentials in welding and explain the certain weld characteristics.
INTRODUCTION
Welding is a practical skill that requires continual practice and careful

attention to the variables that the welder controls to improve. The old golden
rule “practice makes perfect” applies to welding in that the more you do, as
long as you or someone evaluates your welds, the better you become.
The term essentials as used in this text means something the welder has
control of either before welding or during welding.
To produce good welds you must not only know how to manipulate
the electrode, but you need to know certain weld characteristics.
Weld quality consistency only be maintained with respect to the essentials.
The Five Essentials of welding include the use of the current setting, length
of arc, angle of electrode, speed of travel and manipulation of electrode.
1. CURRENT SETTING
The welding current or amperage is essential to producing welds with
good appearance and the required strength characteristics. The welder
controls the amperage variable by setting the amperage on the welding
machine prior to welding.
The amperage is set from recommended ranges according to the size of the
electrode, the type of electrode, and the type of current AC, DCEN or DCEP
you are using.

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Fig. Pictorial appearance of welding machine with current adjustment knob
Low Amperage
If your amperage is too low, your electrode will be especially sticky

when striking an arc, your arc will keep going out while maintaining the
correct arc length or the arc will stutter. If you’re welding with amperage set
too low, your electrode will be especially sticky when striking an arc, the arc
will keep going out while maintaining the correct arc length or the arc will;
stutter.
Fig Pictorial appearance of output from welding in low amperage

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High Amperage
If the current is too high, the electrode melts too fast and the molten
pool is large and irregular. When the current is too low, there is no enough
heat to melt the base metal and the molten pool will be too small. The result
is not only poor fusion but the beads will pile up and be irregular in shape.
Fig Pictorial appearance of output from welding in high amperage

Fig Pictorial appearance of output from welding in different setting
 Low Amperage
 High Amperage
 Correct Amperage

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Polarities
The amperage is set from recommended ranges according to the size of the
electrode, the type of electrode, and the type of current AC, DCEN or DCEP
you are using.
KEY POINT: AC means Alternating Current, DC means direct current and

can be set for Direct Current Electrode Negative (Straight Polarity) or Direct
Current Electrode Positive (Reverse Polarity.
Some electrodes are designed to work best on a given Current and Polarity,
for example an E-6010 should be used with DCEP (direct current electrode
positive).
Some electrodes are designed to work best on DCEN while others allow a
selection of Current to be used.
AC(Alternating Current) transformer welder – Alternating current directions
20 times per second.
AC –DC – Transformer rectifier provides either alternating current or direct
Motor Generator – Produces DC current
Engine Generator – Produces DC current
A. Direct Current Electrode Negative (DCEN) – The specific direction of
current flow through a welding current when the electrode lead is
connected to the negative terminal and the work lead is connected to
the positive terminal of a welding machine. (Current flows from the
base metal to electrode). This is also called as direct current straight
polarity (DCSP).
B. Direct Current Electrode Positive (DCEP) – The specific direction of

current flows through a welding circuit when the electrode lead is
connected to a positive terminal and the work lead is connected to a
negative terminal to a welding machine. (Current flows from the base
metal to the electrode). This is also called as direct current reverse
polarity (DCRP).
Fig. Indicates weld polarities

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Note: Welding leads must connect to correct terminals if machine has a

polarity switch. Otherwise a change in polarity is made by reversing
leads on the terminals.
Factors that determine polarity:
 E6010 DC (+) reverse polarity

 E6010 DC (-) straight polarity
 E7018 AC-DC (+) reverse polarity
 E7024 AC-DC (+) reverse or straight polarity
The chart below shows typical amperage ranges
E-6011. This electrode is similar to the E-6010 except that it is made

especially for AC machines. Although the electrode can be used on DC
machines with reversed polarity, it does not work quite as well as the E-
6010. Its amperage setting is slightly lower than for E-6010.
Current Settings for E-6011 Electrodes

ELECTRODES AMPERES
DIA (INCHES)
3/32 50-90
1/8 80-130
5/32 120-180
3/16 140-220
7/32 170-250
¼ 225-325
Table 1 Chart shows amperage ranges of E-6011
E – 6012 This fill-freeze electrode and maybe used on either DC or Ac

welders. When employed on DC welders the current must be set for straight
polarity. The electrode provides medium penetration, quite type arc, slight
spatter, and dense slag. Although it is considered an all-position electrode, it
is used in greater quantities for flat and horizon position welds.
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Current Settings for E -6012 Electrodes
ELECTRODES AMPERES
DIA (INCHES)
3/32 40-90
1/8 80-120
5/32 120-190
3/16 140-240
7/32 180-315
¼ 225-350

E-6013 Electrodes of this type are very similar to E -6012 with a few slight
exceptions. Slag removal is better and the arc can be maintained easier,
especially with small diameter electrodes.
ELECTRODES AMPERES
DIA (INCHES)
1/16 20-40
5/74 25-50
3/32 30-80
1/8 80-120
5/32 120-190
3/16 120-240
7/32 225-300
¼ 250-350

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E – 7018 The E -7018 is a low –hydrogen type electrode but also contains
iron powder. It is a high speed fast-disposition rate electrode design to pass
the most severe x-ray requirements when applied in all welding positions,
either AC or DC reverse polarity current.
ELECTRODES AMPERES
DIA (INCHES)
3/32 70-120
1/8 100-150
5/32 120-200
3/16 200-275
7/32 275-350
¼ 300-400
Parts of Electrode
Core Rod (Metal Filler)
 Carries Welding current

 Becomes part of the weld
Flux Coating
 Produces a shielding gas

 Can provide additional filler metal the gap or groove between two base
metal
 Forms a slag covering to protect the weld from contaminants during
cooling

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Fig. Indicates the part of electrode
AWS DESIGNATION FOR MANUAL ELECTRODE
The letter and each number used to classify electrodes have a specific
meaning.
E– 60 1
ELECTRODE TENSILE WELDING
0
SPECIAL WELDING
STRENGTH POSITION CHARACTERISTICS
Such as power type

DC polarity
Straight polarity
Arc properties
60 - 60,000 psi 1 Any position

70 – 70,000 psi 2 Horizontal or flat
80 – 80,000 psi 3 Flat only
110 – 110,000 psi 4 Flat, Horizontal, Overhead, downhill

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Two Kinds of Mild Steel Electrodes:

1. Bare Electrodes – were uncoated metal rods
2. Shielded – have heavy coating of various substances such as
cellulose sodium, iron cellulose potassium, Titanium sodium,
titanium potassium, iron oxide, iron powder.
IDENTIFYING ELECTRODES
In this classification, each type of electrode has been assign to specific
symbols, such as E-6010, E-7010, E-8010, etc. The prefix E identifies the
electrode for the electric arc welding.
The first two digits designated the minimum allowable tensile strength of the
deposited weld metal in thousands of pounds per square inch (psi).
The third digit of the symbol indicates possible welding positions. Three
numbers are used for these purposes: 1,2 and 3. Number 1 is for an
electrode which can be used for welding in any position. Number 2
represents an electrode restricted for welding in horizontal and flat positions
only. Number 3 represents an electrodes to be used in the flat position only.
The fourth digit of the symbol simply shows some special characteristic of
the electrode, such as type of coating, weld quality, type of arc, an amount
of penetration.
MILD STEEL ELECTRODE SELECTION
AWS APPLICATION
NUMBER
E -6010 General Purpose – Deep Penetration – Average

E – 6011 Deposition – Light Slag – Fast Freezing – All
Positions
E – 6012 General Purpose – Medium Penetration – Good
E – 6013 Deposition – Easy to Us – Heavy Slag – Low
E – 6014 Spatter – Poor Fit up – Product – Fill Freeze
Qualities – All Position
E – 7024 Production – Iron Powder Coating – Fast Deposit
E – 6027 Rate – Smooth Beads – Drag Technique – Mild
Penetration – Heavy Slag – Fast Fill – Horizontal
and Flat
E – 7018 Low Hydrogen – Crack Resistance – Ray Quality
E - 7028 Problem Steels – Good Penetration – Medium
Slag – All Positions
Table 5 Chart shows application of different electrode

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2.
L
E
N
G
T
H
OF ARC
It is one of the essential for good welding. The length of the arc depends on
the size of electrode used and the kind of welding done.
The correct arc length varies with each electrode and application. As a
good stating pint, arc length should not exceed the diameter of the metal
portion of the electrode, e.g. an 1/8 in. 6010 electrode is held about 1/8 in.
off the base material.
After striking the arc, maintain a 1/8” distance between the electrode and
the workpiece.
Fig. Pictorial appearance of arc length of electrode

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Holding the electrode too closely to the joint decreases welding voltage,
which creates an erratic that may extinguish itself or cause the electrode to
freeze faster and produces a weld bead with a high crown. If the arc length
becomes too short, the electrode will get stuck to the work piece or short
out. It will create greater potential for the electrode sticking to the base
material.
Fig. Pictorial appearance of output from short arc length of electrode
Excessively long arcs (too much voltage) produce spatter, low

deposition rates, undercuts and often leaves porosity. Too long of an arc
length will create excess spatter in the weld joint. There is also a high
potential for undercut.
Fig. Pictorial appearance of output from long arc

length of electrode

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3. ANGLE OF ELECTRODE
Experienced welders vary the angle of the electrode according to the
electrode being used and the job. However, the beginner should lean the
electrode slightly in the direction of travel. A 75 degree to 80 degree angle,
10 to 15 degrees from the vertical (straight up) position is suggested angle of
travel. When welding from left to right, maintain a 0-15 degree angle tilted
towards the direction of travel. This is known as the “drag” or “backhand”
technique.
Fig Pictorial appearance of angle of electrode
Work Angle
The work angle is the angle between the electrode and the work as depicted
on the left.
Work angles can vary depending on the position the weld is being made in.
Fig. Pictorial appearance of work angle
Travel Angle
Also commonly called Lead Angle. The travel (lead) angle is the angle
between the electrode and the plane perpendicular to the weld axis.
Fig. Pictorial appearance of travel angle

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4.SPEED OF TRAVEL
To achieve a uniform rate of travel across the metal requires practice

in arm movement. It requires the welder to be in a comfortable position that
permits such movement. The best way to control the movement is to watch
the welded metal solidifying behind the puddle. When weld material forms
evenly spaced semicircles behind the puddle.
The travel speed is the speed at which the electrode moves along the base
material while welding.
Too fast of a travel speed results in a ropey or convex weld.
Too slow of a travel speed results in a wide weld with an excessive metal
deposit. The travel speed impacts the shape of the bead.
Your travel speed should allow you to keep the arc in the leading one-third
of the weld pool.
Traveling too slowly produces a wide, convex bead with shallow

penetration and the possibility of “cold-lapping” where the weld appears to
be simply sitting on the surface of the material.

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Excessively fast travel speeds also decrease penetration, create a

narrower and/ or highly crowned bead, and possibly underfill or undercut,
which is when the area outside of the weld is concave or recessed. Note
towards the end of the bead appears inconsistent as if the puddle were
trying to keep up.
Fig. Pictorial appearance of output from too fast
travel of electrode
5. Manipulation of Electrode
Each welder manipulates the electrode a little differently than the
next. Develop your own style by observing each others, practicing and
noting which techniques produce the best results. Note that on material
¼ in. and thinner, weaving the electrode is typically not necessary. In
many instances a straight bead is all that is needed.
To create a welder bead on thinker material, manipulate the electrode

from side, creating a continuous series of partially overlapping circles in
a "Z" semi-circle or stutter-step pattern. Limit side-to-side motion to 2_
times the diameter of the d core. To cover a wider area, make multiple
passes or use "stringer beads"
The following pictures indicate the different welding techniques by

manipulating the electrode:

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Self-Check 1B.1-2
I. MULTPLE CHOICE:
Instructions: Read the questions carefully. On your answer sheet,
write the letter of the correct answer.
1. What is the polarity when the electrode is positive?
a. Straight polarity
b. Reverse polarity
c. Balance polarity
d. Forward polarity
2. The next to the last number in the AWS electrode classification
indicates
a. Polarity
b. Covering
c. Position of welding
d. Welding current
3. The first two numbers in the AWS electrode classification
indicates?
a. Polarity
b. Tensile strength
c. Welding current
d. Welding position
4. What is the purpose of electrode coating?
a. Insulate the electrode
b. Add alloying elements to the weld
c. Increase penetration
d. Shield the weld zone atmosphere
5. It is one of the essentials of good welding
a. Travelling
b. Electrode length
c. Flux coating
d. Correct arc length
II. ENUMERATION:
1. What are the 5 essentials in welding?
2. What are the two polarities in welding?

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Answer Key to 1B.1-2
I. MULTIPLE CHOICE
1. A
2. D
3. C
4. B
5. D
II. ENUMERATION
1.
a. Current setting
b. Length of arc
c. Angle of electrode
4. Speed of travel
5. Manipulation of electrode
2.
a. DCEP
b. DCSP

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International Welding Codes and Standard
LEARNING OBJECTIVES:
After reading this information sheet, trainees must be able to:
1. Identify the welding codes and standard.

2. Differentiate the welding Codes and Standards
Welding Codes and Standards: When Are They Used, and How are They
Developed?
Many aspects of the design and fabrication of weld components are
governed by documents known as codes and standards. Other names used
for such documents include guides, recommended practices, regulations,
rules and specifications. These documents are often specified by an end user
as a contractual agreement in order to control the characteristics of the
welded fabrication that may affect its service requirements. They are also
used by the manufacturer to assist in the development and implementation
of their welding quality system.
Many end users of welded components have developed and issued
specifications that have compiled by them to address their specific
requirements. Such specifications may be limited in application and related
such as public safety and reliability has promoted the development of
welding codes and standards that command broader recognition both on a
national and industry-specific basis. Numerous committees have been
developed over the years within national engineering and technical societies
that continue to evaluate the needs of industry and develop new welding
codes and standards. Such committees are comprised of members who are
technical experts and represent all interested parties such manufacturers,
end users, inspection authorities and government agencies.
The membership of these committees is balanced in order to prevent
any one interest group from controlling the committee. On completion of a
new or revised document by the specific committee, it is usually then
reviewed and approved by a review committee, and if accepted, then
published in the name of the applicable engineering society.
Documents that have significant influence upon public health and
safety are sometimes adopted by legislative bodies or by federal regulating
agencies. In those jurisdictions, such documents become law and are often
referred to as Codes or Regulations.
The welding inspector should be aware of what codes or standards are
applicable within their jurisdiction, understand the requirements of the
relevant documents and perform their inspection accordingly.
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Sources of Codes and Standards of Interest to the Welding Industry

The following are some of the more popular sources of welding codes
and standards found in the USA.
American Welding Society (AWS)

Probably the largest producer of welding codes and standards in the
USA. 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.
AWS- is a nonprofit organization dedicated to advancing the science,
technology and application of welding and allied joining and cutting
processes, including brazing, soldering and thermal spraying.
AWS Codes
It is important to become knowledgeable about every type of welding
position in use today for making groove and fillet welds on metal plate and
pipe. As mentioned earlier, the American Welding Society has developed a
system to simplify this process. The system is very easy to understand. If a
“G” appears it indicates that the weld in question is a fillet weld.
The system has been set up to also describe the type of welding
position that is being used. In order to do this the AWS uses four digits. The
numbers one through four are used to identify the types of welding positions
possible. A “1” indicates that the weld was made in the flat position, a “2”
indicates the horizontal position, a “3” the vertical position, and a “4” the
overhead position. In addition to these four digits, a two, a five and six are
used to describe two types of welds used when working with pipe. The “2”
indicates a horizontal position, “5” indicates a vertical up position and the
“6” indicates an inclined 45 degree fixed pipe position.
Some Examples of Weld Names are:

IG – groove weld, in the flat position
2G – groove weld, in the horizontal position
3G – groove weld, in the vertical position
4G – groove weld, in the overhead position

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1F – fillet weld, in the flat position

2F – fillet weld, in the horizontal position
3F – fillet weld, in the vertical position
4F – fillet weld, in the overhead position
2G – groove weld on pipe, in the horizontal position
5G – groove weld on pipe, in the vertical position
6G – groove weld on pipe, in the inclined fixed position
The following is an illustration that adequately shows the AWS system at

work
Welding testing position

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Groove Weld Positions
In most instances it will be necessary to make more than one weld

pass to properly secure a joint. There are few terms that are given to the
types of weld passes needed to adequately join two pieces of metal. Many
times, the first weld pass will be referred to as the stringer, or root pass, and
requires full penetration of the metal being welded. The second pass is
referred to as a hot pass, the third is called a filler pass and the final pass is
called a cap or cover pass. Keep in mind that not all weld joints will require
all four weld passes to be run. Each pass is meant to cover the previous one
and join a bit more of the metal to the welds.
In most instances, full penetration is not required for this type of
weld. In cases that call for full penetration, the plates should be beveled on
the joint edge and the same procedure used. There are many types of
practice methods used to complete butt welds. Acquire the knowledge
needed to master butt welds in the 1G, 2G, 3G, 4G, 5G and 6G positions.
Repeated practice is key to becoming proficient at each of these welds.
Become familiar with the types of weld tests that will be completed to
determine the strength and quality of the welds you produce. Two common
tests used by the American Welding Society (AWS) are the X-ray and Guided
Bend tests.
American Welding Society (AWS) Standards
AWS DII.2 Welding (cast iron)

AWS D10.13 Tube brazing (copper)
AWS D01.8 Structural welding seismic supplement
AWS D01.9 Structural welding (titanium)
AWS D01.7 Structural welding (strengthening and repair)
AWS D01.1 Structural welding (steel)
AWS D01.6 Structural welding (stainless steel)
AWS D01.3 Structural welding (sheet steel)
AWS D01.4 Structural welding (reinforcing steel)
AWS D01.2 Structural welding (aluminum)
AWS A03.0 Standard welding terms and definitions
AWS A02.4 Standard symbols for welding, brazing, and non
destructive examination
AWS D18.2 Stainless steel tube discoloration guide
AWS A05.1 Specification for carbon steel electrodes for shielded metal
arc welding
AWS A05.18 Specification for carbon steel electrodes and rots for gas
shielded arc welding
AWS D09.1 Sheet metal welding
AWS D10.11 Root pass welding for pipe
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American Society of Mechanical Engineers (ASME) – This society is

responsible for the development of the Boiler and Pressure Vessel Code,
which contains eleven sections and covers the design, construction, and
inspection of broilers 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. Both of
these documents are American National Standards.
American Petroleum Institute (API) – This institute publishes many

documents relating to petroleum production, a number of which include
welding requirements. The most well known is possibly API STD 1104-
Standard for Welding Pipelines and Related Facilities.
What the Welding Code and Standard Generally Provides
The specific content and requirements of a welding code or standard

can vary in detail, however, there are a number of elements within these
types of documents which are common and which we will examine.
The Scope and General Requirements: This is found at the beginning of

the document and is important as it will normally provide a description as to
the type and extent of welding fabrication for which the document was
developed and intended to be used. It may also provide information relating
to the limitations for the use of the document. Care should be taken to use
codes and standards that are applicable for your particular application.
Design: If the document provides a section for design, it may refer the user
to a secondary source of information, or it may contain minimum
requirements for the design of specific welded connections.
Qualification: This section of the document will typically outline the

requirements for qualification testing of welding procedure specifications
(WPS) and also those requirements for qualification of welding personnel. It
may provide the essential variables, these being the change limitations that
govern the extent of qualification. Such variables are typically the welding
process, type and thickness of base metal, filler metal type, electrical
parameters, joint design, welding position and others.
This section of the document may also provide the qualification testing
requirements. O Usually this is divided into welding procedure and welder
performance testing requirements. Typically, it will provide the types and
sizes of test samples to be welded and prepared for testing methods to be
used, and the minimum acceptance criteria to be used for evaluation of test
samples.
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Fabrication: This section, when included in the document will typically

provide information associated with the fabrication methods and /or
workmanship standards. It may contain information and requirements on
such items as base materials, welding consumable classification
requirements, shielding gas quality, heat treatment requirements and care
of base material, and other welding fabrication requirements.
Inspection: This section of the document will typically address the welding
inspectors qualification requirements and responsibilities, acceptance
criteria for discontinuities, and requirements relating to procedures for
nondestructive testing.
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Self-Check 1B.1-3
I. Matching Type:
Instructions: Match the welding positions of a grooved butt joint which
corresponds to AWS code. Write your answer on your answer sheet.
1. Flat a. 3G
2. Horizontal b. 4G
3. Vertical c. 1G
4. Overhead d. 2G
II. Answer the following questions:
1. What is American Welding Society and how it helps to the process of

welding?
2. What is the common test used by the American Welding Society?
3. What are the sources of codes and standards of welding industry?
4. What are the welding codes and standard generally provides?
CBLM on Issued by:
Answer Key to 1B.1-3
I.
1. C
2. D
3. A
4. B
II.
1. American Welding Society is a non-profit organization dedication in
advancing the science, technology, and application of welding setting
standard and norms in different welding processes.
3. A. X-ray
B. Guided bend test
3. The source of codes and standards are AWS, ASME, and API
4. The codes and standard provides the Scope and General

Requirements, Design, Qualification, Fabrication, and Inspection.
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Acceptable Weld Profile
Learning Objectives:
After reading this information sheet, you must be able to:

1. Differentiate acceptable and unacceptable weld profile
2. Determine the importance of weld quality
Acceptable and Unacceptable Weld Profile

The number of acceptable and unacceptable weld discontinuities for
welding inspection usually is obtained from welding codes and standards.
Welding codes and standards have been developed for many types of welding
fabrication applications. It is important to choose a welding standard
intended for use within the particular industry or application in which you
are involved.
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DETERMINING THE WELD QUALITY

Weld quality acceptance criteria can originate from a number of
sources. The welding fabrication drawing or blueprint provides weld sizes
and other welding dimensional requirements such as length ad location.
These dimensional requirements are established through design calculations
or are taken from proven designs that meet the performance requirements of
the welded connection.
Fillet Welds
The fillet weld symbol is one of the most widely used symbols and the
shape placed on the reference line to indicate a fillet weld is a triangle that
resembles the side profile of a fillet weld.
The examples of the weld all around and field weld above show a fillet
weld symbol so that the weld to be applied in both cases is a fillet weld.
May consist of one or more beads deposited in the angle formed by

two plates that are at the right angles and they are used to weld a lap joints
and a Tee joints.
Parts of Fillet Weld
Typical illustration on parts of fillet weld

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KEY POINT: Fillet sounds like fill it (pronounce the T) not fillay as in fillet a
fish.
The size of a fillet weld refers to the length of the legs of the weld. The two
legs are assumed to be equal in size unless otherwise specified.
 Face of Bead – a weld approximately triangular cross section joining

the two surfaces approximately at the right angle two each other in a
lap joint, tee joint or corner joint.
 Root – the bottom of the weld that intersects the base metal surfaces.
 The leg length is the distance from the root of the joint to the toe of
the fillet weld.
 The throat is the distance from the root to a point on the face of the
weld along a line perpendicular to the face of the weld. Theoretically,
the face forms a straight line between the toes.
 Toe – the junction between the face of the weld and the base metal.
 Penetration – the depth of fusion
Groove Welds
A weld made in the groove between two members to be joined.
May consist of one or more beads deposited in a groove.
They are used in welding various forms of V-bevel, J, and U – groove butt
joint.
Parts of Groove Weld
Typical illustration on parts of groove weld

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 The face of weld is the exposed surface of a weld on the side from
which the weld was made.
 The toe is the junction between the face of the weld and the base
metal.
 The root of a weld includes the points at which the back of the weld
intersects the base metal surfaces.
 The throat – shortest distance from the root to the face of bead.
TYPES OF WELDS
There are many types of welds. The most common types are the bead,
surfacing, plug, slot, fillet and groove.
A weld Bead is a weld deposit produced by a single pass with one of

the welding processes. A weld bead may be either narrow or wide, depending
on the amount of transverse oscillation (side –to side movement) used by the
welder. A weld bead made without much weaving motion is often referred
toes a stringer bead. On the other hand, a weld bead made with side-to-side
oscillation is called a weave bead.
Typical illustration of simple weld bead

Simple weld bead
Several weld beads applied side –by-side are usually used in Surfacing
which is a welding process used to apply a hard, wear-resistant layer of
metal to surfaces or edges of worn-out parts.
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 A Fillet weld is triangular in shape and this weld is used to join two
surfaces that are at approximately right angles to each other in a lap,
tee, or corner joint.
Typical illustration of fillet weld
 Plug and Slot welds are welds made through holes or slots in one
member of a lap joint. These welds are used to join that member to
the surface of another member that has been exposed through the
hole.
typical illustration of plug and slot weld
 Groove welds (also may be referred to as Butt welds) are simply welds
made in the groove between two members to be joined. The weld is
adaptable to a variety of butt joints, as seen in the figure. Groove
welds may be joined with one or more weld beads, depending on the
thickness of the metal. If two or more beads are deposited in the
groove, the weld is made with multiple-pass layers. As a rule, a
multiple-pass layer is made with stringer beads in manual operations.
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Typical illustration of groove weld
 Groove welds may be joined with one or more weld beads, depending
on the thickness of the metal. If two or more beads are deposited in
the groove, the weld is made with multiple-pass layers. As a rule, a
multiple –pass layer is made with stringer beads in manual
operations.
Typical illustration of multiple – pass layers of groove weld
 The build-up sequence refers to the order in which the beads of a

multiple-pass weld are deposited in the joint. Usually, before adding
the next pass, the previous pass needs to be cleaned from slag,
especially with SMAW, using a wire brush or other appropriate
method.
Typical illustration of weld layer sequence of groove weld

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PARTS OF WELDED JOINTS

The root of a joint is that portion of the joint where the metals are closest to
each other. As shown in the figure, the root may be a point, a line or an
area, when viewed in cross section.
 A groove is an opening or space provided between the edges of the

metal parts to be welded.
 The groove face is that surface of a metal part included in the groove
 A given joint may have a root face or a root edge
 The root face also shown in view A, is the portion of the prepared
edge of the part to be joined by a groove weld that has not been
grooved. As you can see, the root face has relatively small dimensions.
 The root edge is basically a root face of zero width. The groove face
and the root face are the same metal surfaces in some joints.
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The specified requirements for a particular joints are expressed in terms

such as bevel angle, groove angle, groove radius, and root opening.
 Groove Face – is that surface of a metal part included in the groove.

 Root Face – is the portion of the prepared edge of a part to be joined
by a groove weld that has not been grooved.
 The bevel angle is the angle formed between the prepared edge of a
member and a plane perpendicular to the surface of the member.
 The groove angle is the total angle of the groove between the parts to
be joined. For example, if the edge of each two plates were beveled to
an angle of 30 degrees, the groove angle would be 60 degrees.
 The groove radius is the radius used to form the shape of a J- or U-
groove weld joint. It is used only for special groove joint designs.
 The root gap or root opening refers to the separation between the
parts to be joined at the root of the joint.
Typical illustration of root opening
 Root penetration refers to the depth that a weld extends into the root
of the joint. Root penetration is measured on the canter line of the
root cross section.
 Joint penetration refers to the minimum depth that a groove weld
extends from its face into a joint, exclusive of weld reinforcement.
Fig. 049 typical illustration of root and joint penetration

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ROOT OPENING TECHNIQUE

Use rot opening to allow increase in amperage for smoother welding
Whip backwards for penetration
Whip forwards to reduce penetration
Do not weave a root pass
Maintain a short arc gap, stay slightly in front of the puddle at all
times. Use keyholing technique
- 60 degrees included angle

- Root faces
- Tacking
- Feather tacks
In many cases, root penetration and joint penetration, often refer to the
same dimension.
Weld reinforcement is a term used to describe weld metal in excess of the

metal necessary to fill joint. The reinforcement needs to be grinded in some
cases depending on the intended use of the joint.
Typical illustration of weld reinforcement

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Some other terms which are used to describe areas or zones of welds are:
The fusion zone is the region of the base metal that is actually melted. The
depth of fusion is the distance that fusion extends into the base metal or
previous welding pass.
The heat-affected zone (HAZ) refers to that portion of the base metal that
has not been melted; however, the structural or mechanical properties of the
metal have been altered by the welding heat.
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Self-check 1B.1-4
Multiple Choice:
Instructions: Read the questions carefully. On your answer sheet, write the
letter of the correct answer.
1. The exposed surface of the weld on the side from which the weld was
made.
a. throat b. root c. face of the weld d. all of the above
2. The junction between the face of the weld and the base metal.
a. Groove weld b. root c. throat d. leg
3. The distance from the root of the joint to the toe of the fillet weld.
a. Root b. leg length c. penetration d. all of the
above
4. Shortest distance from the root to the face of bead.
a. Penetration b. fillet weld c. face of the weld d. throat
5. Refers to the portion of the base metal that has not been melted.
a. Fusion zone b. weld reinforcement c. HAZ-Heat affected zone
Essay type:
1. What is the importance of weld quality? How will the quality applies in
different welding process?
CBLM on Issued by:
Answer Key 1B.1-4
I. Multiple Choice:
1. Face of the weld
2. Toe
3. Leg length
4. Throat
5. HAZ-heat affected zone
II. Essay:
Weld quality acceptance criteria can originate from a member of

sources. The welding fabrication drawing or blue print provides
weld sizes and other welding dimensional requirements such as
length and location. The member of acceptable and unacceptable
weld discontinuities for welding inspection usually obtain from
welding codes and standard.
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Weld Defects, Causes and Remedies
After reading this Information Sheet, you must be able to:
1. Identify the defects, the probable cause and remedies in welding
A welding defect is any flaw that compromises the usefulness of a weldment.

There is a great variety of welding defects. It is a discontinuity that by
nature or accumulated effect (for example, total crack length) renders a part
or product unable to meet minimum applicable acceptance standards or
specifications. A defect results in rejection of the part or product.
Discontinuity is defined as an interruption of the typical structure of a

material, such as a lack of homogeneity in its mechanical, metallurgical, or
physical characteristics. A discontinuity could be the result of a defect, but
isn’t necessarily a defect.
Weld Defects, causes and remedies:

Fig. typical illustration of causes and remedies of porosity

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Fig. typical illustration of causes and remedies of spatter

Fig. typical illustration of causes and remedies of incomplete fusion

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Fig. typical illustration of causes and remedies on lack of penetration

Fig. typical illustration of causes and remedies of excessive penetration
Fig. typical illustration of causes and remedies of burn – through

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Fig. typical illustration of causes and remedies of waviness of bead

Fig. typical illustration of causes and remedies of distortion
Undercutting
Possible Corrective Actions

Causes
1. Faulty electrode Use a uniform weave in butt welding. Avoid excess weaving.
manipulation Hold electrode at safe distance from vertical plane in
making horizontal fillet weld.
2. Improper electrode Avoid using overly large electrodes.
3. Current too high Use moderate current and weld slowly
Fig. typical illustration of causes and remedies of undercut

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Self-check 1B.1-5
I. Multiple Choice:
Instructions: Read the questions carefully. On your answer sheet,
write the letter of the correct answer.
1. Failure of weld metal to extend into the root of the joint.

a. Slag inclusion
b. Porosity
c. Incomplete fusion
2. Weld metal melting through base metal hanging underneath weld.
a. Distortion
b. Undercut
c. Excessive penetration
3. Small cavities or holes resulting from gas pockets in the weld metal.
a. Slag inclusion
b. Distortion
c. Porosity
4. These are the slag trapped in the weld metal.
a. Overlapping
b. Warpage
c. Slag inclusion
5. The expansion and contraction of a base metal being welded.
a. Incomplete fusion
b. Distortion
c. Weld puddle

CBLM on Issued by:
Answer Key 1B.1-5
I.
1. C
2. C
3. C
4. C
5. B
CBLM on Issued by:

Welding Procedure Specification (WPS)
1. Define the meaning of Welding Procedure Specification.
2. Explain the importance of WPS to the welders.
WPS is a document that describes how welding is to be carried out in

production. They are recommended for all welding operations and many
application codes and standards make them mandatory.
What information about they include?
Sufficient details to enable any competent person to apply the

information and produce a weld of acceptable quality. The amount of detail
and level of controls specified on a WPS is dependent on the application and
critically of the joint to be welded.
For most applications the information required is generally similar to that

recorded on a Procedure Qualification Record (PQR) or Welding Procedure
Approval Record (WPAR), except that ranges are usually permitted on
thickness, diameters, welding current, materials, joint types etc.
If a WPS is used in conjunction with approved welding procedures

then the ranges stated should be in accordance with the approval ranges
permitted by the welding procedure.
However careful consideration should be given to the ranges specified

to ensure they are achievable, as the ranges given by the welding practice.
For example welding positions permitted by the welding procedure standard
may not be achievable or practical for certain welding processes or
consumables.

CBLM on Issued by:
Welding Procedure Specification (WPS) is a formal written

document describing welding procedures, which provides direction to the
welder or welding operators for making sound and quality production welds
as per the code requirements. The purpose of the document is to guide
welders to the accepted procedures so that repeatable and trusted welding
techniques are used. A WPS is developed for each material alloy and for
each material alloy and for each welding type used. Specific coded and /or
engineering societies are often the driving force behind the development of
company’s WPS. A WPS is supported by a Procedure Qualification Record
(PQR or WPQR). A PQR is a record of a test weld performed and tested (more
rigorously) to ensure that the procedure will produce a good weld. Individual
welders are certified with a qualification test documented in a Welder
Qualification Test Record (WQTR) that shows they have the understanding
and demonstrated ability to work within the specified WPS.
A WPS is a document that describes how welding is to be carried out

in production. They are recommended for all welding operations and many
application codes and standards make them mandatory.
What information should they include?
Sufficient details to enable any competent person to apply the

information and produce a weld of acceptable quality. The amount of detail
and level of controls specified on a WPS is dependent on the application and
criticality of the joint to be welded.
Most applications the information required is generally similar to that

recorded on a procedure Qualification Record (PQR) or Welding Procedure
Approval Record (WPAR), except that ranges are usually permitted on
thickness, diameters, welding current, materials, joint types etc.
If a WPS is used in conjunction with approved welding procedures

then the ranges stated should be in accordance with the approval ranges
permitted by the welding procedure. However careful consideration should
be given to the ranges specified to ensure they are achievable, as the ranges
given by welding procedure standards do not always represent good welding
practice. For example welding positions permitted by the welding positions
permitted by the welding procedure standard may not be achievable or
practical for certain welding processes or consumables.

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EN ISO 15609 -1 (formally EN 288 Part 2) European Standard for Welding

Procedure Specifications
EN ISO 15609 defines the contents of a Welding Procedure
Specification in the form of a list of information that should be recorded. For
some applications it may necessary to supplement or reduce the list. For
example only in the case of a procedure requiring heat input control would
there be a necessity to quote travel speed or run-out length for manual
processes.
ASME IX American Boiler and Pressure Vessel Code
QW 250 lists the variables for each welding process, all the variables stated
should be addressed. The range permitted by the WPS id dictated by the
PQR or PQR’s used to qualify it.
Typical Items That Should Be Recorded on WPS
Common to all Processes
 Procedure number
 Process type
 Consumable size, Type and Full Codification
 Parent material grade and spec.
 Thickness range
 Plate or pipe, diameter range
 Welding position
 Joint Fit Up, Preparation, Cleaning, dimensions etc.
 Backing Strip, Back Gouging information
 Pre-Heat (Min Temp and Method)
 Inter pass If Required (Maximum Temp. Recorded)
 Post Weld Heat Treatment (Time and Temp.)
 Welding Technique (weaving, max run width etc.)
 Arc Energy Limits should be stated if impact tests are required or if
the material being welded is sensitive to heat input.

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Specific to Welding Processes MMA TIG MIG SUB

MAG ARC
FCAW
Welding current yes yes yes yes
Type of welding current AC/DC yes yes yes yes

Polarity
Arc Volatge If Auto yes yes

Pulse parameters (Pulse time and If Used If Used
Peak & background current)
Welding Speed if Mechanized yes yes

yes
Wire configuration yes
Shielding gas (comp, flow rate) yes yes
Purge gas (comp, flow rate) If Used If Used
Tungsten electrode Diameter and type yes
Nozzle diameter yes yes
Type of Flux Codification & Brand

yes
Name
Nozzle Stand Off Distance (Distance

From tip of nozzle to workpiece) yes
Table 7 Chart shows welding procedure specification

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Self – check 1B.1 -6
I. Direction: Answer the following questions. Write your answer on

your answer sheet.
1. What is the meaning of WPS?

2. Explain the purpose of WPS?
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Answer Key 1B.1-6
1. WPS or Welding Procedure Specification is a formal written document

describing welding procedures, which provides direction to the welder
or welding operations for making sound and quality production welds
as per the code requirements.
2. The purpose of the document is to guide welders to the accepted

procedures so that repeatable and trusted welding techniques are
used. A WPS is a document that describes how welding is to be
carried out in production.

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Welding Technique & Procedure
After reading this information sheet, you must be able to:
1. Explain the welding process and different welding techniques.

Fig. typical illustration of welding process

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To begin the SMAW Process, you must first strike an arc.
This can be done using one of the following techniques:
STRIKING AN ARC
SCRATCH START – Scratch the electrode on the base metal like a match.
Drag electrode across work piece like striking a match, immediately
lift electrode slightly after touching work. If arc goes out, electrode was lifted
too high. If electrode sticks to the work piece, use a quick twist to free it.
TAP START TECHNIQUE – Tap the rod against the base metal
Bring electrode straight down to work piece’ then lift slightly to start
arc. If arc goes out, electrode was lifted too high. If electrode sticks to work
piece, use a quick twist to free it.

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RESTARTING A BEAD
Here is the proper technique for restarting a weld:

1. Strike arc here
2. Move electrode to crown of crater
3. Resume forward travel
FILLING THE CRATER
Stay on the leading edge of the puddle
Fig. typical illustration of filling the crater

At the end of the weld, the operator breaks the arc which creates a ‘crater

CBLM on Issued by:
Use a short pause or slight back step at the end of the weld to fill the crater.
Large craters can cause weld cracking.

Fig. typical illustration of weave and stringer weld bead
ELECTRODE MOVEMENT DURING WELDING
A single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead
or multiple stringer beads work better.
1. Stringer Bead – Steady movement along seam

2. Weave Bead – side to side movement along seam
3. Weave patterns
Use weave patterns to cover a wide area in one pass of the electrode. Limit
weave width to a maximum of 2 ½ times diameter of electrode
WELD BEAD
Welds weave bead and stringer bead resulting from pass
Fig. typical illustration of weave and stringer weld bead

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TECHNIQUES
STRINGER: (drag) (whip)
WEAVE:
Fig. typical illustration of different welding technique
PROGRESSION (VERTICAL)
UP
- Deeper penetration
- Higher deposit rate
- Use 90 degree travel angle or slightly up
DOWN
- Faster (point to point)
- Less penetration for thin metal
- Less dilution
- Use steep drag angle
Positioning Electrode Holder
After learning to start and hold an arc, practice running beads of weld metal
on flat plates using a full electrode.
Hold the electrode nearly perpendicular to the work, although tilting it

ahead (in the direction of travel) will be helpful.

CBLM on Issued by:
Self –check 1B.1-7

Answer the following questions on your answer sheet.
1. Explain how to do a scratch start technique.
2. Explain the proper technique for restarting a weld.
3. What are the weaving techniques?

CBLM on Issued by:
Answer Key 1B.1-7

1. Drag the electrode across work piece like striking a match,
immediately lift electrode slightly after touching work.
2. The proper technique for starting a bead is first strike an arc then
move the electrode to the crown of crater then resumes your travel
forward.
3. The weaving techniques are: Circle’ zigzag, box weave, and double J.

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Procedures in Weld Carbon Steel Pipes in Horizontal Position
(2G)
1. Perform a groove welding on carbon steel pipes in horizontal

position (2G)
Pipe welding in horizontal position
When welding a pipe in 2G position the pipe is in vertical position and the
weld is horizontal position. The pipe is not moved during welding and the
welder must move around the pipe position.
The preparation and amperage setting should be the same as for the flat
position pipe with E-6011 electrodes used for the root pass and E-7018 or
E-6013 for hot pass, fill pass and final capping. It is important to layer the
fill passes and cover passes from the bottom pipe up to the top pipe, while
keeping the weld straight and properly overlapped.
HORIZONTAL 2G
PIPE POSITION
Fig. typical illustration of welding pipe in horizontal position

CBLM on Issued by:
Self-check 1B.1-8
I. Essay Type:
1. Explain on how to weld carbon steel pipes in horizontal position?

CBLM on Issued by:
Answer key 1B.1-8

1. When welding a pipe in horizontal position, the pipe is in vertical
position and the weld is horizontal. The welder must move around the
position of pipe. The preparation and amperage setting should be the
same as for the flat position of pipe with E-6011 for root penetration
and E-6013 or E-7018 for fill pass and final capping. It is important to
layer the fill passes and cover passes from the bottom pipe up to the
top of pipe, while keeping the weld beads straight and properly jointed

CBLM on Issued by:
JOB SHEET 1B.1-8

Title: Weld v-groove butt joint on carbon steel pipes in horizontal position
(2G)
Performance Objectives: Given the necessary tools and equipment, you
should be able to weld on carbon steel pipes in horizontal position
(2G) following the correct procedures.
Tools and Materials Needed:
Chipping hammer and wire brush

Portable grinder with grinding stone/disk
Two pieces 8” carbon steel pipes
Electrode as specified
Gap wire as specified (root opening may vary)
Straightedge or piece of angle iron
Pliers
Personal protective equipment as specified in welding standard
Equipment:
SMAW welding machine
Procedures:
1. Check work area to make sure it is free of flammable materials and

well ventilated and note the location of the nearest fire extinguisher.
\
Fig. pictorial appearance of practical work area
Note: Wear Personal Protective Equipment before entering the
practical work area
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2. Prepare two pieces of steel pipes for welding

Fig. pictorial appearance of prepared pipes
3. Make a bevel for root face groove using grinder.

The root face thickness must be the same on the thickness of
electrode used.
Fig. pictorial appearance of grooving pipes
4. Attach ground cable to work table or work piece or positioned.

Select correct polarity for electrode. Turn on welding machine.
Put on welding helmet and adjust machine to correct amperage by
running a test bead on scrap metal.
Fig. pictorial appearance of prepared welding machine

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5. Place a gap wire into the pipes for root penetration.

Fig. pictorial appearance of placing a gap wire
6. Tack weld the first, second, third and fourth quarter.
Fig. pictorial appearance of tacking pipe
7. Place electrode E-6011 in electrode holder and adjust to correct

electrode angle. Strike an arc on one of the tacks and quickly adjust to
proper arc length. Make a puddle and immediately form a keyhole and
whip slightly forward to allow keyhole to solidify. Do the same
procedure to other quarter.
Fig. pictorial appearance of establishing root pass

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8. Using chipping hammer, chip slag off stringer bead, brush it, then
grind the entire bead with a hand grinder.
Fig. pictorial appearance of cleaning a root pass
9. Inspect the root pass for good fusion and penetration and for defects
such as undercutting on both outside and inside surfaces.
Fig. pictorial appearance of good penetration
10. djust amperage setting for hot pass procedure by using E-7016 or E-
6013 electrode with 45 degree side to side or dragging/weaving
technique.
Fig. pictorial appearance of performing hot pass

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11. Chip slag of hot pass, brush it and grind off any high spots.
Use the same electrode and with dragging or side to side technique, lay
weld beads for remainder of 30 degree and 70 degree fill pass and be
sure to clean each pass before starting another one.
Fig. pictorial appearance of performing fill pass
12. Use the same electrode and with dragging side to side technique, lay the
capping or final pass to finish the weld. Clean and inspect your work.
Let your instructor check your work.
Fig. pictorial appearance of performing capping
13. Shut down the welding machine.

Check in tools and materials and clean up area.

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Performance Criteria Checklist 1B.1-8

CRITERIA YES NO
Did you…
Perform task in accordance with company or industry
requirement and safety procedure
Perform root pass in accordance with WPS and/ or client
specifications
Check defects and repaired as required
Check weld visually applicable codes and standards
Cleans root pass and free from defects and discontinuities
Weld subsequent/filling passes is performed in accordance with

approved WPS
Perform capping in accordance with approved WPS and /or
client specifications

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Introduction
This learning outcome enhances and upgrades the skill and
knowledge of the previous completion of learning outcome no.1 because this
position of welding is difficult from the previous position but the techniques,
principles and welding code standard is remain the same. It also focuses
the techniques and procedure of welding carbon steel pipes in vertical
position (5G). The trainee may be required to pass this learning outcome
competent before proceeding to the next level, the completion of 2G and 5G
positions, make it easier for the trainee of 6G position. The 2G and 5G
positions are sometimes done to qualify a welder for all pipes welding
positions.

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QUALIFICATION: Shielded Metal Arc Welding NC II

Module Title : Performing groove welding on Carbon Steel Pipes
Learning Outcome #2: Weld v-groove butt joint on carbon steel pipes in
vertical up position (5G)
CONTENT:
 Procedures in weld carbon steel pipes in vertical up position (5G)
ASSESSMENT CRITERIA
1. Root penetration not exceeding allowable tolerance specified by

welding codes/standards on:
 Concavity
 Convexity
 Undercut
 Lack of fusion
 Burn-through
2. Weld capping/final pass not exceeding allowable tolerance specified by

 Underfill
 Porosities
 Undercut
 Cracks
 Cold laps
standards
standards

CBLM on Issued by:

standards for:
 Spatters
 Arc strikes
 Slag
 Uniformity o beads
CONDITIONS:
Trainees must be provided with the following:
1. EQUIPMENT:

 Welding booth
 Portable oven

 Welding mask
 Steel brush
 Clear glass
 Chipping hammer
 Dark glass
 Electrodes

 Safety shoes
 Apron
 Leggings
 Safety goggles
 Leather Gloves

CBLM on Issued by:
 CBLM
ASSESSMENT METHOD:
 Written test
 Demonstration with oral Questioning
 Observation with oral Questioning

CBLM on Issued by:
Learning Outcome No. 2

Weld V groove butt joint on carbon steel pipes in vertical up position
5G
Read Information Sheet No. 1B.2-1 Read the information sheet 1B.2-1
on Procedures in welding carbon and check yourself by answering the
steel pipes in vertical up position self-check 1B.2-1
(5G)
If you feel you can identify the
different procedures and you are
ready to perform the task on welding
carbon steel pipes in vertical up
position (5G) you can now proceed to
do the task
Answer Self –check no. 1B.2-1
Refer/Compare your answer to

answer key
Perform Job Sheet No. 1B.2-1

performance criteria checklist 1B.2-1

CBLM on Issued by:
Procedures in Weld Carbon Steel Pipes in Vertical up Position

(5G)

1. Perform a groove welding on carbon steel pipes in vertical up position
(5G)
Pipe welding in vertical up position
When welding a pipe in 2G position the pipe is in vertical position and

the weld is horizontal position. The pipe is not moved during welding and
the welder must move around the pipe position. The preparation and
amperage setting should be the same as for the flat position pipe with E-
6011 Electrodes used for the root pass and E-7018 or E-6013 for hot pass,
fill pass and final capping. It is important to layer the fill passes and cover
passes from the bottom pipe up to the top pipe, while keeping the weld
straight and properly overlapped.
Always make sure the correct amperage is set for tacking the pieces
and the root pass using E-6010 electrodes. Check the machine setting and
use an amperage from 90-110. Use E-7018 for the fill passes and cover pass
set at approximately 120-150 amps. Use a slight U shape technique with the
E-6010 electrode to open and maintain the keyhole. If the keyhole is too
tight, slow down and force it open with the electrode while welding or stop
and increase the amperage (heat).

CBLM on Issued by:
Self –check 1B.2-1

Essay Type:
1. Explain on how to weld carbon steel pipes in vertical up position?

CBLM on Issued by:
Answer key 1B.2-1

1. In the 5G pipe position the pipe is horizontal and the weld axis is
vertical up so that the welding is essentially a vertical weld. When
welding some pipes for low pressure applications or small diameter
pipe it may be acceptable to weld downward with an electrodes like
the E-6010 for root pass, however, most pipes are welded vertical
upward with an electrode E-6011 for root pass and E-6013 or E-7018
or filler and capping procedure. Always make sure the correct
amperage is set for tacking the pieces and the root pass using E-6010
electrodes. Check the machine setting and use an amperage from 90-
110. Use E-7018 for the fill passes and cover pass set at
approximately 120-150 amps. Use a slight U-shape or stringer
technique for root pass to open and maintain the keyhole. Use a side
to side or circular motion technique with E-6013 or E-7018 electrodes
keeping the ripples close together and the weld profile for filler and
final pass.

CBLM on Issued by:
JOB SHEET 1B.2-1

Title: Weld v-groove butt joint on carbon steel pipes in horizontal position
(5G)

Pliers
Equipment:
Procedures:

\

practical work area
CBLM on Issued by:


electrode used.
4. Attach ground cable to work table or workpiece or positioned.

running a test bead on scrap metal

CBLM on Issued by:



CBLM on Issued by:
10. Adjust amperage setting for hot pass procedure by using E-

7016 or E-6013 electrode with 45 degree side to side or
dragging/weaving technique.

CBLM on Issued by:


CBLM on Issued by:

CRITERIA YES NO
Did you…
specifications

approved WPS

CBLM on Issued by:
Introduction
The previous two consecutive learning outcomes are absolutely

necessary to the trainee to learn and perform of their respective job sheet
before the trainee proceeds in this level. If the trainee is successfully
competent, it is simply for him to weld carbon steel pipes inclined at 45
degree fix position (6G). This is a pipe that is in standing on a 45 degree
angle and cannot be moved. This test incorporates all of the positions. What
makes this position so hard is there is an easy side and a hard side. This all
depends if you are right handed or left handed and the welding processes
being used. This one test will qualify the welder to weld pipe and plate in all
positions. This is the hardest of all welding positions and the test typically
given for the higher paying jobs. If you need to get one welding certification
this is the position to go. Since pipe welders can earn a doctors salary this is
the most wanted welding certification! So obviously a lot of welding students
want to have this welding certification before finishing welding school. I hope
to give any student welders interested a head start on getting ready to pass
this 6G position. The one piece of advice I can give about learning to weld
pipe is, get your structural welding skills down first. Otherwise it will take
more time to learn to weld pipe!

CBLM on Issued by:
QUALIFICATION: Shielded Metal Arc Welding NC II
Module Title : Performing groove welding on Carbon Steel Pipes
Learning Outcome #3: Weld v-groove butt joint on carbon steel pipes
Inclined at 45 degree fix position (6G)
CONTENT:
 Procedures in weld carbon steel pipes inclined at 45 degree fix

position (6G)
ASSESSMENT CRITERIA
1. Root penetration not exceeding allowable tolerance specified by

 Concavity
 Convexity
 Undercut
 Lack of fusion
 Burn-through
 Cracks
2. Weld capping/final pass not exceeding allowable tolerance specified by

 Underfill
 Porosities
 Undercut
 Cracks
 Cold laps
standards
standards

CBLM on Issued by:
standards for:
 Spatters
 Arc strikes
 Slag
 Uniformity o beads
CONDITIONS:
Trainees must be provided with the following:
1. EQUIPMENT:

 Welding booth
 Portable oven

 Welding mask
 Steel brush
 Clear glass
 Chipping hammer
 Dark glass
 Electrodes

 Safety shoes
 Apron
 Leggings
 Safety goggles
 Leather Gloves

CBLM on Issued by:
 CBLM
ASSESSMENT METHOD:
 Written test
 Demonstration
 Interview with oral Questioning

CBLM on Issued by:
Learning Outcome No. 3
Weld V groove butt joint on carbon steel pipes inclined at 45˚ fix
position (6G)
Read Information Sheet No. 1B.3-1 Read the information sheet 1B.3-1
on Procedures in welding carbon and check yourself by answering the
steel pipes inclined at 45º fix self-check B.3-1
position (6G)
If you feel you can identify the
different procedures and you are
ready to perform the task on welding
carbon steel pipes inclined at 45 º fix
(6G) you can now proceed to do the
task
Answer Self –check no. 1B.3-1
Refer/Compare your answer to

answer key
Perform Job Sheet No. 1B.3-1

performance criteria checklist 1B.3-1

CBLM on Issued by:
Procedures in Weld Carbon Steel Pipes Inclined at 45° Fix

Position (6G)
1. Perform a groove weld on carbon steel pipes inclined at 45˚ fix

position (6G)
Pipe welding inclined at 45˚ fix position

In the pipe welding on 6G position, the pipe is fixed in 45˚ inclined
position. The weld in this position covers all position welding because the
bottom of the pipe is in overhead weld position, the top of pipe in flat weld
and the front and back is vertical and horizontal. The pipe is welded using
stringer beads for root pass E-6011 and side to side for filling and final pass
E-6013 or E-7018. The electrode angle should remain the same for all
passes with a slight push angle from bottom to top.
The pipe is welded using stringer beads except that a slight weave
motion must be used to prevent the sides or vertical upward part from
sagging and lumping up in the middle of the weld bead.

CBLM on Issued by:
Self – check 1B.3-1

Essay Type:
1. Explain on how weld a carbon steel pipes inclined at 45˚ fix position?

CBLM on Issued by:
Answer key 1B.3-1

1. In the pipe welding on 6G position, the pipe is fixed in 45˚ inclined
position. The weld in this position covers all position welding because
the bottom of the pipe is in overhead weld position, the top of pipe in
flat weld and the front and back is vertical and horizontal. The pipe is
welded using stringer beads for root pass E-6011 and side to side for
filling and final pass E-6013 or E-7018. The electrode angle should
remain the same for all passes with a slight push angle from bottom
to top.

CBLM on Issued by:
JOB SHEET 1B.3-1

Title: Weld v-groove butt joint on carbon steel pipes inclined at 45˚ fix
position (6G)

Pliers
Equipment:
Procedures:

\

practical work area

CBLM on Issued by:


electrode used.
4. Attach ground cable to work table or workpiece or positioned.

running a test bead on scrap metal

CBLM on Issued by:


CBLM on Issued by:

10. Adjust amperage setting for hot pass procedure by using E-

7016 or E-6013 electrode with 45 degree side to side or
dragging/weaving technique.

CBLM on Issued by:

CBLM on Issued by:
CRITERIA YES NO
Did you…
specifications

approved WPS
CBLM on Issued by:
TERMS AND DEFINITIONS
Alternating Current – an electric current that reverse its direction at

regularly recurring intervals.
Arc Voltage – the voltage across the welding arc.
Arc Welding – a group of welding processes in which fusion is obtained by

heating with an electric arc. Annealing – a comprehensive term used to
describe the heating and cooling cycle of steel in the solid state. The term
annealing usually implies relatively slow cooling magnetic forces.
Arc Cutting – a group of cutting processes in which the cutting of metals is

accomplished by melting with the heat of an arc between the electrode and
the base metal.
Arc length – the distance between thetip of the electrode and the base
metal.
Axis of a Weld – a line through the length of a weld, perpendicular to a

cross section at as center of gravity.
Back Gouging – the removal of weld metal by gouging or grinding from the
other side of a partially welded joint to assure complete penetration upon
subsequent welding from that side.
Back Weld - a weld deposited at the back of a single groove weld.
Bare electrode – an arc welding electrode that has no coating other than
that incidental to the drawing of thefire.
Backing Weld – a weld bead applied to the root of a single groove joint to
assure complete root penetration.
Back Step – a sequence of bead increments are deposited in a direction

opposite to the direction of progress.
Backhand Welding – a welding technique in which the flame is directed

towards the completed weld.
Base Metal – the metal to be welded or cut.

CBLM on Issued by:
Bead weld – a type of weld composed of one or more string or weave beads
deposited on an unbroken surface.
Bevel Angle – the angle formed between the prepared edge of a member and
a plane perpendicular to the surface of the member.
Bridging – a welding defect caused by poor penetration. A void at the root of

the weld is spanned by weld metal.
Buckling – distortion caused by the heat of a welding process.
Butt joint – a joint between two work pieces in such a manner that the weld
joining the parts is between the surface planes of both of the pieces joined.
Butt weld – a weld in a butt joint.
Carbon – Arc Welding – a welding process in which fusion is produced by

an arc between a carbon electrode and the work. Pressure and /or shielding
may or may not be used.
Composite Electrode – filler metal electrode used in arc welding, consisting

of more than one metal component combined mechanically, it may or may
not include materials that improve the properties of the weld, or stabilize the
arc.
Composite Joint – a joint in which both a thermal and mechanical process
are used to unite the base metal parts.
Concave Fillet Weld – a fillet weld in which the welds face in concave
(curved inwards)
Concavity – the maximum perpendicular distance from the face of a

concave weld to a line joining the toes.
Concurrent Heating – Supplemental heat applied to a structure during the

course of welding.
Continuous Weld – a weld extending along the entire length of joint.
Convexity – the maximum perpendicular distance from the face of a convex

fillet weld to a line joining the toes.
Cover Glass – a clear glass used in goggles, hand shield, and helmets to
protect the filter glass from spattering material.
CBLM on Issued by:
Covered Electrode – a metal electrode with a covering material which

stabilizes the arc and improves the properties of the welding metal. The
material maybe an external wrapping of paper, asbestos, and other
materials or a flux coating.
Crack – a fracture type discontinuity characterized by a sharp tp and high

ratio of length and width to opening displacement.
Crater – a depression at the termination of an Arc weld.
Current – another name for amperage. The amount of electricity flowing

past a point in a conductor every second.
Cutting Electrode – an electrode with covering that aids the production of

such an arc that the molten metal is blown away to produced a groove or
cut in the work.
Depth of Fusion – the distance from the original surface of the base metal
to that point at which fusion ceases in a welding.
Direct current – (DC) a method of metal-arc welding in which fused

particles of the electrode wire in contact with the molten pool are detached
from the electrodes in rapid succession by the short circuit current, which
develops every time the wire touches the molten pool.
Direct Current Electrode Negative (DCEN) – the specific direction of

current flow through a welding circuit when the electrode lead is connected
to the negative terminal and the work lead is connected to a negative
terminal to a DC welding machine. Also called Direct Current Reverse
Polarity (DCRP).
Ductility – the property of a metal which allows it to be permanently
deformed, in tension before final rapture.
Edge Joint – a joint between the edge of a joint member for welding.
Edge Preparation – the contour prepared on the edge of a joint member for
welding.
Effective length of weld – the length of weld throughout which the

correctly proportioned cross section exist.
Electrode – filler metal in the form of a wire or rod, whether bare or covered.
Through which current is conducted between the electrode holder and the
arc.
CBLM on Issued by:
Electrode Force – in spot, seam and projection welding, the force between
the electrodes during the actual welding cycle.
Excess penetration bead –excessive metal protruding through the root of a

fusion weld made from one side only.
Face of weld – the exposed surface of a weld, made at the sie of the joint
from which welding was done.
Face reinforcement – reinforcement of weld at the side of the joint from

which welding was done.
Filler metal – a weld approximately triangular cross section, as used in a

lap joint, joining two surfaces at approximately right angles to each other.
Flat position – the position in which welding is performed from the upper
side of the joint and the face of the weld is approximately horizontal.
Flux – a cleaning agent used to dissolve oxides, release trapped gases an

slag, and to cleanse metals for welding and brazing.
Flux Cored Arc Welding (FCAW) – an arc welding process which melts and
joins metals by heating them with an arc between a continuous,
consumable electrode wire and the work. Shielding gas is obtained from a
flux contained within the electrode core.
Forehand welding – a gas welding technique in which the flare is directed

against the base metal ahead of the completed weld.
Forge welding – a group of welding processes in which fusion is produced

by heating in a forge or furnace and applying pressure or blows.
Full Fillet Weld – a fillet weld whose size is equal to the thickness of the
thinner member joined.
Fusion – a thorough and complete mixing between the two edges of the base
metal to be joined or between the base metal and the filler metal added
during welding.
Gas Metal – Arc Welding (GMAW) – an arc welding process in which fusion
is produced by heating with an electric arc between a carbon electrode and
the work. Shielding is obtained from an inert gas such as helium or argon.
CBLM on Issued by:
Gas Tungsten Arc Welding (GTAW) - – an arc welding process in which

fusion is produced by heating with an electric arc between a tungsten
electrode and the work while an inert gas forms around the weld area to
prevent oxidation. No flux used.
Gas Welding – a process in which the welding heat is obtained from a gas
flame.
Groove – the opening between two members to be joined by a groove weld.
Groove angle – the included angle of the groove between parts to be joined
by the groove weld.
Groove weld – a weld made by depositing filler metal in a groove between

two members to be joined.
Heat Affected Zone – the portion of the base metal whose structure or
properties have been changed by the heat of welding or cutting.
Heat Time – the duration of each current impulse welding.
Heat Treatment – an operation or combination of operations involving the

heating and cooling of a metal or an alloy in the solid state for the purpose
of obtaining certain desirable conditions or properties. Heating and cooling
for the sole purpose of mechanical working are excluded from the meaning
of the definition.
Lap Joint – a join between two overlapping members.
Layer – a stratum of weld metal, consisting of one or more weld beads.
Leg of fillet weld – the distance from the root of the join to the toe of the
fillet weld.
Melting point – the temperature at which a metal begins to liquefy.
Metal Arc Welding – an arc welding process in which a metal electrode is

held so that the heat of an arc fuses both the electrode and the work to form
a weld.
Metalizing – a member of overlay or metal bonding to repair worm parts.
Overhead Position – the position in which welding is performed from the

underside of a joint and the face of the weld is approximately horizontal.
CBLM on Issued by:
Overlap – the protrusion of weld metal beyond the bond at the toe of the
weld.
Peening – the mechanical working of metals by means of hammer blows.

Peening tends to stretch the surface of the cold metal, thereby relieving
contraction stresses.
Percussive Welding – a resistance welding process in which a discharge of

electrical energy and the application of high pressure occurs
simultaneously, or with the electrical discharge occurring slightly before the
application of pressure.
Plasma Arc Cutting – an arc cutting process which serves metal by using a
constricted arc to melt a small area of the work. This process can cut all
metals that conduct electricity.
Plug Weld – a weld made a hole on one member of a lap joint, joining that
member to the portion of the surface of the member which is exposed
through the hole. The walls of the holes may or may not be parallel, and the
hole may be partially or completely filled with the weld metal.
Porosity – the presence of gas pockets or inclusions in welding.
Post Heating – the application of heat to an assembly after a welding

operation.
Preheating – the application of heat to a base metal prior to a welding or

cutting operation while welding.
Reinforce weld – the weld metal built up above the surface of the two
abutting sheets or plates in excess of the required for the size of the weld
specified.
Resistance welding - group of welding processes in which fusion is

produced by heat obtained from resistance to the flow of electric current in a
circuit of which the workpiece is a part and by the application of the
pressure.
Reverse Polarity – the arrangement of direct current arc welding leads in

which the work is the negative pole and the electrode is the positive pole of
the welding arc.
CBLM on Issued by:
Root crack – a crack in the weld or base metal which occurs at the root of a
weld.
Root edge – the edge of a part to be welded which is adjacent to the root.
Root face – the portion of the prepared edge of a

member to be joined by a groove weld which is not beveled or groove.
Root of joint – the portion of a joint to be welded where the members

approach closed to each other. In this section, the root o a joint may be a
point, a line, or an area.
Root of weld – the points, as shown in cross section, at which the bottom of
the weld intersects the base metal surfaces.
Root opening – the separation between the members to be joined at the root
of the joint.
Root penetration – the depth a groove weld extends into the root of a joint
measured on the centerline of the root cross section.
Scarping – a process for removing defects and checks which develop in the
rolling of steel billets by the use of a low velocity oxygen deseaming torch.
Series welding – a resistance welding process in which two or more welds

are made simultaneously by a single welding transformer with the total
current passing through each weld.
Sheet Separation – in spot, seam, and projection welding the gap

surrounds the weld between faying surfaces after the joint has been welded.
Shielded welding – an arc welding process in which protection from the

atmosphere is obtained through use of flux, decomposition of the electrodes
covering, or an inert gas.
Shielding gas – protective gas used to prevent atmospheric contamination

of the weld pool.
Slag inclusion – non-metallic solid material entrapped in the weld metal or

between the metal and the base metal.
Soldering – a group of welding procedures which produce coalescence of

materials by heating them to suitable temperature.
CBLM on Issued by:
Spacer strip – a metal strip or bar inserted in the root of a joint prepared for
a groove weld to serve as a backing and to maintain the root opening during
welding.
Spatter – the metal particles expelled during arc gas welding which do not
dorm a part of the weld.
Straight polarity – the arrangement of direct current arc welding leads in

which the work is the positive pole and the electrode is the negative pole of
the welding arc.
Stress relieving – a process of reducing internal residual stresses in a metal

object by heating to a suitable temperature and holding for a proper time at
that temperature.
String bead welding – a method of metal arc welding on pieces ¾ in (19mm)

thick or heavier in which the weld metal is deposited in layers composed of
strings of beads applied directly to the face of the bevel.
Stud welding – an arc welding process in which fusion is produced by

heating with an electric arc drawn between a metal studs , or similar part,
and the other work piece. They are brought together under pressure.
Submerge Arc Welding – an arc welding process in which fusion is

produced by heating with an electric arc or arcs between a bare metal
electrodes and the work. Pressure is not used filler metal is obtained from
the electrode, and sometimes from a supplementary welding rod.
Track weld – a weld made to hold parts of a weldment in proper alignment

until final welds are made.
Throat Depth – in a resistance welding machine, the distance from the

centerline of the electrodes or platens to the nearest point of interference for
the flatwork or sheets. In a seam welding machine with a universal head,
the throat depth is measured with the machine arranged for transverse
welding.
Throat of fillet weld – the distance from the root of the fillet weld to the
center of its face.
Toe Crack – a crack in the base metal occurring at the toe of the weld.
Under bead crack – a crack in the heat affected zone not extending to the
surface of the base metal.
CBLM on Issued by:
Undercutting – an undesirable crater at the edge of the weld caused by poor

weaving technique or high current.
Vertical position – the position of welding in which the axis of the weld is
approximately vertical.
Voltage –the pressure or force that pushes the electrons through a

conductor.
Weave bead – a type of weld bead made with transverse oscillation.
Weld bead – a weld deposit resulting from gas.
Weld metal – the portion of a weld that has been melted during welding.
Welder certification – certification in writing that a welder has produced

welds meeting prescribed standards.
Welding procedure – the detailed methods and practices all joint welding
procedures involved in the production of a weldment.
Welding rod – a filler metal wire or rod form, used in gas welding and
brazing processes and in those arc welding processes in which electrode
does not provide the filler metal.
Welding symbol – the assembled symbol consist of the following right

elements. Or such of these as are necessary: reference line, arrow, basic
weld symbols, dimension and other data, supplementary symbols, finish
symbols, tail specification process, or other references.
Welding technique – the details of a manual, machine or semiautomatic

welding operation which, within the limitations of the prescribe joint welding
procedure are controlled by the welder or welding operator.
Welding transformer – a device for providing current of the desired voltage.
Workpiece connection – a means to fasten the work lead
Workpiece lead – the conductor cable or electrical conductor between the

arc welding machine and the work.
CBLM on Issued by:
WPS – Welding Procedure Specification
Yield Joint _ the yield point is the load per unit area at which a mark
increase in deformation of the specimen occurs with little or o increase of
load.
CBLM on Issued by:
BIBLIOGRAPHY
http:/ /en.wikipedia.org/wiki/Safety Welding Practices
http:/ /en.wikipedia.org/wiki/Safety Welding Essentials
http:/ /en.wikipedia.org/wiki/Shielded Metal Arc Welding
http:/ /en.wikipedia.org/wiki/Stick Welding
http:/ /en.wikipedia.org/wiki/ Welding Practices
http:/ /en.wikipedia.org/wiki/SMAW Pipe Welding
http:/ /en.wikipedia.org/wiki/Arc Welding

CBLM on Issued by:
EVIDENCE PLAN
QUALIFICATION:
SHIELDED METAL ARC METAL (SMAW) NCII
Unit of competency:
Weld Carbon Steel Plate and Pipe Using SMAW
Ways in which evidence will be collected:
Written test
Portfolio
Observation & Questioning
Demonstration& Questioning
Third Party Report

[tick the column]
The evidence must show that the candidate …
Questioning
Performs task in accordance with safety procedures X X
Welds carbon steel pipes in 2G,5G and 6G positions to X X
acceptable standards following the approved WPS *
Performs root pass in accordance with WPS and/or client X X
specifications *
Checks weld visually for defects and repair as required * X X
Inspects visually acceptable weld in accordance with X X
applicable codes and standards *
Clean root pass and free from detects and discontinuities * X X
Performs subsequent/filling and final pass in accordance X X
with WPS *
Prepared by: Engr. Gerson T. Estay Date:
Date:
Note: *Critical aspects of competency
DEMONSTRATION
Candidate’s name:
Assessor’s name:
Project-Based Assessment:
Qualification: SHIELDED METAL ARC WELDING USING SMAW NC II
Date of assessment:
Time of assessment:
Instructions for the demonstration:
Given the necessary materials, tools and equipment, the candidate must
be able to weld carbon steel pipes in combination of ( 2G ) and ( 5G) in 4 hours
/ ( 6G ) in 4hours
Materials and equipment
Welding Machine, personal protective equipment, steel pipes, electrodes, steel
brush, chipping hammer and portable grinder
OBSERVATION  To show if evidence

is demonstrated
During the demonstration of skill, did the candidate: Yes No N/A
Perform task in accordance with safety procedures   
Weld carbon steel pipes in 2G,5G and 6g positions to
 
acceptable standards following the approved WPS 
Perform root pass in accordance with WPS and /or 
 
Check weld visually for defects and repair as required   
Inspect visually acceptable weld in accordance with 
 
applicable codes and standards
Clean root pass and free from defects and 
 
discontinuities
Perform subsequent / filling and final pass in
accordance with WPS
The candidate’s demonstration was:
Satisfactory Not Satisfactory √
QUESTIONING TOOL
Satisfacto
QUESTIONS TO PROBE THE TRAINEE’S
ry
UNDERPINNING KNOWLEDGE
response
Extension / reflection Questions Yes No
1. How will you check if the steel plate is properly welded?  

2. What are the 3 common current used in welding?  
Safety Questions
3. How will you insure safety in the work place while
 
performing the task?
4. What will you do if you encounter electric failure while
 
welding?
Contingency questions
5. What will you do if you encounter welding distortion?  
6. In case after welding the result are not properly joined
 
what will you do?
Rules and regulation
7. Why do you use and follow appropriate personal
protective equipment ( PPE ) and occupation health and  
safety ( OHS ) ?
8. Why do you follow procedures in welding?  
Job role responsibility
9.When you are repairing or welding steel pipes, what is
the first of the 10 responsibilities required by the owner  
/ industry
10. How will you dispose the waste materials after
 
Welding?
Feedback to trainee:
The candidate’s overall performance was:

Satisfactory  Not Satisfactory 
Candidate’s signature: Date:
Trainer’s signature: Date:
ANSWERS GUIDE:
Extension/ Reflection Questions:
1. If we follow the standard procedure in accordance with WPS.

2. Ac,DC,DCEN
Safety Questions:
3. Always apply ( OHS ) operational health safety in workplace
4. Switch off electrical safety switch to future trouble or shortage
Contingency questions
5. Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation

Weld in small segments and allow cooling between welds
6. Clean the work piece using steel brush and grinder and repair weld.
Rules and regulation:

7. To prevent further incidents and insure the health and safety.
8. To have a good output in welding.
Job role responsibility

9. To provide best and good quality weld result.
10. Follow the waste segregation management standard in welding.

TABLE OF SPECIFICATION
Objective/content Knowledge Comprehension Application # of

area/Topics Items/
% of
test
Weld carbon Steel Pipes in Horizontal Position 2G LO1
Safety welding 5% 5% 10%
Practice
Essentials of 5% 5% 10%
welding
International 5% 5% 10%
Welding codes and
standards
Acceptable weld 5% 5% 10%
profile
Weld defects, 5% 5% 10%
causes and
remedies
Welding Procedure 5% 5% 10%
Specification (WPS)
Welding techniques 10% 10%
and procedure
Procedures in 5% 5% 10%
welding carbon
steel pipes in
horizontal position
(2G)
Weld Carbon Steel Pipes in Vertical up Position(5G) LO2
welding carbon
steel pipes in
vertical up
position(5G)
Weld Carbon Steel Pipes inclined at 45° fix Position (6G) LO3
welding carbon
steel pipes inclined
at 45° fix Position
(6G)
TOTAL 30% 30% 40% 100%
TABLE OF SPECIFICATION
Objectives / TEST ITEM DISTRIBUTION Total Percentage

Content No. %
Area / Topics Factual Comprehension Application of
Knowledge Items
Weld carbon Steel Pipes in Horizontal Position 2G LO1
Safety welding 1 1 2 10%
Practice
Essentials of 1 1 2 10%
welding
International 1 1 2 10%
Welding codes
and standards
Acceptable weld 1 1 2 10%
profile
Weld defects, 1 1 2 10%
causes and
remedies
Welding 1 1 2 10%
Procedure
Specification
(WPS)
Welding 2 2 10%
techniques and
procedure
Procedures in 1 1 2 10%
welding carbon
steel pipes in
horizontal
position (2G)
Weld Carbon Steel Pipes in Vertical up Position(5G) LO2
welding carbon
steel pipes in
vertical up
position(5G)
Weld Carbon Steel Pipes inclined at 45° fix Position (6G) LO3
welding carbon
steel pipes
inclined at 45°
fix Position (6G)
TOTAL 6 6 8 20 100%
Written Test
MULTIPLE CHOICE
b. Reverse polarity
c. Balance polarity
d. Forward polarity
Indicates
a. Polarity
b. Covering
d. Welding current
3. The first two numbers in the AWS electrode classification indicates?
a. Polarity
b. Tensile strength
c. Welding current
d. Welding position
a. Traveling
b. Electrode length
c. Flux coating
materials.
a. Leather apron
b. Safety shoes
c. Goggles
d. All of the above
7. Weld carbon steel pipes in horizontal position.
a. 6G
b. 5G
c. 2G
d. None of the above
8. Weld carbon steel pipes in vertical up position
a. 5G
b. 2G
c. 6G
made.
a. Throat
b. Root
c. Face of the weld
d. All of the above
a. Toe
b. Root
c. Throat
d. leg
a. Root
b. Leg length
c. Penetration
d. All of the above
a. Penetration
b. Fillet weld
c. Face of the weld
d. Throat
a. Fusion Zone
b. Weld reinforcement
c. HAZ- Heat Affected Zone
14. It is a document that describes how welding is to be carried out in
production
a. Welding codes
b. WPS
c. Procedure
15. weld metal melting through base metal hanging underneath weld
a. Distortion
b. Undercut
16. Small Cavities or holes resulting from gas pockets in the weld
metal.
a. Slag inclusion
b. Distortion
c. Porosity
a. Overlapping
b. Warfage
c. Slag inclusion
b. Distortion
c. Weld puddle
19.Which of the following statement does not describe the acceptable
weld profile?
a. The faces of fillet welds may be slightly convex, flat, or slightly
concave.
b. Groove welds shall preferably be made with slighter minimum
reinforcement except as may be otherwise provided.
c. Weld shall be free from overlap
d. Surfaces of groove welds not required to be flush.
20. In the case of butt and corner joints, the reinforcement shall not
exceed by how many inch?.
a. 1/16
b. 1/8
c.¼
d.½
Key Answers
I-Multiple Choice
1. a 11. b
2. d 12. d
3. c 13. c
4. b 14. b
5. d 15. c
6. c 16. c
7. c 17. c
8. a 18. b
9. c 19. d
10. a 20. B
SELF – ASSESSMENT GUIDE
Qualification: SHIELDED METAL ARC WELDING (SMAW) NC II
Unit of competency: Weld Carbon Steel Plates and Pipes Using SMAW
Instruction:
 Read each of the questions in the left-hand column of the chart.
 Place a check on each question to indicate your answer.
Can I? Yes No
 Perform task in accordance with safety
procedure Perform root pass in accordance
with WPS and/or client specifications.*
 Welds carbon steel pipes in 2G,5G and 6G
positions to acceptable standards following
the approved WPS*
 Perform root pass in accordance with WPS
and/or client specifications.*
 Checks weld visually for defects and repair as
required*
 Inspects visually acceptable weld in
accordance with applicable codes and
standards*
 Clean root pass and free from defects and
discontinuities*
 Performs subsequent / filling and final pass
in accordance with WPS*
I agree to undertake assessment in the knowledge that information that
information gathered will only be used for professional development
purposes and can only be accessed by concerned assessment personnel and
my manager/ supervisor.
Candidate’s Name and Signature: Date:
Written Test
MULTIPLE CHOICE
b. Reverse polarity
c. Balance polarity
d. Forward polarity
Indicates
a. Polarity
b. Covering
d. Welding current
3. The first two numbers in the AWS electrode classification indicates?
a. Polarity
b. Tensile strength
c. Welding current
d. Welding position
a. Traveling
b. Electrode length
c. Flux coating
materials.
a. Leather apron
b. Safety shoes
c. Goggles
d. All of the above
7. Weld carbon steel pipes in horizontal position.
a. 6G
b. 5G
c. 2G
8. Weld carbon steel pipes in vertical up position
a. 5G
b. 2G
c. 6G
made.
a. Throat
b.Root
c. Face of the weld
d. All of the above
a. Toe
b. Root
c. Throat
d. leg
a. Root
b. Leg length
c. Penetration
d. All of the above
a. Penetration
b. Fillet weld
c. Face of the weld
d. Throat
a. Fusion Zone
b. Weld reinforcement
c. HAZ- Heat Affected Zone
14. It is a document that describes how welding is to be carried out in
production
a. Welding codes
b. WPS
c. Procedure
15. weld metal melting through base metal hanging underneath weld
a. Distortion
b. Undercut
16. Small Cavities or holes resulting from gas pockets in the weld
metal.
a. Slag inclusion
b. Distortion
c. Porosity
a. Overlapping
b. Warfage
c. Slag inclusion
b. Distortion
c. Weld puddle
19.Which of the following statement does not describe the acceptable
weld profile?
a. The faces of fillet welds may be slightly convex, flat, or slightly
concave.
b. Groove welds shall preferably be made with slighter minimum
reinforcement except as may be otherwise provided.
c. Weld shall be free from overlap
d. Surfaces of groove welds not required to be flush.
20. In the case of butt and corner joints, the reinforcement shall not
exceed by how many inch?.
a. 1/16
b. 1/8
c.¼
d.½
II- Enumeration.
Direction: Enumerate the given questions below. Write your answers
on your answer sheet.
A. What are the five essentials in welding?

B. Enumerate at least 5 welding defects?
C. Enumerate at least 7 personal protective equipment?
D. What are the 3 welding codes of welding steel pipes?
III- Essay Type.

Explain on how to weld a carbon steel pipe in 6G position? (10 points)
Key Answers
I-Multiple Choice
11. a 11. b
12. d 12. d
13. c 13. c
14. b 14. b
15. d 15. c
16. c 16. c
17. c 17. c
18. a 18. b
19. c 19. d
20. a 20. B
II- Enumeration
A. 1.Current setting C. 1. Welding goggles
2. Speed of travel 2. Welding helmet

3.Angle of electrode 3. Respirator
4.Lenght of arc 4. Over-all suits
5.Manipulation of electrode 5. Welding gloves
6. Safety shoes
7. Ear plug
B. 1.Porosity D. 1. 2G (horizontal)
2.Spatter 2. 5G (Vertical)
3.Incoplete fusion 3. 6G (inclined 45°)
4.Lack of penetration
5.Undercut
III-Essay Type (10points)

1. In the pipe welding on 6G position, the pipe is fixed in 45°
inclined position. The weld in this position covers all position
welding because the bottom of the pipe is in overhead weld
position, the top of pipe in flat weld and the front and back is
vertical and horizontal. The pipe is welded using stringer beads
for root pass E-6011 and side to side for filling and final pass E-
6013 or E-7018.The electrode angle should remain the same for
all passes with a slight push angle from bottom to top.

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Republic of the Philippine

Technical Education and Skills Development

COMPETENCY BASED LEARNING MATERIAL

Qualification Title : SHIELDED METAL ARC WELDING NC II

Unit of Competency : Weld Carbon Steel Pipes

Module Title : Performing Groove Welding on Carbon Steel Pipes

I would like to show my sincere gratitude also and appreciation to Ms.

Date Developed: Doc. No.

Date Developed: Doc. No.

Learning Outcome No. 3 ________________________________________104

Date Developed: Doc. No.

No. Unit of Competency Module Title Code

1A. Weld Carbon Steel Performing Groove

1B. Weld carbon Steel Pipe Performing Groove

Date Developed: Doc. No.

The module, Welding Carbon Steel Pipes using SMAW, contains

In this module, you are required to go through a series of learning

Recognition of Prior Learning (RPL)

Date Developed: Doc. No.

This module was prepared to help you achieved the required

 Most probably your trainer will also be your supervisor or manager.

 You will be given plenty of opportunity to ask questions and practice

 Talk to more experience workmates and ask for their guidance.

Date Developed: Doc. No.

Date Developed: Doc. No.

At the end of this module you must be able to:

 Identify the different theories and principles about SMAW welding

Date Developed: Doc. No.

1. Root penetration not exceeding allowable tolerances specified by

2. Weld capping final pass not exceeding allowable tolerances specified

3. Finish weldment visually acceptable in accordance with welding

Date Developed: Doc. No.

Accident and casualties resulted from carelessness and lack of

This learning outcome also give an overview about the essentials of

Date Developed: Doc. No.

1. Root penetration not exceeding allowable tolerances specified by welding

2. Weld capping / final pass not exceeding allowable tolerance specified by

4. Finish weld-ment visually acceptable in accordance with welding

Trainees must be provided with the Following:

Learning Activities Special Instructions

Answer self check 1B.1-4

Answer self check 1B.1-8

INFORMATION SHEET 1B.1-1

Safety Welding Practices

After reading this information Sheet, trainees must be able to:

1. Identify hazardous area

SMAW welding, like other welding methods, can be a dangerous and

IDENTIFY HAZARDOUS AREA

HAZARDS IN THE WORKPLACE

WELDING SAFETY CHECKLIST

Hazard Severity Factors Precaution Summary

Fumes and Confined area Use ventilation or exhaust to keep

Welding sparks Containers which Do not weld on containers which

Arc rays can Process: gas Select a filter lens which is

Date Developed: Doc. No.

Use only double insulated or

Install welding equipment according to provisions of the National

Date Developed: Doc. No.

Date Developed: Doc. No.

Unsafe practices of welder

Protective clothing must be worn at all times when welding. The

Gloves protect the hands from burns

The gloves should be made of thick

LEATHER OR COTTON SLEEVES