Fabrication Technology (3361905) Lab Manual 2020 Mech GIA BBIT

B & B Institute of Technology, Vallabh Vidyanagar
Mechanical Engineering Department (GIA)
According to Gujarat Technological University

Diploma Mechanical Engineering 6th Semester Curriculum
Lab Manual
of
Fabrication Technology
(Subject Code: 3361905)
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Developed By:
Prof. Vandan K. Gundale

M.E. (Production)
Workshop Superintendent - Mechanical Engg. (GIA)
BBIT -Vallabh Vidyanagar
Content
1)......................................................................................................... Welding Drawing Interpretation
..................................................................................................................................................................... 3
2)............................................................................................................................... Piping Isometrics

..................................................................................................................................................................... 9
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Experiment No. – 1
Welding Drawing Interpretation
AIM: To learn the method of representing the different welding information in engineering drawings
Drawing or sketching is a universal language used to convey all necessary information to the
individual who will fabricate or assemble an object.
Welding cannot take its proper place as an engineering tool unless means are provided for
conveying the information from the designer to the workmen. Welding symbols provide the means
of placing complete welding information on drawings.
Special symbols are used on a drawing to specify where welds are to be located, the type of
joint to be used, as well as the size and amount of weld metal to be deposited in the joint. These
symbols have been standardized by the American Welding Society (AWS). We need to have a
working knowledge of the basic weld symbols and the standard location of all the elements of a
welding symbol.
A distinction is made between the terms "weld symbol" and "welding symbol". The weld
symbol indicates the desired type of weld. The welding symbol (fig. 01) is a method of representing
the weld symbol on drawings. The assembled "welding symbol" consists of the following eight
elements or any of these elements as necessary: reference line, arrow, basic weld symbols,
dimensions and other data, supplementary symbols, finish symbols, tail, and specification, process,
or other reference. The locations of welding symbol elements with respect to each other are shown
in figure 1.01.
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Standard Locations of Elements of Welding Symbol
[As per American Welding society AWS A2.4 – 1998]
Figure: 1.01
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A standard welding symbol (fig. 01) consists of a reference line, an arrow, and a tail. The
reference line becomes the foundation of the welding symbol. It is used to apply weld symbols,
dimensions, and other data to the weld. The arrow simply connects the reference line to the joint or
area to be welded. The direction of the arrow has no bearing on the significance of the reference
line. The tail of the welding symbol is used only when it is necessary to include a specification,
process, or other reference information.
In the Fig. 01, the arrow is shown growing out of
the right end of the reference line and heading down
and to the right, but many other combinations are
allowed. (Figure 1.02)
Figure 1.02
The joint is the basis of reference for welding symbols. The reference line of
the welding symbol (fig. 1.01) is used to designate the type of weld to be made, its location,
dimensions, extent, contour, and other supplementary information. Any welded joint indicated by a
symbol will always have an arrow side and other side. Accordingly, the terms arrow side, other side,
and both sides are used herein to locate the weld with respect to the joint.
Quite often, there are two sides to the joint to which the arrow points, and
therefore two potential places for a weld. For example, when two steel plates are
joined together into a T shape, welding may be done on either side of the stem
of the T. The weld symbol distinguishes between the two sides of a joint by using
the arrow and the spaces above and below the reference line. The side of the
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joint to which the arrow points is known (rather prosaically) as the arrow side, and its weld is made
according to the instructions given below the reference line. The other side of the joint is known
(even more prosaically) as the other side, and its weld is made according to the instructions given
above the reference line.
The tail of the symbol is used for designating the welding and cutting processes as
well as the welding specifications, procedures, or the supplementary information to be used in
making the weld. If a welder knows the size and type of weld, he has only part of the information
necessary for making the weld. The process, identification of filler metal that is to be used, whether
or not peenning or root chipping is required, and other pertinent data must be related to the welder.
The notation to be placed in the tail of the symbol indicating these data is to be established by each
user. If notations are not used, the tail of the symbol may be omitted. When no specification,
process, or other symbol, the tail may be omitted.
The flag growing out of the junction of the reference line and the arrow is present if the weld
is to be made in the field during erection of the
structure. A weld symbol without a flag
indicates that the weld is to be made in the
shop.
Figure 1.04 Weld All Around
The open circle at the arrow/reference line junction is present if the weld is to go all around
the joint, as in the Figure 04 shown.
Figure 1.06 Arrowhead indicates beveled plate.
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Figure 1.05 weld symbol as applied to the reference line
Weld Symbols
Refer figure 05 & notice that the vertical leg of the weld symbol is shown drawn to the
left of the slanted leg. Regardless of whether the symbol is for a fillet, bevel, J-groove, or flare-bevel
weld, the vertical leg is always drawn to the left.
When only one edge of a joint is to be beveled, it is necessary to show which
member is to be beveled. When such a joint is specified, the arrow of the welding symbol points
with a definite break toward the member to be beveled. This is shown in figure 06.
Figure 1.07
Figure 07 shows the meaning of various welding dimension symbols. Notice that the size of
a weld is shown on the left side of the weld symbol (fig. 07, view A). The length and pitch of a fillet
weld are indicated on the right side of the weld symbol. View B shows a tee joint with 2-inch
intermittent fillet welds that are 5 inches apart, on center. The size of a groove weld is shown in view
C. Both sides are 1/2 inch, but note that the 60-degree groove is on the other side of the joint and
the 45-degree groove is on the arrow side.
Supplementary Symbols
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In addition to basic weld symbols, a set of supplementary symbols may be added to a
welding symbol.
Contour symbols are used with weld symbols to show how the face of the weld is to be
formed. In addition to contour symbols, finish symbols are used to indicate the method to use for
forming the contour of the weld. When a finish symbol is used, it shows the method of finish, not the
degree of finish; for example, a C is used to indicate finish by chipping, an M means machining, and
a G indicates grinding.
Figure 1.08. Additional welding information
Specifying Additional Information

It is sometimes necessary to specify a certain welding process, a type of electrode, or some type of
reference necessary to complete a weld. In this case, a note can be placed in the tail of the
reference line. (See fig. 1.08). If additional information is not needed, then the tail is omitted.
Multiple-Weld Symbols
When we are fabricating a metal part, the part may require
more than one type of weld on the same joint; for example, a
joint may require both a bevel groove weld and a fillet weld.
Two methods of illustrating these weld symbols are shown in
figure 1.09. Note that in each welding symbol, the bevel groove
weld is to be completed first, followed by the fillet weld.
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Figure 1.09 Multiple Welds
Applying a Welding Symbol

Figure 1.10 shows an example of how a
welding symbol may appear on a drawing. This
figure shows a steel pipe column that is to be
welded to a base plate. The symbol tells the
welder that the pipe is to be beveled at a 30-
degree angle followed by a bevel groove weld
all around the joint. This is followed by a 1/2-
inch fillet weld that is also welded all around the
joint. Finally, finish the fillet weld by grinding it
to a flush contour. As the field weld symbol
indicates, all welds are to be accomplished in
the field.
Figure 1.10-Example of welding symbol in use
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EXERCISE
Q.1Draw with neat sketches different Basic Weld Symbols in the format as mentioned below:
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Sr. Form of Actual Representation Sectional Symbol
No. Weld Representation
Q.2Draw with neat sketches different Supplementary Symbols (Surface contour & Finish of Weld)
and Special Instruction Symbols as per IS: 813 – 1961.
Q.3Select an Fabrication Assembly Drawing (e.g. Pressure Wessel / Heat Exchanger / Fabricated
Shed etc. Assembly Drawing) which contains welding symbols. Interpret these welding symbols.
Also prepare the bill of material for this assembly.
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Piping Isometrics
PIPING ISOMETRICS
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The term Piping means not only pipe but includes components like fittings, flanges,
valves, bolts, gaskets, bellows etc. The primary drawings that a Piping/Mechanical Field
Engineer will use in the course of completing a field assignment are:
 PFD (Process Flow Diagram)
A Process Flow Diagram - PFD shows the relationships between the major
components in the system. PFD also tabulate process design values for the components in
different operating modes, typical minimum, normal and maximum. A PFD does not show
minor components, piping systems, piping ratings and designations.
A PFD should include:
o Process Piping
o Major equipment symbols, names and identification numbers
o Control, valves and valves that affect operation of the system
o Interconnection with other systems
o Major bypass and recirculation lines
o System ratings and operational values as minimum, normal and maximum flow,
temperature and pressure
o Composition of fluids
 Piping and Instrument Diagram (P&ID)
It is a diagram of the process industry which shows the piping of the process flow
together with the installed equipment and instrumentation. This diagram shows the
interconnection of process equipment and the instrumentation used to control the process. In
the process industry, a standard set of symbols is used to prepare drawings of processes.
P&ID s play a significant role in the maintenance and modification of the process that it
describes.
 Piping Isometric
An isometric drawing is a type of pictorial drawing in which three sides of an object
can be seen in one view. It’s popular within the process piping industry because it can be
laid out and drawn with ease and portrays the object in a realistic view. Sometimes it is used
in lieu of plans and elevations but typically it is used to supplement the plan drawings.
Isometrics are used as fabrication & shop drawings for pipe run fabrication.
 Piping Class Sheets
Piping class is an assembly of piping components, suitable for a defined service and
design limits, in a piping system. Piping class sheets specify the material and code
requirements for designated piping system pressure and temperature ratings.
 Piping Support & Hanger Drawings
Importance of Piping Isometrics:

Generally in the development of a project, a conceptual 2D drawing is first created. In this all
pipelines are drawn at zero z co-ordinates. This is then converted into a 3D scale model, to check
interference of pipe lines. 2D General Arrangement (GA) drawings are used for fabrication on site. A
GA drawing is generally on A0 or A1 size paper and contains a lot of lines, and may not be easy to
understand pipe routine. A0 or A1 size drawing is to big to handle. A pipe fabricator can understand
GA drawing better only with the help of 3D scale model. But 3D scale model cannot be put on a
paper, and 3D scale model does not indicate dimensions. To aid pipe fabricator on site, isometric
drawings are prepared. An isometric drawing is generally on a A3 size paper. A pipe fabricator can
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read it and understand pipe routine easily. Also pipe fabricator can pick up material required for
fabrication of pipe line from stores, with the help of Bill of Material given in isometric drawing.
Direction & Location: Location and direction helps to orient the isometric drawing properly.
Structural reference points that provide location of column along the grid can be shown on
isometric. Dimensions must always be given to points of reference, such as structures, center line of
existing equipment etc. Co-ordinates should also be shown on the isometric drawing.
Figure 2.01
When orienting fittings or valves it is important to draw the fittings or valves, so that they are inclined
to the last direction change or branch in the pipe. Fittings or valves are drawn the same shape as
they appear on the plan & elevation drawings but they are drawn at an isometric angle.
Figure 2.02
Looking at the orientation of model, go on sketching the line from one end to other. To get the
length of each cut pipe, get distance between two ends of 3D pipe. To get the length of pipe from
center line of fitting to center line of another fitting get distance between insertion points of two
fittings.
If you are sketching with the help of plan drawings, use the difference in elevations of two
adjacent lines as length of the vertical line. For horizontal lines, use the distance between two pipes,
to get length of the pipe. Mark length of each pipeline on each line in the sketch of isometric
drawing.
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Figure 2.03
Mark elbows on the drawing. Show location of valves, with type of flange. The location of the
valve is shown by dimension of the center of valve. Show direction of flow, with pipe NB. If a
horizontal pipe line has a slope, indicate it on that pipe line.
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Figure 2.04
Offsets: To indicate an offset, hatches on isometric drawings are applied, to indicate that a pipe
runs at a certain angle and in which direction the pipe runs. It is done with a fitting (typically a 45°
elbow).
Horizontal Offset: If a line turns at 30° to 45° in horizontal plane, you draw a pipe with a 45° elbow.
But it would look like a vertical line. To avoid confusion, the offset is drawn 22½° horizontal offset to
give the illusion of the angle.
Figure 2.05
Vertical Offset: If a line turns at 30° to 45° in vertical plane, you draw a pipe with a 45° elbow. In
this case, too, to avoid confusion, the offset is drawn 22½° vertical offset to give the illusion of the
angle.
Figure 2.06
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Dimensioning: Dimensions should preferably appear above if the pipe line is horizontal and on left
hand side, if the pipe line is vertical. Best way to dimension a pipe line is between its center lines at
the intersection points. Try to keep all dimensions outside the piping view when possible.
Dimensions should always be shown between points in the same plane. One of the extension lines
of the dimension should be a center line of the run of pipe.
Data carried on a typical piping isometric
 Isometric drawings carry a graphical representation of the 3 dimensional piping systems
being represented.
 Straight lengths of all the pipe runs on the drawing are reported as clearly as possible.
 The line numbers for lines pipe runs represented on the drawing is clearly indicated. This
line number is indicative of the fluid service, piping class and material, insulation etc.
 The operating and design process conditions (pressure and temperature) for the pipe run
may also be reported on the isometric.
 In addition, all the fittings including, valves, flanges, elbows etc. are clearly represented
graphically.
 A table gives the number and detailed description of each type of fittings represented on the
drawing.
 For complex piping systems, individual pipe runs are represented on separate isometric
drawings.
Upon completion and approval of the piping isometrics, they are used for fabrication
and then construction of the piping system.
Isometric drawings are easier to be used for stress analysis of the piping, fabrication
and construction, compared to other orthographic drawings, since they carry all the necessary
information for these tasks. Moreover an isometric is not overcrowded with other information,
useless for piping and it is easy to visualize.
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EXERCISE
Q.1 Draw various piping isometric symbols.
Q.2 Select one piping isometric drawing, interpret the same & prepare bill of material for the
same.
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Annexure I
Piping Coordination Systems
Symbols for Isometrics
Butt weld Socket Weld Threaded

Image Fittings Fittings Image
Symbol Symbol Symbol
Elbow 90° Elbow 90°
Elbow 45° Elbow 45°
Tee equal Tee equal
Tee reducing Tee reducing
Cap Cap
Reducer Reducer
... ... ...
concentric concentric
Reducer Reducer
... ... ...
eccentic eccentic
Butt weld Socket Weld Threaded

Image Fittings Fittings Image
Symbol Symbol Symbol
Flanges Weld Neck Socket Weld Threaded Slip-On Lap-Joint Blind Flanges
Symbol Symbol
Mechanical Engg. (GIA) Fabrication Technology (3361905) 2020
Image Image
Flanges Weld Neck Socket Weld Threaded Slip-On Lap-Joint Blind Flanges
Socket or
Butt weld Flanged
Image Valves Threaded Valves Image
Symbol Symbol
Symbol
Gate Gate
Globe Globe
Ball Ball
Plug Plug
Butterfly ... Butterfly
Needle Needle
Diaph ... Diaph
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Y-type Y-type
Three Three
way way
Check Check
Bottom ... ... Bottom
Relief ... ... Relief
Control Control
... ...
straight straight
Control Control
... ...
angle angle
Image Valves Butt weld Flanged Socket or Valves Image
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Threaded
Symbol Symbol
Symbol
Miscellaneous Symbol Image Miscellaneous
Branch outlet Branch outlet

Weldolet® Weldolet®
Branch outlet Branch outlet

Nipolet® Nipolet®
Flanged branch Flanged branch

outlet outlet
Flangolet Flangolet
Spade Spade
Spectacle Spectacle
blind blind
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Hammer Hammer
blind blind
Spacer Spacer
Restriction Restriction
orifice orifice
Field Weld
Field Weld
Butt weld
Butt weld
Pipe to pipe Pipe to pipe

connection connection
Pipe bend Pipe bend

with with
special radius special radius
Sight glass Sight glass
Direction of
hand wheel Hand wheel
wrench
Y-type Y-type
strainer strainer
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Conical Conical
strainer strainer
Project Work of Fabrication of Laboratory Stool
1. Parts drawing of Laboratory Stool
2. Assembly drawing of Laboratory Stool
3. Assembly Drawing of the Fixture for Laboratory Stool
4. Bill of Materials:
A. Raw Material Cost:
Weight
Sr. No. Material Description & Size Qty. Rate Cost in
in kg.
MS Sq. Pipe 25mm X 25 X

1. 4.5 meter Per kg.
3mm thick
MS Angle 25 X 3 X 300 mm
2. 1.2 meter Per kg
long
Wooden Planks 300 mm X

3. 01 no. ------ per piece
300 mm X 12 mm thick
4. Rubber Plugs 04 Nos. ----- per piece
TOTAL RAW MATERIAL COST `
B. Cost of consumables:
1. Cost of welding rods:
Cost of welding rod per kg = Rs. _______ per kg

Total consumption of welding rod per each Laboratory Stool = 0.230 kg
Cost of welding rods

= ________ X ________
= _____________
2. Cost of Wood Primer for wooden planks & Oil paints
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= Rs. __________ per Laboratory Stool approximately
Total cost of consumables

= _______ + _______
= ______________
Total cost of material for Laboratory Stool

= Total Raw Material Cost + Total cost of consumables
= _________+ ___________
= ____________
4. Selection of Process & Process Parameters:

The process used for job is electric arc welding and the process parameters are as follow:
Welding current
100-140 Amp for Electrode size 3.15 mm dia
Welding Machine specifications:

Model: ADOR – 200
Primary Supply: 440 V AC
Open Circuit Voltage 66 Volts
Operating Arc Voltage: 21- 28 Volts
Welding Current Range: 30- 200 Amps
Max. Cont. hand welding current with 60 % duty cycle: 115 Amps
Max. Automatic welding current with 100 % duty cycle: 90 Amps
Max. Intermittent hand welding current with 20 % duty cycle: 200 Amps
Recommended welding electrode: Min. 1.5 mm Max. 4.0 mm
Dimensions (Approx.): Length: 420 mm
Height: 505 mm
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Width: 425 mm
5. Selection of consumables:
In arc welding process mainly consumable part is electrode, electrode having different diameters,
types, coatings & materials.
Welding Electrode:
ADOR make Welding Electrode SUPERBOND – S, E – 6013, 3.15 mm dia x 450 mm length
6. Edge Preparation:
Ends of all the cut sections of steel (Pipe,) are beveled carefully using Bench Grinder.
7. Process:
Cut to size pipe sections are firmly held in welding fixture. With proper set up of parts welding is
done with above mentioned parameters. First tack welding is done and after checking correct
positions of parts & their alignment final full welding is done.
8. Post Process Treatments:

Chipping operation is carried out using chipping hammer & wire brush.
9. Inspection
Visual inspection is done for correctness & right angle positions of parts.
After this structure is painted with oil paints & wooden planks which are prepared previously
by sizing, finishing & painting are fitted properly as per drawing using nuts & bolts.
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
EXERCISE
Q.1 Find the weights of the steel sections used in project. Accordingly find the cost of raw
materials used & subsequently find the total cost of materials.
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Q.2 Describe the welding rod used for welding & interpret the same. Also record the magnitude
of current used.
Q.3 Describe the safety precautions you observed during welding work of project.
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Industry Visit Report
Write brief industry visit report where you have visited during the current term covering the
following details:
1. Name & address of industrial unit visited

2. Date & time of visit
3. Business of the unit
4. Products detail in brief
5. Details of the facilities available (Include specifications of machine/equipments)
6. Describe the salient features of the process you observed
7. Any other important matter you would like to cover
8. Conclusion sharing your learning experience
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Study Of Welding Procedure Specification (WPS)
&
Welder Performance Qualification (WPQ) Documents
INTRODUCTION:
Section IX of the ASME Boiler and Pressure Vessel Code relates to the qualification of
welders, welding operators, brazers, and brazing operators, and the procedures employed in
welding or brazing in accordance with the ASME Boiler and Pressure Vessel Code. Section IX
establishes the basic criteria for welding and brazing which are observed in the preparation of
welding and brazing requirements that affect procedure and performance. Section IX does not
contain rules to cover all welding and brazing factors affecting production weld or braze properties
under all circumstances. Where such welding or brazing factors are determined by the Manufacturer
to affect weld or braze properties, the Manufacturer shall address those welding or brazing factors
to ensure that the required properties are achieved in the production weldment or brazement.
Welding Procedure Specification (WPS)
The Welding Procedure Specification is a required document for all code welding. Customer
either directly or indirectly specifies to what code your company must qualify. The WPS outlines all
of the parameters required to perform your welding operation.
It is a written document that provides direction to the welder for making production
welds in accordance with code requirements. Any WPS must be qualified by the manufacturer.
WPS specifies the condition (ranges) under which welding must be performed called variables.
WPS addresses essential, supplementary essential and non essential variables.
In short the WPS is the recipe for your welding operation. It describes the welding
process or processes used, the base materials used, the joint design and geometry, gases and flow
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rates, welding position and includes all of the process conditions and variables. Each code has a
recommended format.
Welding Procedure Qualification Record
The Welding Procedure Qualification Record is the document that qualifies the
Welding Procedure Specification. In order to qualify your WPS, a procedure qualification plate is
welded the code requirements. The actual test parameters are recorded at the time of welding to
ensure the WPS was being followed. Generally any supporting documentation, such as material
specifications, electrode specifications and shielding gas specifications, are included as part of the
WPQR. All required testing, both non-destructive and destructive, is recorded as well. These tests
typically include X-Ray examinations, ultrasonic examinations, tensile testing, bend testing and
when required impact testing.
The WPQR combines all of the information of the WPS and adds the test results to
provide a complete document that certifies the welding specification. This document is also required
by all codes unless you are qualifying under American Welding Society (AWS) specifications. Under
certain conditions the WPS may be considered prequalified in which the WPQR is not required.
The WPQR is a record of welding data to weld a test coupon. It also contains test results.
Completed WPQR shall document all essential variables including ranges. WPQR to be certified
accurate and shall not be subcontracted. If there are more than one weld passes, then weld deposit
thickness for each pass and filler metal to be recorded.
Purpose of WPS Qualification
 To determine that the weldment is capable of providing the required properties for the
intended application.
 WPS establishes the properties of the weldment and not the skill of the welder.
Welder Performance Qualification
This document is required by all codes for all welders. It details and summarizes the
following information:
 Indicates the WPS referenced during the qualification test

 Identifies the welder by name and/or clock number
 Lists what the essential parameters were during this test
 Reports the results of the required qualification tests
 Specifies qualified limits for welder
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For most codes there is a time limit associated with the welder qualification test. However,
the American Welding Society provides an unlimited qualification period if certain conditions are
met. As with the WPS and WPQR, each code has a recommended format.
Weld Orientation
Plate groove positions 1G, 2G, 3G, 4G
Pipe groove positions 1G, 2G, 5G, 6G
Plate fillet positions 1F, 2F, 3F, 4F
Pipe fillet positions 1F, 2F, 2FR, 4F, 5F
1F - 0 to 30
2F - +15 -10 wrt 45
4F - 0 - 125
3F - 125 – 235
Base Metal Classification
P numbers depend on composition, weldability & mechanical properties. Group numbers
classify metals within P numbers for procedure qualification where notch toughness requirements
are specified. But base metals cannot be indiscriminately substituted.
Base Metal P Numbers

P1 - P11 Steel
P21 - P25 Al alloys
P31 - P35 Cu alloys
P41 - P47 Ni alloys
P51 - P53 Ti alloys
P61 - P62 Zr alloys
Filler Metal F Numbers

Based on usability characteristics i.e ability of welders to make satisfactory welds with given
filler
F1 E XX20
F2 E XX12, E XX13
F3 E XX10, E XX11
F4 E XX18
F5 ASS, Duplex SS
F6 Bare rods
Filler Metal A Numbers

Based on chemical composition
A1 Mild steel
A2 C - Mo steel
A3 Cr - Mo steel (Cr 0.4 - 2%)
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A4 Cr - Mo steel (Cr 2 - 6%)

A5 Cr - Mo steel (Cr 6 - 10.5%)
A6 Cr Martensitic
A7 Cr Ferritic
A8 Cr Ni steels (Cr 14.5 - 30% Ni 7.5 - 15%)
A9 Cr Ni steels (Cr 19 - 30% Ni 15 - 37%)
A10 Ni steels (Ni 0.8 - 4%)
A11 Mn Mo steels(Mn 1.25-2.25 Mo 0.25-0.75%)
A12 Ni Cr Mo steels (Cr 1.5% Mo 0.25-0.8% Ni 1.25 -2.8%)
Types of Variables for Welding Procedure Specifications (WPS)

Essential Variables
Essential variables are those in which a change, as described in the specific
variables, is considered to affect the mechanical properties of the weldment, and shall require
requalification of the WPS.
Supplementary essential variables are required for metals for which other Sections specify
notch-toughness tests and are in addition to the essential variables for each welding process.
Nonessential Variables
Nonessential variables are those in which a change, as described in the specific
variables, may be made in the WPS without requalification.
WPS for SMAW

Essential variables
 Change in qualified Thickness

 Change in P no
 Change in F no of filler metal
 Change in A no of filler metal
 Change in deposited metal thickness
 Decrease of more than 100 F in preheat
 Change in PWHT
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WPS for SMAW

Supplementary Essential variables
 Change in Group no of base metal

 Change in T limits for impact test
 Change in dia of filler metal > 1/4”
 Change in AWS class of filler metal
 Change in welding position
 Increase of more than 100 F in preheat
 Change in PWHT Time and temp range
 Change in current or polarity
WPS for SMAW

Non Essential variables
 Change in Groove design, backing, root spacing, retainers etc

 Change in dia of filler metal
 Change in AWS class of filler metal
 Change in welding position
 Change in preheat maintenance
 Change in current or polarity
 Change in string/weave, cleaning, back gouging, peening, manual/automatic
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EXERCISE
Q.1 Explain in brief the Welding Procedure Specification with its essential contents.
Q.2 State the need or importance of Welding Procedure Qualification Record.
Q.3 What is Welder Performance Qualification Record. Explain in brief with its important contents.
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Annexure-I
Page 33
Page 34
Annexure- II
Page 35
Annexure-III
Page 36
Page 37
Annexure- IV
Page 38
Annexure- V
Page 39
Page 40
Annexure- VI
Page 41
Page 42
Annexure- VII
Page 43
Annexure- VIII
Page 44
Page 45
Annexure-IX
Page 46
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Effect Of Change Of Welding Parameters On Weld Quality
AIM:
To study about effect of change in various welding parameters on work piece in metal Arc
welding process.
Equipments: Electric arc welding set up
Introduction:
Metal arc welding also referred to as “Shielded metal arc Welding” or “conventional metal arc
welding” uses on arc struck between the workpiece and a shielded filler metal electrode. This is by
far the most common arc welding process used in general welding situations. The Process is mostly
manual and makes use of either a DC or an AC source. The common AC source is a step down
transformer designed to suit the requirements of a welding arc.
The current values used are on the underside of 400 amperes. The electrodes are made in
standard lengths of about 450mm and in different diameters varying from about 1.5 o 10mm.
Electrodes are available for different material to be welded for different welding conditions and
joints. Both ferrous and non ferrous metals and alloys can be welded by arc welding processes with
proper electrodes. The arc and the weld metal pool are protected by the arc flame and slag
produced.
List of various welding parameters are:

1) Current
2) Voltage
3) Electrode size
4) Electrode coating
5) Arc length
6) Speed of Travel
7) Angle of Electrode
8) Size of material (Including thickness limits)
9) Electrode Polarity
Here we will study effect of few important welding parameters on work piece.
Variations in Current values:
Page 48
If the welding current is too high a flat wide bead with coarse ripples results from the
increased arc force. The arc force also produces a deep penetration accompanied by an excessive
amount of spatter. Though striking of arc is made easier, the crater is deep with blowholes and
sometimes has cracks in the centre. Porosity (gas entrapped in the weld) is sometimes the result of
too high a current. Overheating, particularly on this section material being welded and also of the
electrode result in unsatisfactory welded joints.
If the welding current is too low the arc is difficult to control and often the electrode end fuses
to the plate. This causes a short circuit and the electrode becomes red hot due to resistance heating
unless it is broken off. Other features of welding with too low current are: the weld bead tends to be
high and globular and of irregular width with slag trapped in crevices and difficult to remove. The
penetration is shallow in the centre of the bead whilst the toes of the weld are often just adhered to
the plate.
Variations in speed of travel:

It is important that speed of travel is correct as this dictates the length of weld deposited per
electrode and from this other factors develop. For instant, excess heat concentration (slow travel)
leads to wide flat deposits and to metal collapse on root runs. The slog often tends to run in front of
the arc and make deposition difficult to control especially when welding in the flat position.
When the speed of travel is too fast the result is lack of penetration and fusion with a weld
bead which tends to trap the slag in the toe of the weld. The ripples on the weld bead will show
whether the speed was fast (elongated ripples) or slow (Coarse and flat) similar to the major and
minor axis of an ellipse.
Variation in Angles of Electrode (Slope and Tilt):

For welding in the flat position it is important that the angle of tilt is 90° to ensure that the
weld bead is deposited symmetrically (even about its centre line) There is also a tendency for cold
laps to form on the one side and undercutting to take place on the other side when the electrode is
tilted too far to one side.
The electrode slope, which varies between 65° and 75°, affects the depth of penetration and
also the height and shape of the weld bead. The steeper the angle the flatter the bead and the
greater the tendency to penetrate, especially on single V root runs. Slag also tends to flood the
weld. On the other hand , a very shallow angle results in the arc pushing up the molten weld metal
into a higher bead with less penetration, and danger of slag traps.
Effects of Defective Electrode coatings:

It is important that electrodes are stored in a warm dry place, approximately 10° to 15°c with
atmospheric humidity not above 40 %, and used in rotation, i-e. New electrodes are not piled on top
of old stock. Sometimes very old electrodes have a coating of white fur caused by water glass in the
Page 49
electrode. Electrodes should be carefully stacked and not dropped which would cause cracking and
chipping of the coating. Poor quality welds usually result if chipped, damp or defective electrodes
are used. If dry electrodes are shaken in the hands they produce a hard metallic sound, but damp
ones have a hollow sound.
Size of material (including thickness limits)

The thermal effect using the same size electrode and current differ widely with different sizes
and thickness of material.
Briefly, with thin plate, overheating and a wide flat bead and excessive penetration result
with “burning” though unless the rate of travel is rapidly increased.
With thick plates the heat supplied now is not enough as it is dissipated through the thick
metal. The weld bead is now rounded with root penetration and may be slightly harder cracking
occurs in some cases.
Variations in voltage and Are length:

A striking voltage which initiates the arc, which once selected is fairly constant. The arc
voltage, which is less than half the striking voltage, is not constant and fluctuates with the arc length
during welding.
It should be noted that

(a) When the arc length increases, the arc voltage rises and the current decreases;
(b) When the arc length decreases, the arc voltage decreases and the current rises;
(c) The total power output remains unaffected, i.e. volts X amps = watts (power)
If the arc length is too long the current is reduced and hence the arc force. The results in a
lack of penetration, increased spatter, a coarser weld bead. With a brighter arc, loss of heat
through dissipation, loss of some of the gaseous shield and slag which results in an inferior weld
deposit.
There are certain types of electrodes (touch type) with which it is impossible to maintain too
short an arc under normal conditions. The general purpose electrode, if used with too short an arc
length, produces a weld bead which has heaped-up layers and often holes in the surface of the
weld. These holes indicate that the weld metal has solidified at the instant the gas was escaping
from the weld. An irregular and rounded bead with slag flooding the arc, in addition to the electrode
“Striking”, are symptoms of the arc length being too short.
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***********************************************************************
EXERCISE
Q.1List different arc welding variables, which effect on weld quality.
Q.2Explain the effect of value of current on weld quality.
Q.3What is the effect of speed of travel on weld quality?
Q.4Explain the role of electrode coating in arc welding.
Page 51
Liquid Penetrant Test
INTRODUCTION:
Non-destructive Testing is one part of the function of Quality Control and is complementary
to other long established methods. By definition non-destructive testing is the testing of materials,
for surface or internal flaws or metallurgical condition, without interfering in any way with the integrity
of the material or its suitability for service. The technique can be applied on a sampling basis for
individual investigation or may be used for 100% checking of material in a production quality control
system.
• Radiography
• Magnetic Particle Crack Detection
• Dye Penetrant Testing
• Ultrasonic Flaw Detection
• Eddy Current and Electro-magnetic Testing
INTRODUCTION TO LIQUID PENETRANT TESTING
This method is also called Dye Penetrant Testing which is used to detect surface connected
cracks and other flaws, such as laps and pores in all metals, as well as in most plastics and
ceramics. It is widely used for determining the integrity of a weld.
This method is frequently used for the detection of surface breaking flaws in non-
ferromagnetic materials. The subject to be examined is first of all chemically cleaned, usually by
vapour phase, to remove all traces of foreign material, grease, dirt, etc. from the surface generally,
and also from within the cracks. Next the penetrant (which is a very fine thin oil usually dyed bright
red or ultra-violet fluorescent) is applied and allowed to remain in contact with the surface for
approximately fifteen minutes. Capillary action draws the penetrant into the crack during this period.
The surplus penetrant on the surface is then removed completely and thin coating of powdered
chalk is applied.
After a further period (development time) the chalk draws the dye out of the crack, rather like
blotting paper, to form a visual, magnified in width, indication in good contrast to the background.
The process is purely a mechanical/chemical one and the various substances used may be applied
in a large variety of ways, from aerosol spray cans at the most simple end to dipping in large tanks
on an automatic basis at the other end. The latter system requires sophisticated tanks, spraying and
drying equipment but the principle remains the same.
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Liquid penetrant testing is one of the most widely used NDT methods. Its popularity
can be attributed to two main factors:
 its relative ease of use and

 its flexibility.
It can be used to inspect almost any material provided that its surface is not
extremely rough or porous. Materials that are commonly inspected using this method
include; metals, glass, many ceramic materials, rubber and plastics. However, liquid
penetrant testing can only be used to inspect for flaws that break the surface of the sample
(such as surface cracks, porosity, laps, seams, lack of fusion, etc.)
STEPS OF LIQUID PENETRANT TESTING
The exact procedure for liquid penetrant testing can vary from case to case
depending on several factors such as the penetrant system being used, the size and
material of the component being inspected, the type of discontinuities being expected in the
component and the condition and environment under which the inspection is performed.
However, the general steps can be summarized as follows:
1. Surface Preparation:
One of the most critical steps of a liquid penetrant testing is the surface preparation.
The surface must be free of oil, grease, water, or other contaminants that may prevent
penetrant from entering flaws. The sample may also require etching if mechanical
operations such as machining, sanding, or grit blasting have been performed. These and
other mechanical operations can smear metal over the flaw opening and prevent the
penetrant from entering.
2. Penetrant Application:
Once the surface has been thoroughly cleaned and dried, the penetrant material is
applied by spraying, brushing, or immersing the part in a penetrant bath.
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3. Penetrant Dwell:
The penetrant is left on the surface for a sufficient time to allow as much penetrant as
possible to be drawn from or to seep into a defect. Penetrant dwell time is the total time that
the penetrant is in contact with the part surface. Dwell times are usually recommended by
the penetrant producers or required by the specification being followed. The time may vary
depending on the application, penetrant materials used, the material, the form of the
material being inspected, and the type of discontinuity being inspected for. Minimum dwell
times typically range from five to 60 minutes. Generally, there is no harm in using a longer
penetrant dwell time as long as the penetrant is not allowed to dry. The ideal dwell time is
often determined by experimentation and may be very specific to a particular application.
Figure 7.01
4. Excess Penetrant Removal:
This is the most delicate part of the inspection procedure because the excess
penetrant must be removed from the surface of the sample while removing as little
penetrant as possible from defects. Depending on the penetrant system used, this step may
involve cleaning with a solvent, direct rinsing with water, or first treating the part with an
emulsifier and then rinsing with water.
Figure 7.02
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5. Developer Application:
A thin layer of developer is then applied to the sample to draw penetrant trapped in
flaws back to the surface where it will be visible. Developers come in a variety of forms that
may be applied by dusting (dry powders), dipping, or spraying (wet developers).
6. Indication Development:
The developer is allowed to stand on the part surface for a period of time sufficient to
permit the extraction of the trapped penetrant out of any surface flaws. This development
time is usually a minimum of 10 minutes. Significantly longer times may be necessary for
tight cracks.
Figure 7.03
7. Inspection:
Inspection is then performed under appropriate lighting to detect indications from any
flaws which may be present.
8. Clean Surface:
The final step in the process is to thoroughly clean the part surface to remove the
developer from the parts that were found to be acceptable.
PENETRANTS :
Penetrants are carefully formulated to produce the level of sensitivity desired by the
inspector. The penetrant must possess a number of important characteristics:
Page 55
 spread easily over the surface of the material being inspected to provide
complete and even coverage.
 be drawn into surface breaking defects by capillary action.
 remain in the defect but remove easily from the surface of the part.
 remain fluid so it can be drawn back to the surface of the part through the drying
and developing steps.
 be highly visible or fluoresce brightly to produce easy to see indications.
 not be harmful to the material being tested or the inspector.
Penetrant materials come in two basic types:
Type 1 - Fluorescent Penetrants: they contain a dye or several dyes that fluoresce when
exposed to ultraviolet radiation.
Type 2 - Visible Penetrants: they contain a red dye that provides high contrast against the
white developer background.
Fluorescent penetrant systems are more sensitive than visible penetrant systems because
the eye is drawn to the glow of the fluorescing indication. However, visible penetrants do not require
a darkened area and an ultraviolet light in order to make an inspection.
DEVELOPERS:
The role of the developer is to pull the trapped penetrant material out of defects and
spread it out on the surface of the part so it can be seen by an inspector. Developers used
with visible penetrants create a white background so there is a greater degree of contrast
between the indication and the surrounding background. On the other hand, developers
used with fluorescent penetrants both reflect and refract the incident ultraviolet light,
allowing more of it to interact with the penetrant, causing more efficient fluorescence.
According to standards, developers are classified based on the method that the
developer is applied (as a dry powder, or dissolved or suspended in a liquid carrier). The six
standard forms of developers are:
Form a - Dry Powder
Form b - Water Soluble
Form c - Water Suspendable
Form d - Nonaqueous Type 1: Fluorescent (Solvent Based)
Form e - Nonaqueous Type 2: Visible Dye (Solvent Based)
Form f - Special Applications
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ADVANTAGES OF LIQUID PENETRANT TESTING
 Simplicity of operation.
 Best method for surface breaking cracks in non-ferrous metals.
 Suitable for automatic testing
 It produces a flaw indication that is much larger and easier for the eye to detect than
the flaw itself. Many flaws are so small or narrow that they are undetectable by the
unaided eye (a person with a perfect vision cannot resolve features smaller than
0.08 mm).
 It improves the detectability of a flaw due to the high level of contrast between the
indication and the background which helps to make the indication more easily seen
(such as a red indication on a white background for visable penetrant or a penetrant
that glows under ultraviolate light for flourecent penetrant).
 High sensitivity (small discontinuities can be detected).
 Few material limitations (metallic and nonmetallic, magnetic and nonmagnetic, and
conductive and nonconductive materials may be inspected).
 Rapid inspection of large areas and volumes.
 Suitable for parts with complex shapes.
 Indications are produced directly on the surface of the part and constitute a visual
representation of the flaw.
 Portable (materials are available in aerosol spray cans)
 Low cost (materials and associated equipment)
DISADVANTAGES OF LIQUID PENETRANT TESTING
 Restricted to surface breaking defects only

 Decreased sensitivity
 Uses a considerable amount of consumables
 Only surface breaking defects can be detected.

 Only materials with a relatively nonporous surface can be inspected.
 Pre-cleaning is critical since contaminants can mask defects.
 Metal smearing from machining, grinding, and grit or vapor blasting must be
removed.
 The inspector must have direct access to the surface being inspected.
 Surface finish and roughness can affect inspection sensitivity.
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 Multiple process operations must be performed and controlled.

 Post cleaning of acceptable parts or materials is required.
 Chemical handling and proper disposal is required.
IMPORTANT POINTS:
Leak test (through-flaw) inspection

Flaws which extend completely through thin-wall metal containers - tanks, tubing, and
vessels - are readily detected by the dye penetrant process. The procedure differs from the
standard process: dye penetrant is applied to one side while developer is applied to the opposite
side; there is no dye penetrant removal step.
Perform dye penetrant leak test first

Flaw passages must be free of contaminants - water, solvents, oils, etc. Moisture from air
pressure tests conceivably can interfere with through penetration. Use the dye penetrant leak test
prior to other tests, such as hydrostatic and ultrasonic, to minimize the possibility of flaw passage
contamination.
An extended dye penetrant dwell time is necessary

Dye penetrant leak testing has limitations and, typically, the process is restricted to wall
thicknesses of 1/4 inch or less. The rate of through penetration depends in part, on the shape of the
capillary passage. A narrow tube provides the best passage.Porosity retards dye penetrant
movement. If wall thickness is near maximum and if poor capillary action is anticipated, the dwell
time should be extended to 30 minutes. A second application of dye penetrant during the 30 minute
dwell may prove advantageous.
************************************************
EXERCISE
Q.1 List different Non Destructive Testing Methods used for weldment inspection.
Q.2 List the different types of defects which can be detected by Liquid Penetrant Testing.
Q.3 List important characteristics of pentrants.
Q.4 Name the different form of Developers.
Q.5 Write the advantages & disadvantages of LPT.
Page 58
Page 59
STUDY OF WELDING JIGS AND FIXTURES
INTRODUCTION:
Jigs, Fixtures & Positioners are important elements of semiautomatic & fully automatic welding
process. They are important due to following reasons:
1. To permit welding in a more convenient position

2. To increase welding efficiency and productivity.
3. To minimize fit-up problems.
4. To minimize distortion caused by heat of welding.
With welding jig or a fixture, the components of weldment can be assembled in to accurate
alignment and held securely in proper relationship and with correct fit-up during positioning and
during welding so that all finished parts coming from the jig or fixture will be uniform.
WELDING JIGS :
Welding jigs are specialized devices which enable the component being welded to be easily and
rapidly set up and held.
Required qualities of welding jigs:

A welding jig should be
i. Rigid and strong since it has to withstand contractional stresses without deforming.
ii. Simple to operate, yet it must be accurate.
iii. Designed such that it is not possible to put the work in the wrong way.
iv. Faced with wear-resistant material to withstand continual wear.
In certain cases, as in inert gas welding, the jig is used as a means of directing the inert gas on to
the underside of the weld. Jig may also serve as backing strip to avoid warpage.
WELDING FIXTURES:
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A welding fixture serves the same purpose as a welding jig; but in addition, it permits the changing
of the position of the work during actual welding, so as to place the welds in a plane convenient to
the operator at all times. This increases welding speed.
Fixtures are considered to be of more general character not specialized as jigs. Fixtures may
include rollers, clamps wedges etc., used for convenience in positioning of the work.
Required characteristics of Fixtures:

The action provided by the fixtures may be
i. Supporting
ii. Clamping
iii. Grounding and
iv. Imparting movement (usually referred to as travel or travelling)
Welding fixtures may also perform other functions that are not directly related to actual welding
operation. Fixturing may be internal part of a conveyor system. Or it may position the work for
machining operations such as drilling, milling and grinding.
FIXTURE CLASSIFICATIONS
Welding fixtures fall into two broad classifications:

1. Those that act on the Work being welded.
2. Those that act on the Welding Equipment.
1. A welding fixture for the work may clamp the parts together while simultaneously supporting
them, the objective being to effect a weld in the flat position.
 This fixture may hold the work stationary – in which case the welding equipment moves
or is travelled over it – or may be mechanized and move the work under the stationary
welding equipment.
 Some typical work-moving types of fixtures are rotating positioners, power turning rolls,
lathes and mill type set ups etc.
2. Welding equipment fixtures (some are called welding manipulators) may provide only stationary
support—or both support and travel—to the welding equipment. The equipment may be more than a
welding head or welding gun—or may include all o the equipment in the welding circuit, including
the power sources and even the flux recovery unit.
-- The fixture for holding the head stationary, range from a simple arm and mounting bracket, to the
very complex installations common in continuous mill welding.
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The types of fixtures that both support travel the welding equipment include the beam with carriage,
the self propelled tractor, the stud welding unit and a variety of boom type welding manipulators.
(Fig. 8.01)
Figure 8.01
Variations in the boom type manipulators include column stationary and boom travel variable and
both boom and column movable with variable travel.
CONSIDERATIONS IN FIXTURE SELECTION

In selecting fixture for mechanized welding, engineer must evaluate following considerations such
as
1. Production Volume
2. Joint geometry
a) Circular welds
b) Welds in straight line
3. Movability of the welding head
a) Stationary Welding Head
b) Movable Welding Head
CHARACTERISTICS OF GOOD WELDING JIGS AND FIXTURES:
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1. The fixture should be strong & light but rigid enough to ensure accurate alignment.
2. Whenever should be possible, fixture should be a positioned, enabling all welds to brought to
a convenient welding position.
3. The fixture should permit quick and easy positioning (by one hand, if possible). Thus the
balancing of the fixture may be necessary.
4. The use of light alloys for moving parts reduces weight. Air or electric motors should be used
for revolving and air or hydraulic rams for tilting the fixture assembly.
5. Joints must be readily accessible for welding. By slots or other means, the fixture should
readily present seams on the reverse side of the object.
6. For accurate & quick positioning of work indexing arrangements should be used.
7. Use of nuts and bolts, wrenches, C-clamps, wedges and hammers & hand screws should be
minimum. Instead use of electrics and cams, cranks, pinions & racks, air or hydraulic rams,
solenoids or magnetic clamps is preferred.
8. Method of grounding the work should be such that it should make good contact with work
through the medium of copper, copper graphite brushes, sliding shoes etc.
9. The fixture should be designed for ease of accessibility to the welding head when procedure
adjustments and servicing are necessary.
10. The design of fixture should be such that the weldment can be easily and quickly removed
from the fixture.
VARIOUS TYPES OF JIGS AND FIXTURES:
1. A C-clamp is good enough for most welding jobs. It can be quickly and cheaply made in the
shop. (Fig –8.02)
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Figure 8.02
2. Simple but effective Vee rest supporting short bars or pieces of pipe for tacking or welding
on the bench. (Fig – 8.03)
Figure 8.03
3. Rotating fixtures for making circumferential welds are very valuable, as they speed up the
job and make neater welds quickly. (Fig – 8.04)
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Figure 8.04
4. A Turntable also save lot of handling time when a large number of small parts are to be
welded with same operation. (Fig – 8.05)
Figure 8.05
Welding frequently necessitates turning the work while it is held in the fixture, as when both
sides of a weld are to be completed before removing the work.
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5. To turn over very large pieces of work for positioning in welding, it is often useful to build
adapters which bolt or clamp to the work and contain the trunnions. Then there are only
trunnion bearings required and work can be turn around and is accessible for welding. (Fig –
8.06)
Figure 8.06
6. Figure 8.07 shows the positioner that rotates and tilts the workpiece.
Figure 8.07
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******************************************
EXERCISE
1. Why jigs, Fixtures & Positioners are important elements of welding process?
2. What is difference between welding jigs & welding fixture?
3. What should be the required qualities of welding jigs?
4. List the characteristics of good welding jigs & welding fixtures.
5. Name different types of welding jigs & fixtures.
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Seminar Topic “_____________”
(Power Point Presentation)
Instructions:
1. Prepare power point presentation on assigned topic
2. This presentation must include at least 20 to 22 slides.
3. The slide must include the important points of the topic assigned & not the lengthy
paragraphs.
4. Wherever possible include relevant tables, graphs, figures, etc.
5. PPT may include the short video clip on relevant topic.
6. Each student will be given 12 to 15 minutes time to present his topic.
7. After presentation make necessary corrections as suggested by your respective teachers in
your PPT & then take print out to include 2 slides per A4 size page. File this print out in
journal.
10
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Assignment Question Bank
CHAPTER 1. Introduction to Fabrication Technology

Q. 1. Describe the importance of Fabrication Technology & list the applications of
Fabrication Technology in industries.
Q. 2. Define the fabrication work and state advantages & disadvantages of fabrication
work.
Q. 3. Explain the scope of Fabrication Technology in industry.
Q. 4. Compare the Fabrication Process with other manufacturing processes.
Q. 5. Why Fabrication is called secondary manufacturing process ? Explain.
Q. 6. Explain the concept of weldability and state the factors affecting weldability.
Q. 7. Define weldability & explain the importance of weldability.
Q. 8. Explain the role of Flux in welding.
Q. 9. Classify welding power sources. State the applications & selection criteria for power
sources.
Q. 10. State the different features of welding power source & list advantages, limitations &
applications of it.
Q. 11. Differentiate between AC Arc Welding & DC Arc Welding Process.
Q. 12. What is Arc Blow? What are the corrective measures to be taken to avoid Arc Blow?
Q. 13. List the National & International Fabrication Industries.
Q. 14. What is Third Party Inspection? List at least five different Third Party Inspection
Agencies.
Q. 15. List Arc Welding equipments.
Q. 16. List Gas Welding equipments.
Q. 17. State the colour of following gas welding equipments : Acetylene Cylinder, Oxygen
Cylinder, Acetylene hose pipe, Oxygen hose pipe
CHAPTER 2. Drawing Interpretation

Q. 18. Prepare Bill of Materials for Arc Welding Equipments & Gas Welding Equipments.
Q. 19. Explain the standard locations of elements of welding symbol with neat sketch.
Q. 20. State the rules to be followed while applying welding symbols.
Q. 21. Draw ten types of basic welding joints with their symbols.
Q. 22. Draw at least five types of welding supplementary symbols.
Q. 23. State different plate & pipe welding positions with abbreviations used for them.
Q. 24. List the names of any ten welding processes with their standard abbreviations.
Q. 25. Explain the need & importance of codes (Standards) in fabrication work. Give the
names of at least five institutes which prepare different standards related to
fabrication work.
Q. 26. What is an edge preparation? Explain its need & importance in welding work. Also
state its applications.
Q. 27. List the factors affecting the selection of proper type of edge preparation.
Q. 28. List the different methods used for edge preparation. Also discuss their relative
advantages & limitations.
Q. 29. Draw neat sketch for the following arrangements:
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i) Square edge joint

ii) Single “V” joint
iii) Double “V” joint
iv) Single “J” joint
v) Double “J” joint
vi) Single “U” joint
vii) Double “U” joint
viii) Single Bevel Joint
ix) Double Bevel Joint
Q. 30. raw neat figures & explain the importance & applications for following
basic joints:
i) Butt Joint
ii) Corner Joint
iii) Lap Joint
iv) Edge Joint
v) T Joint
Q. 31. Draw at least 10 Pipe Fitting symbols with nomenclature, which are used in Piping
Isometric.
Q. 32. Explain Welding Procedure Specification (WPS) with its sample format.
Q. 33. Prepare a list of welder performance qualification.
Q. 34. Explain Welder Performance Qualification Record (WPQR) with its sample format.
Q. 35. Explain the Shop Weld Plan.
Q. 36. Explain the Weld Test Plan.
Q. 37. Write a brief short note on ASME Section IX.
CHAPTER 3. Fabrication Processes and Safety

Q. 38. List the equipments/machines used for the edge preparation work & write the
features of at least two of them.
Q. 39. List the different methods of preheating & post heating.
Q. 40. Write the need & applications of preheating.
Q. 41. Write the need & applications of post heating.
Q. 42. Write the need & applications of Post Weld Heat Treatment (PWHT).
Q. 43. Describe the method of stress relieving by Induction coil.
Q. 44. List the different methods of relieving thermal stresses & describe any three of them.
Q. 45. List the different Arc Welding parameters & explain each of them.
Q. 46. With the help of neat sketch describe Ultrasonic Welding Process. Also list its
applications.
Q. 47. With the help of neat sketch describe Laser Beam Welding Process. Also list its
applications.
Q. 48. With the help of neat sketch describe Friction Stir Welding Process. Also list its
applications.
Q. 49. With the help of neat sketch describe Electron Beam Welding Process. Also list its
applications.
Q. 50. Explain the concept of Welding Automation & give its classification.
Q. 51. List the different steps of Process Equipment Fabrication Process & explain each of
them.
Q. 52. List the fabrication steps of
i) Electric Power/Communication Transmission Tower
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ii) Pressure Vessel

iii) Heat Exchanger
Q. 53. Explain the need of welding safety.
Q. 54. List the necessary precautions for Welding Safety.
Q. 55. Write Safety norms for Arc Welding.
Q. 56. Write Safety norms for Gas Welding.
Q. 57. Write the common safety norms equally applicable to both Arc & Gas Welding.
CHAPTER 4. Inspection and Testing

Q. 58. List the common welding defects with their causes & remedies.
Q. 59. State remedies for preparing defect free weld.
Q. 60. Explain the need & importance of quality control in fabrication work.
Q. 61. Describe the difference between Inspection & Testing of weld.
Q. 62. Explain the thermal distortion. State the causes of its occurrence & its effects.
Q. 63. Describe different types of thermal distortions.
Q. 64. Write the methods to control the thermal distortion.
Q. 65. Explain the concept of Weld Quality & its importance in fabrication work.
Q. 66. Explain the factors affecting weld quality.
Q. 67. Explain the process of Inspection & Testing for weldments.
Q. 68. List the different stages of weldment inspection & also list the activities at each stage.
Q. 69. Explain the importance of Destructive Testing (DT).
Q. 70. List the different Destructive Testing (DT) methods & explain any two in detail.
Q. 71. Explain the concept of Non Destructive Testing (NDT).
Q. 72. Explain Die penetration test.
Q. 73. List different methods of Non Destructive Testing (NDT) & explain Eddy Current
Testing detail.
Q. 74. Describe following Non Destructive Testing methods:
a. Magnetic Particle Test b. Radiographic Test c. Ultrasonic Test
Q. 75. List the different Special types of Tests for the inspection of weldments & describe
the Hydro Test Pneumatic Test.
CHAPTER 5. Surface Preparation, Finishing and Coating Methods

Q. 76. Explain the meaning & need of Surface Preparation.
Q. 77. List the different methods used for Surface Preparation & Surface Finishing.
Q. 78. State different methods of surface cleaning & explain any two of them.
Q. 79. Describe the processes of Sand Blasting & Ball Blasting for surface preparation.
Q. 80. Explain in brief brushing & grinding methods of surface finishing.
Q. 81. Explain surface colour coating by brush.
Q. 82. Explain surface colour coating using a roller.
Q. 83. List different colour coating methods using spray & describe any two.
Page 71
CHAPTER 6. Installation, Erection and Commissioning

Q. 84. Explain the meaning of Installation & Commissioning.
Q. 85. Explain the erection of common fabricated structure.
Q. 86. Explain the erection procedure of fabricated equipment.
Q. 87. Explain the erection procedure of piping.
Q. 88. Explain the procedure of alignment of equipments.
Q. 89. Describe Accuracy test & Technological test of machine.
Q. 90. List different foundation materials.
Q. 91. Explain the term erection & list the different activities involved in erection.
Q. 92. Explain the procedure of erection of common equipments.
Q. 93. Define grouting and explain its procedure.
Q. 94. Draw different types of foundation bolts.
*******************************************************************************************************
Page 72
About Author
Prof. Vandan Kamlakar Gundale holds degree of B.E. (Mechanical) & M.E.
(Production) from M. S. University, Vadodara.
He is currently serving as a Workshop Superintendent (Selection Grade) in

Mechanical Engineering (GIA) at B & B Institute of Technology, Vallabh
Vidyanagar since February, 1999. He has 15 years of industrial work experience
also.
His area of teaching encompasses domain of production engineering subjects

like Engineering Workshop Practice, Design of Machine Elements, Fabrication
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B & B Institute of Technology, Vallabh Vidyanagar

Mechanical Engineering Department (GIA)

According to Gujarat Technological University

Prof. Vandan K. Gundale

Workshop Superintendent - Mechanical Engg. (GIA)

BBIT -Vallabh Vidyanagar

2)............................................................................................................................... Piping Isometrics

Welding Drawing Interpretation

Figure 1.04 Weld All Around

Figure 1.06 Arrowhead indicates beveled plate.

Figure 1.08. Additional welding information

Specifying Additional Information

Applying a Welding Symbol

Figure 1.10-Example of welding symbol in use

Importance of Piping Isometrics:

Butt weld Socket Weld Threaded

Elbow 90° Elbow 90°

Elbow 45° Elbow 45°

Tee equal Tee equal

Tee reducing Tee reducing

Butt weld Socket Weld Threaded

Butterfly ... Butterfly

Diaph ... Diaph

Bottom ... ... Bottom

Relief ... ... Relief

Image Valves Butt weld Flanged Socket or Valves Image

Miscellaneous Symbol Image Miscellaneous

Branch outlet Branch outlet

Branch outlet Branch outlet

Flanged branch Flanged branch

Pipe to pipe Pipe to pipe

Pipe bend Pipe bend

Sight glass Sight glass

2. Assembly drawing of Laboratory Stool

3. Assembly Drawing of the Fixture for Laboratory Stool

A. Raw Material Cost:

MS Sq. Pipe 25mm X 25 X

Wooden Planks 300 mm X

4. Rubber Plugs 04 Nos. ----- per piece

TOTAL RAW MATERIAL COST `

1. Cost of welding rods:

Cost of welding rod per kg = Rs. _______ per kg

Cost of welding rods

= Rs. __________ per Laboratory Stool approximately

Total cost of consumables

Total cost of material for Laboratory Stool

4. Selection of Process & Process Parameters:

Welding Machine specifications:

8. Post Process Treatments:

1. Name & address of industrial unit visited

Welding Procedure Specification (WPS)

Welding Procedure Qualification Record

Purpose of WPS Qualification

Welder Performance Qualification

 Indicates the WPS referenced during the qualification test

Base Metal P Numbers

Filler Metal F Numbers

Filler Metal A Numbers

A4 Cr - Mo steel (Cr 2 - 6%)

Types of Variables for Welding Procedure Specifications (WPS)

WPS for SMAW

 Change in qualified Thickness

WPS for SMAW

 Change in Group no of base metal