Welder Handbook

PHASE IV WELDER

Module 1.2
Weld Thin Gauge Carbon Steel Plate in the 3G Vertical Position (SMAW)

Training & Development

October 2011
 © Copyright Saudi Aramco, 2011.
All rights reserved. No portion of this book may be reproduced, by any process
or technique, without the express written consent of Saudi Aramco.
 TABLE OF CONTENTS

Unit 1: Weld Small Bore Carbon Steel Pipe (SMAW)

Module 1.2

Weld Thin Gauge Carbon Steel Plate in the 3G Vertical Position (SMAW)

WELDER HANDBOOK

Information Sheets 1

Exercise 3

Task Aid 7

October 2011
 INFORMATION SHEET

Enabling Objective
Terminal Objective
1.2.1 Given SAEP-1112, E6010
Unaided, the welder will correctly weld thin gauge a n d E 7 0 1 8 we l d i n g
carbon steel plate in the 3g vertical position electrodes, welding tools,
(smaw). equipment, and materials.
Weld thin gauge carbon
steel plates in the 3G
introduction
ver tical position, in
In the previous module, you have learned how to accordance with SAEP-
prepare, set up and weld thin gauge carbon steel 321. Your finished work
plates in the 2G position. The finished welds were must meet the weld
acceptable to visual standards SAEP-321. standards (visual and
x-ray) of SAEP-1112.

Module 1.2 October 2011 1

 INFORMATION SHEET

objective 1.2.1

Weld Thin Gauge Carbon Steel Plate in the 3G

Vertical Position (SMAW)

introduction

In this part, you will put everything you have

learned into practice and weld thin gauge carbon
steel in the 3G position. The finished welds must
be acceptable to visual standards SAEP-321.

2 October 2011 Phase IV Welder

 INFORMATION SHEET

EXERCISE
Directions: Using a correctly setup SMAW welding
machine, PPE, welding equipment, carbon steel electrodes, Your instr uctor will first
correctly prepared carbon steel plate 50mm × 150mm × demonstrate how to correctly
10mm; You will correctly weld thin gauge carbon steel plate weld thin gauge carbon
in the 3G position your finished work must meet SAEP-321 steel plate in the 3G vertical
inspection requirements. position.

1. Prepare two 50mm × 150mm × 10mm carbons

steel plate for welding.

2. Set up and adjust arc welding machine for the

correct type and size of electrode.

3. Tack weld one runoff at both ends of the two

plates (flat with bottom of plate).

4. Position both plates root faces together, bevel

facing down and check for parallel.

5. Open root faces and place gap wire 1.5mm

+/- 1mm (gap wire is only used to set root
opening).

6. Tack weld runoffs, not the joint (this keeps the

butt free from stops and starts).

7. Position the butt in the (3G) position.

8. Use E6010 electrode for the root only.

Module 1.2 October 2011 3

 INFORMATION SHEET

9. Begin by striking an arc on the runoff, wait

for the weld pool to build up. Used the
straight pattern. The electrode should be
pushed deeply into the root to establish a
keyhole. Once the keyhole is established, the
electrode is moved forward and back or in and
out of the molten weld pool at a steady,
rhythmic rate. Watch the molten weld pool
and keyhole size to determine the speed,
distance to move the electrode. If the keyhole
decreases in size, slow down the rate of
electrode movement and shorten the distance
the electrode is moved away from the weld
pool. If the keyhole increases in size, speed up
the rate and make the distance longer from the
weld pool (approximate electrode angle; side
70°–80° travel 60°–80°).

10. Use electrode until consumed. If the full

length of weld cannot be completed, clean
carter and restart just behind weld crater,
repeat until complete.

11. Use grinder to remove slag and spatter. Inspect

the root run for defects (take care to remove
all slag and spatter).

12. Begin second run (hot pass) using E7018, use

slight circular weave pattern.

13. Have your instructor check the root/hot passes.

14. Use grinder to remove slag, spatter and reshape

the hot pass. Inspect the hot pass for defects
(remove all slag and spatter).

4 October 2011 Phase IV Welder

 INFORMATION SHEET

15. Begin filler passes using E7018 electrodes. Weld

in sequence.

16. Have your instructor check the filler passes.

17. Begin capping runs.

18. Have your instructor check the cap.

19. Continue until your instructor passes your

work.

Module 1.2 October 2011 5

6 October 2011 Phase IV Welder
 TASK AID

OBJECTIVE

Given SAEP-1112, E6010 and E7018 welding

electrodes, welding tools, equipment, and materials.
Weld thin gauge carbon steel plates in the 3G
vertical position, in accordance with SAEP-321. Your
finished work must meet the weld standards (visual
and x-ray) of SAEP-1112.

TOOLS, EQUIPMENT, AND MATERIAL

o Shielded Metal Arc Welding (SMAW) machine
o Welding equipment
o PPE
o Carbon steel welding electrodes
o 10mm Carbon steel plates

SAFETY REQUIREMENTS

If in doubt about any aspect of safety ask your

instructor for clarification. Safety is your
responsibility. Wear appropriate protective equipment
at all times. This includes safety shoes, safety glasses,
ear protection etc. Follow all safe working practices
when performing task steps.

TASK INTRODUCTION

In this task aid, you will prepare carbon steel plates,

set-up SMA welding machine and weld thin gauge
carbon steel plates in the 3G vertical position in
accordance with SAEP-321. Your finished work
must meet the weld standards visually of SAEP-321.
This task aid is divided into two separate tasks.

Module 1.2 October 2011 7

 TASK AID

Weld a Root Run/Hot Pass on Thin

Gauge C/S Plates (3G)

To complete this part, you will prepare carbon steel

plates, set-up SMA welding machine and weld a
root/hot pass on thin gauge carbon steel plates in
the (3G) vertical position in accordance with SAEP-
321. Your finished work must meet the weld
standards visually of SAEP-321.

1. Prepare two 50mm × 150mm × 10mm

carbons steel plate for welding.

2. Set up and adjust arc welding machine for the

correct type and size of electrode.

3. Tack weld one runoff at both ends of the two

plates (flat with bottom of plate).

4. Position both plates root faces together, bevel

facing down and check for parallel.

5. Open root faces and place gap wire 1.5mm +/-

1mm (gap wire is only used to set root
opening).

6. Tack weld runoffs, not the joint (this keeps

the butt free from stops and starts).

7. Position the butt in the (3G) position.

8. Use E6010 electrode for the root only.

8 October 2011 Phase IV Welder

 TASK AID

9. Begin by striking an arc on the runoff, wait for

the weld pool to build up. Used the straight
pattern. The electrode should be pushed deeply
into the root to establish a keyhole.

10. Use electrode until consumed. If the full length

of weld cannot be completed, clean carter and
restart just behind weld crater, repeat until
complete.

11. Use grinder to remove slag and spatter. Inspect

the root run for defects (take care to remove all
slag and spatter).

12. Begin second run (hot pass) using E7018, use

slight circular weave pattern.

Weld Thin Gauge Carbon Steels

Plate (3G)

To complete this part, you will prepare carbon steel

plates, set-up SMA welding machine and weld thin
gauge carbon steel plates in the (3G) vertical
position in accordance with SAEP-321. Your
finished work must meet the weld standards visually
of SAEP-321.

1. Prepare two 50mm × 150mm × 10mm carbons

steel plate for welding.

2. Set up and adjust arc welding machine for the

correct type and size of electrode.

3. Tack weld one runoff at both ends of the two

plates (flat with bottom of plate).

Module 1.2 October 2011 9

 TASK AID

4. Position both plates root faces together, bevel

facing down and check for parallel.

5. Open root faces and place gap wire 1.5mm +/-

1mm (gap wire is only used to set root
opening).

6. Tack weld runoffs, not the joint (this keeps

the butt free from stops and starts).

7. Position the butt in the (3G) position.

8. Use E6010 electrode for the root only.

9. Begin by striking an arc on the runoff, wait

for the weld pool to build up. Used the
straight pattern. The electrode should be
pushed deeply into the root to establish a
keyhole.

10. Use electrode until consumed. If the full

length of weld cannot be completed, clean
carter and restart just behind weld crater,
repeat until complete.

11. Use grinder to remove slag and spatter. Inspect

the root run for defects (take care to remove
all slag and spatter).

12. Begin second run (hot pass) using E7018, use

slight circular weave pattern.

13. Have your instructor check the root/hot passes.

10 October 2011 Phase IV Welder

 TASK AID

14. Use grinder to remove slag, spatter and reshape

the hot pass. Inspect the hot pass for defects
(remove all slag and spatter).

15. Begin filler passes using E7018 electrodes. Weld

in sequence.

16. Have your instructor check the filler passes.

17. Begin capping runs.

Module 1.2 October 2011 11

12 October 2011 Phase IV Welder