Welder Handbook

PHASE IV WELDER

Module 1.1
Weld Thin Gauge Carbon Steel Plate in the 2G Horizontal 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 1.1

Weld Thin Gauge Carbon Steel Plate in the 2G Horizontal Position (SMAW)

WELDER HANDBOOK

Information Sheets 1

Exercise A 5

Exercise B 12

Task Aid 15

October 2011
 INFORMATION SHEET

Enabling Objectives
Terminal Objective
1.1.1 Given SAEP-1112, E6010
Unaided, the welder will correctly identify the a n d E 7 0 1 8 we l d i n g
categories of structural service. electrodes, welding tools,
equipment, and materials.
1.1.2 Weld thin gauge carbon
Unaided, the welder will correctly weld thin gauge steel plates in the 2G
carbon steel plate in the 2G horizontal position horizontal position, in
(SMAW). accordance with SAEP-
321. Your finished work
must meet the weld
INTRODUCTION
standards (visual and
The Shielded Metal Arc Welding (SMAW) is a x-ray) of SAEP-1112.
process well suited to the fabrication and repair of
piping systems. Welded steel pipe is used in
factories, power plants, refineries and buildings to
carry liquids and gases for a variety of purposes.
Pipe is used to carry such materials as water, steam,
chemicals, gases, petroleum, radioactive materials and
many others. Oil and gas are distributed through
cross country piping systems all over the world. Pipe
and tubing are also used for structures such as
handrails, columns in buildings, and light posts as
well as many other items we come into contact with
each day.

In Unit 1, you will use the SMAW process to weld:

o Thin gauge carbon steel plate in the 2G

horizontal position
o Thin gauge carbon steel plate in the 3G
vertical position
o Thin gauge carbon steel plate in the 4G
overhead position

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 INFORMATION SHEET

o Small bore carbon steel pipe in the 2G

horizontal position
o Small bore carbon steel pipe in the 5G vertical
position

In this module, you will learn about:

o The categories of structural service

o How to weld carbon steel plate in the 2G
horizontal position

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 INFORMATION SHEET

PART I OBJECTIVE 1.1.1

Identify the Categories of Structural Service

CATEGORIES OF STRUCTURAL SERVICE

The purpose for which pipe will be used largely

determines how it is welded. This text group’s pipe
welds into the following three general categories:

o Low pressure or light structural service

o Medium pressure or medium structural service
o High pressure or heavy structural service

Low Pressure or Light Structural Service

Low pressure or non critical, piping systems may be

used to carry water, residential natural gas, non
corrosive or non combustible chemicals and non
hazardous materials used in the industry. These types
of non critical piping assemblies are also found on
such structural item as handrails, truck racks,
columns for residences and other light duty
products. These pipe joints must be free from such
defects as pinholes, undercut, slag inclusions or any
other defect that may cause the joints to leak or
break prematurely. The weld does not require 100%
penetration, although penetration should be
uniform. Most of the strength of these pipe joints
comes from the reinforcement. These welds should
always be located so that they are easily repairable if
necessary. Usually no x-ray is carried out on any
joints.

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 INFORMATION SHEET

Medium Pressure or Medium Structural

Service

Medium pressure piping is used for low pressure

steam heat, corrosive or flammable chemicals, waste
disposal, ship plumbing and medium to heavy
service structural items such as highway signs,
railings or light posts, trailer axles and equipment
frames or stands. These pipe joints must withstand
heavy loads, but their failure will not be disastrous.
Most of their strength is due to weld reinforcement,
but there should be 100% root penetration around
most joints. Only a percentage of welds are usually
x-rayed and pressured tested.

High Pressure or Heavy Structural

Service

High pressure or critical, piping systems are used

for high pressure steam, radioactive materials, pipe
lines, fired or unfired boilers, refinery reactor lines;
air craft air frames, offshore oil platforms and many
other critical heavy duty applications. The welds on
critical piping systems must be strong or stronger
than the pipe itself. Often, the pipe used for these
applications is extra heavy duty pipe with a heavier
wall thickness. The weld must be 100% root
penetration with no defects in the joint. Root, filler
and reinforcement weld passes are made with
E7018 or stronger electrode. All welds are usually
100% x-rayed and pressured tested.

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EXERCISE A
Directions: Answer the following by filling in the blanks.

1. Low pressure or light structural piping

system welds are considered
.

2. Low pressure piping system welds do not

require
penetration.

3. pressure
piping system welds require 100% x-ray and
pressure testing.

4. Only a percentage of
pressure piping system welds are x-rayed or
pressure tested.

5. High pressure weld passes require

or stronger
electrodes.

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 INFORMATION SHEET

PART II OBJECTIVE 1.1.2

Weld Thin Gauge Carbon Steel Plate in the 2G

Horizontal Position (SMAW)

PLATE PREPARATION

The plate must be prepared to ensure a sound weld.

The type of groove used in preparing plates for
welding will vary depending upon the plate
material, thickness and application (WPS). The
most often used grooves on carbon steel are single
V, single J and single U, single bevel groove. The
single V can be easily flame cut or ground. This
factor makes it the most frequently used groove for
training.

The plate is prepared with a 30° +/- 2.5° bevel,

with a root face of 1mm to 2mm. when both plates
are prepared in this manner; they form a 55° to
65° single V groove. The groove angle allows good
visibility of the weld with minimum amount of
filler metal required to fill the groove the root face
removes the sharp root edge, commonly referred to
as a ‘feather edge’. Failure to remove the root edge
will result in the weld burning back the material,
leaving a keyhole that is larger than needed. This
also may result in a concave root surface.

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 INFORMATION SHEET

ROOT RUN (FULL

2
PENETRATION) KEYHOLE
MOVE FORWARD

The straight step weave

pattern is used when using
E6010 electrodes for the root
run, see figure 1.
1 3

ALLOW WELD TO MOVE BACK

BUILD UP KEYHOLE ALLOW WELD TO
BUILD UP KEYHOLE
Figure 1
Root Run

Figurein
To ensure complete root penetration 1 a groove
Root Run
joint, the keyhole method shouldPhase
be used. The
IV Welder
Module 1.1
keyhole is only seen on the root run, as the weld
pool forms and melts through the thinner metal at
the root face, a small hole is formed. The hole looks
like the old fashioned keyhole. The keyhole is
constantly filled in as the weld moves ahead. If the
diameter of the keyhole is kept constant, the
amount of penetration will be uniform, see figure 2.

TRAVEL
E

KEY HOLE
OD
TR
EC
EL

TOP VIEW

Figure 2
Keyhole

Figure 2
Keyhole
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 INFORMATION SHEET

The surface of the root run may be irregular, have

undercut, overlap, slag inclusions or other defects.
The surface of a root run must be cleaned by
grinding. This grinding eliminates weld
discontinuities caused by slag entrapments. It can
also remove most of the E6010 metal so that the
stronger E7018 weld metal can make up most of
the weld, see figure 3.

TRAPPED SLAG

UNDERCUT
ROOT PASS REMAINING
AFTER BACK GRINDING

ROOT PASS-CLEANED
READY FOR NEXT WELD PASS

Figure 3
Figure 3
Root Run Surface
Root Run Surface
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HOT PASS

The hot pass is called a hot pass because the welder

has to deposit the run before the root run cools.
The hot pass uses a slightly higher than normal
amperage setting and a faster travel speed to reshape
the root run and burn out some trapped slag. The
small circular weave pattern should be used when
depositing the hot pass, care should be taken not to
blow through the root run, see figure 4.

ROOT PASS

HOT PASS

HOT PASS CLEAN

Figure 4
Hot Pass
Figure 4
Hot Pass
FILLER PASSES
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After the root and hot pass has been completed and
it has been cleaned by grinding, the groove is filled
with weld beads. These weld beads make up the
filler pass. Not every butt is welded in this sequence;
it all depends on how wide the joint is. Instead of
two runs making a layer it could be a number of
runs depending on the width, see figure 5.

7 6 5
4 3
2
1
Figure 5
Filler Passes

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Figure 5
Filler Passes
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Filler passes are made with stringer or weave beads,

the welds beads must overlap each other usually
50%. The finished bead should be smooth and care
should be taken not to leave slag in the natural V,
see figure 6.

NATURAL ‘V’ SLAG TRAP

Figure 6
Figure 6 “V” Slag Trap
Natural
Natural “V” Slag Trap
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Each bead must be cleaned before the next bead is
started. Slag left in the butt between runs cannot be
burned out completely, see figure 7.

SLAG

TRAPPED
SLAG
(WAGON TRACKS)
X RAY

SLAG TRAPPED BETWEEN PASSES WILL SHOW ON X RAY

Figure 7
Figure
Slag 7
Trapped Between Passes Will Show on X-Ray
Slag Trapped Between Passes will Show on X-Ray
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FLUSHING LAYER

Flushing layer is the layer of weld before the

capping runs are deposited (just below or in-line
with the top of the joint).

CAPPING RUNS

The last runs of a weld are called the capping runs

or cap. Keeping the capping uniform and neat
looking is important. The weld inspection sometimes
only visual, the appearance might be the only factor
used to accepting or rejecting a weld. The capping
runs should be free of any visual defects such as
undercut, porosity, overlap and slag inclusions. The
welding specification will tell the welder the
maximum width and reinforcement required.

SUMMARY

You have now learned the information that will help

you weld thin gauge carbon steel plate. This is the
first step in learning how to weld small bore carbon
steel pipe in the (2G) horizontal position.

Good arc welding practice depends on trying slightly

different current settings and electrode positions. In
this way, any welder, new or experienced, develops
his own personnel technique.

Module 1.1 October 2011 11

 INFORMATION SHEET
Yo u r i n s t r u c t o r w i l l fi r s t
demonstrate how to correctly
weld thin gauge carbon steel
plate in the (2G) horizontal
position.
12
EXERCISE B
Directions: Using a correctly setup SMAW welding
machine, PPE, welding equipment, carbon steel electrodes,
correctly prepared carbon steel plate 50mm × 150mm ×
10mm; You will correctly weld thin gauge carbon steel plate
in the (2G) position. Your finished work must meet SAEP-
321 inspection requirements.
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 (2G) position.
8. Use E6010 electrode for the root only.
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 INFORMATION SHEET

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

the weld pool to build up. Use 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).

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 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.

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 TASK AID

OBJECTIVE

Given SAEP-1112, E6010 and E7018 welding

electrodes, welding tools, equipment, and materials.
Weld thin gauge carbon steel plates in the 2G
horizontal 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 2G horizontal 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.

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 TASK AID

Weld a Root Run/Hot Pass on Thin

Gauge C/S Plates (2G)

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 (2G) horizontal 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 (2G) position.

8. Use E6010 electrode for the root only.

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 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 Steel

Plate (2G)

To complete this part, you will prepare carbon steel

plates, set-up SMA welding machine and weld thin
gauge carbon steel plates in the (2G) horizontal
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 1.1 October 2011 17

 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 (2G) 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.

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 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 1.1 October 2011 19

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