Local 597 Welding Manual

Welding
Instruction Manual
For Local 597 Pipe Fitters Training Center

Apprentice Welding Program
Pipe Fitters Training Center
Local Union 597 Chicago

10850 West 187th Street
Mokena, IL 60448

Edition No. 1, Revision No. 2, March 29, 2013
Issued June 1, 2012

Manual Number 1

Table of Contents
General
A. Statement of Policy and Authority

B. Organization Chart

C. Terms & Abbreviations

Section 1.0 Arc Initiation & Maintaining the Arc (SMAW)

Section 2.0 Plate Welding (SMAW)

Section 3.0 Pipe Welding: 1G 6 Sch 80 (SMAW)

Section 4.0 Pipe Welding: Position Welds 6 Sch 80 (SMAW)

Section 5.0 Pipe Welding: Position Welds 2 XXH (SMAW)

Section 6.0 Introduction to GTAW

Section 7.0 Pipe Welding: 1G 4 STD (GTAW)

Section 8.0 Pipe Welding: Position Welds 4 STD (GTAW)

Section 9.0 Pipe Welding: Position Welds 2 Sch 80 (GTAW)

Section 10.0 Introduction to Stainless Steel (GTAW)

Section 11.0 Introduction to Inconel (GTAW)

Section 12.0 Introduction to Chromium (GTAW & SMAW)

Section 13.0 Introduction to GMAW & FCAW Processes

Section 14.0 Introduction to Stainless Steel & Inconel Covered Electrodes (SMAW)

Section 15.0 Supplementary Documents

Section 16.0 Errata/Addendum with Revision No. 2, March 29, 2013

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Revision No. 1

A. Statement of Policy and Authority

This Welding Instruction Manual has been established to assure compliance with the applicable training
procedures and techniques that shall be taught by all welding staff personnel.

This Welding Instruction Manual is intended to be used in the training of all apprentices and journeymen
while being instructed at the Training Center.

The responsibility and authority for implementation of this system has been assigned to David Hintz,
Welding Coordinator for Local 597. The Lead Instructor has been given the authority and organizational
freedom to identify quality control and teaching technique problems and to initiate, recommend and
provide solutions. Problems that cannot be resolved by the Lead Instructor shall be brought to the Welding
Director for final resolution based on standard welding techniques, practices and issues in consultation with
the Assistant Coordinator and also the Training Coordinator.

Changes or revisions to the manual shall be reviewed with, and have concurrence of, the Welding Director,
Assistant Training Coordinator and the Training Coordinator prior to implementation.

Training Coordinator
Signature ______________________
Date ______________________
Title ______________________

3

B. Organization Flow Chart:
Pipe Fitters Training Center Local Union 597

Training Coordinator- John W. Leen
Assistant Training Coordinator- Kevin Lakomiak
Daily Operations Manager- Matt Majszak
Welding Director- Dave Hintz

Welding Staff (Full-Time):
Glen Burch (Authorized)
Calvin Gordon (Authorized)
Rick Hobson (Authorized
Monte Kimes (Authorized)
Mike Pelegrino (Authorized)
Marc Randulich (Authorized)
Jon Walker (Authorized)

Welding Staff Mokena (Part-Time):

Bob Borgia
Jonathan Neu
Rob Carhart
Joe Newren
Jim Cebulski
Dean Rapp
Dan Neary
Aaron Rose
Joe Esposito
Esteban Senesias
Tyler Johnson
Ted Slattery
Paul Kadlec
Randy Smith
Pete Larou
Kyle White
Vince Macaluso
Joel Zacarias
Kevin Potter
Dorjan Zoni

Welding Staff Volo (Part-Time)
Dave Barthelt Franz Quidayan
Richard Hering Andrew Schlabowske
Arlan Nathan Edward Whalen

4

C. Terms & Abbreviations:

ANSI
American National Standards, Institute, Inc.

ASME
American Society of Mechanical Engineers

CODE
ASME Boiler and Pressure Vessel Section IX
API-1104

GMAW
Gas Metal Arc Welding

GMAW-S
Gas Metal Arc Welding Short Arc

GTAW
Gas Tungsten Arc Welding (TIG)

MTR
Material Test Reports or certificates of compliance as applicable

NDE
Non-Destructive Examination

PQR
Procedure Qualification Record

SMAW
Shielded Metal Arc Welding

WTS
Welding Test Specifications

Glossary of Terms TBD if needed

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Revision No. 1

Section 1 - Arc Initiation & Maintaining the Arc

1.1 Two Methods tap or scratch
1.2 Start with 1/8 E6010
Set amps at 100
Lower amps as they become more comfortable
Continue to lower amperage until it becomes more difficult (40 amps)
1.3 As the student becomes proficient with striking the arc have them run short beads about 2-3 inches

Teaching Topics:
Stress the importance of amperage and its effect on welding (see attached Six Basic Fundamentals for
SMAW)
Electrode angle, travel speed and arc length shall be demonstrated by the welding instructor

Note:
All students will be shown a Welding Safety Power Point and an Introduction to Welding Power Point
prior to starting any hands-on welding. 1st year apprentices will not be allowed to weld prior to their first
assigned school day.
All students will be given a copy of the Weld Shop Rules & Regulations. This hand-out will be presented to
them and once understood by all they will sign-off for compliance. Dismissal from the Weld Shop shall be
enforced for any infraction. All welding staff personnel have the authority to address any safety violation.
All Power Points, hand-outs, or any other documents that are being used for the Welding Program will be
provided and found in the Section Supplementary Documents.

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Revision No. 1

Section 1 Padding Plate (E6010-1/8) [Running Stringers]

1.4 Whipping technique to be demonstrated on 6 scrap pipe
Maximum whip length will be 5/32 - 3/16
Allow weld puddle to widen to 1.5 to 2 times the electrode diameter (amperage will vary per
machine, range shall be 75 -125)
Direction of travel will be toward the dominant hand (Right handed left to right, Left handed
right to left)

Teaching Topic:
The use of the drag technique shall not be demonstrated for the E6010 electrode. The instructor should
watch and stop long whipping. Demonstrate arc length and the differences between a short and long arc.
Show variances in travel speed and electrode angles and their effects on the weld bead.
References to this exercise can be found in Chapter 10 of the UA Oxy-Fuel Cutting & Welding and SMAW
Book that each apprentice has received during their Orientation. Refer to Exercise 3, page 191.

Acceptance Criteria:
Apprentice shall show proficiency throughout weldment prior to moving on to the next exercise. The
instructor shall evaluate the width, build-up and voids in between deposited weld metal. There shall be no
undercutting, excessive spatter or poor appearance to the weld bead. Bead overlap and tie-ins to adjacent
bead shall be uniform, leaving no hills or valleys (lack of fusion).

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Revision No. 1

Section 1 Padding Plates (E7018-1/8) [Running Stringers]

1.5 Proper arc initiation using Low-Hydrogen Electrodes
No long arcing
Start to ahead of starting point and come back
Immediately after establishing the arc, lift the electrode up a short distance from the work and
holding it there for a second or two, allow a few drops of molten steel to fall from the tip of the
electrode. The arc will bring the tip of the electrode up to operating temperature quickly, enabling
the core wire to burn up inside the flux coating and initiate the gassing effect of the flux. Then,
when the electrode is lowered to the work, the weld will be properly shielded, and porosity will be
minimized.

Teaching Topic:
Demonstrate amperage changes, travel speed and electrode angles. Allow to the student to see the
differences in the weld bead. Show possible weld bead discontinuities on their weldments.
References to this exercise can be found in Exercise 6, page 196 & Exercise 7, page 197-201.

Apprentice shall show proficiency throughout weldment prior to moving on to the next exercise. The
instructor shall evaluate the width, build-up and voids in between deposited weld metal. There shall be no
undercutting, excessive spatter or poor appearance to the weld bead. Bead overlap and tie-ins to adjacent
bead shall be uniform, leaving no hills or valleys (lack of fusion).

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Revision No. 1

Section 2 Plate Welding (SMAW)

2.1 2F Horizontal T-joint (2x10x3/8 plate)
Joint Set-up will demonstrated by instructor
o Use 3/32 gap rod to simulate open root on pipe
Each pass will be demonstrated by instructor
o E6010 1/8 for the root (1) pass
o E7018 3/32 for the hot (1) pass
o E7018 3/32 for the fill (2) passes
o E7018 3/32 for the cap (3) passes
Maximum whipping motion is 5/32 - 3/16 for the root
Hot pass shall be demonstrated with either a weave technique or stringer, no figure 8s or
elongated J-hook weave
Fill pass shall be demonstrated with a stringer technique or slight oscillation
Cap pass shall be demonstrated with a stringer technique or slight oscillation

Teaching Topic:
Instructor needs to stress MAXIMUM whipping motion is 5/32 3/16 for the E6010 1/8 root technique.
The Introduction to Welding presentation will provide a descriptive procedure for 2F and also 3F plate
welding. The instructor will be able to view this presentation in Section 15 Supplementary Documents. In
the UA SMAW book Exercise 10, Step 3, page 205 depicts a whipping diagram.

The use of the I-Pad for acceptance of welds starts at this step.

End Prep will always be accepted on plate. The Tack-up/Fit-up will either be acceptable or rejectable
based on the sample being aligned and with a proper gap. The inspection for the welding of the root
through the cap will follow the columns on the I-Pad. The root pass shall not exhibit any undercutting or
lack of fusion between the plates or the weld deposit in front or behind it (skips or voids). Please review the
Acceptable and Unacceptable Fillet Weld Profiles hand-out found in Section 15 of this manual.

In the event of an acceptable weldment on a Saturday (Tack-up to cap), the instructor shall have two full-
time (CWI & ATR) instructors evaluate the weld based on the 1st Year Welding Criteria specification. At no
time should anyone else measure, or say it looks good to me, only to have the sample rejected creating a
confrontational situation. Once the sample is accepted then the student will move on to the next
requirement.

If the acceptable sample is done on a week night then it will be evaluated by the Night Time Inspector
(full-time [CWI & ATR] instructor).

NOTE:
The Cap shall be accepted on the I-Pad only by full-time (CWI & ATR) instructors.

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Revision No. 1

Section 2 Plate Welding (SMAW)

2.2 3F Vertical-Up T-Joint (2x10x3/8 plate)
Each pass will be demonstrated by the instructor
o E6010 1/8 for the root (1) pass
o E7018 3/32 for the hot (1) pass
o E7018 3/32 for the fill (1) pass
o E7018 3/32 for the cap (1) pass
Enforce maximum whipping length 5/32 to 3/16 for root pass
o Watch student for pausing at the keyhole (holding too long or holding too little)
o No drag technique for root pass
Hot pass weave technique, forward progression uphill
o Pause at the side just long enough to cover the entire root pass
o Must fuse into the plates
Fill pass weave technique past edge of the hot pass
Cap pass weave technique past edge of the fill pass

Teaching Topic:
Pausing and the speed across the center of the weld, show excessive convexity and review the acceptable
weld profile with the student.

The use of the I-Pad for acceptance of welds continues for the remainder of the apprentice welding
program.

End Prep will always be accepted on plate. The Tack-up/Fit-up will either be acceptable or rejectable
based on the sample being aligned and with a proper gap. The inspection for the welding of the root
through the cap will follow the columns on the I-Pad. The root pass shall not exhibit any undercutting or
lack of fusion between the plates or the weld deposit in front or behind it (skips or voids). Please review the
Acceptable and Unacceptable Fillet Weld Profiles hand-out found in Section 15 of this manual.

In the event of an acceptable weldment on a Saturday (Tack-up to cap), the instructor shall have two full-
time (CWI & ATR) instructors evaluate the weld based on the 1st Year Welding Criteria specification. At no
time should anyone else measure, or say it looks good to me, only to have the sample rejected creating a
confrontational situation. Once the sample is accepted then the student will move on to the next
requirement.

If the acceptable sample is done on a week night then it will be evaluated by the Night Time Inspector
(full-time [CWI & ATR] instructor).

NOTE:
The Cap shall be accepted on the I-Pad only by full-time (CWI & ATR) instructor.

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Revision No. 1

Section 3 - Pipe Welding: 1G 6 Sch 80 (SMAW)

3.1 End Prep
Removal of dross from ID of pipe
Removal of scale on flame cut bevel without damaging the outer edge (file or grinder)
Shall be demonstrated by the instructor with a 9 grinder (all instructors shall demonstrate safe
working habits)
o Whole disc completely flat on pipe to create land
o Portion of disc resting on pipe to create land
o Remove burrs on ID of pipe prior to checking the land size
Land size shall be 1/8
o Use a 1/8 welding rod to identify the correct land size
o Must conform to 1/8 prior to moving to next step
o Use file to fine tune the land

3.2 Tack-Up/Fit-Up
Place 1st pipe coupon in the 2G position in pipe fixture
Use 1/8 welding rod to create 1/8 gap on 1st coupon
Place 2nd pipe coupon on top of 1st coupon
Maintain a 1/8 gap all around the joint
Use 1/8 E6010 to start tacking, explain that this step not only secures the pipe joint, but also
allows the student to set the amperage based on key hole size
(4) equally spaced tacks are mandatory
o Tack length shall be
o Fully penetrated, whether they are tying-in or burning through

Teaching Topics:
Each step shall be demonstrated in groups, then individually to personalize instruction. Stress good work
and travel angles while tacking. Key hole size shall be no larger than 3/16.

The maximum misalignment allowed is 1/16. All four tacks shall show complete penetration and the gap
shall not have any tight nor wide areas. Failure to do so will result in two outcomes, they are: either the
student will have to cut it apart until it is correct, or the student will be allowed to continue but will fail the
Tack-Up/Fit-Up hold point. If the sample is rejected at this time the sample will fail no matter what the
other passes look like.

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Revision No. 1


3.3 Grinding Tacks (feathering tacks)
Heavy end of tack should be feathered edged without ruining the bevel or the land prior to the
tacks
Key hole of tack shall also be feathered
Care shall be taken with the grinding disc to only make contact with the tack area
Grind one tack at a time if consuming tacks
Allowed to grind all four tacks at once if tying into tacks

Teaching Topic:
Care should be taken not to over grind, as this may cause the tacks to break and the joint to close up. Refer
to Exercise 23, Step 6 for a descriptive drawing of the feathered tacks.

Watch student while they grind and correct any bad techniques. Encourage them to purchase a 4 grinder
with various sized discs for cutting and grinding. This is not a hold point or inspection point, just
informative.

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Revision No. 1


3.4 Root Pass
Only two (2) techniques will be demonstrated and taught
o Whip
o Circle
No Drag technique will demonstrated or taught for the root pass
E6010 1/8 (Amperage Range: 75 125 DCEP)
o Initiate the arc in the work area (bevels) and long arcing the rod is required prior to
depositing metal
o Proceed forward into keyhole
Electrode Angle
o Plus or minus 5 to 10, push to drag angle, from center line of pipe
o Keep electrode perpendicular in the bevels to help avoid key holing of only one side
Key hole
o Using an 1/8 electrode, the key hole size should be between 5/32 and 3/16
o Demonstrate welding the key hole
o Amps and travel will be dictated by the key hole size
Penetration
o Minimum acceptance criteria flush with the ID
o Maximum acceptance criteria 1/8 past the ID
Grinding on the Root pass
o Light grinding is recommended (making it all shine) may cause a possible burn-
through on the hot pass. If this type of grinding is necessary, then this would indicate
problems with the students welding technique and further instruction should follow.

The root pass shall be free from excessive penetration, lack of penetration, lack of fusion between
deposited weld ripples (voids/holes/under flushed craters) and undercut. Poor tie-ins and double roots shall
be rejected or repaired. The student shall be allowed one (1) attempt at a repair and visually inspected prior
to starting the hot pass.
The student should gain some proficiency with welding the roots prior to attempting any repairs. The
instructor must limit the repair time to a minimum as this is counterproductive to the students progress.
Use of a hammer and chisel to remove excessive penetration will never be allowed. The student will not be
allowed to fix a root from the inside, all root repairs are from the outside only for all sizes, diameters and
processes while at the Training Center.

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Revision No. 1


3.5 Hot Pass
o Initiate the arc in the work area
o No long arcing, will cause porosity
o Demonstrate starting to ahead of starting point and come back
When tying into a stopping point, come back into half of the crater and continue
Width/Height
o Weld the edges of the root pass to the bevels by weaving side to side with a forward
progression
o Hold the electrode at these points long enough to allow the arc force to dig into the
bevels and tie-in
One Pass for the Hot
o Reiterate to student that this is the same as the 3F plate technique

Teaching Topic:
Grinding the root pass very deep and narrow will create problems for student on their hot pass;
demonstrate good grinding techniques that will maintain the original bevel faces and opening without over
grinding.

Undercutting, porosity, slag inclusions, lack of fusion, poor tie-ins and crowning or excessive convexity will
be cause for rejection of the hot pass. Arc striking on the OD of the pipe within 2 of either side of the joint
will not be tolerated. If the arc strike occurred while tacking the student should explain this to the instructor
while it is being inspected during the tack-up hold point.

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Revision No. 1


3.6 Fill Pass
E7018 1/8 (Amperage Range: 115 165)
o Arc initiation and tie-ins are the same as the hot pass
o Stagger starts/stops to eliminate heavy spots and to avoid clusters of porosity

Teaching Topic:
The weld metal shall be 1/32 to 1/16 below flush with the outside surface. The weld metal should be
level, without excessive convexity and concavity. If a grinder is needed to fix these problems the welders
technique should be addressed.
The welder must evaluate each pass to assure they are within tolerances.

be cause for rejection of the fill pass.

This criterion is for all positions: 2G, 5G, 6G and the 1G, including but not limited to all 6 and 2 pipe.

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Revision No. 1


3.7 Cap Pass
1/8 E7018 (Amperage Range: 115 165)
Placement of half the electrode diameter over the edge of the bevels is recommended

Weld reinforcement shall be flush (minimum) to 1/8 (maximum) above the outside surface. The weld shall
not exceed 1/8 on either side of the joint (per the UA). Undercut is allowed up to 1/32 deep. Undercut
indicates that the welder is depositing metal incorrectly. Repairs are allowed on the cap. The repairs must
be 2-3 in length and must be re-welded (for all diameters of pipe).

Note:
2G or 6G: three (3) stringer beads are required for 6 and the 2 (bottom, middle & top).

(3) Acceptable samples shall be required prior to testing.

One full-time welding instructor shall be required to accept or reject the final, overall weld on all samples
throughout the students welding career at the Training Center, except for the samples being submitted to
Mr. Hintz prior to a UA test, then two instructors shall be required to accept it. The proper paperwork shall
be filled out and submitted to Mr. Hintz for his approval.

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Revision No. 1
Section 4 - Pipe Welding: Position Welds 6 Sch 80 (SMAW)

2G 6 Sch 80

4.1 End Prep
Refer to Section 3.1 of this manual

4.2 Tack-up/Fit-up

Teaching Topics:
All students will be given a demonstration on each new position. Most students progress quickly with the
2G. Reiterate that this is the same joint as their (7) pass 2F T-joint. This is a Hold Point; do not allow the
student to bypass any step.


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Revision No. 1


2G 6 Sch 80


Teaching Topic:
The student shall be allowed to rotate the coupon in the fixture, rather than walk around it. This is a safety
concern. Some students have wrapped their cords or cables around their legs and tripped. They will not be
allowed to remove or flip the coupon once they start the root pass. All grinding will be done in place. The
fixture shall not be allowed to change elevation (must stay at one height until complete). In order to inspect
tacks or the root pass please show the student how to change from a 2G to a 5G to check the root.

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Revision No. 1


2G 6 Sch 80

4.4 Root Pass
Whipping technique or circle technique shall be taught
The key hole is to be 5/32- 3/16 maximum
Penetration
o Light grinding is recommended (making it all shine) may cause a possible burn-through
on the hot pass. If this type of grinding is necessary, then this would indicate problems with
the students welding technique and further instruction should follow.


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Revision No. 1


2G 6 Sch 80

4.5 Hot Pass
E7018 3/32 (Amperage Range 70-100 DCEP)
Single pass
Technique
o Stringer (drag)
o Weave/oscillate
This is the same technique that was demonstrated on the 2F plate
o
lllll, lllll, wwwww , ______

Teaching Topic:
No excessive motions, try to limit the amount of weld deposit. Over filling will not allow the fill passes to go
in properly, causing the student to grind off welds.

be cause for rejection of the hot pass.

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Revision No. 1


2G 6 Sch 80

4.6 Fill Pass
(2) stringers are required
1/8 E7018 will be used
Equal sized passes
This is the same as the 2F T-joint

Teaching Topic:
Overfilling the joint and then grinding out the top or bottom 1/3rd of every pass shall not be demonstrated.
Removal of slag or etching lines to see the joint shall be allowed, but not excessive, limit the practice to
about 1/32.


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Revision No. 1


2G 6 Sch 80

4.7 Cap Pass
1/8 E7018
Equally sized passes

Teaching Topic:
Grinding shall be limited to skimming starts/stops, in order to check for porosity. Refer to Ch. 12 in the UA
SMAW book for more details in regards to grinding.


Note:
(2) Acceptable samples shall be required prior to advancing to the 5G position

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Revision No. 1


5G 6 Sch 80

4.1a End Prep

4.2a Tack-up/Fit-up
This step is a Hold Point for the student

Teaching Topic:
All students will be given a demonstration on each new position. This joint is the same as the 1G, except
the student is the one rolling. Relate this to the 3F T-joint.
No rotating to grind or change in height, once it is set in the fixture the student will mark the top and the
coupon shall stay in a fixed position.


Notes:
The welding progression is uphill. Welding shall start approximately at the 6 oclock position, and then
proceed to either 9 oclock or 3 oclock with the uphill progression.
Downhill/Opposite direction shall be 1/2 maximum off of center. See letter that pertains to this topic in
Section 15.

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Revision No. 1


5G 6 Sch 80

4.3a Grinding Tacks (feathering tacks)

Teaching Topic:
The student will not be allowed to remove or flip the coupon once they start the root pass. All grinding will
be done in place. The fixture shall not be allowed to change elevation (must stay at one height until
complete).

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Revision No. 1


5G 6 Sch 80

4.4a Root Pass
1/8 E6010 (Amperage Range: 75 125 DCEP)
The keyhole is to be 5/32-3/16 maximum, using the same techniques stated earlier
o Whipping
o Circle
Penetration
o Light grinding is recommended, remove humps and create an area that will enable
proper welding technique on the hot pass. Stress the importance of maintaining the
original bevel shape.

Teaching Topic:
Suggest that the student weld out on the bottom of the joint to familiarize themselves with this new
position.

The student should gain some proficiency with welding the root pass prior to attempting any repairs. The

25

Revision No. 1


5G 6 Sch 80

4.5a Hot Pass
E7018 3/32 (Amperage Range 70 100 DECP)
Single pass
Weave technique
o Wide enough to cover the root pass
o This should not fill out the remainder of the joint

Teaching Topic:


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Revision No. 1


5G 6 Sch 80

4.6a Fill Pass
Weave technique, going wide enough to cover the hot pass
Single pass

Teaching Topic:
Overfilling the joint and then grinding out the weld pass shall not be demonstrated. The weld metal shall be
1/32 to 1/16 below flush with the outside surface. The weld metal should be level, without excessive
convexity and concavity. If a grinder is needed to fix these problems the welders technique should be
addressed.


27

Revision No. 1


5G 6 Sch 80

4.7a Cap Pass
1/8 E7018 shall be used (Amperage Range: 110 -150 DCEP)
Single pass, no split caps

Teaching Topic:

be 2-3 in length and must be re-welded (for all diameters of pipe and processes).
Remind the students that the weld shall be left in the as welded condition; filing or grinding on the
finished product shall be cause for rejection, just like a UA test.

Note:

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Revision No. 1


6G 6 Sch 80

4.1b End Prep

4.2b Tack-up/Fit-up

Teaching Topic:
All students will be given a demonstration on each new position. This joint is the same as the 2F plate and
also the 2G, except it is now on a 45 angle.


Notes:
Section 15.

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Revision No. 1


6G 6 Sch 80

4.3b Grinding Tacks (feathering tacks)

Teaching Topic:
complete).

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Revision No. 1


6G 6 Sch 80

4.4b Root Pass
o Whipping
o Circle
Penetration

Teaching Topic:
Suggest that the student weld out on the bottom of the joint to familiarize themselves with this new
position. Body and head placement are crucial in achieving a sound weld. Offer a different approach, such
as kneeling as opposed to standing.


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Revision No. 1


6G 6 Sch 80

4.5b Hot Pass
Single pass
Weave technique

Teaching Topic:


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Revision No. 1


6G 6 Sch 80

4.6b Fill Pass
(2) Stringers are required
Equal sized passes
Prohibit large weaves and the use of a grinder to open joint or to remove perfectly good weld metal

Teaching Topic:
addressed.

be cause for rejection of the fill pass. Over filling the joint (past flush) as well as hills and valleys shall also
be cause for rejection.

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Revision No. 1


6G 6 Sch 80

4.7b Cap Pass
1/8 E7018 (Amperage Range 110 - 150 DCEP)

Teaching Topic:


Note:
(2) Acceptable samples shall be required prior to advancing to the 2G position on 2 XXH

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Revision No. 1

Section 5 - Pipe Welding: Position Welds 2 XXH (SMAW)

2G 2 XXH

5.1 End Prep

5.2 Tack-up/Fit-up

Teaching Topic:
No bridge tacks, or droplets of metal will be allowed for tack-up. The student will be allowed to use a minimum
of (3) tacks. The tacks shall be fully penetrated, no longer than 3/8 and placed at the 12, 3, 6, or 9 oclock areas.

This is a Hold Point; do not allow the student to bypass any step. The student will be allowed to rotate the
coupon in the fixture rather than walk around it. The coupon will remain at one height through its entirety. The
coupon can be placed in the 5G position to check the root pass. Remind the student that all grinding will take
place in the 2G position.


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2G 2 XXH

5.4 Root Pass
Whipping technique or circle technique shall be taught
The key hole is to be 5/32- 3/16 maximum
Penetration
o Light grinding is recommended (making it all shine) may cause a possible burn-through
on the hot pass. If this type of grinding is necessary, then this would indicate problems with
the students welding technique and further instruction should follow.


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2G 2 XXH

5.5 Hot Pass
E7018 3/32 (Amperage Range 70-100 DCEP)
Single pass
Technique
o Stringer (drag)
o Weave/oscillate
This is the same technique that was demonstrated on the 2F plate
o
lllll, lllll, wwwww , ______

Teaching Topic:


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Revision No. 1


2G 2 XXH

5.6 Fill Pass
3/32 E7018 will be used
Equal sized passes
This is the same as the 2F T-joint

Teaching Topic:
Overfilling the joint and then grinding out the top or bottom 1/3rd of every pass shall not be demonstrated.
Removal of slag or etching lines to see the joint shall be allowed, but not excessive, limit the practice to
about 1/32.


38

Revision No. 1


2G 2 XXH

5.7 Cap Pass
3/32 E7018

Teaching Topic:


Note:

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Revision No. 1


5G 2 XXH

5.1a End Prep

5.2a Tack-up/Fit-up

Teaching Topic:
All students will be given a demonstration on each new position.
coupon shall stay in a fixed position. Students are allowed to use (3) or (4) tacks.

The maximum misalignment allowed is 1/16. All tacks shall show complete penetration and the gap shall
not have any tight nor wide areas. Failure to do so will result in two outcomes, they are: either the student
will have to cut it apart until it is correct, or the student will be allowed to continue but will fail the Tack-
Up/Fit-Up hold point. If the sample is rejected at this time the sample will fail no matter what the other
passes look like.

Notes:
Section 15.


Teaching Topic:
complete).

40

Revision No. 1


5G 2 XXH

5.4a Root Pass
o Whipping
o Circle
Penetration

Teaching Topic:
Suggest that the student adjust amperage to familiarize themselves with this new position during the
welding of the root pass. Go back to the basics; remind them about the length of whipping motion. The
student does not have to use one electrode to go from bottom to top. The student should stop welding as
needed to maintain correct technique.


41

Revision No. 1


5G 2 XXH

5.5a Hot Pass
Single pass
Weave technique

Teaching Topic:
No excessive motions, try to limit the amount of weld deposit. Over filling will not allow the fill pass to go in
properly, causing the student to grind off welds.


42

Revision No. 1


5G 2 XXH

5.6a Fill Pass
3/32 E7018
Weave technique, going wide enough to cover the hot pass
Single pass, due to the amount of grinding a student may need an extra fill pass to flush out joint,
this is permissible

Teaching Topic:
addressed.



43

Revision No. 1


5G 2 XXH

5.7a Cap Pass
3/32 E7018 shall be used
Single pass, no split caps

Teaching Topic:

be 2-3 in length and must be re-welded (for all diameters of pipe and processes).
Remind the students that the weld shall be left in the as welded condition; filing or grinding on the
finished product shall be cause for rejection, just like a UA test.

Note:

44

Revision No. 1


6G 2 XXH

5.1b End Prep

5.2b Tack-up/Fit-up

Teaching Topic:
All students will be given a demonstration on each new position. This joint is the same as the 2F plate and
also the 2G, except it is now on a 45 angle.

The maximum misalignment allowed is 1/16. All tacks shall show complete penetration and the gap shall
not have any tight nor wide areas. Failure to do so will result in two outcomes, they are: either the student
will have to cut it apart until it is correct, or the student will be allowed to continue but will fail the Tack-
Up/Fit-Up hold point. If the sample is rejected at this time the sample will fail no matter what the other
passes look like.

Notes:
Section 15.

45

Revision No. 1

Section 5 - Pipe Welding: Position Welds 2XXH (SMAW)

6G 2XXH

5.3b Grinding Tacks (feathering tacks)

Teaching Topic:
complete).

46

Revision No. 1


6G 2 XXH

5.4b Root Pass
o Whipping
o Circle
Penetration

Teaching Topic:
Body and head placement are crucial in achieving a sound weld. Offer a different approach, such as kneeling
as opposed to standing.


47

Revision No. 1


6G 2 XXH

5.5b Hot Pass
Single pass
Weave technique

Teaching Topic:


48

Revision No. 1


6G 2 XXH

5.6b Fill Pass
3/32 E7018
(2) Stringers are required
Equal sized passes
Prohibit large weaves and the use of a grinder to open joint or to remove perfectly good weld metal

Teaching Topic:
addressed.

be cause for rejection of the fill pass. Over filling the joint (past flush) as well as hills and valleys shall also
be cause for rejection.

49

Revision No. 1


6G 2 XXH

5.7b Cap Pass
3/32 E7018

Teaching Topic:


All samples that are to be turned in for approval by Mr. Hintz shall be free from any repairs, whether it is the root
pass or the cap pass. Checking of the root pass after the hot pass goes in shall not be allowed. The UA testing
procedure does not accept this practice.

Note:
th
(4) Acceptable samples shall be required prior to testing. The 4 sample shall be turned in for Mr. Hintzs
approval before the student tests. A Request to Test form shall be generated and signed by two instructors,
one of which will be a full-time, ATR and CWI.

50

Revision No. 1

Section 6 - Introduction to GTAW

6.1 The Gas Tungsten Arc Welding Process/Getting Started
All students shall be issued a TIG Kit from the Training Center
The items that have been provided shall be used for all training purposes while practicing for the UA 15
and the UA 41
The TIG Kit includes the following items:
o Weld Craft Torch WP-17V, with coupler and 10ft Argon Hose
o (3) Pieces of 1/8- 2% Thoriated Tungsten (unsharpened)
o (1) # 4 Ceramic Cup
o (1) Pin vise
o (1) Long Tail Cap
o (1) 1/8 Collet Body/Holder
o (1) 1/8 Collet
o (1) Klein Bag
o (1) Klein Side Cutter
The use of non-issued items shall not be used for training until the student advances past the UA 41.
Welding practices done outside of the Training Center shall remain outside of the Training Center.

Teaching Topic:
The instructor shall provide an explanation of the GTAW process. Demonstration of machine set-up along
with the assembly of the torch shall be done with each student on an individual basis. Stress the difference in
the polarity that will be used on the GTAW process, DCSP as opposed to DCRP. All couplings and threaded
attachments shall be tightened with an adjustable wrench rather than a pair of channel locks. Suggest
purchasing a couple of adjustable wrenches.

nd
All 2 Year apprentices will be shown a Power Point regarding GTAW Basics by Lincoln Electric prior to
rd
starting their 3 Year. Refer to Section 15 of this manual to view this presentation.

51

Revision No. 1

Section 6 - Introduction to GTAW

6.2 Practical Understanding of the GTAW Process/Preparation
Practice shall start on 6 scrap from the dumpster
o Removal of the coating
Grind off coating using a grinder
Clean the pipe, leaving the weld intact
Torch Set-up
o Use adjustable wrenches for all threaded connections
o Check all connections for leaks
Argon
o Argon flow should be set at 20-25cfm for adequate coverage in the shop (depending on other
variables at the time of welding, i.e. drafts or excessive air movement)
Sharpening of Tungsten(2% Thoriated 1/8 shall be used for all GTAW)
o Pedestal Grinders shall be used NEVER sharpen with a hand grinder
o Taper approximately 2-3 times the diameter of the tungsten
o Sharpen so striations are lengthwise, not winding or rotational around the tungsten; refer to
Section 15 for more information by viewing the hand-out from Arc Zone.
o Encourage the use of the whole face of the grinding wheel on the pedestal grinder
Sharpening of Tungsten Safety
o Clear safety glasses shall be worn at all times
o Gloves should be avoided near rotational equipment
o Face shields shall be worn (at all times) over the safety glasses while grinding
o The use of a drill to sharpen the tungsten is allowed and may also be a safer alternative to using
the pin vise
NOTE:
The Instructor shall demonstrate all safe working practices while demonstrating any procedure in the shop!

6.3 Practical Understanding of the GTAW Process/Method and Technique
Use wrap-around to trace lines on the outer diameter of the pipe, this will become their guide
Practice arc initiation by using the scratch method
Practice walking the cup without the machine turned on following the guide lines
o once proficiency has been achieved then advance the student to the next step
Practice walking the cup without filler wire while the machine is on
The instructor shall assess the quality of work
o Once proficiency has been achieved then advance the student to the next step
Practice walking the cup with 1/8 filler wire (ER70S-2)
The student shall be instructed to use the #4, #6 and the #8 cups while walking over the wire
o Once proficient at this task the student shall start welding on 4 pipe

Teaching Topic:
The instructor shall demonstrate all steps listed in Section 6. The width of the walking motion will vary with each
cup size, varying amps and speed should be demonstrated prior to moving on to 4 pipe. Please keep in mind
52

that the torches are rated for 150 amps, if the student burns-up their torch they will purchase a new one from
the Training Center (price to be determined by the rate of our supplier). Please refer student to the UA Weld Test
Specification Binder for more details in regards to the test they are working on. The UA 15 gives an amperage
range of 75-165 for 1/8 filler wire.

Revision No. 1

Section 7- Pipe Welding: 1G 4 STD (GTAW)

7.1 End Prep
Clean back on ID and OD of 4 pipe using pencil grinder
o Booth 107 is designated for prepping coupons
Bevels should stay intact, unless a land is present, then remove the land

7.2 Tack-up/Fit-up
Use 1/8 ER70S-2 for the gap rod
Tack-up
o Place in the fixture and tack in the 2G position
o Place in the angle iron on the table and tack in the 1G position
o Free hand or walking can be utilized
Use 1/8 ER70S-2 for the consumable filler metal on the tacks
All tacks shall be equally spaced around the joint, (4) tacks are required
All tacks should be approximately long
No bridge tacks or droplets of metal shall be accepted for this Hold Point
All tacks shall be fully penetrated and the gap should be approximately 1/8 wide
o The 1/8 filler metal should not drop through, nor should the bottom of the wire rest
completely on top of the joint
o Protrusion of filler metal prior to welding should be noted

Feathering can be accomplished by use of:
o File
o Grinder
Care shall be taken to remove weld metal only and not contacting the bevel face
Grind one tack at a time if consuming tacks
Grind all 4 tacks if tying into them by creating a ramp-like area

Teaching Topic:
End Prep and Fit-Up is a hold point and also an inspection point on the I-Pad. Do not allow the student to advance
until these steps have been followed correctly.
Remind the student that over grinding may create other problems while welding, such as: joint to close up, or
excessive penetration approaching and leaving tack.
If the student does not have a 4 grinder at this time, then encourage them to purchase one.
Feel free to have the student cut apart their coupon if it is not done correctly and reassemble it the right way.

53

Revision No. 1


7.4 Root Pass
Students shall be instructed to use the #4 ceramic cup for the root pass
o Maximum tungsten stick-out shall be approximately 1/8 past the end of the cup
o Maximum Argon shall be 35cfm (20-25cfm provides sufficient coverage in the shop)
Filler Metal
o 1/8 ER70S-2 shall be used for the root (as well as the remainder of the joint)
o Amperage Range for 1/8 ER70S-2 specifies 75 - 165(per UA 15)
Technique
o Use a side to side motion past the edge of the filler wire
o We will instruct the student to use a wash over method
o No dip transfer
o No free handing
Penetration
o Minimum flush with the ID
o Maximum 3/32 past the ID

Teaching Topic:
Demonstrate changes in amperage (up and down) to show penetration and fusion issues. Show the angle of the
torch in relationship to the filler metal and the joint, discussing the balling up of filler wire and keyholing of
joint. Demonstrate variances in travel speed and discuss the differences between the two.

The root pass shall be inspected on the ID and the OD to ensure proper welding techniques have been used. Lack
of fusion at the bevel face shall be cause for rejection. Review possible causes of the defects. Grinding and filing
should be limited to tacks and cleaning, not grinding the whole root until it shines to remove lack of fusion.
The student should gain some proficiency with welding the roots prior to attempting any repairs. Welds can be
acceptable after repairs have been made, but if all tie-ins need to be fixed then teaching better techniques
should employed rather than piecing the root in.

54

Revision No. 1


7.5 Hot Pass
The student shall be instructed to use a # 6 ceramic cup
o Tungsten stick out shall be no further than the ID of the ceramic cup
o Tungsten stick out should not have any unground areas protruding beyond the cup
Filler Metal
o 1/8 ER70S-2 shall be used for the hot pass
o Amperage Range for 1/8 ER70S-2 specifies 75 - 165(per UA 15), torch is only rated to 150 amps
Technique
o The weave pattern shall be wide enough to cover the root pass
o Walking over the wire shall be shown
o One pass

Teaching Topic:
Stress the importance of good fusion at the bevel face with a flat appearance, remind the student to remove the
glass-like material prior to welding the next pass.

No lack of fusion, undercut, or suckback shall be allowed. Travel speed and amperage need to be high enough not
to burn up the root pass.

55

Revision No. 1


7.6 Fill Pass
The student shall be instructed to use a # 6 or #8 ceramic cup
o Tungsten stick out shall be no further than the ID of the ceramic cup
o Tungsten stick out should not have any unground areas protruding beyond the cup
Filler Metal
o 1/8 ER70S-2 shall be used for the fill pass
Technique
o The weave pattern shall be wide enough to cover the hot pass
o Fill joint to flush or slightly below flush

Teaching Topic:
If joint is not filled enough, allow an extra pass prior to capping. Etching lines should be avoided. Refer to
Hand-out in Section 15 for more details.
Stress importance of cleaning in between passes and allowing the pipe to cool down without quenching in water.
Suggest sharpening tungsten in between passes or cutting wire for the subsequent pass. Avoid resting the fume
extractor on the sample.
The practice of cleaning the coating off of the filler wire will not be demonstrated.

Voids in between the weave pattern, lack of fusion, undercut, porosity or any other defect shall not be accepted.
Visual examination as described in ASME Section, QW-194 is used to determine that the final weld surfaces meet
specified quality standards. Each pass shall be considered a final weld surface.

56

Revision No. 1


7.7 Cap Pass
Filler Metal
o 1/8 ER70S-2 shall be used for the cap pass
Technique
o The weave pattern shall be wide enough to cover the fill pass, ensuring that the weld metal has
been carried wide enough to cover the edges of the joint
o Walking over the wire shall be applied
Reinforcement
o The cap pass shall be minimum flush to outer surface
o The cap pass shall be maximum 1/8 past the outer surface
o Weld bead should not be wider than 1/16 on either side of joint

Discontinuities such as lack of fusion, undercut (past 1/32) porosity, underfill or any other item listed on the
welder tracking sheet shall not be accepted. Use a V-Wac gage to determine underfill, undercut or excessive
height reinforcement. All roots passes shall be visually inspected one more time. If the root pass has been suck
backed then the weld shall not be acceptable any longer and the cap pass will be marked as rejected on the I-
Pad.

Note:

57

Revision No. 1

Section 8 - Pipe Welding: Position Welds 4 STD (GTAW)

2G 4 STD

8.1 End Prep

8.2 Tack-up/Fit-up


Teaching Topic:
Remind the student that over grinding may create other problems while welding, such as: joint to close up, or
excessive penetration approaching and leaving tack.
Feel free to have the student cut apart their coupon if it is not done correctly and reassemble it the right way.

58

Revision No. 1


2G 4 STD

8.4 Root Pass
Filler Metal
o Amperage Range for 1/8 ER70S-2 shall be 75 - 150
Technique
o No dip transfer
o No free handing
Penetration

Teaching Topic:
Demonstrate changes in amperage (up and down) to show penetration and fusion issues. Show the angle of the
torch in relationship to the filler metal and the joint, discussing the balling up of filler wire and keyholing of
joint. Demonstrate variances in travel speed and discuss the differences between the two. Offer suggestions on
the height of the coupon and head/body placement. This weld may be rotated in the fixture rather than walking
around it. There shall be no change in height once the welding has started.

of fusion at the bevel face shall be cause for rejection. Review possible causes of the defects.
Grinding and filing should be limited to tacks and cleaning, not grinding the whole root until it shines to remove
lack of fusion.

59

Revision No. 1


2G 4 STD

8.5 Hot Pass
Filler Metal
Technique
o One pass

Teaching Topic:
glass-like material prior to welding the next pass. Wire brushing in between passes is highly recommended.


60

Revision No. 1


2G 4 STD

8.6 Fill Pass
Filler Metal
Technique
o One pass is required

Teaching Topic:
Etching lines should be avoided. Refer to Hand-out in Section 15 for more details.


61

Revision No. 1


2G 4 STD

8.7 Cap Pass
Filler Metal
Technique
o (2) passes are required
o The instructor shall demonstrate proper placement of the filler wire and of the weld beads
Reinforcement

Pad.

Note:

62

Revision No. 1


5G 4 STD

8.1a End Prep

8.2a Tack-up/Fit-up


Teaching Topic:

63

Revision No. 1


5G 4 STD

8.4a Root Pass
Filler Metal
Technique
o No dip transfer
o No free handing
Penetration

Teaching Topic:
Show the angle of the torch in relationship to the filler metal and the joint, discussing the balling up of filler
wire and keyholing of joint. The use of a flashlight to show where the arc is generated in relation to the filler and
the joint could be a useful illustration by using the angle iron on the table as the joint.
Offer suggestions on the height of the coupon and head/body placement. This weld shall remain in the fixture
without any rotating. There shall be no change in height once the welding has started.
Progression shall be from bottom of pipe to the top in an uphill fashion. The top of the coupon should be marked
in some manner to show top of pipe.

The root pass shall be inspected on the ID and the OD.
Lack of fusion at the bevel face shall be cause for rejection. Review possible causes of the defects.
Grinding and filing should be limited to a minimum.
The student should gain some proficiency with welding the roots prior to attempting any repairs.

64

Revision No. 1


5G 4 STD

8.5a Hot Pass
Filler Metal
Technique
o One pass

Teaching Topic:


65

Revision No. 1


5G 4 STD

8.6a Fill Pass
Filler Metal
Technique

Teaching Topic:


66

Revision No. 1


5G 4 STD

8.7a Cap Pass
Filler Metal
Technique
Reinforcement

height reinforcement.
All roots passes shall be visually inspected one more time. If the root pass has been suck backed then the weld
shall not be acceptable any longer and the cap pass will be marked as rejected on the I-Pad.

Note:
(2) Acceptable samples shall be required prior to advancing to the 6G position on 2 Sch 80

67

Revision No. 1

Section 9 - Pipe Welding: Position Welds 2 Sch 80 (GTAW)

6G 2 Sch 80

9.1 End Prep

9.2 Tack-up/Fit-up

Minimum of (3) tacks are allowed, omitting the fourth tack, not equally spaced around the joint

Teaching Topic:

68

Revision No. 1


6G 2 Sch 80

9.4 Root Pass
Filler Metal
Technique
o No dip transfer
o No free handing
Penetration

Teaching Topic:
Offer suggestions on the height of the coupon and head/body placement. This weld shall remain in the fixture
with the top of pipe being marked. There shall be no change in height once the welding has started.

of fusion at the bevel face shall be cause for rejection. Review possible causes of the defects.
lack of fusion.

69

Revision No. 1


6G 2 Sch 80

9.5 Hot Pass
Filler Metal
Technique
o One pass

Teaching Topic:


70

Revision No. 1


6G 2 Sch 80

9.6 Fill Pass
Filler Metal
Technique

Teaching Topic:
Inform students that the practice coupons have a slightly thinner wall than the test coupons due to the ID bore of
the machining process.


71

Revision No. 1


6G 2 Sch 80

9.7 Cap Pass
Filler Metal
Technique
o (2) passes are required
o The instructor shall demonstrate proper placement of the filler wire and of the weld beads
Reinforcement

Pad.

Note:
rd
(3) Acceptable samples shall be required prior to testing. The 3 sample shall be turned in for Mr. Hintzs

72

Revision No. 1

Section 10 Introduction to Stainless Steel (GTAW)

Practice on 4 STD 1G Position
All students shall start on 4 pipe (I-Pad will not track this sample)
Necessary coupon to introduce the student to Stainless Steel

10.1 End Prep

10.2 Tack-up/Fit-up
Filler Metal
o 1/8 ER 309
o Amperage Range 1/8 75 - 125
Backing Gas (Argon) shall be incorporated at this time prior to tacking up
o Argon shall be set at 5 to 15 CFH
o The use of a 4 adapter and back cap shall be used for tacking and throughout the weldment
Purge time should be approximately 1-2 minutes maximum for the samples being welded in the shop
o This practice should not be incorporated out on a jobsite
o Explain that diameters and lengths of pipe will vary as well as the purge time
The joint should be sealed adequately to prevent the presence of Oxygen
Tailing out on the bevel is an important technique used to avoid a fisheye or hole at the termination
point on the weld

Failure to remove fisheye at this point will most likely be a cause for the root being rejected

73

Revision No. 1



10.4 Root Pass
Students will continue to use the #4 ceramic cup that was issued to them by the Training Center
Filler Metal
o 1/8 ER 309
Backing Gas (Argon)
o Purge should still be applied with the joint taped and the end of the pipe adequately sealed
o 5 15 CFH
Technique
o Walking over the wire, side to side with good fusion at the bevel faces
o NO DIP TRANSFER
o No free handing
Penetration
o Minimum flush to 1/8maximum protrusion

Teaching Topic:
Backing gas is used for the prevention of an Oxygen rich environment. Oxygen will cause the weld surface to be
rough and coarse with a heavy black oxide layer. If there is slight discoloration -a golden hue then it is an
indication that a bit of Oxygen was still present.

of fusion at the bevel face should be discussed. Review possible causes of the defects.
lack of fusion.

74

Revision No. 1



10.5 Hot Pass
Filler Metal
o 1/8 ER 309
Backing Gas (Argon)
o Purge should still be applied and the end of the pipe adequately sealed
o Lower purge to 5 CFH
Technique

Teaching Topic:
Stress the importance of good fusion at the bevel face with a flat appearance. Instruct the student to use a
Stainless Steel wire brush when welding Stainless Steels and various other materials. Wire brushing in between
passes is highly recommended.

Discontinuities shall be discussed and solutions shall be demonstrated by the instructor.

75

Revision No. 1



10.6 Fill Pass
Filler Metal
o 1/8 ER 309
Backing Gas (Argon)
o Purge may still be applied and the end of the pipe adequately sealed
Technique

Teaching Topic:
Interpass temperatures should be under 600F. Temperature sticks are available at the Training Center. Explain
that the color change also indicates the temperature; faint straw - 390 F, light straw - 445F, dark straw -
465F, all the way up to purples reaching 540F to blue which is 575F. The blue would be the indicator prior to
reaching 600F. These colors may not be as evident on the carbon steel coupons.

Voids in between the weave pattern, lack of fusion, undercut, porosity or any other defect shall be pointed out.

76

Revision No. 1



10.7 Cap Pass
The student shall be instructed to use the #8 ceramic cup
Filler Metal
o 1/8 ER 309
Backing Gas (Argon)
Technique
o Walking over the wire, side to side with good fusion at the edges
o The weave pattern shall be wide enough to cover the fill pass
o Fill joint up to 1/8 past flush

This coupon is not being tracked on the I-Pad, but it is required. Teach the basic fundamentals using the 4 first,
and then proceed to 2 Sch 80 in the 6G position. This is your opportunity to introduce the student to Stainless
Steel.
This is typically where the student actually wants to learn how to weld.
The student may need to do an extra coupon prior to starting 2 Sch 80. It will be the instructors good judgment
to make that decision.

77

Revision No. 1


2 Sch 80 6G Position

10.1a End Prep

10.2a Tack-up/Fit-up
Filler Metal
o 1/8 ER 309
Backing Gas (Argon) shall be incorporated at this time prior to tacking up
o Argon shall be set at 5 to 15 CFH
o The use of a 2 adapter and back cap shall be used for tacking and throughout the weldment
Purge time should be approximately 1-2 minutes maximum for the samples being welded in the shop
o This practice should not be incorporated out on a jobsite
o Explain that diameters and lengths of pipe will vary as well as the purge time
The joint should be sealed adequately to prevent the presence of Oxygen
Tailing out on the bevel is an important technique used to avoid a fisheye or hole at the termination
point on the weld

Failure to remove fisheye at this point will most likely be a cause for the root being rejected

78

Revision No. 1



10.4a Root Pass
Filler Metal
o 1/8 ER 309
Backing Gas (Argon)
o Purge should still be applied with the joint taped and the end of the pipe adequately sealed
o 5 15 CFH
Technique
o NO DIP TRANSFER
o No free handing
Penetration
o Minimum flush to 1/8maximum protrusion

Teaching Topic:
Backing gas is used for the prevention of an Oxygen rich environment. Oxygen will cause the weld surface to be
rough and coarse with a heavy black oxide layer. If there is slight discoloration -a golden hue then it is an
indication that a bit of Oxygen was still present.

of fusion at the bevel face should be discussed. Review possible causes of the defects.
lack of fusion.
The same criteria shall be used to evaluate these samples. This coupon is being tracked on the I-Pad; it should be
Step/Weld # 43.

79

Revision No. 1



10.5a Hot Pass
Filler Metal
o 1/8 ER 309
Backing Gas (Argon)
Technique

Teaching Topic:
Stress the importance of good fusion at the bevel face with a flat appearance. Wire brushing in between passes is
highly recommended.

Discontinuities shall be discussed and solutions shall be demonstrated by the instructor. The same criteria listed
on the I-Pad shall be used to evaluate these samples.

80

Revision No. 1



10.6a Fill Pass
Filler Metal
o 1/8 ER 309
Backing Gas (Argon)
Technique

Teaching Topic:
Interpass temperatures should be under 600F. Temperature sticks are available at the Training Center.

Voids in between the weave pattern, lack of fusion, undercut, porosity or any other defect shall be cause for
rejection.

81

Revision No. 1



10.7a Cap Pass
The student shall be instructed to use the #8 ceramic cup
Filler Metal
o 1/8 ER 309
Backing Gas (Argon)
Technique
o Walking over the wire, side to side
o (2) stringers shall be required
o Wide enough to cover the edges, not exceeding a 1/16 on either side
o Fill joint up to 1/8 past flush

The coupon shall be free from defects as noted on the I-Pad.

Note:
(2) Acceptable samples shall be required prior to testing. The 2nd sample shall be turned in for Mr. Hintzs

THIS COMPLETES THE STUDENTS WELDING REQUIREMENTS

HE OR SHE WILL NO LONGER BE TRACKED ON THE I-PAD

82

Revision No. 1

Section 11 Introduction to Inconel (GTAW)

11a Terminology:
Explain to students this is basic, not advanced and encourage the Clad Class at night
Inconel- a nickel containing NiCrMo (ER NiCrMo-10 or 3 will be provided by the Training Center)

Nickel Oxides surface oxide coating which needs to be removed prior to welding subsequent passes.
This oxide melts at approximately 1000F above the melting point of the base metal. This oxide will not
be consumed and will cause lack fusion imperfections. Clean surface with a suitable tool; grinder or
brush.

Nickel Alloy Weld Metal characteristics include the sluggish nature of the molten weld metal which
does not spread and the lower weld penetration inherent with nickel alloys. The nickel alloy conducts
heat much more slowly than carbon or certain stainless steels. This accelerates warping and shrinkage in
the weld joint. Due to the slower diffusion of heat the metal remains hotter longer, allow coupon to cool
slightly prior to welding again.

Dip Transfer Method technique developed for the GTAW process for open root joints. Special
parameters and procedures are involved: bridge tacks are recommended, internal shielding (Argon), key
hole dip transfer by using the cup walking method.

11b Tools and Materials

Hand grinder with abrasive discs and cut-off wheels
Stainless steel wire brush
Aluminum tape or masking tape, whichever is available
Backing purge adapters and caps for 4 and 2 samples
4 and 2 carbon steel coupons ( STD, Sch 80 or XXH, depends on availability)

11c Welding Materials
ERNiCrMo-3 or 10 (Inconel 625 or 622 respectively) depends on availability
3/32 and 1/8 diameter (stored on the UA side in a controlled cabinet)

11d Torch Assembly
Gas Lenses
o Large
o Jumbo
Cup Sizes
o No. 6, 8, 10 or 12
2% Thoriated Tungsten
o Allow 3/32 per UA test specifications

83

*References for this Section: CRA Technology and Welder Training Manual in conjunction with UA Weld Test
Specifications 35 & 66 and field related good working practices

Revision No. 1


All students shall start on 4 pipe
Necessary coupon to introduce the student to Inconel

11.1 End Prep
Clean back on ID and OD of pipe with a pencil grinder
Land may be desired on larger bore pipe, the UA 35 and the UA 66 allow up to 1/8 land
During training keep knife edge intact

11.2 Tack-up/Fit-up (Referenced per UA 35 & UA 66)
Root gap 1/8
Bridge tacks may be demonstrated at this point
Traditional tacks may be demonstrated also
Purging techniques learned prior will be incorporated
o Shielding gas Argon 12 25 CFH (determined by welding conditions in the shop)
o Backing gas Argon 3 5 CFH (determined by welding conditions in the shop)
3/32 ERNiCrMo-10 or 3 shall be used to tack
o Amperage Range 40-70

11.3 Grinding (feathering tacks or start/stops)/Removal of bridge tacks
Same as previously taught for starts or stops
Removal of bridge tacks without ruining bevels
o These tacks are not incorporated into the weld

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Revision No. 1



11.4 Root Pass
Demonstrate the dip transfer method for the open root
o Select a #6 or 8 for the root pass with the gas lens
3/32 ERNiCrMo-10 or 3 shall be used for the root pass
Purging shall be maintained

Teaching Topic:
Commit to adding wire, do not approach the keyhole slowly or the wire will ball up. Maintain good shielding on
the wire, being careful not to pull it out of the shielding shroud. This distance is approximately 1 from the OD of
the cup. The oxidized wire tip should be removed prior to adding additional weld metal.

Referencing the UA Test Specifications the maximum interpass temperature shall be 300F. Use a temp stick to
assess the heat of the coupon. Allow the piece to cool in between passes by staying busy in the weld booth.
There should be no need for the student to quench their coupon.

Welded surfaces shall be free from coarse ripples, grooves, overlaps, abrupt ridges and valleys. Before welding
over deposited weld metal, all slag and oxides shall be removed and the weld and the adjacent base metal shall
be brushed clean. Suitable methods of cleaning include the use of abrasive discs, filing or brushing. No power
brushes will be allowed while training, but are allowed on UA tests in a controlled environment away from the
masses, using all safety protocol.

The weld should have a slightly convex surface. Flat and concave surfaces should be avoided.

85

Revision No. 1



11.5 Hot Pass
The student shall be instructed to use a #6 or #8 ceramic cup
Filler Metal
o 1/8 ERNiCrMo-10 or 3
o Amperage Range 85 to 150 (torch limitations)
Backing Gas (Argon)
Technique
o The weld should have a slightly convex surface.

Teaching Topic:
Before welding over deposited weld metal, all slag and oxides shall be removed and the weld and the adjacent
base metal shall be brushed clean. Suitable methods of cleaning include the use of abrasive discs, filing or
brushing.

86

Revision No. 1



11.6 Fill Pass
The student shall be instructed to use a # 6, #8 or #10 ceramic cup
Filler Metal
Backing Gas (Argon)
Technique
o One pass is required but may need an extra pass to flush out
More passes will be required when using thicker materials, such as 2 XXH and also
the Super coupons
Demonstrate what flushed out is

Teaching Topic:
The maximum interpass temperature shall be 300F.

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Revision No. 1



11.7 Cap Pass
The student shall be instructed to use a #8 or #10 ceramic cup
Filler Metal
Backing Gas (Argon)
Technique
o Walking over the wire, side to side with good fusion at the edges
o The weave pattern shall be wide enough to overlap 1/16 past the original joint
o Cap joint flush to 1/8 past OD surface
o One pass is required unless doing 2G and 6G position welds

Teaching Topic:
Once the student has become proficient with the 4 pipe they shall be advanced to the 2 Sch 80 or XXH in the
6G position.

*Please note that all techniques in Section 11 shall be employed on the 2 samples*

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Revision No. 1

Section 12 Introduction to Chromium (GTAW & SMAW)

12a Terminology
Chromium - this pipe has become a standard in the power generation industry and the petro-chemical
industry, not only because of its tensile strength, corrosion resistance and high-temperature strength,
but also for its cost-effectiveness. Grades P-11, P-22, P-91 & P-92 are prevalent for the power industry,
while P-5&P-9 are the major refinery processing grades utilized. These steels are designed to provide
improved creep strength, fatigue, oxidation, and corrosion resistance at elevated temperatures.
UA 91 This test will introduce the student to the use of different filler metals and also to different
covered electrodes using welding processes that they have become skilled with already.

Hand grinder with discs
Stainless steel wire brush
Aluminum tape or masking tape
Backing purge adapters and caps for 2 pipe
2 XXH carbon steel coupons

12c Preheat
Oxy-fuel torch set with a preheat tip
Minimum preheat of 400F
Temp stick
For training purposes only the preheat will start after the tacks have been put in due to the size of the
coupon (safety while handling)
Possible use of induction heating on jobsites

12d Welding Materials
ER 90S-B9
3/32 or 1/8 diameter (stored on the UA side in a controlled container)
E 9015-B9 or E9018-B9
3/32 or 1/8 diameter (stored in cabinet by Booth 1) DO NOT PUT IN ROD OVENS WHILE TRAINING
*PLEASE DO NOT MIX THIS WITH THE OTHER ELECTRODES OR FILLER WIRES*

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Revision No. 1

Section 12 Introduction to Chromium (GTAW & SMAW)

Practice on 2 XXH 6G
All students are allowed to use 2 XXH

12.1 End Prep
Clean back on ID and OD of pipe with a pencil grinder

12.2 Tack-up/Fit-up (Referenced per UA 91)
Root gap 1/8
Traditional tacks
Purging techniques learned prior will be incorporated
o Shielding gas Argon 12 25 CFH (determined by welding conditions in the shop)
o Backing gas Argon 3 5 CFH (determined by welding conditions in the shop)
1/8 ER 90S-B9

12.3 Grinding (feathering tacks)
Same as previously taught for starts or stops

12.4 Root Pass (GTAW)
Same techniques previously taught on UA 15 may be demonstrated
Flush to 1/8 maximum penetration
Welding will begin once coupon is heated to 400F

12.5 Hot Pass (GTAW)
ER 90S-B9
Interpass temperature will be maintained at 400F
(1) Pass only is allowed

12.6 Fill Pass (SMAW)
E 9015-B9 or E 9018-B9, 3/32 diameter electrodes
Amperage Range 40-80
Stringer techniques learned previously shall be demonstrated
(2) passes required, possible second layer of fill passes may be needed to flush out

12.7 Cap Pass (SMAW)
(3) or (4) stringers are allowed
Cap width will not exceed 1/16 either side of original joint

The completed sample coupon shall be inspected after tack-up/fit-up and then after each pass (root, hot, fill pass
or second layer of fill passes and then the cap). This is to ensure the student continues with good welding
practices.
90

Note:
(1) Acceptable sample shall be required prior to testing. The sample shall be turned in for Mr. Hintzs approval
before the student tests. A Request to Test form shall be generated and signed by two instructors, one of which
will be a full-time, ATR and CWI.

Revision No. 1

Section 13 Introduction to GMAW and FCAW

13a Terminology
GMAW Gas metal arc welding or MIG (metal inert gas)
UA 30: manual welding process with the direction of rolling away from welder
GMAW-S ; the S stands for short-circuit mode of transfer
FCAW Flux core arc welding, uses tubular wire with the flux inside

Hand grinder with discs
Wire brush
Wire cutters

13c Welding Materials
6 Sch 80, carbon steel pipe
GMAW machine
Table positioner

13d Welding Wire and Shielding Gas
ER 70S-3 or 6, .035 or .045 (solid wire)
E 71T-1, .035 or .045 (tubular wire)
75% Argon/25% CO cylinders

13e Parameters for Short Circuit Transfer:
17-20 Volts
Amperage Range- 100-175
WFS 76-175 ipm
Nozzle size (cup) to ID
Stick out to 3/8 from cup while welding
Gas set at 25-45 CFH, adjust per shop conditions

13f Parameters for FCAW Globular/Spray Transfer:
Switch Guns
24-32 Volts
Amperage Range- 140-430
WFS 120-500 ipm
Nozzle size (cup) to ID
Stick out to 5/8 from cup while welding
Gas set at 15-40 CFH

91

Revision No. 1


13.1 End Prep
Clean 1 back on ID and OD
Establish 1/16 to 3/32 land as desired

13.2 Tack-up /Fit-up
Gap at 1/8
Tack up in the 2G position
tacks, (4)evenly spaced
Tail in to tack by starting on bevel and tail out of tack by ending on bevel

13.3 Grinding Tacks (feathering)
Remove the tails off of bevel faces
Feather both ends of tacks, keeping enough metal in the middle to stop joint from closing
Do not reduce lands at end of tacks

13.4 Root Pass ER 70S-6 GMAW-S
Start weld downhill from 12 oclock
Tail into center of tack, heating up for tie-in
If the gap is too wide simply weave torch for the first 1 or so to help bridge metal across gap
Hold torch 45 to 55 from vertical toward the puddle , staying on the leading edge
Continue welding while positioner is moving away from the welder
Keep torch in the 1-2 oclock range
Grind all start and stops

13.5 Hot Pass E71T-1 FCAW
Clean the root pass, remove glass-like material
Remove crown of root pass, as this will hinder the hot pass
Make the root surface fairly flat to avoid stubbing of wire
Follow parameters listed above
Weave pattern wide enough to ensure good fusion

13.6 Fill Pass E71T-1 FCAW
Clean hot pass
Remove crown if needed
Weave wider without filling entire joint
Leave 1/16-3/32 below flush

13.7 Cap Pass E71T-1 FCAW
Clean fill , flatten out remove crown if needed
Weave enough to cover edges and ensure joint is filled completely

92

Once the student becomes proficient and the coupon has been accepted from root to cap then it may be
submitted following the same protocol for any other test.

Revision No. 1


13g Position Welds
Once student passes their test (UA 30) they may either proceed to the 2G, 5G and 6G positions to test in
the 6G with these processes
(Or)
The student may proceed to the UA 79 using the Short circuit and the Spray/Pulsed transfer mode

13h UA 79
Parameters for the UA 79 shall be adhered to, please refer to the Weld Test Specification
Basic parameters for the Pipe Pro Miller machine are attached to the machine itself
Root Pass should be #4 on panel display
Balance should be #8 on panel display
Root should be at the 2 oclock position
Stay on top for the balance
No movement for the root pass technique
Root gap can be up to 5/32 along with a land size to 1/8 as per UA 79 specification

Student shall become proficient with process and then submit a sample for the UA 79. The request form will be
filled out in the same manner as any other UA test sample.

Students will be asked to proceed to 1 thick plate in preparation for the UA 23, UA 9T or the UA 78. These
weldments shall also be used to gain experience with stainless steel covered electrodes, Inconel covered
electrodes and larger diameter carbon steel covered electrodes.

93

Revision No. 1

Section 14 - Introduction to Stainless Steel & Inconel Covered Electrodes (SMAW)

14a Objective:
To gain experience with stainless steel covered electrodes, using different diameters and classifications,
such as E309-15 or 309-17, 3/32 or 1/8
To gain experience with Inconel covered electrodes, using different diameters and classifications, such
as ENiCrFe-3 or ENiCrMo-3, 3/32 or 1/8

The instructor shall accept or reject each pass following the same criteria that has previously been followed for all
welding samples and UA tests. Once the student has produced an acceptable sample a Test Request form
shall be filled out and the sample shall be sent to Mr. Hintz for his approval.

The student will be encouraged to continue their welding education by being challenged with advanced
techniques and processes under the supervision of their welding instructors. This may include, but is not limited
to: position welds in field-like conditions, socket welds, sleeves, saddles and branch connections, projects based
on drawings that are provided, mock-up of pressure vessels or any other UA test they would like to attempt.

94

Revision No. 1

Section 15 Supplementary Documents

Document 1: Welding Safety PPT (Provided on Faculty Folder)

Document 2: Introduction to Welding PPT (Provided on Faculty Folder)

Document 3: Weld Shop Rules & Regulations (Separate binder located outside of Weld Shop)

Document 4: Six Basic Fundamentals (Separate binder located outside of Weld Shop)

Document 5: Lincoln Electric Low Hydrogen Article (Separate binder located outside of Weld Shop)

Document 6: Acceptable Weld Profiles (Separate binder located outside of Weld Shop)

Document 7: UA Oxy-Fuel / SMAW Manual Chapters 8-12 (Separate binder located outside of Weld Shop)

Document 8: Feathering Tacks (Separate binder located outside of Weld Shop)

Document 9: Down Hand Progression (Separate binder located outside of Weld Shop)

Document 10: Arc Zone Tungsten Preparation (Separate binder located outside of Weld Shop)

Document 11: Request to Test Form (Sample) (Separate binder located outside of Weld Shop)

Document 12: Shop Floor Plan (Separate binder located outside of Weld Shop)

Document 13: Apprentice Welding Criteria per Year (Separate binder located outside of Weld Shop)

95

Revision No. 2

Section 16 Errata/Addendum

Revision No. 2, March 29, 2013:
Newly Defined Progression List of Weldments for the Apprentice:
1. UA 21
2. UA 76
3. UA 15
4. UA 41
5. UA 35
6. UA 14 & 45 (to be done at the same time)
7. UA 91
8. UA 30 & 79 (to be done at the same time)
9. UA 77 and/or TIP TIG (dependent on availability)
10. Advanced/individualized training (various SMAW Electrodes and also GMAW/FCAW in
position)

96

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