HOW TO USE THIS MODULE This module entitled Performing groove welding on carbon steel plate pipe is one

of the core competencies of Shielded Metal Arc Welding (SMAW) NC II under the Construction Sector It covers the knowledge, skills and attitudes required to obtain, interpret and convey information in response to workplace communication. All trainees are required to browse, go over this module and participates the different activities required for the said qualification. As you go through this module, you can encounter different instruction sheets for you to fill up. You can write your answers to the different sheets located in the module. If you have any questions, please do not hesitate to ask your trainer so that he assists you in filling-up all the sheets as being required. These are the following Instruction sheets: Information Sheet This will provide you with information (Concepts, principles and other relevant information) needed in performing certain activities. Activity Sheet This is designed to guide you how to do activity that will contribute to the attainment of the learning outcome.

RECOGNITION OF PRIOR LEARNING (RPL) Recognition of Prior Learning (RPL) is a form of assessment that acknowledges your formal and informal learning gained through: Previous training and education Past and current work experience Life experience

The RPL process will involve validation of your existing skills and knowledge. Through this process you will be able to obtain credits in a course and, in some cases, a full qualification. The assessment can take place by viewing existing academic records, Certificates of Competency from previous trainings/workshop attendance, written support by previous employers and by viewing procedures and process undertaken in your workplace. If you can demonstrate to your trainer that you are competent in a particular skills, talk to him/her about having them formally recognized so you dont have to do the same training again. This module was prepared to help you achieve the required competency, in Shielded Metal Arc Welding NC II. This will be the source of information for you to acquire knowledge and skills in this particular trade independently and at your own pace, with minimum supervision or help from your instructor. *Talk to your trainer and agree how you will both organize the training under this module. Read through module carefully. It is divided into sections that cover all the skills and knowledge you need to successfully complete.

*Work through all information and complete the activities in each section. Read the information sheets and complete the self-checks provided in this module

CONSTRUCTION INDUSTRY SECTOR SMAW NC II QUALIFICATION / LEVEL COMPETENCY-BASED LEARNING MATERIALS No. Basic Competencies Module Title 1. Participate in workplace Participating in workplace communication communication 2. Work in team environment Working in team environment 3. Practice career Practicing career professionalism professionalism 4. Practice occupational Practicing occupational health health and safety and safety procedures procedures No. Common Competencies 1. Apply safety practices 2. Interpret drawing and sketches 3. Perform industry calculation 4. Contribute to quality system 5. Use hand tools 6. Prepare weld materials 7 Set-up welding equipment 8. Fit-up weld materials 9. Repair Weld No. Core Competencies 1. Perform groove welding on carbon steel plate 2. Perform groove welding on Module Title Applying safety practices Interpreting drawing and sketches Performing industry calculation Contributing to quality system Using hand tools Preparing weld materials Settling-up welding equipment Fitting-up weld materials Repairing Weld Module Title Performing groove welding on carbon steel plate Performing groove welding on Code DS

carbon steel pipe

carbon steel pipe

Code 500311105 500311106 500311107 500311108

MODULES OF INSTRUCTIONS UNIT OF COMPETENCY: MODULE TITLE: MODULE DESCRIPTOR: NOMINAL DURATION: PREREQUISITE: 80 hours

Pr

Code

SUMMARY OF LEARNING OUTCOMES: Upon completion of this module you will be able to : LO1. Performing groove welding on carbon steel plate LO2. Performing groove welding on carbon steel pipe ASSESMENT CRITERIAS

TABLE OF CONTENTS QUALIFICATION TITLE OF COMPETENCY MODULE TITLE : : : PERFORMANCE CRITERIA PAGE NO.

Learning Outcome 1 (LO1): Performing groove welding on carbon steel pipe Objective: Able to perform weld carbon steel pipe. INFORMATION SHEET #1

CORE COMPETENCY ELEMENTS

Pipe Positions

The four principal positions of pipe welding are classified according to the position of the pipe, not of the weld: 1G - pipe in the horizontal position that is rolled; 2G - pipe in the fixed vertical position; 5G - pipe in the fixed horizontal position; and 6G - pipe in a fixed 45-degree position. In addition to these four positions are special case positions or welds: R - pipe in a restricted position; F - a fillet weld; and G - a groove weld. There are four positions used for a groove welding job, the standard type of welding. Of these numbered positions, 3G references a vertical welding job, which is a required skill to pass a welding certification test.

Welding pipes is one of the simplest and most durable ways to join piping together and steel pipes can simply be welded together with MIG (metal inert gas), TIG (tungsten inert gas or SMAW (stick metal arc) welding. Before welding two pipes together, avoid any gaps between the two pipes. While welding, take measures to ensure the continual alignment of the two pipes. Align the two pipes and use clamps to hold them together, if necessary. Fire your welding torch or strike your welding electrode on the steel to open an arc between the welding tool and pipes. Allow the torch to form a small welding puddle on the surface of the steel, called a tack weld.

 Move the arc slightly and create another welding puddle elsewhere on the circumference of the pipes. Continue to move the arc and create more welding puddles until you have formed a series of tack welds at regular intervals along the circumference. Move the welding tool thoroughly along the circumference of the pipes creating a welding puddle that extends fully around the circumference and connects the two pipes together. Extinguish the arc and allow the welding puddle several minutes to dry.

Before the pipes can be fit up and welded, the welder has to prepare the ends of the pipes. The standard configuration for pipe welding is a single-vee butt weld. In this case, the outer edge of the pipe is beveled so that when the edges of the pipe are brought together, they form a vee-shaped groove that will contain the weld. The edges of the pipe can be beveled using a torch cutter and cleaned up by grinding, or by using a pipe cutting machine. In some cases, the pipes may be pre-beveled as part of the manufacturing process. The pipe edges are then cleaned and de-greased to remove contaminants from the surface that could adversely affect the weld. Welding the two pieces together requires the use of three welding techniques: inverted, vertical and flat.

Pipe welding requires special attention to equipment and safety precautions. Pipe fitting and welding is a very common activity for welders, and requires different techniques and a higher skill level than standard flat welds. Many pipes require welds to be performed overhead or in tight confines, and the welder has to maintain a consistent bead while continuously moving the equipment around the pipe.

SELF CHECK # 1 Learning Outcome 1: Weld Carbon Steel Pipe Direction: Multiple choice Answer the following questions: 1. What are the required three welding techniques when welding the two pieces together? A. horizontal, inverted, vertical B. vertical, horizontal, inverted C. inverted, vertical and flat
2. What are the four principal positions of steel pipe welding?

ANSWER KEY # 1 Learning Outcome 1: 1. C 2. A 3. B

A. 1G, 2G, 5G ,and 6G B. 1G, 2G, 3G, and 4G C. 1F, 2F 4F, 5F 3. What is the standard configuration for pipe welding? A. horizontal B. single-vee butt weld C. vertical

JOB SHEET #1 Learning Outcome: 2: Weld Carbon Steel Pipes in Fixed Pipe Horizontal Position (5G) Objective: Able to perform weld carbon steel pipe horizontal position (5G) Procedure:

Learning Outcome 2 (LO2): Weld Carbon Steel Pipes in Fixed Pipe Horizontal Position (5G) Objective: Able to perform weld carbon steel pipe Horizontal Position (5G)

INFORMATION SHEET #2

The 5G test places the pipe in a horizontal position from which it cannot be moved. This requires the welder to transition from vertical to horizontal and overhead positions. These are similar to the welds required in the 6G position. There are two general procedures for welding pipes in a horizontal position: uphill welding and downhill welding. Uphill pipe welding is a technique most applicable to thick walled pipes that can retain heat. The weld begins at the lowest point of the pipe the welder builds the bead up one side of the pipe to the top of the pipe. The welder then repeats this process on the other side of the pipe, starting the weld at the lowest point and moving the bead upwards. Downhill pipe welding is performed on thin walled pipes that can dissipate heat quickly. In this case, the welder will start the weld at the top of the pipe and work the bead down to the lowest point of the pipe, repeating the process on the other side. welding requires safety equipment including face and eye protection. Other than orientation, the general welding procedure is no different than flat welding, and will depend on the type of welding and the material of the pipes.

Allow the welded joint and steel pipe to cool. Test the strength of the joint by applying pressure to the pipe near the weld.

Restricted Position Tests

The 2G, 5G and 6G tests can be given with a restricting ring, restricted boiler plate tube or a box type restriction. These tasks are designed to test the welder in unusual positions, and in some cases welding with either hand. The box type restriction is additionally designed to test the welder in shipyard applications where access and vision is difficult. Ensure welding goggles cover your eyes during the melting process to protect them from bright light. Heat the steel pipe ends to be welded. Melt the welding rod into the joint of the steel pipe. Or solder the welding rod into the joint of the steel pipe using a propane torch. Ensure the melted welding rod or solder joint covers the entire surface of the pipe joint.

SELF CHECK # 2 Learning Outcome 2: Weld Carbon Steel Pipes in Fixed Pipe Horizontal Position
(5G)

ANSWER KEY # 2 Learning Outcome 2: 1. Uphill welding and downhill welding. 2. The weld begins at the lowest point of the pipe. 3. Downhill pipe welding is performed on thin walled pipes. 4. Because a thin walled pipes can dissipate the heat quickly.

Direction: Write down the correct answer. Answer the following questions: 1. What are the two general procedures for welding pipes in a horizontal position? 2. Where to begin when performing uphill pipe welding? 3. What kind of pipes will be used when performing downhill pipe welding? 4. Why is it necessary to use thin walled pipes when performing downhill pipe welding?

profession where technicians are required to pass specific tests to achieve certification and employment. JOB SHEET #1 Learning Outcome 3: Weld carbon steel pipes in fixed pipe, inclined at 45
position (6G)
Learning Outcome 3: (LO3)

: Weld carbon steel pipes in fixed pipe, inclined at 45

position (6G)
Objective: Weld carbon steel pipes in fixed pipe, inclined at 45 position (6G)

Objective: Able to perform weld carbon steel pipes in fixed pipe, inclined at 45
position (6G)

INFORMATION SHEET #3 The 6G Welding Learn to identify 6G welding, the most commonly used kind of weld to test a welder for certification. The letter "G" stands for the type of weld, which is a groove weld and the number "6" designates the position of the pipes welded. A groove weld is a joint in two metal pipes where the space in between them is filled up with the welding material.

Procedure:

The 6G Welding Position

The easiest way to join two sections of pipe without complicated joint designs or special threading equipment is by welding. Because the pipes are fused together into what is essentially a single pipe, welded piping has reduced flow restrictions compared to mechanical connections. The primary pipe welding methods are the shielded metal-arc process and gas-shielded arc methods. Because of the hazardous materials that most pipelines carry, pipe welding has become recognized as a

Welds are of three main types; flat welds are the easiest to make, horizontal welds more difficult and vertical welds are the most demanding. This is because the molten filling metal flows downwards during the welding process, pulled by gravity into the joint cavity. In a vertical weld this may occur too quickly, so it requires much practice. In welding, a 6G position requires one pipe to be positioned at a 45-degree angle to the other. Both are horizontal. This presents a very challenging position for a welder, who uses all his skills and a variety of body positions to accomplish the most difficult weld in the 6G join: the overhead weld.

* This weld is considered the most difficult type of weld to perform because it requires welds that are made in all positions using both hands. It also simplifies testing, removing the need for testing each position used to perform a 6G weld individually.

The 6G Welding Test

The 6G welding test, also known as the Arkansas bell hole test, is a means to identify the skills or lack of them in a welder. It's stringent test, because the welder must use a variety of techniques, such as flat, vertical and horizontal welding to achieve a successful 6G weld. 6G welds are made by workers in trades like steel working that require skillful welding ability. When a welder can produce a good 6G weld, he is tested on it and receives certification when he passes this test.

5. Start welding the root passes with a 6010 rod in an inverted position, from the 6 oclock to the 9 oclock position. You will, of course, transition from inverted to vertical as you progress. During the inverted phase, your welding rod should be held straight up and down, but angled back slightly from the direction of travel. All welds are done in push mode to prevent undercut on the top piece of pipe.

The 6G stick, or arc weld, pipe test, consists of welding two pieces of 6-inchdiameter, schedule 40 pipe together. The two pieces are beveled at a 60-degree angle. The beveled ends are held about 1/8 inch apart in clamps at a 45-degree angle. Welding the two pieces together requires the use of three welding techniques: inverted, vertical and flat. * Groove welds, including 6G welds, are used on all kinds of joints except for joints constructed from two overlapping pipes, known as lap joints. It's rare a certified welder will encounter pipes requiring 6G welds while working, but it's a common pre-employment test.

6. Make sure you are getting adequate penetration on your root welds. You should hear the arc coming from inside the pipe. Make sure you have a good keyhole. If it is too small and tries to close up, turn the amperage up by 5 amps. If it is too big, go down 5 amps. 7. Feather the end of your welds with a grinder. Remove all porosity.

12. Run your fill welds on each side of the cap weld so that you just cover the edges of the bevels.

8. From the end of the weld. Shape the ground area like a ramp so you can penetrate into the end of the weld when you start your next weld.

9. Change the angle of the rod so it is perpendicular to the pipe as you go vertical. Do not end a weld on a tack weld. Burn through the tack welds for adequate penetration in that area.

10. Do not weld from the 12 oclock position down to the 3 oclock position. Downhill vertical welds have no strength and you will fail the test. When you reach the 12 oclock position, move back down to the 6 oclock position and start over, moving in a counterclockwise direction

11. Start your cap weld with a 7018 rod. Follow the same direction of travel as in the root welds with the rod held in the same positions as in the previous steps. Keep the rods moving to prevent sticking, and keep it close to the pipe to prevent porosity.

* A 6GR test is a variant of the 6G test. The conditions are all the same as the 6G test, with one additional factor. The letter "R" in 6GR stands for restricted and means the test weld is performed with a ring made from steel plate placed an inch under the weld site. This extra degree of difficulty tests the ability of a welder to make a joint where impediments, such as brackets, attach the pipe to another structure or wall.

SELF CHECK # 3 Learning Outcome 3: Weld carbon steel pipes in fixed pipe, inclined at 45
position (6G)

ANSWER KEY # 3 Learning Outcome 3: 1. This weld is considered the most difficult type of weld to perform because it requires welds that are made in all positions using both hands. It also simplifies testing, removing the need for testing each position used to perform a 6G weld individually.

Direction: Enumeration Answer the following questions: 1. Why 6G is the Most Difficult of Welds? 2. What are 6G Welds used for? 3. What is a 6GR Test?

2. Groove welds, including 6G welds, are used on all kinds of joints except for joints constructed from two overlapping pipes, known as lap joints. It's rare a certified welder will encounter pipes requiring 6G welds while working, but it's a common pre-employment test. 3. A 6GR test is a variant of the 6G test. The conditions are all the same as the 6G test, with one additional factor. The letter "R" in 6GR stands for restricted and means the test weld is performed with a ring made from steel plate placed an inch under the weld site. This extra degree of difficulty tests the ability of a welder to make a joint where impediments, such as brackets, attach the pipe to another structure or wall.