COMPETENCY BASED

LEARNING MATERIALS

Sector : METALS AND ENGINEERING

Qualification Title : Shielded Metal Arc Welding NCII

Unit of Competency : Weld Carbon Steel Plates

Module Title : Performing Groove Welding on

Carbon Steel Plates

Golden Heritage Polytechnic College

Va menta Blvd., Carmen, 9000 Cagayan de Oro City, Misamis Oriental, Philippines
HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIALS

Welcome!
The unit of competency, “Weld Carbon Steel Plates”, is one of the
competencies Shielded Metal Arc Welding NCII, a course which comprises
the knowledge, skills and attitude required for a TVET trainee to posses.

The module, Weld carbon steel plates, contains training materials and
activities related to identifying learner’s requirements, preparing session
plan, preparing basic instructional materials and organizing learning and
teaching activities for you to complete.

In this module, you are required to go through a series of learning

activities in order to complete each learning outcome. In each learning
outcome are Information Sheets, Self-Check and Task Sheets. Follow and
perform the activities based on instructions given. If you have questions, do
not hesitate to ask for assistance from your trainer.

Remember to read Information Sheets and complete the Self-Check.

Suggested references are included to supplement the materials provided in
this module. Perform Task Sheet until you are confident that your outputs
conform to the Performance Criteria Checklist that follows the sheets.
Submit outputs of the task sheets to your trainer for evaluation and
recording in the Achievement Chart. Outputs shall serve as your portfolio
during the Institutional Competency Evaluation. When you feel confident
that you have had sufficient practice, ask your trainer to evaluate you. The
results of your assessment will be recorded in your Progress Chart.

You must pass the Institutional Competency Evaluation for this

competency before moving to another competency.
 List of Competencies

No. Unit of Competency Module Title Code

Weld Carbon Steel
Plates and Pipes Using Welding Carbon Steel
1. SMAW Plates and Pipes Using MEE721306
SMAW
MODULE CONTENT

UNIT OF COMPETENCY: Weld Carbon Steel Plates

MODULE TITLE: Performing Groove Welding on Carbon Steel Plates

MODULE DESCRIPTOR: This module covers the knowledge, skills and attitude in
performing groove welding on carbon steel plates in different positions such as 1G,
2G, 3G, & 4G

NOMINAL DURATION: 120 Hours

LEARNING OUTCOMES:

At the end of this module you MUST be able to:

LO1. WELD CARBON STEEL PLATES IN FLAT POSITION (1G)

LO2. WELD CARBON STEEL PLATES IN HORIZONTAL POSITION (2G)

LO3. WELD CARBON STEEL PLATES IN VERTICAL POSITION (3G)

LO4. WELD CARBON STEEL PLATES IN OVERHEAD POSITION (4G)

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
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ASSESSMENT CRITERIA:
1. Root penetration not exceeding allowable tolerances specified by welding
codes/ standards on
 concavity
 convexity
 undercut
 excess penetration
 lack of fusion
 burn-through
 cracks
2. Weld capping/ final pass not exceeding allowable tolerances specified by
welding codes/ standards on
 height of reinforcement
 underfill
 porosities
 undercut
 cracks
 cold laps
3. Uniformity of bead ripples must be in accordance with welding standards
4. Stringer or layered beads deposited in accordance with welding standards
5. Finish weldment visually acceptable in accordance with welding
standards for:
 spatters
 arc strikes
 slag
 uniformity of beads

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
2019
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 LEARNING OUTCOME NO. 1
WELD CARBON STEEL PLATES IN FLAT POSITION (1G)

Contents:

 Essentials of welding
 International welding codes and standards
 Acceptable weld profiles
 Weld defects, causes and remedies
 Welding Procedure Specifications (WPS)
 Welding techniques and procedures
 Safe welding practices

Assessment Criteria
1. Root penetration not exceeding allowable tolerances specified by welding
codes/ standards on
 concavity
 convexity
 undercut
 excess penetration
 lack of fusion
 burn-through
 cracks

2. Weld capping/ final pass not exceeding allowable tolerances specified by

welding codes/ standards on
 height of reinforcement
 underfill
 porosities
 undercut
 cracks
 cold laps
SHIELDED METAL ARC Document No.
WELDING NC II Date Revised: August
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 3. Uniformity of bead ripples must be in accordance with welding standards
4. Stringer or layered beads deposited in accordance with welding standards
5. Finish weldment visually acceptable in accordance with welding standards
for:
 spatters
 arc strikes
 slag
 uniformity of beads

Conditions

Trainees must be provided with the following:

1. Equipment
- Welding machine (AC or AC/DC)
- Welding table or jig
- Portable grinder
- Welding booth
- Portable oven

2. Tools/Accessories
- Welding mask
- Steel brush
- Clear glass
- Chipping hammer
- Dark glass

3. Supplies/ Materials
- Electrodes
- Carbon steel plates
- Cutting grinding disk

4. Personal protective equipment

- Safety shoes
- Apron
SHIELDED METAL ARC Document No.
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 - Leggings
- Safety goggles
- Gloves

5. Training Materials
- Arc welding manuals
- Welding procedures specifications (WPS)
- Welding standards

Assessment Method

 Written/Oral
 Interview
 Direct observation

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
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 LEARNING EXPERIENCES

Learning Outcome 1

WELD CARBON STEEL PLATES IN FLAT POSITION (1G)

Learning Activities Special Instructions

1. Read Information Sheet This information sheet required
1.1.1 to read and define essential of
Essential of welding welding
2. Answer Self-Check 1.1.1 Compare answer with the answer
key. You are required to get all
answers correct. If not, read the
information sheets again to
answer all questions correctly.
3. Read Information Sheet This information sheet discusses
1.1.2 International welding international welding codes and
codes and standards standards.

4. Answer Self-Check 1.1.2 Compare answer with the answer

key. You are required to get all
answers correct. If not, read the
information sheets again to
answer all questions correctly.
5. Read Information Sheet This information sheet discusses
1.1.3 acceptable weld Acceptable weld profiles
profiles

6. Answer Self-Check 1.1.3 Compare answer with the answer

key. You are required to get all
answers correct. If not, read the
information sheets again to
answer all questions correctly.
7. Read Information Sheet This information sheet identify
SHIELDED METAL ARC Document No.
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 1..1.4 weld defects, causes and
Weld defects, causes and remedies
remedies

8. Answer Self-Check 1.1.4 Compare answer with the answer

key. You are required to get all
answers correct. If not, read the
information sheets again to
answer all questions correctly.
9. Perform Job Sheet 1.1.4 Evaluate your own work using
the Performance Criteria.
Prepare and Store laundry Present your work to your trainer
items for evaluation and recording.
10. Read Information This information sheet discusses
Sheet 1.1.5 welding procedure specification
Welding Procedure (WPS)
Specifications (WPS)
11. Answer Self-Check Compare answer with the answer
1.1.5 key. You are required to get all
answers correct. If not, read the
information sheets again to
answer all questions correctly.
12. Read Information This information sheet discusses
Sheet 1.1.6 Welding techniques and
Welding techniques and procedure.
procedure
13. Answer Self-Check Compare answer with the answer
1.1.6 key. You are required to get all
answers correct. If not, read the
information sheets again to
answer all questions correctly.
14. Read Information This information sheet discusses
Sheet 1.1.7 Safe welding practices
Safe welding practices
15. Answer Self-Check Compare answer with the answer
1.1.7 key. You are required to get all

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
2019
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 answers correct. If not, read the
information sheets again to
answer all questions correctly.

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
2019
Issued by:

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 Information Sheet 1.1.1
Essentials of welding

Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
1. Define welding and SMAW.
2. Essentials of welding.

Definitions of terms:
Welding is a fabrication or sculptural process that joins materials,
usually metals or thermoplastics, by causing coalescence. This is often
done by melting the workpieces and adding a filler material to form a
pool of molten material (the weld pool) that cools to become a strong
joint, withpressure sometimes
used in conjunction with heat, or
by itself, to produce the weld. This
is in contrast
with soldering and brazing, which
involve melting a lower-melting-
point material between the
workpieces to form a bond between
them, without melting the work
pieces.
There are several different ways to
weld, such as: Shielded Metal Arc
Welding, Gas Tungsten Arc
Welding, Tungsten Inert Gas and
Metallic Inert Gas. MIG or Metallic
Inert Gas involves a wire fed "gun"
that feeds wire at an adjustable speed and sprays a shielding gas
(generally pure Argon or a mix of Argon and CO2) over the weld puddle
to protect it from the outside world. TIG or Tungsten Inert Gas involves
a much smaller hand-held gun that has a tungsten rod inside of it.
SHIELDED METAL ARC Document No.
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With most, you use a pedal to adjust your amount of heat and hold a
filler metal with your other hand and slowly feed it. Stick welding or
Shielded Metal Arc Welding has an electrode that has flux, the
protectant for the puddle, around it. The electrode holder holds the
electrode as it slowly melts away. Slag protects the weld puddle from
the outside world. Flux-Core is almost identical to stick welding except
once again you have a wire feeding gun, the wire has a thin flux
coating around it that protects the weld puddle.
Many different energy sources can be used for welding, including a
gas flame, an electric arc, a laser, an electron beam, friction, and
ultrasound. While often an industrial process, welding may be
performed in many different environments, including open air, under
water and inouter space. Welding is a potentially hazardous
undertaking and precautions are required to avoid burns, electric
shock, vision damage, inhalation of poisonous gases and fumes, and
exposure to intense ultraviolet radiation.
Until the end of the 19th century, the only welding process was forge
welding, which blacksmiths had used for centuries to join iron and
steel by heating and hammering. Arc weldingand oxyfuel welding were
among the first processes to develop late in the century, and electric
resistance welding followed soon after. Welding technology advanced
quickly during the early 20th century as World War I and World War II
drove the demand for reliable and inexpensive joining methods.
Following the wars, several modern welding techniques were
developed, including manual methods like shielded metal arc welding,
now one of the most popular welding methods, as well as semi-
automatic and automatic processes such as gas metal arc
welding, submerged arc welding, flux-cored arc welding and electroslag
welding. Developments continued with the invention of laser beam
welding, electron beam welding,electro magnetic pulse
welding and friction stir welding in the latter half of the century.
Today, the science continues to advance. Robot welding is
SHIELDED METAL ARC Document No.
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commonplace in industrial settings, and researchers continue to
develop new welding methods and gain greater understanding of weld
quality.

Shielded metal arc welding (SMAW)

Also known as manual metal arc

welding (MMA or MMAW), flux
shielded arc welding or
informally as stick welding, is a
manual arc welding process that
uses a
consumable electrode coated
in flux to lay the weld. An electric
current, in the form of
either alternating current or direct
current from a welding power
supply, is used to form an electric
arc between the electrode and the metals to be joined. As the weld is
laid, the flux coating of the electrode disintegrates, giving off vapors
that serve as a shielding gas and providing a layer of slag, both of
which protect the weld area from atmospheric contamination.
Because of the versatility of the process and the simplicity of its
equipment and operation, shielded metal arc welding is one of the
world's most popular welding processes. It dominates other welding
processes in the maintenance and repair industry, and thoughflux-
cored arc welding is growing in popularity, SMAW continues to be used
extensively in the construction of steel structures and in industrial
fabrication. The process is used primarily to
weld iron and steels (including stainless steel)

SHIELDED METAL ARC Document No.

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but aluminium, nickel andcopper alloys can also be welded with this
method.
ESSENTIALS OF WELDING

Five essentials of welding

1. CORRECT ELECTRODE SIZE

The correct choice of electrode size involves consideration of a
variety of factors, such as the type, position, preparation of the
joint, the ability of the electrode to carry high current values
without injury to the weld metal or loss of deposition efficiency,
the mass of work metal and its ability to maintain its original
properties after welding, the characteristics of the assembly with
reference to effect stresses set up by heat application, the
practicability to heat treatment before and / or after welding, the
specific requirement before and / or after welding, the specific
requirements as to welding quality and cost of achieving the
desired results.

2. CORRECT CURRENT
If current on equipment is too high or too low, you are certain to
be disappointed in your weld. If too high, the electrode melts too
fast and your molten pool is large and irregular, if too low, there
is no enough heat to melt the base metal and your molten pool
will be small, will pile up, look irregular.

3. CORRECT ARC LENGTH

If the arc is too long or voltage too high the metal melts off the
electrode is large globules which wobble from side to side as the
arc wavers, giving a wide, spattered and irregular bead-with poor
fusion between original metal and deposited metal.

If the arc is too short, or voltage too low, there is not enough
heat to melt the base metal properly and the electrode quite

SHIELDED METAL ARC Document No.

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 often sticks to the work, giving a high, uneven bead, having
irregular ripples with poor fusion.

4. CORRECT TRAVEL SPEED

When your speed is too fast your pool does not last long enough,
impurities an gas locked in. The bead in narrow and ripples
pointed. When speed is too slow the metal piles up, the bead is
high and wide with a rather straight ripple.

5. CORRECT ELECTRODE ANGLE

The electrode angle is of particular importance in fillet welding and

deep groove welding. Generally speaking, when making a fillet weld,
the electrode should be held so that bisects
the angle between the plates (as shown at
right) and is perpendicular to the line of weld, if under cut occurs in
the verticle member, lower the angle of the arc and direct the arc
toward the vertical member.

SHIELDED METAL ARC Document No.

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 Self- Check 1.1.1

True or False. Write TRUE if the statement is correct and FALSE if it

is wrong. Write your answers on your answer sheet.

1. If too high, the electrode melts too fast and your molten pool is
large and irregular, if too low, there is no enough heat to melt
the base metal and your molten pool will be small, will pile up,
look irregular.

2. Electrode angle is of particular importance in fillet welding and

deep groove welding.

3. If the electrode is too long or voltage too high the metal melts
off the electrode is large globules which wobble from side to
side as the arc wavers, giving a wide, spattered and irregular
bead-with poor fusion between original metal and deposited
metal.
4. Robot welding is commonplace in industrial settings, and
researchers continue to develop new welding methods and
gain greater understanding of weld quality.
5. The correct choice of arc size involves consideration of a
variety of factors, such as the type, position, preparation of the
joint, the ability of the electrode to carry high current values
without injury to the weld metal or loss of deposition efficiency

SHIELDED METAL ARC Document No.

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Answer Key 1.1.1

1. True
2. True
3. False
4. True
5. False

SHIELDED METAL ARC Document No.

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 Information Sheet 1.1.2
International Welding Codes and standards

Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
1. International Welding Codes and standards

International Welding Codes and standards

The American Society of Mechanical Engineers (ASME) Boiler and
Pressure Vessel Code (BPVC) covers all aspects of design and
manufacture of boilers and pressure vessels. All sections contain
welding specifications, however most relevant information is contained
in the following:

Code Description

ASME BPVC Part C: Specifications for Welding Rods, Electrodes,

Section II and Filler Metals.

ASME BPVC
Nondestructive Examination
Section V

ASME BPVC
Welding and Brazing Qualifications
Section IX

ASME B16.25 Buttwelding ends

SHIELDED METAL ARC Document No.
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 Code Description

American Welding Society (AWS) Standards

The American Welding Society (AWS) publishes over 240 AWS-
developed codes, recommended practices and guides which are written
in accordance with American National Standards Institute (ANSI)
practices. The following is a partial list of the more common
publications:

Standard
Title
Number†

Standard symbols for welding, brazing, and non-

AWS A02.4
destructive examination

AWS A03.0 Standard welding terms and definitions

Specification for carbon steel electrodes for shielded

AWS A05.1
metal arc welding

Specification for carbon steel electrodes and rots for

AWS A05.18
gas shielded arc welding

AWS B01.10 Guide for the nondestructive examination of welds

SHIELDED METAL ARC Document No.
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 Standard
Title
Number†

Specification for Welding Procedure and Performance

AWS B02.1
Qualification

AWS D01.1 Structural welding (steel)

AWS D01.2 Structural welding (aluminum)

AWS D01.3 Structural welding (sheet steel)

AWS D01.4 Structural welding (reinforcing steel)

AWS D01.5 Bridge welding

AWS D01.6 Structural welding (stainless steel)

AWS D01.7 Structural welding (strengthening and repair)

AWS D01.8 Structural welding seismic supplement

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 Standard
Title
Number†

AWS D01.9 Structural welding (titanium)

AWS D09.1 Sheet metal welding

AWS D10.10 Heating practices for pipe and tube

AWS D10.11 Root pass welding for pipe

AWS D10.12 Pipe welding (mild steel)

AWS D10.13 Tube brazing (copper)

AWS D10.18 Pipe welding (stainless steel)

AWS D11.2 Welding (cast iron)

AWS D14.1 Industrial mill crane welding

AWS D14.3 Earthmoving & agricultural equipment welding

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 Standard
Title
Number†

AWS D14.4 Machinery joint welding

AWS D14.5 Press welding

AWS D15.1 Railroad welding

AWS D16.2 Robotic arc welding system installation

AWS D16.3 Robotic arc welding risk assessment

AWS D18.2 Stainless steel tube discoloration guide

AWS D18.3 Hygienic equipment welding

American Petroleum Institute (API) Standards

The American Petroleum Institute (API) oldest and most successful
programs is in the development of API standards which started with its
first standard in 1924. API maintains over 500 standards covering the
oil and gas field. The following is a partial list specific to welding:

SHIELDED METAL ARC Document No.

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Standard Number Description

API RP 577 Welding Inspection and Metallurgy

API 1104 Welding of pipelines and related facilities

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Australian / New Zealand (AS/NZS) Standards
Standards Australia is the body responsible for the development,
maintenance and publication of Australian Standards. The following is
a partial list specific to welding:

Standard
Description
Number

AS/NZS 1554.1 Structural steel welding - Welding of steel structures

Structural steel welding - Stud welding (steel studs to

AS/NZS 1554.2
steel)

AS/NZS 1554.3 Structural steel welding - Welding of reinforcing steel

Structural steel welding - Welding of high strength

AS/NZS 1554.4
quenched and tempered steels

Structural steel welding - Welding of steel structures

AS/NZS 1554.5
subject to high levels of fatigue loading

Structural steel welding - Welding stainless steels for

AS/NZS 1554.6
structural purposes

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 Standard
Description
Number

Structural steel welding - Welding of sheet steel

AS/NZS 1554.7
structures

AS/NZS 3992 Pressure equipment - Welding and brazing qualification

Canadian Standards Association (CSA) Standards

The Canadian Standards Association (CSA) is responsible for the
development, maintenance and publication of CSA standards.The
following is a partial list specific to welding:

Standard
Description
Number

CAN/CSA-G401-
Corrugated Steel Pipe Products
07

Welding consumables - Wire electrodes and weld

CAN/CSA-ISO
deposits for gas shielded metal arc welding of non
14341:11
alloy and fine grain steels -

CAN/CSA- Safety in Welding, Cutting and Allied Processes

W117.2-06
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(R2011)

G40.20-04/
General Requirements for Rolled or Welded
G40.21-04
Structural Quality Steel/ Structural Quality Steel
(R2009)

W178.1-08 Certification of Welding Inspection Organizations

W178.2-08 Certification of Welding Inspectors

W47.1-09 Certification of companies for fusion welding of steel

Certification of companies for fusion welding of

W47.2-11
aluminum

Filler Metals and Allied Materials for Metal Arc

W48-06 (R2011)
Welding

Certification of companies for resistance welding of

W55.3-08
steel and aluminum

W59-03 (R2008) Welded Steel Construction (Metal Arc Welding)

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W59.2-M1991
Welded Aluminum Construction
(R2008)

British Standards (BS)

British Standards are developed, maintained and published by BSI
Standards which is UK's National Standards Body.The following is a
partial list of standards specific to welding:

Standard
Description
Number

Welding terms and symbols. Glossary for welding,

BS 499-1
brazing and thermal cutting

Welding terms and symbols. European arc welding

BS 499-2C
symbols in chart form

Specification for Class I arc welding of ferritic steel pipe

BS 2633
work for carrying fluids

Specification for class II arc welding of carbon steel

BS 2971
pipework for carrying fluids

BS 4515-1 Specification for welding of steel pipelines on land and

offshore - Part 1: Carbon and carbon manganese steel
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 Standard
Description
Number

pipelines

Specification for welding of steel pipelines on land and

BS 4515-2
offshore. Duplex stainless steel pipelines

Structural use of steel and aluminum. Recommendations

PD 6705-2
for the execution of steel bridges to BS EN 1090-2

Structural use of steel and aluminum. Recommendations

PD 6705-3 for the execution of aluminum structures to BS EN
1090-3

International Organization for Standardization (ISO) Standards

International Organization for Standardization (ISO) has developed
over 18500 standards and over 1100 new standards are published
every year. The following is a partial list of the standards specific to
welding:

Standard
Description
Number

ISO 2553 Welded, brazed and soldered joints - symbolic

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Standard
Description
Number

representation on drawings (1992)

Welding consumables. Covered electrodes for manual

ISO 2560 metal arc welding of non-alloy and fine grain steels.
Classification

Covered electrodes for manual arc welding of creep-

ISO 3580
resisting steels - Code of symbols for identification

Covered electrodes for manual arc welding of stainless and

ISO 3581 other similar high alloy steels - Code of symbols for
identification

Quality requirements for fusion welding of metallic

ISO 3834
materials, five parts.

Welding and allied processes - Nomenclature of processes

ISO 4063
and reference numbers

Welding. Fusion-welded joints in steel, nickel, titanium

ISO 5817 and their alloys (beam welding excluded). Quality levels for
imperfections

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Standard
Description
Number

Welding and allied processes — Classification of geometric

ISO 6520-1 imperfections in metallic materials — Part 1: Fusion
welding

Welding and allied processes — Classification of geometric

ISO 6520-2 imperfections in metallic materials — Part 2: Welding with
pressure

Welds. Working positions. Definitions of angles of slope

ISO 6947
and rotation

Qualification test of welders — Fusion welding, parts 1 to

ISO 9606
5

Welding and allied processes. Recommendations for joint

preparation. Manual metal-arc welding, gas-shielded
ISO 9692-1
metal-arc welding, gas welding, TIG welding and beam
welding of steels

Welding and allied processes. Joint preparation.

ISO 9692-2
Submerged arc welding of steels

ISO 9692-3 Welding and allied processes. Joint preparation. Part 3:

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Standard
Description
Number

TIG and MIG welding of aluminum and its alloys

Petroleum and natural gas industries - Pipeline

ISO 13847
transportation systems - Welding of pipelines

Welding - Guidance on the measurement of preheating

ISO 13916 temperature, inter pass temperature and preheat
maintenance temperature

ISO 13918 Welding - Studs and ceramic ferrules for arc stud welding

Welding - Electron and laser-beam welded joints -

ISO 13919-1
Guidance on quality level for imperfections - Part 1: Steel

Welding - Electron and laser-beam welded joints -

ISO 13919-2 Guidance on quality level for imperfections - Part 2:
Aluminum and its weldable alloys

Welding - General tolerances for welded constructions -

ISO 13920
Dimensions for lengths and angles - Shape and position

ISO 14112 Gas welding equipment - Small kits for gas brazing and

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Standard
Description
Number

welding

Welding consumables — Gases and gas mixtures for

ISO 14175 fusion welding and allied processes. Replaced EN
439:1994 in Europe.

Welding consumables. Wire electrodes and deposits for

ISO 14341 gas shielded metal arc welding of non alloy and fine grain
steels. Classification

ISO 14554 Resistance welding

ISO 14744 Electron beam welding, six parts

Specification and qualification of welding procedures for

ISO 15607
metallic materials - General rules

ISO/TR Welding - Guidelines for a metallic material grouping

15608 system

ISO 15609 Specification and qualification of welding procedures for

metallic materials - Welding procedure specification, five

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Standard
Description
Number

parts.

Specification and qualification of welding procedures for

ISO 15610 metallic materials — Qualification based on tested welding
consumables

Specification and qualification of welding procedures for

ISO 15611 metallic materials — Qualification based on previous
welding experience

Specification and qualification of welding procedures for

ISO 15612 metallic materials — Qualification by adoption of a
standard welding procedure

Specification and qualification of welding procedures for

ISO 15613 metallic materials — Qualification based on pre-
production welding test

Specification and qualification of welding procedures for

ISO 15614
metallic materials - Welding procedure test, 13 parts.

ISO 15615 Gas welding equipment. Acetylene manifold systems for

welding, cutting and allied processes. Safety requirements

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Standard
Description
Number

in high-pressure devices

Qualification testing of welders for under-water welding.

ISO 15618-1
Diver-welders for hyperbaric wet welding

Qualification testing of welders for under-water welding.

ISO 15618-2 Diver-welders and welding operators for hyperbaric dry
welding

Non-destructive testing of welds. General rules for metallic

ISO 17635
materials

ISO/TR Welding — Grouping systems for materials — European

20172 materials

ISO/TR Welding — Grouping systems for materials — American

20173 materials

ISO/TR Welding — Grouping systems for materials — Japanese

20174 materials

ISO 24394 Welding for aerospace applications. Qualification test for

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 Standard
Description
Number

welders and welding operators. Fusion welding of metallic

components

European Union (CEN) standards

The European Committee for Standardization (CEN) had issued
numerous standards covering welding processes, which unified and
replaced former national standards. Of the former national standards,
those issued by BSI and DIN were widely used outside their countries
of origin. After the Vienna Agreement with ISO, CEN has replaced most
of them with equivalent ISO standards (EN ISO series).

Standard
Description
Number

Qualification test of welders — Fusion welding — Part 1:

EN 287-1
Steels

Execution of steel structures and aluminum structures -

EN 1090-1 Part 1: Requirements for conformity assessment of
structural components

Execution of steel structures and aluminum structures -

EN 1090-2
Part 2: Technical requirements for steel structures

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 Standard
Description
Number

Execution of steel structures and aluminum structures -

EN 1090-3
Part 3: Technical requirements for aluminum structures

Welding — Recommendations for welding of metallic

EN 1011-1
materials — Part 1: General guidance for arc welding

Welding — Recommendations for welding of metallic

EN 1011-2
materials — Part 2: Arc welding of ferritic steels

Welding — Recommendations for welding of metallic

EN 1011-3
materials — Part 3: Arc welding of stainless steels

EN 1011-4 Welding — Recommendations for welding of metallic

materials — Part 4: Arc welding of aluminum and
aluminum alloys

Welding. Recommendations for welding of metallic

EN 1011-5
materials. Welding of clad steel

Welding. Recommendations for welding of metallic

EN 1011-6
materials. Laser beam welding

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 Standard
Description
Number

Welding — Recommendations for welding of metallic

EN 1011-7
materials — Part 7: Electron beam welding

Welding. Recommendations for welding of metallic

EN 1011-8
materials. Welding of cast irons

EN 1418 Welding personnel. Approval testing of welding operators

for fusion welding and resistance weld setters for fully
mechanized and automatic welding of metallic materials

Welding. Basic welded joint details in steel. Pressurized

EN 1708-1
components.

Welding. Basic weld joint details in steel. Non-internal

EN 1708-2
pressurized components.

Welding. Basic weld joint details in steel. Clad, buttered

EN 1708-3
and lined pressurized components.

Eurocode 3: Design of steel structures – Part 1-8: General

EN 1993-1-8
– Design of joints

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 Standard
Description
Number

EN 13133 Brazing - Brazer approval

Welded, brazed and soldered joints – Symbolic

EN 22553
representation on drawings. (CEN version of ISO 2553)

Additional requirements for welding exist in CEN codes and standards

for specific products, like EN 12952, EN 12953, EN 13445, EN 13480,
etc.

German Standards (DIN and others)

NA 092 is the Standards Committee for welding and allied processes
(NAS) at DIN Deutsches Institut für Normung e. V. The following is a
partial list of DIN welding standards:

Code Description

Welding; terms dependent on materials for metal

DIN 1910-100
welding

Self Check 1.1.2

True or False. Write True if the statement is correct and False if it is

wrong. Write your answers on your answer sheet.
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 1. EN 1708-1 Basic welded joint details in steel. Pressurized
components.
2. EN 1090-1 Execution of steel structures and aluminium
structures .
3. DIN 1910-100 terms dependent on materials for metal welding.
4. SEW 088 Grouping systems for materials — Japanese materials
5. ISO 14112 Gas welding equipment - Small kits for gas brazing
and welding.

Answer key. 1.1.2

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1. True
2. True
3. True
4. False
5. True

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 Information Sheet.1.1.3
Acceptable weld profile

Learning Objectives:

After reading this INFORMATION SHEET, YOU MUST be able to.

1. Acceptable weld profile.

Acceptable and Unacceptable Weld Profiles

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ACCEPTANCE CRITERIA FOR COMPLETED WELDS

 No cracks are permitted

 As-welded surfaces are permitted; however, the surface of welds

shall be sufficiently free from overlaps, abrupt ridges, and
valleys.

 The thickness of reinforcement shall not exceed 3/16 in.

 Undercuts shall not exceed 1/32 in. or 12½ % of the wall
thickness whichever is less.

 For single-welded joints (i.e. butt joints welded from one side),
concavity of the root surface shall not reduce the total thickness
of the joint, including reinforcement, to less than the nominal
thickness of the thinner component being joined.

 For single welded joints, the excess root penetration shall be

exceed the lesser of 1/8 in. or 5 % of the inside diameter of the
pipe.

 The total joint penetration shall not be less than the thickness of
the thinner component being joined, except that incomplete root
penetration is acceptable if it does not exceed the lesser of 1/32
in. or 20 % of the required thickness, and its extent is not more
than 1 ½ in. in any 6 in. length of weld.

 Concavity of the root surface shall not be reduced the total

thickness of the joint, including reinforcement, to less than the
thickness of the thinner of the components being joined.

 The length of unfused bead or layer areas shall not be more than
20 % of the circumference of the pipe, or of the total length of the
weld, and no more than 1½ inches in any 6 in. length of weld.

 Seal, Socket, and Fillet Welds

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  As-welded surfaces are permitted; however, the surface of welds
shall be sufficiently free overlaps, abrupt ridges, and valleys.

 Limitation on imperfections in socket, fillet and seal welds are

the same for cracks, lack of fusion, and undercut.

 1Socket and fillet welds may vary from convex to concave. The
size of a fillet weld is determined. Typical minimum fillet weld
details for slip-on

WELDING BASICS

                                                                      
     The first thing that will be discussed it the different Joints then the
different positions.  There are 5 basic types of Joints there is the Butt
Joint, Corner Joint, T-Joint, Lap Joint, and the Edge Joint.  Some of
the Joints might include a Bevel with or without a Land (Root
Face).  Another thing that must be defined to describe any joint would
be the type of welding position.  The different welding positions are:
Flat, Horizontal, Vertical and Overhead.  Each will also indicate
whether it is a groove, fillet, etc.

     When you get ready to weld on a part it is important to make sure

the weld size is correct.  This can be done by many different methods, I
would recommend getting the book Design of Weldments by Omer W.
Blodgett.  This book is a great resource and can help you in
determining the weld sizes that you will need.  Also check with any
code that you are designing to they may have a pre-determined weld
size that you have to use.

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THE BUTT JOINT

Butt Joint Configurations

     The Butt Joint is a common joint that is usually seen with a Bevel
and a Land.  The Joint can have the pieces placed flush against each
other, but more commonly has a root opening.  There are many
different types of Butt Joints which are: Square, Single Bevel, Double
Bevel, Single-V, Double Bevel, Closed Square, Single-J, Double-J,
Single-U, and the Double-U.
     
     The Joint is welded in all the different positions and is almost

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always labeled as a groove weld.  It is commonly used in the pipe and
sheet metal industries.  

THE CORNER JOINT

     The Corner Joint is where the two pieces form a V or L-shape.  The
weld will be performed on the outside edge of the piece.  This is used
often in the sheet metal industry.  The T-Joint is also welded in all the
different positions.

THE T-JOINT

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     The T-Joint is where the 2 pieces come together to form a T-shape.
This joint is a very common joint and is considered to be a fillet type
joint.  The weld is performed on the inside of the T-joint.  It sometimes
will have a Beveled edge.  This joint can have a single Fillet, Double
Fillet and a Single Bevel.

THE LAP JOINT

     The Lap Joint is when you have to members actually lapping over
each other.  This type of joint can have a Slot or Plug Weld, Fillet Weld
or a Resistance Weld performed.  This type of joint is used regularly in
the sheet metal industry.

THE EDGE JOINT

     The Edge Joint is where to members are placed side by side and
welded on the edge.  

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Name:____________________________________

Self Check 1.1.3

True or False. Write True if the statement is correct and False if it is

wrong. Write your answers on your answer sheet.

1. The Lap Joint is when you have to members actually lapping

over each other.

2. Limitat
3. ion on imperfections in socket, fillet and seal welds are the
same for cracks, lack of fusion, and undercut.

4. Undercuts shall not exceed 1/32 in. or 12½ % of the wall

thickness whichever is less.

5. The corner joint is where the 2 pieces come together to form a

T-shape.  This joint is a very common joint and is considered
to be a fillet type joint.

6. Concavity of the root surface shall not be reduced the total

thickness of the joint, including reinforcement, to less than
the thickness of the thinner of the components being joined.

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Answer key. 1.1.3

1. True
2. True
3. True
4. False
5. True

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 Information Sheet.1.1.4
Weld defects, causes and remedies

Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
1. Identify weld
 Defect
 Causes
 Remedies

Weld Defect, Causes and Remedies

Common weld defects include:

 Lack of fusion
 Lack of penetration or excess penetration
 Porosity
 Inclusions
 Cracking
 Undercut
 Lamellar tearing
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any flaw that compromises the usefulness of a weldment. There is a
great variety of welding defects. Welding imperfections are classified
according to ISO 6520while their acceptable limits are specified in ISO
5817  and ISO 10042. 

Types of defect
Cracks

Defects related to fracture.

Arc strike cracking
Arc strike cracking occurs when the arc is struck but the spot is
not welded. This occurs because the spot is heated above the
material's upper critical temperature and then essentially
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quenched. This forms martensite, which is brittle and micro-cracks.
Usually the arc is struck in the weld groove so this type of crack
does not occur, but if the arc is struck outside of the weld groove
then it must be welded over to prevent the cracking. If this is not an
option then the arc spot can be postheated, that is, the area is
heated with an oxy-acetylene torch, and then allowed to cool slowly.

Cold cracking
Residual stresses can reduce the strength of the base material, and
can lead to catastrophic failure through cold cracking, as was the
case with several of the World War II Liberty ships' hulls. Cold
cracking is limited to steels and is associated with the formation
of martensite as the weld cools. The cracking occurs in the heat-
affected zone of the base material. To reduce the amount of
distortion and residual stresses, the amount of heat input should
be limited, and the welding sequence used should not be from one
end directly to the other, but rather in segments.
Cold cracking only occurs when all the following preconditions are
met:

 susceptible microstructure (e.g. martensite)

 hydrogen present in the microstructure (hydrogen
embrittlement)
 service temperature environment (normal atmospheric pressure):
-100 to +100 °F
 high restraint

Eliminating any one of these will eliminate this condition.

Crater crack
Crater cracks occur when a crater is not filled before the arc is
broken. This causes the outer edges of the crater to cool more
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quickly than the crater, which creates sufficient stresses to form a
crack. Longitudinal, transverse and/or multiple radial cracks may
form.
Fusion-line cracks
The following is an excerpt from a research on Damage Behavior of
Welded Joints with Defects on Fusion Line
Two kinds of welded joints damage models,with notch and crack on
fusion line,were applied to analyse the influences of the mechanical
property heterogeneity and geometric heterogeneity such as
intensity matching, base metal rupture strain,base metal strain-
hardening exponential and welding line width on the damage
distribution and the relationship between damage parameter and
rupture paremater. In addition, in the presence of entire damage
zone method, the crack extension behaviors of the welded joints
were investigated.
Base metal mechanical property has great effects on the damage
distribution of the welded joints. On condition of similar
load,the welded joints damage value increases with the decreasing
base metal rupture strain and the increasing base metal strain-
hardening exponential and intensity matching.
For under-matched welded joints,the damage concentration zone of
the welded joints near the notch will transfer from the welded metal
side to the base metal side as the base metal rupture strain
decreases and strain-hardening exponential increases. but for over-
matched welded joints, the damage concentration zone will transfer
from the base metal side to the welded metal side as the base metal
rupture strain increases and strain-hardening exponential
decreases.
On the other hand, the varied welded line width has little effect on
the damage distribution of the welded joints.For the welded joints

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with crack on fusion line,when loaded and when the crack mouth
opening distance reaches the same level,the maximum damage
value in front of the crack increases as the base metal strain-
hardening exponential and intensity matching increase,but
decreases as the base metal rupture strain increases.
The establishment of the failure principle on the welded structure
should take mechanical property heterogeneity into serious
consideration. The numerical calculations of the crack extension
behavior which is based on the entire damage zone viewpoint reveal
that the crack extension path is parallel to the fusion line on
condition of plane stress but on condition of plane strain the angle
between the crack extension path and the fusion line is
approximate 45°.The numerical calculations and analysis indicate
that micro-damage parameter and macro -rupture parameter both
can describe the stress-strain behaviors,and their relationship
intensively relies on mechanical property heterogeneity. The
investigation on the micro-damage parameter and macro -rupture
parameter is undoubtedly supplement to the safety evaluation and
life-span prediction of the welded joints,which is of great theory
significance.
Hat crack

Hat cracks get their name from the shape of the cross-section of the
weld, because the weld flares out at the face of the weld. The crack

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starts at the fusion line and extends up through the weld. They are
usually caused by too much voltage or not enough speed.
Hot cracking
Hot cracking, also known as solidification cracking, can occur with
all metals, and happens in the fusion zone of a weld. To diminish
the probability of this type of cracking, excess material restraint
should be avoided, and a proper filler material should be
utilized.Other causes include too high welding current, poor joint
design that does not diffuse heat, impurities (such
as sulfur and phosphorus), preheating, speed is too fast, and long
arcs.
Underbead crack
An undercut crack, also known as a heat-affected zone (HAZ)
crack, is a crack that forms a short distance away from the fusion
line; it occurs in low alloy and high alloy steel. The exact causes of
this type of crack are not completely understood, but it is known
that dissolved hydrogen must be present. The other factor that
affects this type of crack is internal stresses resulting from:
unequal contraction between the base metal and the weld metal,
restraint of the base metal, stresses from the formation of
martensite, and stresses from theprecipitation of hydrogen out of
the metal.
Longitudinal crack
Longitudinal cracks run along the length of a weld bead. There are
three types: check cracks, root cracks, and full centerline cracks.
Check cracks are visible from the surface and extend partially into
weld. They are usually caused by high shrinkage stresses,
especially on final passes, or by a hot cracking mechanism. Root
cracks start at the root and extent part way into the weld. They are
the most common type of longitudinal crack because of the small

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size of the first weld bead. If this type of crack is not addressed then
it will usually propagate into subsequent weld passes, which is how
full centerline cracks (a crack from the root to the surface) usually
form.
Reheat cracking
Reheat cracking is a type of cracking that occurs in HSLA steels,
particularly chromium, molybdenum and vanadium steels, during
postheating. The phenomenon has also been observed in austenitic
stainless steels. It is caused by the poor creep ductility of the heat
affected zone. Any existing defects or notches aggravate crack
formation. Things that help prevent reheat cracking include heat
treating first with a low temperature soak and then with a rapid
heating to high temperatures, grinding or peening the weld toes,
and using a two layer welding technique to refine the HAZ grain
structure.
Root and toe cracks
A root crack is the crack formed by the short bead at the root(of
edge preparation) beginning of the welding, low current at the
beginning and due to improper filler material used for
welding.Major reason for happening of these types of cracks is
hydrogen embrittlement. These types of defects can be eliminated
using high current at the starting and proper filler material. Toe
crack occurs due to moisture content present in the welded area,it
as a part of the surface crack so can be easily detected. Preheating
and proper joint formation is must for eliminating these types of
defects.

Transverse crack
A gap or break in the surface of a weld perpendicular to the weld
axis that may be completely within the weld metal or may extend
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from the weld metal into the base metal. Excess hydrogen, an
excessively strong weld metal, and high levels of residual stress
result in transverse cracks.
Distortion
Welding methods that involve the melting of metal at the site of the
joint necessarily are prone to shrinkage as the heated metal cools.
Shrinkage then introduces residual stresses and distortion.
Distortion can pose a major problem, since the final product is not
the desired shape. To alleviate certain types of distortion the
workpieces can be offset so that after welding the product is the
correct shape. 

The following pictures describe various types of welding distortion:

Transverse shrinkage
 

Angular distortion
 

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 

Longitudinal shrinkage
 

Fillet distortion
 

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 

Neutral axis distortion

Gas inclusion
Gas inclusions is a wide variety of defects that
includes porosity, blow holes, and pipes (or wormholes). The
underlying cause for gas inclusions is the entrapment of gas within
the solidified weld. Gas formation can be from any of the following
causes: high sulphur content in the workpiece or electrode,
excessive moisture from the electrode or workpiece, too short of
an arc, or wrong welding current or polarity.
Inclusions
There are two types of inclusions: linear inclusions and rounded
inclusions. Inclusions can be either isolated or cumulative. Linear
inclusions occur when there is slag or flux in the weld. Slag forms
from the use of a flux, which is why this type of defect usually
occurs in welding processes that use flux, such as shielded metal
arc welding, flux-cored arc welding, andsubmerged arc welding, but
it can also occur in gas metal arc welding. This defect usually
occurs in welds that require multiple passes and there is poor
overlap between the welds. The poor overlap does not allow the slag
from the previous weld to melt out and rise to the top of the new
weld bead. It can also occur if the previous weld left an undercut or
an uneven surface profile. To prevent slag inclusions the slag
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should be cleaned from the weld bead between passes
via grinding, wire brushing, or chipping.
Isolated inclusions occur when rust or mill scale is present on the
base metal.
Lack of fusion and incomplete penetration
Lack of fusion is the poor adhesion of the weld bead to the base
metal; incomplete penetration is a weld bead that does not start at
the root of the weld groove. Incomplete penetration forms channels
and crevices in the root of the weld which can cause serious issues
in pipes because corrosive substances can settle in these areas.
These types of defects occur when the welding procedures are not
adhered to; possible causes include the current setting, arc length,
electrode angle, and electrode manipulation. Defects can be varied
and classified as critical or non critical. Porosity (bubbles) in the
weld are usually acceptable to a certain degree. Slag inclusions,
undercut, and cracks are usually non acceptable. Some porosity,
cracks, and slag inclusions are visible and may not need further
inspection to require their removal. Small defects such as these can
be verified by Liquid Penetrant Testing (Dye check). Slag inclusions
and cracks just below the surface can be discovered by Magnetic
Particle Inspection. Deeper defects can be detected using the
Radiographic (X-rays) and/or Ultrasound (sound waves) testing
techniques.
Lamellar tearing
Lamellar tearing is a type of welding defect that occurs
in rolled steel plates that have been welded together due to
shrinkage forces perpendicular to the faces of the plates. Since the
1970s, changes in manufacturing practices limiting the amount
of sulfur used have greatly reduced the incidence of this problem.
Lamellar tearing is caused mainly by sulfurous inclusions in the
material. Other causes include an excess of hydrogen in the alloy.
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This defect can be mitigated by keeping the amount of sulfur in the
steel alloy below 0.005%.Adding rare earth elements, zirconium,
or calcium to the to control the configuration of sulfur inclusions
throughout the metal lattice can also mitigate the problem.
Modifying the construction process to use casted or forged parts in
place of welded parts can eliminate this problem, as Lamellar
tearing only occurs in welded parts.

Undercut

Undercutting is when the weld reduces the cross-sectional

thickness of the base metal, which reduces the strength of the weld
and workpieces. One reason for this type of defect is excessive
current, causing the edges of the joint to melt and drain into the
weld; this leaves a drain-like impression along the length of the
weld. Another reason is if a poor technique is used that does not
deposit enough filler metal along the edges of the weld. A third
reason is using an incorrect filler metal, because it will create
greater temperature gradients between the center of the weld and
the edges. Other causes include too small of an electrode angle, a
dampened electrode, excessive arc length, and slow speed.

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 Remedies
To minimize the chance of welding defects be sure to consider 1) the
travel speed of the pass; 2) the size and type electrode; 3) machine
settings; 4) make sure the welding is done in accordance with the plan
and the current conditions.

Most of, or a great deal of, welding defects can be identified by the
"naked eye." By knowing what is likely to produce welding defects you
will learn how to avoid them. Production without defects saves time,
materials, repair costs, and a decrease in productivity.

The two following causes for weld rejection should not be but are often
overlooked 1) is the weldor proficient with the process being used? 2) is
the welding rod supply up to standards? One remedy to welding
defects is to use only properly stored, dried, and maintained welding
rods. (Check out our entire inventory of Welding Rod Ovens.)

Welding defects include poor penetration. It's the failure of the welding
rod and base metal to fuse together. It's caused by a root face that is
too big; a root opening that is too small; an electrode that's too large;
slow travel speed or a machine setting that's too low.

Poor fusion is the failure to blend the layers of weld metal together with
the base metal. A lack of fusion is caused by " . . . failure to raise to the
melting point of the base metal or the deposited weld metal," (Miller
Electric Mfg. Co.) It's caused by improper fluxing; dirty plate surfaces;
improper electrode size or type; wrong current settings. Electrodes that
do not meet the storing, drying and maintenance specifications also
cause it.

Undercutting is another problem that causes welding defects. It

burns away the base metal at the toe of the weld. It's caused by a
current adjustment that is too high; an arc gap that is too long or
failure to fill up the crater completely with weld metal.

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Porosity looks "sponge like," or like tiny "bubbles" in the weld. It's
caused by gases being released by the cooling weld because a current
setting is too high or arc is too long.

Slag inclusion occurs when the slag is not chipped and cleaned
properly and then another pass is made over the top. To avoid, 1)
prepare the groove and weld properly before each pass; 2) thoroughly
clean in between passes; check the machine settings against those
suggested by the manufacturer; 3) hold a smaller weld puddle.

WELDING TROUBLESHOOTING

Porosity
Porosity − small cavities or holes resulting from gas pockets in weld
metal.

 Possible Causes Corrective Actions

Arc length too long. Reduce arc length. Workpiece dirty. Remove all
grease, oil, moisture, rust, paint, coatings, slag, and dirt from work
surface before welding. Damp electrode. Use dry electrode.

Excessive Spatter
Excessive Spatter − scattering of molten metal particles that cool to
solid form near weld bead.

 Possible Causes Corrective Actions

Amperage too high for electrode.Decrease amperage or select larger
electrode. Arc length too long or voltage too high.Reduce arc length or
voltage.

Incomplete Fusion
Incomplete Fusion − failure of weld metal to fuse completely with base
metal or a preceding weld bead.

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  Possible Causes Corrective Actions
Insufficient heat input. Increase amperage. Select larger electrode and
increase amperage.
Improper welding technique. Place stringer bead in proper location(s)
at joint during welding. Adjust work angle or widen groove to access
bottom during welding. Momentarily hold arc on groove side walls
when using weaving technique. Keep arc on leading edge of weld
puddle. Workpiece dirty. Remove all grease, oil, moisture, rust, paint,
coatings, slag, and dirt from work surface before welding.

Lack Of Penetration
Lack Of Penetration – shallow fusion between weld metal and
base metal. Lack of Penetration Good Penetration

 Possible Causes Corrective Actions

Improper joint preparation.Material too thick. Joint preparation and
design must provide access to bottom of groove. Improper weld
technique. Keep arc on leading edge of weld puddle. Reduce travel
speed. Insufficient heat input. Increase amperage. Select larger
electrode and increase amperage.

Excessive Penetration
Good Penetration
Excessive Penetration − weld metal melting through base metal and
hanging underneath weld. Excessive Penetration

 Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.
Improper weld technique. Adjust travel speed.

Burn-Through
Burn-Through − weld metal melting completely through base metal
resulting in holes where no metal remains.

 Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.

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 Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.

 Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

Distortion
Distortion − contraction of weld metal during welding that forces base
metal to move. Base metal moves in the direction of the weld bead.

 Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in
position. Make tack welds along joint before starting welding operation.
Predict anticipated weld distortion and pre camber base metal. Select
lower amperage for electrode. Increase travel speed. Weld in small
segments and allow cooling between welds.

Self Check 1.1.4

Multiple Choice. Read the questions carefully. Choose a letter for the
best answer. Write your answers on your answer sheet.

1. Contraction of weld metal during welding that forces base

metal to move.
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 a. Welding b. concavity c. Distortion d. valet

2. Small cavities or holes resulting from gas pockets in weld

metal.
a. Porosity b. undercut c. cracks d. laps

3. Type of welding defect that occurs in rolled steel plates that have

been welded together due to shrinkage forces perpendicular to
the faces of the plates.
a. Convexity b. cracks c. lamellar tearing d. laps

4. Type of cracking that occurs in HSLA steels,

particularly chromium, molybdenum and vanadium steels,
during post heating.
a. Distortion b. Reheat Cracking c. crack d. welding

5. Weld metal melting completely through base metal resulting in

holes where no metal remains.

a. Cracks b. Penetration c. Burn-Through d. distortion

Answer Key 1.1.4

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1. C
2. A
3. C
4. B
5. C

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 Information Sheet 1.1.5
Welding procedure specification (WPS)

Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
1. Welding procedure specification (WPS)

Welding Procedure Specification

A Welding Procedure
Specification (WPS) is a formal written
document
describing welding procedures, which
provides direction to the welder or
welding operators for making sound
and quality production welds as per
the code requirements . The purpose of
the document is to guide welders to the
accepted procedures so that repeatable
and trusted welding techniques are used. A WPS is developed for each
material alloy and for each welding type used. Specific codes and/or
engineering societies are often the driving force behind the
development of a company's WPS. A WPS is supported by a Procedure
Qualification Record (PQR or WPQR). A PQR is a record of a test weld
performed and tested (more rigorously) to ensure that the procedure
will produce a good weld. Individual welders are certified with a
qualification test documented in a Welder Qualification Test Record
(WQTR) that shows they have the understanding and demonstrated
ability to work within the specified WPS.
A welded construction applies, quality prescriptions concerning design
production and use. Therefore clients in Petro and chemical industry
claims approved welding procedures. Welding requires skill.
Determining "how to weld" requires knowledge regarding the materials
being welded and welding process, among numerous other factors.

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Because of huge number of variables involved, the knowledge of the
welding engineer and the skill of the welder need to be validated by a
series of tests.

This information is documented Section IX of the ASME Boiler and

Pressure Vessel Code (BPVC), on:
1. Welding Procedure Specification (WPS)
2. Welding Procedure Qualification Record (WPQR)
3. Welding Performance Qualification (WPQ)

Welding Procedure Specification

The Welding Procedure Specification is a required document for all
code welding. Your customer either directly or indirectly specifies to
what code your company must qualify. The WPS outlines all of the
parameters required to perform your welding operation.
In short the WPS is the recipe for your welding operation. It describes
the welding process or processes used, the base materials used, the
joint design and geometry, gases and flow rates, welding position and
includes all of the process conditions and variables. Each code has a
recommended format.

Welding Procedure Qualification Record

The Welding Procedure Qualification Record is the document that
qualifies the Welding Procedure Specification. In order to qualify your
WPS, a procedure qualification plate is welded the code requirements.
The actual test parameters are recorded at the time of welding to
ensure the WPS was being followed. Generally any supporting
documentation, such as material specifications, electrode
specifications and shielding gas specifications, are included as part of

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the WPQR. All required testing, both non-destructive and destructive,
is recorded as well. These tests typically include X-Ray examinations,
ultrasonic examinations, tensile testing, bend testing and when
required impact testing.
The WPQR combines all of the information of the WPS and adds the
test results to provide a complete document that certifies the welding
specification. This document is also required by all codes unless you
are qualifying under American Welding Society (AWS) specifications.
Under certain conditions the WPS may be considered prequalified in
which the WPQR is not required.

Welder Performance Qualification

This document is required by all codes for all welders. It details and
summarizes the following information: Indicates the WPS referenced
during the qualification test Identifies the welder by name and/or clock
number Lists what the essential parameters were during this test
Reports the results of the required qualification tests Specifies qualified
limits for welder For most codes there is a time limit associated with
the welder qualification test.
However, the American Welding Society provides an unlimited
qualification period if certain conditions are met. As with the WPS and
WPQR, each code has a recommended format.

The following are definitions for WPS and PQR found in various codes
and standards:
According to the American Welding Society (AWS), a WPS provides in
detail the required welding variables for specific application to
assure repeatability by properly trained welders. The AWS defines
welding PQR as a record of welding variables used to produce an
acceptable test weldment and the results of tests conducted on the
weldment to qualify a Welding Procedure Specification. For steel
construction (civil engineering structures) AWS D1.1 is a widely used
standard. It specifies either a pre-qualification option (chapter 3) or
aqualification option (chapter 4) for approval of welding processes.
The American Society of Mechanical Engineers (ASME) similarly
defines a WPS as a written document that provides direction to the
welder or welding operator for making production welds in accordance
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with Code requirements. ASME also defines welding PQR as a record of
variables recorded during the welding of the test coupon. The record
also contains the test results of the tested specimens.
The Canadian Welding Bureau, through CSA Standards
W47.1, W47.2and W186, specifies both a WPS and a Welding
Procedure Data Sheet (WPDS) to provide direction to the welding
supervisor, welders and welding operators. The WPS provides general
information on the welding process and material grouping being
welded, while the WPDS provides specific welding
variables/parameter/conditions for the specific weldment. All WPS and
WPDS must be independently reviewed and accepted by the Canadian
Welding Bureau prior to use. These CSA standards also define
requirements for procedure qualification testing (PQT) to support the
acceptance of the WPDS. A record of the procedure qualification test
and the results must be documented on a procedure qualification
record (PQR). All PQTs are independently witnessed by the Canadian
Welding Bureau.
In Europe, the European Committee for Standardization (CEN) has
adopted the ISO standards on welding procedure qualification (ISO
15607 to ISO 15614), which replaced the former European standard
EN 288. EN ISO 15607 defines a WPS as "A document that has been
qualified by one of the methods described in clause 6 and provides the
required variables of the welding procedure to ensure repeatability
during production welding". The same standard defines a Welding
Procedure Qualification Record (WPQR) as "Record comprising all
necessary data needed for qualification of a preliminary welding
procedure specification". In addition to the standard WPS qualification
procedure specified in ISO 15614, the ISO 156xx series of standards
provides also for alternative WPS approval methods. These
include: Tested welding consumables (ISO 15610), Previous welding
experience (ISO 15611),Standard welding procedure (ISO 15612)
and Preproduction welding test (ISO 15613).
In the oil and gas pipeline sector, the American Petroleum Institute API
1104 standard is used almost exclusively worldwide. API 1104 accepts
the definitions of the American Welding Society code AWS A3.0.

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Self Check 1.1.5

True or False. Write True if the statement is correct and False if it is

wrong. Write your answers on your answer sheet.

1. In the oil and gas pipeline sector, the American Petroleum

Institute API 1104 standard is used almost exclusively
worldwide.
2. According to the American Welding Society (AWS), a WPS
provides in detail the required welding variables for specific
application to assure repeatability by properly trained welders.
3. The Welding Performance Qualification Record is the document
that qualifies the Welding Procedure Specification.
4. WPS is the recipe for your welding operation. It describes the
welding process or processes used, the base materials used, the
joint design and geometry, gases and flow rates, welding position
and includes all of the process conditions and variables.
5. American Society of Mechanical Engineers (ASME) similarly
defines a WPS as a written document that provides direction to
the welder or welding operator for making production welds in
accordance with Code requirements. 

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Answer key 1.1.5

1. True
2. True
3. False
4. True
5. True

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 Information Sheet 1.1.5
Welding techniques and procedures

Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
1. Welding techniques and procedures.

Welding Techniques and Procedures

Our engineers specialize in solving welding engineering problems, weld

failure analysis, eliminating weld defects, soldering, brazing, expert
witness services, and developing welding procedures.  We provide
procedure and techniques to solve your arc, MIG, TIG, laser, electron
beam, resistance, or plasma welding procedures.  We provide solutions
to steel, stainless steel, aluminum, nickel, or titanium welding
processes.   
Our Principal Engineer has experience in Aluminum, Steel, Stainless
Steel, Nickel alloys, and various types of metals and welding
procedures including aircraft, industrial machinery, ships, and under
sea pipelines.  We can solve your soldering, brazing, and welding
problems.

 
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Engineering Consulting
We provide welding engineering solutions to our customers industrial
problems.  Common procedures such as flux cored arc welding, TIG,
MIG, arc welding are among our specialty. Our goal is to identify
problems and specify techniques to enhance customer capabilities. 
Examples of AMC's experience includes oil refineries, petrochemical
plants, pipelines, aircraft, food industry, medical supplies, ships, and
gas turbine engines.

Our experience include a range of welding, soldering and brazing

processes using various alloys.  If you do not see information on your
specific joining process or alloy system please contact us about your
individual consulting needs. 

GTAW Welding, TIG welding

Gas Tungsten Arc Welding (GTAW) is frequently referred to as TIG

welding.  TIG welding is a commonly used high quality welding
process.  TIG welding has become a popular choice of welding
processes when high quality, precision welding is required.

In TIG welding an arc is formed between a nonconsumable tungsten

electrode and the metal being welded. Gas is fed through the torch to
shield the electrode and molten weld pool.  If filler wire is used, it is
added to the weld pool separately.

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TIG Welding Benefits

 Superior quality welds

 Welds can be made with or without filler metal
 Precise control of welding variables (heat)
 Free of spatter
 Low distortion
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 Shielding Gases

 Argon
 Argon + Hydrogen
 Argon/Helium

Helium is generally added to increase heat input (increase welding

speed or weld penetration).  Hydrogen will result in cleaner looking
welds and also increase heat input, however, Hydrogen may promote
porosity or hydrogen cracking.

GTAW Welding Limitations

 Requires greater welder dexterity than MIG or stick welding

 Lower deposition rates
 More costly for welding thick sections

Common GTAW Welding Concerns

We can help optimize your welding

process variables. Evaluate your current
welding parameters and techniques.  Help
eliminate common welding problems and
discontinuities such as those listed below:

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Weld Discontinuities

 Undercutting
 Tungsten inclusions
 Porosity
 Weld metal cracks
 Heat affected zone cracks

TIG Welding Problems

 Erratic arc
 Excessive electrode consumption
 Oxidized weld deposit
 Arc wandering
 Porosity
 Difficult arc starting

MIG Welding

Gas Metal Arc Welding (GMAW) is frequently referred to as MIG

welding.  MIG welding is a commonly used high deposition rate welding
process.  Wire is continuously fed from a spool.  MIG welding is
therefore referred to as a semiautomatic welding process.

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MIG Welding Benefits

 All position capability

 Higher deposition rates than SMAW
 Less operator skill required
 Long welds can be made without starts and stops
 Minimal post weld cleaning is required

MIG Welding Shielding Gas

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 The shielding gas, forms the arc plasma, stabilizes the arc on the metal
being welded, shields the arc and molten weld pool, and allows smooth
transfer of metal from the weld wire to the molten weld pool.  There are
three primary metal transfer modes:

 Spray transfer
 Globular transfer
 Short circuiting transfer

The primary shielding gasses used are:

 Argon
 Argon - 1 to 5% Oxygen
 Argon - 3 to 25% CO2
 Argon/Helium

CO2 is also used in its pure form in some MIG welding processes. 
However, in some applications the presence of CO2 in the shielding gas
may adversely affect the mechanical properties of the weld.

Common MIG Welding Concerns

We can help optimize your MIG welding process variables. Evaluate

your current welding parameters and techniques.  Help eliminate
common welding problems and discontinuities such as those listed
below:

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 Weld Discontinuities

 Undercutting
 Excessive melt-through
 Incomplete fusion
 Incomplete joint penetration
 Porosity
 Weld metal cracks
 Heat affected zone cracks

MIG Welding Problems

 Heavily oxidized weld deposit

 Irregular wire feed
 Burnback
 Porosity
 Unstable arc
 Difficult arc starting

SHIELDED METAL ARC Document No.

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Stick Welding Benefits

 Equipment used is simple, inexpensive, and portable

 Electrode provides and regulates its own flux

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 Lower sensitivity to wind and drafts than gas shielded welding
processes
 All position capability

Common Stick Welding Concerns

We can help optimize your welding process variables. Evaluate your

current welding parameters and techniques.  Help eliminate common
welding problems and discontinuities such as those listed below:

Weld Discontinuities

 Undercut
 Incomplete fusion
 Porosity
 Slag Inclusions
 Cracks

Stick Welding Problems

 Arc Blow
 Arc Stability
 Excessive spatter
 Incorrect weld profile
 Rough surface
 Porosity

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 STICK WELDING TECHNIQUES
"stick welding."
Before welding make a final check
and remove consumable material.
Remove the cigarette lighter from
you pocket. Check your machine
to make sure it's on and adjusted
to the approximate settings. Clean
the joint. Clamp the rod in the
stinger at a 45 to 90 degree angle.
Warn those around you. Place the
rod about two inches from the
work. Adjust your hood so that
when you nod your head the hood
will fall over your face.

Strike the arc using the tip of the

rod on the surface using a wrist motion, just like when you strike a
wooden match. When the arc is struck lift the rod about 1/8" above
the base material. If the rod "sticks" snap the stinger backward from
the direction of the work. Become light handed. Practice on scrap
pieces.

Proper Stick Welding Techniques

Run a practice bead. Strike an arc moving the welding rod across the
plate at a uniform speed and at an incline of about 20 degrees in the
direction of travel. A right handed person usually welds from left to
right. Steady your elbow against your body, the table, or the work. Use
the free hand as needed to control the stinger. Run beads that
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consume the entire rod. Let the arc penetrate the base metal and
deposit the filler metal (from the rod) into the joint.

Continue to strike arcs and run beads across the joint making proper
adjustments until you start and stop as desired, with no problems. No
further adjustments should be needed. Burn the rod down to about 1
and 1/2" from the end. One welding rod usually produces a weld about
1" long.

To continue or to restart the bead:

When you stop there is a "crater." Chip the slag and re-strike the arc a
little bit ahead of the crater and then run the bead. In time this
method will produce uniform welds of high strength without trapping
any slag in the bead that cause defects. At the end of a weld or when
the rod is used up, pause slightly to fill the crater then pull the rod
away. Chip the slag and inspect the weld.

Good welds are dependent on five techniques: correct amperage

setting; correct arc length; correct rod selection and angle to the work;
correct travel speed; and welding rods that have been stored and
maintained properly.

When electrodes absorb moisture from the atmosphere, they must be

dried in order to restore the ability to deposit quality welds. Electrodes
with too much moisture cause unexplained cracking, poor operating
characteristics, and porosity. If you've experienced these conditions it
usually is due to your storage methods or re-drying procedures. All
electrodes, even those outside of the "stick" category, must be stored
and then dried to the right level to work well. Even a small amount of
moisture in low hydrogen electrodes, for example, can lead to major
weld problems such as internal porosity and weld cracking.

Too little amperage causes a weak arc that is hard to strike. Too much
amperage causes a large crater, or a flat bead with excessive spatter.

An arc that is too short will make the rod stick. Too long and large
drops of melted metal will drip off the rod and it will tend to "blow' and
spatter. A long arc also produces uneven bead with poor penetration.

SHIELDED METAL ARC Document No.

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The rod angle affects the penetration. An important welding technique
is holding the rod nearly perpendicular to the joint increase
penetration but can cause slag to get trapped in the weld. Lowering the
rod too flat or low lessens the penetration and causes ripples.

Speed affects the amount of rod deposited and the uniformity of the
bead. Correct speed produces about 1" of weld per rod. Travel too fast
and it makes a thin bead with little penetration. Too slow lets the bead
build up with edges that overlap the base metal. Too slow of travel on
thin metal will blow a hole through.

JOB SHEET 1.1.6

Title: Weld carbon steel plates

Performance Objective: Given all the information assigned to you, you

should be able to demonstrate welding technique
and procedures

Supplies/Materials : pen and paper, plastic bag, cardboard box

Tools : Welding mask, steel brush, clear glass,

chipping hammer, dark glass

Equipment : welding machine, welding table, portable

grinder, welding booth, portable oven

Steps/Procedure:
Techniques:
1. Prepare tools and materials needed for welding.
2. Check the equipment before using.
3. Prepare welding machine.
4. Evaluate your current welding parameters and techniques.
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 5. Select appropriate steel plates
6. Check steel plates if same size before welding
7. Label the item.
8. Present your work to your trainer.

Performance Criteria Checklist 1.1.6

Trainee’s Name: _________________________ Date: _______

CRITERIA
YES NO
Did the trainee.
1. Are the materials and tools prepared?
2. Does clothes for welding prepared?
3. Does the different types of weld techniques
done?
4. Is there Excessive melt-through in steel plate?

5. Are the steel platewith appropriate size?

6. Does the steel plate clean before weld?
7. Are the techniques and procedures applied?
8. Does label the items?
9. Does your work present to your trainer?
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Comments:__________________________________________________________
_____________________________________________________________________
___________

___________________
Trainer’s Signature

Information Sheet 1.1.7

Safe Welding Practices

Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
1. Safe welding practices

Arc welding is a safe occupation when sufficient measures are taken to

protect the welder from potential hazards. When these measures are
overlooked or ignored, however, welders can encounter such dangers
as electric shock, overexposure to radiation, fumes and gases, and fire
and explosion; any of which may result in fatal injuries.

So that you may recognize and safeguard yourself against these

hazards, every welder should be familiar with the ANSI Z49. 1
document, "Safety in Welding and Cutting," and should follow the
safety practices in the document whenever possible. However, you may
find yourself working at a job-site where your supervisor is unavailable
for advice, or where proper noise or air measurements cannot be
taken. In these and other cases, you can help protect yourself and
others by using six of the best safety measures you already have: your
sight, smell, hearing, touch, taste and common sense.

Personal Protection

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 PROTECTIVE CLOTHING

As in any career, it's important that you dress the part. A football
player has his shoulder pads and helmet; a policeman carries his gun
and nightstick. Very different forms of protection, but they are
necessary to prevent personal and professional injuries.

Arc welders require similar precautions. The actual gear varies with
the job being performed, but generally protective clothing must allow
freedom of movement while providing adequate coverage against burns
from sparks, weld spatter, and arc radiation. Many types of clothing
will protect you from ultraviolet radiation exposure, which appears as a
skin burn (much like sunburn). Under the worst conditions, however,
severe burns and skin cancer may result from excessive radiation.

Because of its durability and resistance to fire, wool clothing is

suggested over synthetics (which melt when exposed to extreme heat)
or cotton, unless it is specially treated for fire protection. If possible,
keep your clothes clean of grease and oil, as these substances may
ignite and burn uncontrollably in the presence of oxygen.

Avoid rolling up your sleeves and pant-cuffs, because sparks or hot

metal could get stuck in the folds; also, wear your trousers overlapping
your work boots, not tucked in, to keep particles from falling into your
boots. While we're on the subject, we suggest leather high-tops with
steel toes (especially when doing heavy work).

Other protective wear for heavy work or especially hazardous

situations includes: flame-resistant suits, aprons, leggings, leather
sleeves/shoulder capes, and caps worn under your helmet.

Heavy, flame-resistant gloves, such as leather, should always be worn

to protect your hands from burns, cuts, and scratches. In addition, as
long as they are dry and in good condition, they will offer some
insulation against electric shock.

As to preventing electric shock, the key word is dry! We'll have more on
the subject later, but for now keep in mind that moisture can increase
the potential and degree of electric shock. When working in wet
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conditions, or when perspiring heavily, you must be even more careful
to insulate your body from electrically "live" parts.

Type of PPE is available when welding?

The chart below summarizes the types of personal protective

equipment that can be used when welding.

Welding - Personal Protective Equipment

Body Part Equipment Illustration Reason

Eyes and Welding Protects

face helmet, from:
hand
shield, or  radiation
goggles  hot slag,
sparks
 intense
light

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  irritation
and
chemical
burns

Wear fire
resistant
head
coverings
under the
helmet
where
appropriate

Lungs Respirators Protects

(breathing) against:

 fumes
and
oxides

Exposed Fire/Flame Protects

skin (other resistant against:
than feet,  clothing
hands, and and aprons  heat, fires
head)  burns

Notes:
pants
should not
have cuffs,
shirts
should have
flaps over
pockets or
be taped
closed

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 Ears - Ear muffs, Protects
hearing ear plugs against:

 noise

Use fire
resistant
ear plugs
where
sparks or
splatter
may enter
the ear.

Feet and Boots, Protects

hands gloves against:

 electric
shock
 heat
 burns
 fires

Why is eye protection important?

Eye injury can occur from the intense light and radiation that a
welding arc can produce.  Eye injury can also occur from hot slag that
can fly off from the weld during cooling, chipping or grinding.

 Protect your eyes from welding light by wearing a welder's helmet

fitted with a filter shade that is suitable for the type of welding you
are doing.
 ALWAYS wear safety glasses with side shields or goggles when
chipping or grinding a work piece if you are not wearing a welding
helmet.

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 What type of eye and face protection is appropriate for my welding
task?
The various types of eye protection are broken down into classes in the
Canadian Standards Association (CSA) standard Z94.3.1 "Selection,
use, and care of protective eyewear".  Each class has a specific use
that it has been designed for.  Common protectors for welding
operations are listed below:

 Class 2C - direct non-ventilated goggles with radiation protection

 Class 3- welding helmets
 Class 4- hand shields
 Class 5C - non-rigid helmets with radiation protection
 Class 6B – face shields with radiation protection
 Class 7B - respirator face piece with radiation protection

The following operations require full face protection from either a

welding helmet or a hand shield:

 arc welding,
 plasma arc cutting, gouging or welding, and
 air carbon arc cutting.

For gas cutting, welding, or brazing, the intensity of the light is much
less than from arc welding, cutting or gouging processes.  Lighter
shade filter lenses can be used with goggles in place of a helmet.

More information can be found in the OSH Answers on Safety glasses

and face protectors. 

What are the various components of welding hand shields and

helmets?
Hand shields or helmets provide eye protection by using an assembly
of components:

 Helmet shell - must be opaque to light and resistant to impact, heat

and electricity.
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 Outer cover plate made of polycarbonate plastic which protects from
UV radiation, impact and scratches.
 Filter lens made of glass containing a filler which reduces the
amount of light passing through to the eyes. Filters are available in
different shade numbers ranging from 2 to 14. The higher the
number, the darker the filter and the less light passes through the
lens.
 Clear retainer lens made of plastic prevents any broken pieces of the
filter lens from reaching the eye.
 Gasket made of heat insulating material between the cover lens and
the filter lens protects the lens from sudden heat changes which
could cause it to break. In some models the heat insulation is
provided by the frame mount instead of a separate gasket.

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 What else should you know about eye protection?

 Choose a tight fitting helmet to help reduce light reflection into the
helmet through the space between the shell and the head.
 Wear the helmet correctly. Do not use it as a hand shield.
 Protect the shade lens from impact and sudden temperature changes
that could cause it to crack.
 Use a cover lens to protect the filter shade lens. Replace the cover
lens if it gets scratched or hazy.
 Make sure to replace the gasket periodically if your helmet uses one.
 Replace the clear retaining lens to protect your eyes from broken
pieces.
 Clean lenses periodically.
 Discard pitted or damaged lenses.

What should you know about filter shade selection?

For Arc welding, the correct filter shade is selected according to the
welding process, wire diameter, and operating current. The table below
gives the correct shade numbers for different situations.

 ALWAYS use suggested shade numbers instead of minimum shades

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 .

 Provide additional task lighting that suits welders' needs.

 Use the same shade as the welder's if you are directly observing the
welding arc.
 Do not use gas welding goggles for arc welding.
 Do not substitute modified glasses, sunglasses, smoked plastic or
other materials for proper welding lenses.

The correct shade numbers for oxyfuel cutting are shown in the table
below.

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 Can you wear contact lenses when welding?
The CSA Standard W117.2 states that contact lenses should not be
worn by welders and welding personnel.  Contact lenses do not provide
protection from ultraviolet radiation and flying objects. All workers in
proximity to welding procedures must wear appropriate eye protection
according to the circumstances. The OSH Answers document Contact
Lenses at Work discusses how dust particles or chemicals can irritate
the eyes.

Note that in Canada, Prince Edward Island's Occupational Health and

Safety Act Regulations (E.C. 180/87) Section 45.11 specifically bans
wearing contact lenses while welding.

What measures can you use for skin protection from welding
radiation?

 Wear tightly woven work-weight fabrics to keep UV radiation from

reaching your skin.
 Button up your shirt to protect the skin on the throat and neck.
 Wear long sleeves and pant legs.
 Cover your head with a fabric cap to protect the scalp from UV
radiation.
 Protect the back of your head by using a hood.
 Protect your face from UV radiation by wearing a tight-fitting, opaque
welder's helmet.

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 Make sure that all fabric garments are resistant to spark, heat and
flame. Keep the fabrics clean and free of combustible materials that
could be ignited by a spark.

What should you know about using respirators when welding?

Respiratory protection is needed when ventilation is not sufficient to
remove welding fumes or when there is risk of oxygen deficiency. 
Select and use respirators in compliance with your workplace
regulation. Seek expert advice and initiate a proper respiratory
protection program.

For more information on selecting the appropriate respirators, see the

OSH Answers onRespirator Selection.

The process of selecting appropriate respiratory protection is outlined

in Canadian Standards Association (CSA) standard Z94.4 and
American National Standards Institute (ANSI) Z88.2 standard
"Respiratory Protection".

What are some tips to know when using protective clothing?

DO

 Wear clothing made from heavyweight, tightly woven, 100% wool or

cotton to protect from UV radiation, hot metal, sparks and open
flames. Flame retardant treatments become less effective with
repeated laundering.
 Keep clothing clean and free of oils, greases and combustible
contaminants.
 Wear long-sleeved shirts with buttoned cuffs and a collar to protect
the neck. Dark colours prevent light reflection.
 Tape shirt pockets closed to avoid collecting sparks or hot metal or
keep them covered with flaps.
 Pant legs must not have cuffs and must cover the tops of the boots.
Cuffs can collect sparks.
 Repair all frayed edges, tears or holes in clothing.
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 Wear high top boots fully laced to prevent sparks from entering into
the boots.
 Use fire-resistant boot protectors or spats strapped around the pant
legs and boot tops, to prevent sparks from bouncing in the top of the
boots.
 Remove all ignition sources such as matches and butane lighters
from pockets. Hot welding sparks may light the matches or ignite
leaking lighter fuel.
 Wear gauntlet-type cuff leather gloves or protective sleeves of similar
material, to protect wrists and forearms. Leather is a good electrical
insulator if kept dry.
 Direct any spark spray away from your clothing.
 Wear leather aprons to protect your chest and lap from sparks when
standing or sitting.
 Wear layers of clothing. To prevent sweating, avoid overdressing in
cold weather. Sweaty clothes cause rapid heat loss. Leather welding
jackets are not very breathable and can make you sweat if you are
overdressed.
 Wear a fire-resistant skull cap or balaclava hood under your helmet
to protect your head from burns and UV radiation.
 Wear a welder's face shield to protect your face from UV radiation
and flying particles.

Arc Rays

It is essential that your eyes are protected from radiation exposure.

Infrared radiation has been known to cause retinal burning and
cataracts. And even a brief exposure to ultraviolet (UV) radiation can
cause an eye burn known as "welder's flash." While this condition is
not always apparent until several hours after exposure, it causes
extreme discomfort, and can result in swelling, fluid excretion, and
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temporary blindness. Normally, welder's flash is temporary, but
repeated or prolonged exposure can lead to permanent injury of the
eyes.

Other than simply not looking at an arc (obviously, pretty hard to do if

you're welding every day), the only preventive measure you can take is
with the use of proper eye shading.  The general rule is to choose a
filter too dark to see the weld, then move to lighter shades without
dropping below the minimum rating. The filters are marked as to the
manufacturer and shade number, the impact-resistant variety are
marked with an "H."

Helmet-type shields and hand-held face shields offer the most

complete shading against arc radiation. The shade slips into a window
at the front of the shield so that it can be removed and replaced easily.
The shields are made from a hard plastic or fiberglass, to also protect
your head, face, ears, and neck from electric shock, heat, sparks, and
flames. You should also use safety glasses with side shields or goggles
to protect your eyes from flying particles.

Visible light can also be harmful, but it is easy to tell if the light is
dangerous: if it hurts to look at, then it's too bright. The same is true
for infrared radiation: it can usually be felt as heat. However, there's
no real way for you to tell if you're being exposed to UV radiation, so
just don't take chances: always wear eye protection.

Noise

There are two good reasons to wear ear muffs or plugs:

a) to keep flying sparks or metal out of your ears; and

b) to prevent hearing loss as a result of working around noisy arc

welding equipment, power sources, and processes (like air carbon arc
cutting or plasma arc cutting).

As with radiation exposure to the eyes, the length and number of times
that you are exposed to high levels of noise determine the extent of the
damage to your hearing, so be sure to avoid repeated exposure to
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noise. If it is not possible to reduce the level of noise at the source (by
moving either yourself or the equipment, utilizing sound shields, etc.),
then you should wear adequate ear protection.

If the noise in your work area becomes uncomfortable, causing a

headache or discomfort of the ears, you could be damaging your
hearing and should immediately put on ear muffs or plugs.

In fact, the use of ear protection at all times is a good idea, as hearing
loss is both gradual and adds up over time. Damage to your hearing
may not be noticed until you have a complete hearing test at the
doctor's, and then it could be too late.

Inspection and Maintenance of Equipment and Work

Before starting any arc welding operation, you should make a complete
inspection of your equipment. All it takes on your part is 5-10 minutes
before you turn on your welder; is that too much to spend in
preventing injury to yourself or your co-workers?

To begin with:

 Have you read the instruction manual and do you

understand the instructions?
 Have you read the warnings and instructions on the
equipment nameplates and decals as well as the    
consumables' material safety data sheets?

For the welder:

 Are all the connections tight, including the earth ground?

 Are the electrode holder and welding cable in good
condition?
 Are the settings correct for the job you're about to begin?

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For an engine-driven welder:

 Is it running OK?
 Are all the hoses on tight?
 Is the fuel cap on tight?
 Is the engine leaking gasoline or oil?
 Is the original enclosure and fan guarding in place? Check
with your welding equipment distributor if you are   
unsure.

For the work in general:

 Are the work area conditions such that normal safety

precautions can be observed or must special equipment
(i.e., welding equipment, protective equipment, safety
equipment) or procedures be used?
 Are the cables the right size for your job?
 Are they spread out and run neatly to prevent
overheating?
 Is the gas cylinder connected properly?
 Is the cylinder secure?
 Is the work stable and easy to reach from where you're
standing?
 Is the Work Lead connected securely?
 Is there enough insulation between your body and the
work piece?
 Is there adequate ventilation in your work area?

Care and Cleaning of the Work Area

Keeping the area around your work neat is as important as

maintaining your equipment. Perhaps even more-so, as the risk of
injury is amplified by the larger group of people involved. You may
have already inspected your equipment and found it to be OK, but all
your caution won't matter when, for example, a co-worker trips over
your cable, causing you, and/or the people around you, to be injured
by shock, hot metal, or from falling.

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Keep all your equipment, cables, hoses, cylinders, etc. out of any traffic
routes such as doors, hallways, and ladders. A good practice is to
avoid clutter ... and clean up your work area when you're done! Not
only will it help to protect yourself and others, you'll find it much
easier for you to work efficiently (how many times have you set a tool
down, and been unable to find it only five minutes later?)

Also, bear in mind that while you're paying attention to your work,
other welders may be preoccupied with their own tasks and not
watching where they're going. So be sure that there are protective
screens in place, just in case somebody happens to be passing into
your work area or walks into a shower of sparks or spatter.

Consider whether the area in which you will be working creates or

increases the level of hazard to you thus requiring special procedures
or equipment. Factors such as electrical safety, fume ventilation and
risk of fire or explosion may be affected.

Gas Cylinders

Because of the explosive nature of cylinders, you must pay particularly

close attention to their storage and use. Examine the cylinders as you
did the rest of your equipment; check the cylinder label to make sure it
is the correct shielding gas for the process, and that the regulators,
hoses, and fittings are the right ones for that gas and pressure, and
are in good condition.

Cylinders must be secured in an upright position, with the valve caps

in place, in an area away from combustibles and fuels, and
safeguarded from damage, heat, and flames. When in use, keep them
out of traffic routes and flying sparks, with all hoses run neatly to the
welding area. Never allow the electrode or other "electrically hot" parts
of your welder to touch a cylinder. "Crack" the valve open to prevent
SHIELDED METAL ARC Document No.
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dirt from entering the regulator; open the cylinder valve only when
standing to one side of the cylinder, away from welding or other
sources of ignition. Return damaged cylinders to the supplier.

Specific Concerns

POSSIBLE SHOCK HAZARDS

The hazard of electric shock is one of the most serious and immediate
risks facing you as a welder. Contact with metal parts which are
"electrically hot" can cause injury or death because of the effect of the
shock upon your body or a fall which may result from your reaction to
the shock. The electric shock hazard associated with arc welding may
be divided into two categories which are quite different:

Primary Voltage Shock (i.e., 230, 460 volts); and

Secondary Voltage Shock (i.e., 60-100 volts).

The primary voltage shock is very hazardous because it is much

greater than the welder secondary voltage. You can receive a shock
from the primary (input) voltage if you touch a lead inside the welder
with the power to the welder "on" while you have your body or hand on
the welder case or other grounded metal. Remember that turning the
welder power switch "off" does not turn the power off inside the welder.
The input power cord must be unplugged or the power disconnect
switch turned off. You should never remove fixed panels from your
welder; in fact, always have a qualified technician repair your welder if
it isn't working properly. Also, your welder should be installed by a
qualified electrician so it will be correctly wired for the primary voltage
which supplies it power and so the case will be connected to an earth
ground. The case must be grounded so that if a problem develops
inside the welder a fuse will blow, letting you know that repair is
SHIELDED METAL ARC Document No.
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2019
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required. Never ignore a blown fuse because it is a warning that
something is wrong.

A secondary voltage shock occurs when you touch a part of the

electrode circuit -perhaps a bare spot on the electrode cable - at the
same time another part of your body is touching the metal upon which
you're welding (work). To receive a shock your body must touch both
sides of the welding circuit - electrode and work (or welding ground) -
at the same time. To prevent secondary voltage shock, you must
develop and use safe work habits:

 Wear dry gloves in good condition when welding.

 Do not touch the electrode or metal parts of the
electrode holder with skin or wet clothing.
 Keep dry insulation between your body (including
arms and legs) and the metal being welded or
ground (i.e., metal floor, wet ground).
 Keep your welding cable and electrode holder in
good condition.

These rules are basic to welding and you should already know them.
Check out the warning on your welder or electrode box next time you
weld. You will probably not have a shock while welding if you follow
these rules.

Sometimes the conditions under which you weld increase the

likelihood of a severe shock:

 wet conditions, and

 welding in or on the workpiece (such as a metal
framework or metal tank).

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
2019
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Though it may be more difficult to follow the rules under some
conditions, the rules still apply. Use plywood, rubber mats, or some
other dry insulation to stand or lie upon. Keep your gloves dry even if
you have to keep an extra pair. Don't rest your body, arms, or legs on
the work piece, especially if your clothing is wet or bare skin is exposed
(and it should not be if you are dressed properly). Under very poor
conditions, such as welding inside a metal tank or ship when the area
is wet, if you cannot follow these rules you should use a semiautomatic
constant voltage welder with cold electrode or a stick welder equipped
with a device to reduce voltage at the electrode when no welding is
being performed.

The condition of your electrode holder and electrode cable is also very
important. The plastic or fiber insulation on the electrode holder
protects you from touching the metal "electrically hot" parts inside.
Always inspect your electrode holder before turning the welder on.
Replace the holder if it is damaged---don't try to repair it unless you
have replacement parts.

The same is true of the electrode cable except that when not replaced it
may be repaired using good electrical tape. If your cable has been
repaired, be sure to check and see that the tape is secure before you
turn the welder on.

Remember, stick electrode is always "electrically hot" when the welder

is on -treat it with respect. If you do experience a shock, think of it as a
warning---check your equipment, work habits and work area to see
what is wrong before continuing to weld.

FIRE HAZARDS

Because of the extreme temperatures associated with any arc welding

process, you should always be aware of fire hazards. The heat of the
welding arc can reach temperatures of 10,000 0F, but this heat in itself
is not generally a fire hazard. The danger of fire actually results from
the effects of this intense heat upon your work and in the form of
sparks and molten metals. Because these can spray up to 35 feet from
your work, you must recognize and distance yourself from combustible
materials. It is also important to be sure the work is not in contact
SHIELDED METAL ARC Document No.
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2019
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with any combustible which it may ignite when heated. These
materials fall into three categories: liquid (gasoline, oil, paints, and
thinners); solid (wood, cardboard, and paper); and gaseous (acetylene
and hydrogen).

Watch where the sparks and metals are falling from your work: if there
are flammable materials including fuel or hydraulic lines in your work
area and you can't move either your work or the combustible
substances, put a fire-resistant shield in place. If you're welding above
the ground or off a ladder, make sure that there are no combustibles
underneath. Also, don't forget about your co-workers, and everybody
else who may be in the work area, as they probably wouldn't
appreciate being hit with slag or sparks from your work.

Particular care must be taken when welding or cutting in dusty

locations. The nature of the dust may be extremely volatile in the heat
of the arc or in the presence of a hot spark. Fine dust particles may
readily oxidize and without warning result in a flash fire or even an
explosion.

If you are not sure of the combustible or volatile nature of residue or

dust in the work area, no welding or cutting should take place until a
responsible person has inspected the area and given approval for the
work.

Before you start welding, inspect the surface of your work, looking for
flammable coatings or any unknown substances that would ignite
when heated. Because of the extreme fire and explosion hazards
inherent to welding on or around containers and piping that may have
combustible materials, such work should be handled only by
experienced welders who review and follow the safety practices
recommended in the American Welding Society document F4.1,
"Recommended Safe Practices for the Preparation for Welding and
SHIELDED METAL ARC Document No.
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Cutting of Containers and Piping Which Had Held Hazardous
Substances."

Know where the fire alarms and fire extinguishers are located, and
check the pressure gauges so you don't happen to come across one
that's empty. If there are none in the area, make sure that you have
access to fire hoses, sand buckets, fire-resistant blankets, or other fire
fighting equipment. If you're welding within 35 feet or so of flammable
materials, you should have a fire watcher to see where your sparks are
flying, and to grab an extinguisher or alarm if needed. Both you and
the fire watcher should wait for a half hour after all welding is finished
to find and put out any smoldering fires that may have resulted from
your welding.

As with other emergencies that may result from welding accidents, the
first rule is: don't panic. Depending on the size of the fire, shut off your
welder; sound the fire alarm to warn others and the fire department;
and get to the fire exits as quickly as possible.

FUMES AND GASES

Because of the variables involved in fume and gas generation from arc
welding and allied processes (such as the welding process and
electrode, the base metal, coatings on the base metal, and other
possible contaminants in the air), we'll have to treat the subject in a
rather general way, lumping all but the more hazardous situations
together. Although the health considerations will vary according to
fume and gas composition and individual reactions, the precautions we
specify will hold true for all fumes and gases. Again, it really boils
down to you and your senses.

The fume plume contains solid particles from the consumables, base
metal, and base metal coating. Depending on the length of exposure to
these fumes, most acute effects are temporary, and include symptoms
of burning eyes and skin, dizziness, nausea, and fever. For example,
zinc fumes can cause metal fume fever a temporary illness that is
similar to the flu. Chronic long-term exposure to welding fumes can
lead to siderosis (iron deposits in the lungs) and may affect pulmonary
function.
SHIELDED METAL ARC Document No.
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Cadmium, however, is a different story. This toxic metal can be found
on steel as a coating, or in silver solder. Cadmium fumes can be fatal
even under brief exposure, with symptoms much like those of metal
fume fever. These two shouldnot be confused. 20 minutes of welding in
the presence of cadmium can be enough to cause fatalities, with
symptoms appearing within an hour, and death five days later.

The gases that result from an arc welding process also present
potential hazard.  Most of the shielding gases (argon, helium, and
carbon dioxide) are non-toxic, but as they are released they displace
oxygen in your breathing air, causing dizziness, unconsciousness, and
death the longer your brain is denied its needed oxygen. In contrast,
the heat and the UV radiation can cause the eyes to tear and irritate
the lungs. Some degreasing compounds such as trichiorethylene and
perchlorethylene can decompose from the heat and ultraviolet
radiation of an arc. Because of the chemical breakdown of vapor-
degreasing materials under ultraviolet radiation, arc welding should
not be done in the vicinity of a vapor-degreasing operation. Carbon-arc
welding, gas tungsten-arc welding and gas metal arc welding should be
especially avoided in such areas, because they emit more ultraviolet
radiation than other processes. Also, keep in mind that ozone and
nitrogen oxides are formed when UV radiation hits the air. These gases
cause headaches, chest pains, irritation of the eyes, and an itchiness
in the nose and throat.

There is one easy way to reduce the risk of hazardous fumes and
gases: keep your head out of the fume plume! As obvious as this
sounds, it is a common cause of fume and gas overexposure because
the concentration of fume and gases is greatest in the plume. In
addition, use mechanical ventilation or local exhaust at the arc to
direct the fume plume away from your face. If this is not sufficient, you
may need fixed or moveable exhaust hoods to draw the fume from the
general area. Finally, it may be necessary to wear an approved
SHIELDED METAL ARC Document No.
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respiratory device if sufficient ventilation can not be provided. As a rule
of thumb, if the air is visibly clear and you are comfortable, then the
ventilation is probably adequate for your work.

The most effective way to identify these fumes and gases is to have a
specialist take a sample of the air around you. If this is impractical,
however, there are steps that you can take to identify hazardous
substances. First, read the material safety data sheet for the electrode
posted in the work place to see what fumes can be reasonably expected
from use of the product. Secondly, know what the base metal is, and
determine if there is any paint or coating that would cause toxic fumes
and/or gases. If you start to feel dizzy or nauseous, there is a
possibility that you are being overexposed to fumes and gases, or
suffering from oxygen deficiency. In either case, try to improve the
ventilation in your area. If that doesn't work: turn off your welder; get
some fresh air immediately; and notify your supervisor and co-workers.

Ventilation

The respiratory health hazards associated with welding operations are

caused principally by inhalation of gases, dusts, and metal fumes. The
type and quantity of toxic fumes in a welding area depend on the type
of welding being done, the filler and base metals used, contaminants
on the base metal, solvents in the air, and the amount of air movement
or ventilation in the area. Good ventilation is the key to avoiding or
minimizing respiratory hazards.

When welding and cutting mild steels, natural ventilation is usually

considered sufficient to meet requirements, provided that:

I. The room or welding area contains at least 10,000 cubic feet (about
22' x 22'

        x22') for each welder.

2. The ceiling height is not less than 16 feet.

3. Cross ventilation is not blocked by partitions, equipment, or other

structural barriers.
SHIELDED METAL ARC Document No.
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4. Welding is not done in a confined space.

Spaces that do not meet these requirements should be equipped with

mechanical ventilating equipment that exhausts at least 2000 cfm of
air for each welder, except where local exhaust hoods or booths, or air-
line respirators are used.

EXHAUST HOODS AND BOOTHS

Local exhaust of welding fumes can be provided by adjustable hoods or

by fixed enclosures or booths. Individual movable hoods are
particularly suitable for bench welding, but can be used for any
welding or cutting job provided that the hood can be moved so that it is
always close to the joint being welded. These hoods are more
economical to operate than a general ventilation system, particularly in
the winter, because they require less replacement air to be brought
into the room and heated.

Minimum required air velocity at the zone of welding is 100 fpm when
the hood is at its farthest position from the joint being welded. For a 3
inch wide-flanged suction opening, this velocity requires an air velocity
of 150 cfm at 4 to 6 inches from the arc, and 600 cfm at 12 inches
from the arc.

A ventilated booth is a second type of local exhaust arrangement. A

booth is a fixed enclosure that consists of a top and at least two sides
that surround the welding operation. Airflow requirements are similar
to those for movable hoods - sufficient to maintain a velocity away from
the welder of at least 100 fpm.

WORKING IN CONFINED SPACES

When arc welding in a confined area, such as a boiler, a tank, or the

hold of a ship, bear in mind that all the hazards associated with
normal arc welding are amplified, so the precautions mentioned here
are even more important. There is a greater danger that enough
flammable gases may be present in the confined space to cause an
explosion. The metal of the enclosure can become part of the welding
circuit, so any metal you touch (the walls, floor, ceiling) is electrically
SHIELDED METAL ARC Document No.
WELDING NC II Date Revised: August
2019
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"hot." Welding fumes can accumulate more rapidly, with a higher
concentration; gases can force out the breathable air, suffocating you
in the process.

You can see the danger involved in this area of welding: you really have
to be on your guard. Spare no effort in making sure that your body is
insulated from the work piece and ground by dry insulation. Wear dry
gloves and only use a well-insulated electrode holder. Semiautomatic
constant voltage welders with cold electrode or stick welders equipped
with a device to lower the no-load voltage are recommended, especially
when the work area is wet. Make sure that there is adequate
ventilation (be it forced or through an air supplied respirator), and that
there are no flammable coatings, liquids or gases nearby. Lastly, you
must have someone outside the enclosure trained to handle
emergencies, with rescue procedures and a means to disconnect power
to your equipment and pull you out if danger arises. We cannot stress
this strongly enough: however experienced you are, do not attempt
work of this nature without constant communication with the person
outside the confined area. You cannot be too careful when welding
within a confined area; any, repeat any, problem that arises can
immediately become life-threatening.

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
2019
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 References

www.yahoo.com

goggle.wiki encyclopedia network

http.//www.reproline.hkp/English
ytconv.photos download

Other Materials

National TVET Trainer Academy

Competency Based Learning Materials
Marikina City

Welding: Principles and ApplicationsHardcover

By: Larry Jeffus 

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
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SHIELDED METAL ARC Document No.
WELDING NC II Date Revised: August
2019
Issued by:

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Developed by: ROVELIE
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Evidence Plan
Competency Shielded Metal Arc Welding NCII
standard:
Unit of Weld Carbon Steel Plates
competency:
Ways in which evidence will be collected:
[tick the column]

Third party Report

Demonstration &
Observation &

Portfolio

Written
The evidence must show that the trainee…
 Correctly Apply welding techniques
/

Correct handling welding tools and equipment

/

Operate welding machine equipment

/
accordance with manufacturer’s instructions
Check items after welding process to ensure
/
quality cleaning
Record any damage arising from welding
process and notify appropriate person(s)
/
is/are accordance with establishment
procedures
Record Welding facilities and equipment /

NOTE: *Critical aspects of competency

SHIELDED METAL ARC Document No.

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Table of Specification

# of
Objectives/Content
Knowledge Comprehension Application items
area/Topics

 Correctly Apply
welding
1 1 1 3
techniques

Correct handling
welding tools and
2 1 3
equipment

Operate welding
machine
equipment
1 1 1 3
accordance with
manufacturer’s
instructions

Check items after

welding process to
1 1 2
ensure quality
cleaning

Record any damage 1 2 1 4

arising from
welding process
and notify
appropriate
person(s) is/are

SHIELDED METAL ARC Document No.

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 accordance with
establishment
procedures

TOTAL 3 7 5 15

HOUSEKEEPING SCHEDULE

Qualificatio : Shielded Metal Station

n Arc Welding NC II

Area / : Practical Work Tools /

SHIELDED METAL ARC Document No.
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Section Area Eqpt.

In - Charge : Service
s
Schedule for the Month of _________________
Responsi Dail Eve Wee Ever Month Remarks
ble y ry kly y ly
ACTIVITIES
oth 15th
Person er Day
Day
1. Clean the Trainees X Complied
work area
from ceiling
to floors,
corner to
corner.

2. Check the Trainees X Complie

electrical d
and
dangling
wires for
the entire
work area.
3. Check the Trainees X Complie
floors d
breakage
and
stripping.
4. Clean the Trainees X Complie
floors d
regularly to
avoid
slippery.

5. Arrange the Trainees X Complie

SHIELDED METAL ARC Document No.
WELDING NC II Date Revised: August
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tools and d
equipment
in order.

SHIELDED METAL ARC Document No.

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EQUIPMENT MAINTENANCE SCHEDULE
EQUIPMENT TYPE Welding machine
EQUIPMENT CODE 0020 – Welding Machine
LOCATION Practical Work Area
Schedule for the Month of_____________
ACTIVITIES MANPOW Dail Ever Week Ever Month Remark
ER y y ly y ly s
Oth 15th
er Day
Day
1. Check the X
parts of the
welding
machine
and their
function
and
damages
before use.
 Parts
of
weldin
g Trainees
machi
ne are
well
install
ed.

2. Check the X
parts of
welding
machine
SHIELDED METAL ARC Document No.
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 which are
cleaned.
 Clean and
kept dry Trainees
 Parts are
well-
secured/
attached
 Inspect
for
damages
and
replace
parts if
necessary
3. Clean the
exterior, tub
and lid
every time
you used. Trainees
4. Check the x
overall
condition of
the welding
machine. Trainees
 Parts
and
function
s/
damages
5. Check the x
store room Trainees
area for
welding
machine
storage

SHIELDED METAL ARC Document No.

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 * Free from
dust and well
ventilated area

6. x
Check/Clean Trainees
wire
adjustment);
remove used
dust; keep dry.
x
7. Use the
equipment Trainees
for a
minimum of
30 minutes
and observe
abnormal
operation; if
there is
unnecessary
, send to
technician.

SHIELDED METAL ARC Document No.

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 HOUSEKEEPING INSPECTION CHECKLIST

Section/Area Practical Working Area

In-Charge

YES NO INSPECTION ITEMS

1. Are the work area cleaned from ceiling to floors,
corner to corner?

2. Are the electrical and dangling wires checked for the

entire work area?

3. Are the floors checked for breakage and stripping?

4. Are the floors cleaned regularly to avoid slippery?

5. Are the tools and equipment arranged in order?

Inspected by: Date:

SHIELDED METAL ARC Document No.

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MAINTENANCE INSPECTION CHEKLIST

Equipment Type : Welding Machine

Property Code/Number : MO380
Location : Practical Work Area
Person – In – Charge :
Inspected by :
Date of Inspection :

Yes No Inspection Items

/ Are the parts of the welding machine and their function and
damages checked before used?

/ Are the parts of welding machine checked which are cleaned?

/ Are the exterior, circuit breaker, and wire checked every time
used?

/ Is the condition of the welding machine checked?

/ Are storing room area for welding machine checked?

/ Are the wires, removed used dust, dry and cleaned?

/ Is the equipment used for a minimum of 30 minutes of

operation?

SHIELDED METAL ARC Document No.

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Template No.6: TAG-OUT BILL

DANGER/CAUTION TAG-OUT INDEX AND RECORD AUDITS

LOG DATE TYPE DESCRIPTION DATE

SERIAL ISSUED ( (System Components, COMPLETED
Danger/Caution) Test reference ,etc.

01 5/20/19 Danger Clogs Obstruction 5/20/19

under repair
5/ 22/19
02 5/21/19 Warning Defective male plug

Prepared by: Approved:

Rovelie D. Panlilio ___________________

Trainer Supervisor

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
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Template No. 7:

WASTE SEGREGATION LIST

Section/Area Practical Work Area / Computer Laboratory

GENERATED / WASTE SEGREGATED METHOD

ACCUMULATED WASTE

Recycle Compost Dispose

Paper X X X

Pins X
X
Damp Cloth X

Sharp objects X
X
Toilet Tissue

SHIELDED METAL ARC Document No.

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Empty Bottles X X

Hand cloves X X

Dusting Cloth X

TEMPLATE No. #8 : BREAKDOWN / REPAIR REPORT

Area / : Practical Work Area

Section

Area / :
Section
NATURE OF
FACILITY TYPE RECOMMENDATION
BREAKDOWN

Welding Machine Ground Clamp Replace

Reported by:
Date:

Rovelie D. Panlilio May 8, 2019

Signature Over Printed Name

SHIELDED METAL ARC Document No.

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TEMPLATE # 9: WORK REQUEST

Unit Description
No.
Welding Machine Ground Clamp
5-20
Observation:

Replacement of Welding Machine Ground Clamp

Date Reported:

May 20, 2019

Reported by:

Rovelie D. Panlilio
Activity: Date completed:

New welding machine ground clamp May 8, 2019

Sign:
Spare parts used:

Ground Clamp
SHIELDED METAL ARC Document No.
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 Template 10 : SALVAGE REPORT

Area / : Practical Work Area

Section

Area / :
Section

FACILITY TYPE PART ID RECOMMENDATION

Welding Machine Circuit Breaker Keep items for future
usage.

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
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Reported by:

Date:

Rovelie D. Panlilio May 8, 2014

Signature Over Printed Name

Template No. 12

OPERATION OF EQUIPMENT
Equipment Type Welding Machine

Equipment Code 0020 welding machine

Location
Practical Working Area
Operation Procedures :

1. Before turning on the unit make sure the welding machine,

clean, and in good condition .

SHIELDED METAL ARC Document No.

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 2. Set the voltage to required .

3. Set the time.

4. Turn on welding machine. Do not pick up any material on the
machine. Keep it off.

5.When finished turn off (position O – all switches where necessary)

And disconnect the unit from the power point.

6. Keep it clean and dry.

Template No. 11

INSPECTION REPORT

FACILITY INCIDENT ACTION PROGRESS/REMARKS

TYPE TAKEN

Welding Ground Sent to repair Replacement

Machine clamp damage shop

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
2019
Issued by:

Weld Carbon Steel

Developed by: ROVELIE
Plates and Pipes D. PANLILIO
Revision
Using SMAW
Reported by:

Date:

Rovelie D. Panlilio May 10, 2014

Signature Over Printed Name

Evaluation Check List

Name of Trainee:
Name of Agency:
Training duration: 268 hrs.

Please check ( √ ) the appropriate box corresponding to trainee’s rating

for each criteria. The results of this evaluation shall serve as a basis for
improving the knowledge and skill of the trainee as benefits of the said
Program. Thank you for your cooperation.
Legend:
SHIELDED METAL ARC Document No.
WELDING NC II Date Revised: August
2019
Issued by:

Weld Carbon Steel

Developed by: ROVELIE
Plates and Pipes D. PANLILIO
Revision
Using SMAW
1. 70-74% 2. 75-80% 3.81-85 4.86-90% 5. 91-95%

Ratings
CRITERIA 1 2 3 4 5
Follows shop policies
Attendance
Punctuality
Maintains personal grooming and hygiene
Attitude to job
Attitude toward supervision
Ability to function within a working group
Knows the relevant forms of non-verbal
communication
Communicates effectively and politely
Provides information about property
Provides information about community
Handle guest request well
Demonstrates use of welding machine
Lends and retrieves property’s equipment
Handles complaints
Protects guests’ privacy
Identifies symbols for controlled products
Identifies fire safety information
Comments

Evaluated By: Date:

SHIELDED METAL ARC Document No.
WELDING NC II Date Revised: August
2019
Issued by:

Weld Carbon Steel

Developed by: ROVELIE
Plates and Pipes D. PANLILIO
Revision
Using SMAW
 Marivhel J. Rivera _______________
Housekeeping Supervisor

Monitoring Sheet

Name of Trainee:
Name of Agency:
Training duration: 268 hrs.
Direction: Pls. mark check the column that best describe the
performance of the trainee.
Did the trainee? Yes No
Follows shop policies
Attain work every day
Punctual
Maintains personal grooming and hygiene
Have good attitude to job
Attitude toward supervision
Relationships with staff and co-workers
Understands the chain of command
Ability to function within a working group
Communicates effectively and politely
Handle guest request well
Demonstrates use of welding machine
Lends and retrieves property’s equipment
Handles complaints
Protects guests’ privacy
Handles items left by customer
Provides turn-down service
Begins and ends shift systematically
SHIELDED METAL ARC Document No.
WELDING NC II Date Revised: August
2019
Issued by:

Weld Carbon Steel

Developed by: ROVELIE
Plates and Pipes D. PANLILIO
Revision
Using SMAW
 Comments :

Monitored by: Date: _______

TRAINEE’S RECORD BOOK

Trainee’s No.10456
NAME: ANALEE M. MERCADO
QUALIFICATION :SHIELDED METAL ARC WELDING NC II
TRAINING DURATION: 55 DAYS
TRAINER:

Instructions:
This Trainees’ Record Book (TRB) is intended to serve as record of all
accomplishment/task/activities while undergoing training in the industry. It
will eventually become evidence that can be submitted for portfolio assessment
and for whatever purpose it will serve you. It is therefore important that all its
contents are viably entered by both the trainees and instructor.
The Trainees’ Record Book contains all the required competencies in your
chosen qualification. All you have to do is to fill in the column “Task Required”
and “Date Accomplished” with all the activities in accordance with the training
program and to be taken up in the school and with the guidance of the
instructor. The instructor will likewise indicate his/her remarks on the
“Instructors Remarks” column regarding the outcome of the task accomplished
by the trainees. Be sure that the trainee will personally accomplish the task and
confirmed by the instructor.

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
2019
Issued by:

Weld Carbon Steel

Developed by: ROVELIE
Plates and Pipes D. PANLILIO
Revision
Using SMAW
 It is of great importance that the content should be written legibly on ink.
Avoid any corrections or erasures and maintain the cleanliness of this record.
This will be collected by your trainer and submit the same to the Vocational
Instruction Supervisor (VIS) and shall form part of the permanent trainee’s
document on file.

THANK YOU

NOTES:

SHIELDED METAL ARC Document No.

WELDING NC II Date Revised: August
2019
Issued by:

Weld Carbon Steel

Developed by: ROVELIE
Plates and Pipes D. PANLILIO
Revision
Using SMAW
 SESSION PLAN
Sector : METAL AND ENGINEERING
Qualification Title : SHIELDED METAL ARC WELDING NCII
Unit of Competency : WELD CARBON STEEL PLATES
Module Title : PERFORMING GROOVE WELDING ON CARBON STEEL PLATES
Learning Outcomes:
1. Weld carbon steel plates in flat position (1G).
2. Weld carbon steel plates in horizontal position (2G)
3. Weld carbon steel plates in vertical position (3G)
4. Weld carbon steel plates in overhead position (4G)

A. INTRODUCTION
B. LEARNING ACTIVITIES:
LO1: Weld carbon steel plates in flat position (1G)
Learning Content Methods Presentation Practice Feedback Resources Time
1. Essential of Discussion Read Information sheet Answer Self Compare Goggle 120hrs
welding Demonstration 1.1.1 Essential of welding Check 1.1.1 answers Wikipedia
Written with
Welding:
Examination Answer Principles and
Key
Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
 Applications
Hardcover

by:Larry
Jeffus

2. International Discussion Read Information sheet Answer Self Compare Goggle 120
welding codes and Demonstration 1.1.2 International welding Check 1.1.2 answers Wikipedia hrs
standards Written codes and standards with
Welding:
Examination Answer Principles and
Key ApplicationsH
ardcover

by:Larry
Jeffus

3. Acceptable weld profile Discussion Read Information sheet Answer Self Compare Goggle 120
Demonstration 1.1.3 check 1.1.3 answers Wikipedia hrs
Written Acceptable weld profile with
Welding:
Examination Answer Principles and
Key Applications
Hardcover

by:Larry
Jeffus

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
4. Weld defect, causes Discussion Read Information sheet Answer Self Compare Goggle 120
and remedies Demonstration 1.1.4 check 1.1.4 answers Wikipedia hrs
Written Weld defect, causes and with
Welding:
Examination remedies Answer Principles and
Key Applications
Hardcover

by:Larry
Jeffus

5. Welding procedure Discussion Read Information sheet Answer Self Compare Goggle 120
specification (WPS) Demonstration 1.1.5 Welding procedure check 1.1.5 answers Wikipedia hrs
Written specification with
Welding:
Examination Answer Principles and
Key Applications
Hardcover

by:Larry
Jeffus

6. Welding techniques Discussion Read Information sheet Answer Self Compare Goggle 120
and procedures Demonstration 1.1.6 check 1.1.6 answers Wikipedia hrs
Written Welding techniques and with
Welding:
Examination procedures Answer Principles and

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
 Key Applications
Hardcover

by:Larry
Jeffus

7. Safe welding practices Discussion Read Information sheet Answer Self Compare Goggle 120
Demonstration 1.1.7 Safe welding practices check 1.1.7 answers Wikipedia hrs
Written with
Welding:
Examination Answer Principles and
Key Applications
Hardcover

by:Larry
Jeffus

C. ASSESSMENT PLAN
 Written Test
 Performance Test

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
D. TEACHER’S SELF-REFLECTION OF THE SESSION

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
 FORM 4.1-5.1
TRAINING PLAN
Qualification: SHIELDED METAL ARC WELDING NC II

Facilities/ Date
Trainees’ Training Training Mode of Assessment
Staff Tools and Venue and
Requirements Activity/Task Training Method
Equipment Time
Weld Carbon Steel
Plates
1. Essentials of  Operate the On the job Operation Welding GHPC Observation
welding welding training Supervisor machine with Oral May7,
machine questioning
equipment 2019
May
11,201
8:00Am-
12:00No
on

1:00Pm-

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
 5:00Pm

2.International  Identify On the job Operation Welding GHPC Observation May 12

welding codes and International training Supervisor machine with Oral 2019
standards codes and questioning
standards
May 16
2019

8:00am
12:00pm

3.Acceptable weld  Identify On the job Operation Welding GHPC Observation

profiles acceptable training Supervisor machine with Oral May7,
weld profile questioning
2019
 Differentiate
acceptable May
weld profile 11,201
8:00Am-
12:00No

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
 on

1:00Pm-
5:00Pm

4.Weld defects,  Identify the On the job Operation Welding GHPC Observation May 12
causes and weld defects training Supervisor machine with Oral 2014
remedies questioning
 Identify the
weld causes
and remedies May 16
2019

8:00am
12:00pm

5.Welding  On the job Operation Welding GHPC Observation

procedure training Supervisor machine with Oral May7,
specification (WPS) questioning
2019

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
 May
11,201
8:00Am-
12:00No
on

1:00Pm-
5:00Pm

6.Welding  Operate On the job Operation Welding GHPC Observation May 11

techniques and welding training Supervisor machine with Oral 2019
procedures machine questioning
 Identify
welding May 14
techniques 2019

8:00am
12:00pm

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
7.Safe welding  Identify On the job Operation Welding GHPC Observation
practices welding training Supervisor machine with Oral May7,
safety questioning
equipment 2014
 Operate May
welding 11,201
safety 8:00Am-
equipment 12:00No
on

1:00Pm-
5:00Pm

 On the job Operation Welding GHPC Observation May 12

training Supervisor machine with Oral 2019
questioning

May 16
2019

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
 8:00am
12:00pm

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
 Training Activity Matrix-SHIELDED METAL ARC WELDING NC II

Training Activity Facilities/Tools

and Equipment
Trainee Venue Date & Time Remarks

Prayer
Recap of Activities
Unfreezing Activities All trainees
Feedback of Training
Rejoinder/Motivation

Weld Carbon Steel

Plates Welding machine Welding
(AC or AC/DC) Workshop June. Competent
1. Weld carbon steel Welding table or jig 20,2014
Ford, Gerald G.
plates in flat position Portable grinder
(1G)
Portable oven

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
 Welding mask 12:00nn – For
1:00pm Assessment
Marco, Glenn B. Steel brush
Clear glass
Dark glass

For
Reassessment
Paglinawan, Rose D.
2. Weld carbon steel
plates in horizontal Welding machine
Opal, Jerry M. Competent
position (2G) (AC or AC/DC)
Welding table or jig
Santos,Marvin D. Competent
Portable grinder
Portable oven
Welding mask
Steel brush
Clear glass
Dark glass

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
3. Weld carbon steel Welding machine
plates in vertical (AC or AC/DC) Welding
position (3G) Welding table or jig Workshops
Portable grinder
Ladao, Keith M. June For
Portable oven 27,2014 Reassessment
Welding mask
Steel brush
Clear glass
Dark glass 1:00 pm – Ongoing
Marco, Glenn B. 2:00pm

4. Weld carbon steel Waban, Mark K.

plates in overhead Welding machine
position (4G) (AC or AC/DC) Welding
Welding table or jig Workshops
Portable grinder Junewl For

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01
Aragon, Jasper H Portable oven 27,2014 Reassessment
Welding mask
Reyes, Voltaire O. Steel brush
Clear glass 1:00 pm – Ongoing
2:00pm
Dark glass
Ongoing

Date Developed:
May 2019
Shielded Metal Arc Welding
NCII Prepared by:
Rovelie D. Panlilio
Revision # 01