LEARNING MODULE

Sector: METALS AND ENGINEERING

Subject Code: SMAW

Subject Description: Welding

Module Title: Welding Carbon Steel Plates

Using SMAW
 LEARNING OUTCOME #5
WELD SUBSEQUENTLY/FILLING PASSES

CONTENTS:
1. Welding Procedure and Specification
2. Parameters to produce quality weld
3. Welding subsequently/filling passes

ASSESSMENT CRITERIA:

1. Subsequent/ filling passes is performed in accordance with approved WPS

2. Weld is visually checked for defects and repaired, as required.
3. Weld is visually acceptable in accordance with applicable codes and
standards.

CONDITIONS: The student must be provided with the following:

4. Equipment: welding machine, portable grinder
5. Tools: chipping hammer, half-round/bastard file, steel brush
6. Materials: carbon steel plate, grinding stone/pad, electrodes

ASSESSMENT METHODS:
 Written Test
 Oral Questioning/Interview
 Demonstration/Role Play
 Learning Experiences

Learning Outcome 5

WELDING SUBSEQUENTLY/FILLING PASSES

Learning Activities Special Instructions

Read Information Sheet 5.3-1 on This Learning Outcome deals with the
“Welding Procedure and development of the Institutional Competency
Specification” Evaluation Tool which trainers use in evaluating
their trainees after finishing a competency of the
Read Information Sheet 5.3-2: qualification.
“Five Essentials of Welding”
Go through the learning activities outlined for you
on the left column to gain the necessary
information or knowledge before doing the tasks
to practice on performing the requirements of the
evaluation tool.

The output of this LO is a complete Institutional

Competency Evaluation Package for one
Competency of Welding. Your output shall serve
as one of your portfolio for your Institutional
Competency Evaluation for Welding Carbon
Steel Plates and Pipes Using SMAW.

Feel free to show your outputs to your trainer as

you accomplish them for guidance and
evaluation.

After doing all the activities for this LO, you are
ready to proceed to the next LO: Performing
Capping
 Information Sheet 5.3-1

WELDING PROCEDURE AND SPECIFICATION

Learning Objectives:
After reading this information sheet, you MUST be able to:
1.) Identify welding procedure specification; and
2.) Interpret welding procedures specification.

A Welding Procedure and Specification (WPS) is a formal document describing welding

procedures. 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.

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.
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 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.

In Europe, the European Committee for Standardization (ECS) has adopted the ISO
standards on welding procedure qualification (ISO 15607 to ISO 15614) and on welder
qualification (ISO 9606), with the exception of qualification for steel welders, where a
new version of the old European EN 287-1 standard still applies. EN ISO 15706 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.z
Welding Procedure and Specification :-( Example FORM)

Weld Procedure Number 30 P1 TIG 01 Issue A

Qualifying Welding Procedure [WPAR] WP T17/A

Manufacturer: National Fabs Ltd. Method of

25 Lane End Preparation Machine and
Birkenshaw and Cleaning Degrease
Leeds
Parent Metal Grade 304L
Location: Workshop Specification: Stainless Steel

Welding Manual TIG Parental Metal 3 to 8mm wall

Process: Thickness

Joint type: Single Sided Butt Weld Pipe Outside 25 to 100mm

Diameter

Welding Position: All Position

Welding
Progression: Upwards

Joint Design Welding Sequences

Welding Consumables:-Type, BS 2901 Part Production
Designation Trade Name: 2 :308S92 Sequence
Any Special Banking or Dying: No
Gas Flux Argon 99.99% 1. Clean weld and
Gas Flow Rate – Shield: Purity 25mm borders to
- Backing: 8 – 12 LPM bright metal using
Tungsten Electrode Type/Size: 5 LPM approved solvent.
Detail of Back Gouging/Backing: 2% Thoriated 2. Position items
Preheat Temperature: 2.4mm Di to be welded
Post Weld Treatment Gas Backing ensuring good fit
Time, temperature, Method: 5 C Min up and apply
Heating and Cooling Rates: 200 C Max purge.
Not Required 3. Tack weld part
together using TIG
tacks to at least
5mm min length.
4. Deposit root
run using 1.2mm
dia. Wire.
5. Inspect root run
internally
6. Complete weld
using 1.6mm dia.
Wire using
stringer beads as
required.
7. 100% visual
Inspection of
Completed weld
 Information Sheet 5.3-2

FIVE ESSENTIALS OF WELDING

After reading the Information Sheet, the student MUST be able to determine the Five
essentials of quality weld.

Weld quality and consistency can only be maintained with respect to the five essentials.
The five essentials of welding include the use of correct electrode size, current, arc length
or voltage, travel speed and electrode angles. All five must be collectively and
consistently maintain to successfully control the puddle and produce a weld that is
uniform in appearance, have consistent ripples, smooth face contour, and no noticeable
defect. Once the welder masters the ability to consistently maintain the five essentials,
the ability to control the puddle will follow.

ELECTRODE SIZE
Choosing the correct electrode size involves many factors. If a smaller recommended
electrode is used, welding time and heat to the joint will increase. It can result in
increase of costs, heat affected zone, cracking or distortion. Larger electrode can cause
melt –through and can be difficult to control in out of position joints. Poor appearance
and possible defects can result. The welding procedure designates the correct electrode
size, generally based on metal type and thickness. However, if no procedure or
instruction is available the welder will have to choose the correct electrode size.
CURRENT
The correct current setting is vital for maintaining consistency in weld quality. If the
current is too high, the electrode melts too fast, and the molten pool is larger and
irregular. If the current is too high when welding single V-groove, it might blow holes
through the joint and cause large molten metal droplets to fall out of the groove. If the
current is too low, there is not enough heat to melt the base metal. The molten pool will
be too small, piles up, and looks irregular. Poor penetration and incomplete fusion in the
joint can result.

TRAVEL SPEED
Incorrect travel is a common mistake. Sometimes travel speed is the only condition a
welder may need to change. Travelling too fast causes the puddle to freeze too quickly.
Because of this, impurities and gases can become entrapped, making the bead face
narrow with pointing ripple. Incomplete penetration due to loss of the keyhole in root
pass is possible. Travelling too slow will cause the puddle to be large, with pile –up, and
a straight ripple pattern. For out of position welding, slow travel sped can cause the
puddle to drip out the joint.
ELECTRODE ANGLE
One of the most essentials is the use of the correct electrode angles. For fillet and groove
welds, correct electrode angles are vital for preventing undercut and inadequate fill.
When depositing a fillet weld the electrode should be held so that it bisects the angle
between the plates and is perpendicular to the line of the weld. On groove weld, the
technique is much the same; although varying slightly with multiple pass welding. There
are two teams to specify electrode angles. These are travel angle and work angles. The
travel angle applies to the position the electrode make with a reference perpendicular to
the axis of the weld in plane of the weld axis. It can be either a drag angle push angle. A
drag angle is when the electrode is pointing backward, meaning the welder’s hand and
electrode holder proceeds the puddle. A push angle is when electrode is pointing just the
opposite of the drag. The work angle is the position the electrode makes with reference to
the surface of the plate on a plane perpendicular to the weld axis. On butt joints the
work angle is usually 90 degrees to the surface of the plate .To some degree, you can
correct for an improper condition by varying the essential variables. It is better though to
have all conditions as correct as possible.
ARC LENGTH
Arc length is very important for weld puddle control. Correct arc length will
Cause the deposit to be neat of even ripple and of good penetration.
Too long arc length will cause the deposit to coarse rippled and flatter than normal with
an increase in spatter. When welding a root pass in an open root V-groove, the keyhole
can grow too large and loose of weld control can result.
Too short an arc will cause deposited to be narrow, uneven and irregular rippled and
with poor fusion. The arc length reduces the voltage and increases the amperage slightly
but the electrode may stick to the work. When welding root passes, too short an arc
length often results in loss of the keyhole.

Prepared by Mam Ghem