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Introduction to Pipe Welding Class Description 1.
Purpose- The purpose of this course is to provide students with a learning
environment that will develop basic skills for welding pipe using the SMAW
process. 2.
Prerequisites- Students should have the ability to perform the following tasks prior
to welding on pipe. All welds described shall meet the visual acceptance
criteria of AWS D1.1, ASME Sec IX, ASME B31.1 or similar industry code or
standard. These skills may be developed during the class but this development
will minimize the actual pipe welding time. The following abilities shall exists
and may be verified at any time during the training or prior to entry. 2.1.
Weld a
single pass fillet weld in the vertical and overhead position using 3/32 or
1/8 E 7018 meeting the visual acceptance as indicated above. 2.2.
Weld a
root pass using 1/8 E6010 in a square groove joint 3/16 thick. The root
side of the weld must show complete fusion between both edges with no overlap at
tie ins or undercut/underfill greater than 1/32. Vertical, Overhead and
horizontal welds required. 2.3.
Fill a
simulated groove joint using 1-1/2 Flat Bars forming a 60 Degree included
angle at the joint. Weld shall be made in Vertical, Overhead, and Horizontal.
Cross Section of the weld cut from a random area shall show no more than 1/8
Accumulated discontinuities. 2.4.
Weld a
Single Vee Groove weld with an open root on 3/8 thick material with no
visible discontinuities in 2 random cross sections cut from the plate. Guided
bend tests may be performed. 2.5.
For
students who complete all qualification testing for SMAW pipe welding, GTAW pipe
welding techniques will be introduced at the discretion of the instructor. All
of the above tasks will be completed using GTAW prior to Pipe Welding using GTAW. 3.
Course Tasks 3.1.
Safety-The
student shall be familiar with the following safety rules for the shop and shall
be monitored during training. 3.1.1.
Eye
Protection-All Grinding, Chipping, or wire brushing of welds shall be performed
with eye protection. 3.1.1.1.
Safety
glasses are required for Chipping and Hand Wire brushing . 3.1.1.2.
Full face
protection is required for any activities requiring power tools. 3.1.2.
Gloves
shall be worn at all times when welding, chipping, grinding, wire brushing, or
handling hot metal. For SMAW welding, gloves shall have cuffs that cover the
wrist. 3.1.3.
Leather
shoes shall be worn. 3.1.4.
Cotton or
other non-synthetic shirts/coats must be worn during welding. Leather sleeved
jackets will be provided. 3.1.5.
Shirt/Jacket
collars should be buttoned 3.1.6.
Frayed or
Torn clothes are to be repaired/covered prior to welding. 3.1.7.
Hearing
protection must be worn when grinding. Ear Buds are NOT hearing protection. 3.2.
Theory-
The student shall become familiar with the terms and definitions related to
shielded metal arc welding, gas tungsten arc welding, and Semi-Automatic wire
feed welding processes. These shall include the following topics. 3.2.1.
Welding
Equipment Descriptions 3.2.2.
Basic
Weld Joint/Groove Types 3.2.3.
Process
Descriptions and Advantages/Disadvantages 3.2.4.
Material
Properties 3.2.5.
Material
Designations and specifications 3.2.6.
Welding
Defects and possible causes 3.2.7.
Welding
Metallurgy and Distortion. 3.2.8.
Use of
Welding Procedure Specifications 3.2.9.
Performance
Qualification Testing 3.3.
Practical-
Students shall develop basic skills for welding 6 pipe using a series of
exercises/skill evaluations below. The basic welding skills as indicated in the
prerequisites will be built upon. These exercises will
develop the the students hand/eye coordination in a manner to allow for
maintaining electrode angles, travel speed, and arc length when traveling around
the circumference of the pipe. In addition students will become familiar with
beveling and fitting pipe coupons for performance qualification testing in
accordance with asme Sec IX. The 3.3.1.
Weld a
single pass fillet weld on a pipe to plate configuration using 3/32 E7018.
The position shall be 2F, 5F, and 6F. 3.3.2.
Using the
satisfactory weld produced in 3.3.1, students shall weld multiple passes
increasing the fillet weld size. Emphasis will be on maintaining a smooth weld
profile on individual beads and the overall weld layer. 3.3.3.
Weld 6
Sch 40 pipe coupons in the 2G,5G, and 6G positions using 1/8 E6010 for root
passes and 3/32 for fill and cap. All beads shall be no wider than Ό.
Finished practice welds that meet the acceptance criteria shall be cut and
polished across the weld area. If no discontinuities are noted then guided bend
tests shall be prepared. 3.3.4.
Weld 6
Schedule 80 Welder Performance Qualification Testing using 1/8 E6010 for root
passes and 3/32 or 1/8 E 7018 for fill and cap passes. Students will cut
and prepare the guided bend test specimens in accordance with the requirements
in accordance with ASME Sec IX and guided bend testing will be performed. 3.3.5.
Weld 2
Schedule 40 coupons in the 2G, 5G, and 6G position using GTAW for the root, fill
and cap passes. This will be performed using both Free Hand/Finger Resting
techniques and Walking the cup. 4. Qualification and Certification Testing-For students who have completed satisfactory practical tasks and theory testing, welding performance qualification testing shall be performed and documented on and ASME Sec IX equivalent Welder Performance Qualification Record (WPQR). This document will certify that the students has welded a satisfactory performance qualification test in accordance with ASME Sec IX. This document will indicate that it shall not be used evidence of qualification for any work to be performed in production/manufacturing environments.
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