Electrodes in the EXX18 classification pro-

duce hydrogen-free weld deposits. The lack of

hydrogen reduces the tendency for underbead
cracking and microcracking when welding low
alloy steel. It also reduces the amount of pre-
heat required. The preheat temperature may be
as much as 300F less than that required for
other electrodes. They are typically used for
intermediate and cover passes. However, they
can be used for open-root beads if joint fitup
tolerances are maintained with minimum root
face and maximum root opening. The current
and polarity should be a.c. or DCEN on root
beads only.
Low hydrogen electrodes are used to weld
the low alloy pipe used in many inner plant high
pressure and high temperature applications.
Mild steel pipe with wall thickness over 12 inch
is sometimes welded with these electrodes
because of their superior cleaning properties
and an overall speed advantage over E6010 elec-
trodes. The E7018 electrodes produce weld Fig. 16-8 Typical 30-inch headers for a gas conditioning system. The head-
ers are made of pipe with a 30-inch outside diameter and 516-inch wall thickness.
deposits with a tensile strength of 65,000 to Nozzles of the same material have outside diameters of 30 inches, 24 inches, and
80,000 p.s.i.; the E9018G electrodes, 90,000 1234inches. Welding saddles were used for all nozzles except the 30-inch size,
to 105,000 p.s.i.; and the E11018G electrodes, which were reinforced with welded rings. Crane Co.
110,000 to 115,000 p.s.i.

Joint Design
The most common types of joint in welded piping sys-
tems are the circumferential butt joint and the socket or
(lap) joint. A groove weld is used for the butt joint, and
a fillet weld is used for the socket joint. Fillet-welded
joints often join flanges, valves, and fittings to pipe
2 inches and smaller in diameter. The fabrication shown
in Fig.16-8 is composed of several of the basic types of
joints and welds used in the fabrication of piping systems.

Butt Joint
The butt joint, Fig. 16-9, is readily welded by all of the stan-
dard welding processes. Butt joints may not have inside
support or they may be set up with an inner liner called
a backing ring or chill ring. The butt joint is not difficult
to prepare for welding, and it can be welded in all posi-
tions without great difficulty. This joint design provides
good stress distribution and has maximum strength while
permitting the unobstructed flow of materials through the
pipe. It is also pleasing in appearance. Its general field of
application is pipe to pipe, pipe to flanges, pipe to valves,
and pipe to other types of fittings. The butt joint can be used
for any size or thickness of pipe and for any type of service.
While there are no universally accepted welding
grooves, the bevels specified in Table 16-3 are considered,
Fig. 16-9 This welding student is making a circumferential
V-groove weld on a butt joint in pipe in the horizontal fixed position
(5G). Location: Northeast Wisconsin Technical College McGraw-Hill
Education/Mark A. Dierker, photographer
for all practical purposes, as standard for industrial piping.
Bevels may be made by mechanical means or flame cut.
Socket Joints
Socket joints are fillet welded. They are generally used for
joining pipe to pipe, pipe to flanges, pipe to valves, and
pipe to socket joints in pipe about 3 inches in diameter and

Pipe Welding and Shielded Metal Arc Welding Practice: Jobs 16-J1J17 (Pipe) Chapter 16477
 Table 16-3 Recommended Pipe Bevels

Type of Position of Direction of No Backing With

Material Welding Welding Ring Backing Ring Bevel Angle1 Root Face2 Root Opening3
Carbon steel All Up 30 to 3712 16
1 1
16
Carbon steel All Up 30 to 37 21 1
8 3
16
Carbon steel All Down 3712 16
1 1
16
Bevel angle may be 212.
1

Root face may be 132.

2

Root opening may be 116.

3

under. This type of joint permits unrestricted fluid flow
in small pipe. Figure 16-10 illustrates three typical fillet
welded socket joints. Adequate penetration of the pieces
being joined is an absolute requirement.
Note the 116-inch minimum clearance in Fig. 16-10,
which is required by many codes. If the pipe is bottomed
out in the socket with no clearance, the weld will crack in
service. The function of the gap is to permit thermal ex-
pansion of the pipe. Without the gap, the heat of welding
can cause the pipe to expand at a faster rate than the fitting.
If the pipe is resting against the socket fitting, the thermal
growth of the pipe stains the weld and will lead to cracking.
Failures have also occurred in socket welds subjected to
thermal and mechanical cycling during service. The same
situation that occurs during
vessels are usually the most difficult to weld. Factory-
wrought fittings are preferred for the layout of the pip-
ing system since they are the equivalent in strength to the
pipe being used. Moreover, their installations involve butt
joints only. Cutting and beveling may be done manually
or with a machine beveler designed for that purpose.
Figure 16-11 illustrates the three forms of preparation
for 90 intersection joints. In type A, the header opening
is equal to the inside diameter of the branch, and only
B may be increased when backing ring is used.
A
B
B B

1.25 to 1.5 T welding can occur during A

A

T
service with rapid changes in
service temperature causing
Type A
1/16
the pipe to expand against the
Clearance
bottom of the fitting, strain-
A
ing and cracking the weld.
Welded Sleeve
Coupling A Gap-a-Let is a device in- A
B

serted into the socket to hold B

B
this clearance. A

Socket joints are not always

Type B
1/16 Clearance
acceptable. Butt joints with
groove welds with complete
A
penetration to the inside of the
Socket Detail for Small
Welding End Valve
piping are required for piping A
B
systems containing radioac- A B B

tive solutions, food products, or

gases and those solutions sub-
Clearance 1/16
jected to corrosive service with
materials that are likely to cause
crevice or stress corrosion.
Socket End Welding Intersection Joints
Elbow
Intersection joints such as
Fig. 16-10 Typical fillet medium and large Ts, lat-
welded lap joints. erals, Ys, and openings in
Type C
Angle A to be not less than 45 for any wall thickness
of pipe.
B to be not less than 1/16 nor more than 1/4.
Acceptable types of preparation for 90 full size and 90
reduced size branch connections.
Fig. 16-11 Acceptable types of preparation for 90 full size and
90 reduce size branch connections.

478Chapter 16Pipe Welding and Shielded Metal Arc Welding Practice: Jobs 16-J1J17 (Pipe)
the branch is beveled. This type of branch
permits the use of a specially shaped backing
ring if necessary. In type B, the header open-
ing is large enough to permit insertion of the 90 Long 90 Short
branch so that only the header opening must be Radius Radius
beveled. Type C is a third form of preparation Elbow Elbow 45 Long Radius Elbow

in which both the header and the branch are

beveled. This form of unreinforced branch is
adequate only when the pipe is to be used at
pressures of 50 to 75 percent of the full pres-
sure that the pipe can withstand. Reinforce- Straight Tee Reducing Outlet Tee Straight Cross
ment or manufactured welded fittings are
required to make 90 intersections equivalent
in strength to the pipe from which they are fab-
ricated. Intersection joints at an angle of 45 or
less produce a condition at the heel of the in-
Cap Straight Lateral Reducing Elbow
tersection that makes it difficult, if not impos-
sible, to secure the degree of penetration and
soundness of weld deposit that is necessary for
severe service conditions. Wherever possible,
intersection joints should be made under shop
conditions where the work can be positioned Welding Neck Flange Slip-on Flange Lap Joint Flange

for welding in the flat position.

Welded Fittings
Pipe manufacturers have kept pace with design 180
for welding by providing the industry with a 180 Long Radius Return Extra Long Radius Return 180 Short Radius Return
line of seamless and welded fittings especially
for welding. They are available in most grades
of material suitable for welding and in many
combinations of size and thickness. They com-
bine the best characteristics for unimpaired
Concentric Reducer Eccentric Reducer Lap Joint Stub End
flow conditions with wide availability, ease of
Welding
welding, and maximum strength. Rings
Insulation can be applied to ready-made
fittings without difficulty. The system can be
installed in less space than when fittings are
fabricated for the job, and system changes can Scale-free Coupling Sleeve Ridge Groove
be made without difficulty. The piping re-
quires less maintenance, and new systems are
easy to design. The use of these fittings also Welding
saves a great deal of time and eliminates a Neck
Orifice
considerable amount of the cutting, tacking, Threaded Flange Blind Flange Flange
and fitting required in the hand fabrication of
various types of joints. They also enhance the Fig. 16-12 Machine-beveled manufactured welding fittings. Source: Sypris
appearance of the job. They make the use of Technologies, Inc.
hand-mitered construction obsolete.
Manufactured fittings for welding that are available are
shown in Fig. 16-12. The application of welding to flanges Backing Rings The term backing ring is applied to a ring-
is illustrated in Fig. 16-13, page 480. The sequence of shaped structure, Fig. 16-15, page 480, which is fitted to the
manufacturing steps from flat plate to the finished fitting inside surface of the pipe before welding. Its functions are
is shown in Fig. 16-14, page 480. to assist the welder in securing complete penetration and

Pipe Welding and Shielded Metal Arc Welding Practice: Jobs 16-J1J17 (Pipe) Chapter 16479
 Fillet Weld
Socket Flange

Fillet Weld
Slip-on Flange Fig. 16-14 The manufacturing steps necessary to fabricating a welded L
with machined ends. Crane Co.

Groove Weld
Joint Coupling

A B
Groove Weld
Neck Flange
Fig. 16-15 (A) A machined ring. (B) A ring with chamfered nubs for quick
Fig. 16-13 Typical welding flanges. strike off sets the pipe root opening for the root pass. Nubs melt with the
weld metal. Robvon Backing Ring Co.

fusion without excessive melt-through (Fig. 16-16), to

prevent spatter and slag from entering the pipe at the
joint, and to prevent the formation on the inside of the
joint of irregularly shaped masses of metal, sometimes
called icicles or grapes. The prevention of icicles is es-
pecially important in pipe joints ahead of such units as
valves and turbines. Backing rings also help to secure
proper alignment of the pipe ends. There are two types
of backing rings: split and solid. Split backing rings are
designed to fit on the inside of the pipe without ma-
chining. They can be expanded or contracted to fit the
inside diameter of the pipe. The solid type is machined
and requires that the pipe also be machined to receive
it. Its use is usually restricted to pipe that is to s ustain
severe service conditions. The installation cost of solid Fig. 16-16 The root side of a V-groove butt joint on pipe welded without a
rings is higher than that of split rings due to the higher backing ring. Note the excess melt-through (icicles, grapes, etc.) in several places.

480Chapter 16Pipe Welding and Shielded Metal Arc Welding Practice: Jobs 16-J1J17 (Pipe)
cost of the ring itself and Pipe Clamps One difficulty encountered in assembling
the cost of preparing the pipe to be fabricated is the positioning of the pipe before
pipe. A solid ring is shown tacking. One method is to clamp the pipe in a fixture in the
in Fig. 1615A, and a split exact position desired for welding. The joint must be care-
ring, in Fig.16-15B. These fully mounted in the proper alignment in the pipe clamp or
types of devices are also fixture. Pipe clamps of various types and sizes are avail-
available for square and able to align and hold pipe joints in preparation for tacking.
rectangular tubing. Figures 16-19 through 16-25 (pp. 481482) show various
Correct spacing be- pipe joints properly clamped and ready for tacking.
tween the pipe ends is es-
sential to securing sound Special Fabrications Sometimes manufactured welded fit-
welds. Most backing rings tings are not available, and the welders must fabricate
contain a series of small their own fittings or make special connections on the
nubs, ranging from 116 job. There are a variety of special designs in welded-
to 34 inch in length, on pipe construction that may be fabricated when necessary.
the outer surface of the Among these are Ls and laterals, side outlet fittings, mi-
ring. Backing rings for tered joints, elbows, Ys, and expansion joints, Figs.1626
pipe sizes 4 inches and through 16-28, page 483. Joints should be carefully laid
under are 332 inch thick
by 58 inch wide. For pipe Fig. 16-17 The consumable
sizes 5 inches and over, insert ring becomes part of the root
they are 18 inch thick by weld bead and ensures complete
penetration and smoother flow of
1 inch wide. Root-spacer materials inside the pipe. Fitup is
nubs may be 18 to 316 inch easy. The GTAW process is used on
in diameter. The material root pass when consumable insert
of the ring should be sub- rings are used. Source:Robvon
stantially the same chemi- Backing Ring Co.
cal analysis as the pipe or
tube that is to be welded.
Consumable insert rings, 25
Fig. 16-17, improve the quality
of the weld. They must be of
the proper c omposition and di- 1/4 R

mensions. In piping for atomic

Fig. 16-19 Standard butt joint clamped and ready for tacking.
reactors, stainless-steel piping Mathey Dearman
is best installed with consum- 3/64 1/8 R
3/8
able insert rings. These rings 15
provide the most favorable J - Groove
weld contour to resist cracking
from weld metal shrinkage 30
and hot-shortness (brittleness
in hot metal), and they elimi-
nate notches at the weld root.
They also ensure weld metal
composition with the best pos-
sible properties of strength, 3/64 1/8 R
3/8
ductility, and toughness. See 15
Fig.16-18 for end preparation V - Groove
of pipe for consumable insert
rings. These are typically Fig. 16-18 Typical pipe
welded autogenously with the end preparation for consum-
GTAW process. able insert rings for pipe wall Fig. 16-20 An L is being set up with a length of pipe for a butt
thicknesses up to 1 inch. joint. Mathey Dearman

Pipe Welding and Shielded Metal Arc Welding Practice: Jobs 16-J1J17 (Pipe) Chapter 16481
 Fig. 16-23 This fast, easy-to-use clamp can be used to hold small
fittings in position for welding. This clamp can adjust Hi-LoTM of the
elbow level checks the a lignment. Mathey Dearman

Fig. 16-21 A flange is being set up with a length of pipe for a

butt joint. Note the internal clamp. Mathey Dearman

Fig. 16-24 Clamps are available in several types and m odels from
2- to 60-inch diameters. This type of cage clamp is fast and efficient
when only alignment is required. Mathey Dearman

Fig. 16-22 The Spacing Screw is used to obtain a precise root Fig. 16-25 This hydraulic cage clamp produces the extra strength
opening between pipes or other fittings. Spacing Screw assemblies necessary for aligning large pipe diameters. Pipes can be effort-
are available for steel and stainless-steel applications. Mathey lessly aligned due to the design of the Hydraulic Closure Mechanism.
Dearman Clamps are available for 16- to 60-inch pipes. Mathey Dearman

482Chapter 16Pipe Welding and Shielded Metal Arc Welding Practice: Jobs 16-J1J17 (Pipe)
 out with templates and standard layout curves. These fit-
tings may be formed on the job from straight lengths of
pipe by hand or machine flame cutting.

90-A 90-B 90-C Codes and Standards

3 Segment 4 Segment 5 Segment
Elbow Elbow Elbow You will recall that piping systems are subject to wide
variations in pressure and temperature, that corrosion is a
problem in many systems, and that many of the materials
carried are dangerous to life and property. Piping systems
must be insurable against any loss resulting from the fail-
ure of the pipe or the welding.
45-A 45-B 45-C
2 Segment 3 Segment 4 Segment
Elbow Elbow Elbow Code-Making Organizations
Fig. 16-26 Hand-fabricated segmental 45 and 90 Ls. In order to ensure uniform practices in the design, instal-
lation, and testing of piping systems, various codes and
standards applicable to welded piping systems have been
prepared by committees of leading engineering societ-
ies, trade associations, and standardization groups. These
are generally written to cover minimum requirements of
quality and safety. A few insurance companies, manufac-
turers, and the military set up their own codes to cover
the fabrication of welded piping systems. All of these
codes have been set up for the purpose of establishing
welding procedures and inspecting and testing methods
to provide assurance that the work meets the purchasers
specifications and to give protection against accident.
Our prime concern in this chapter will be with the quali-
fication tests for welders rather than with the procedure
qualification tests.
Fig. 16-27 A steel 90 three-segment elbow with flange, tacked Following is a brief description of a few of the prin-
and ready to be loaded into a welding positioner for final welding. cipal code-making organizations.
Piping Systems, Inc.

The American Society of Mechanical

90
Engineers (ASME) This society is responsi-
45
ble for the ASME Boiler and Pressure Vessel
Code, which covers piping connected to boil-
ers. It is recognized in almost all states and is
a prerequisite to acceptance of the installation
by the states and insurance companies. It cov-
Double Tee Saddle Pressure Vessel Special Y ers the installation of piping systems in con-
Lateral Reinforced 2,000 lb. at 1,0508F
nection with power boilers, nuclear vessels,
and unfired pressure vessels.

The American Petroleum Institute (API) This

group is concerned with the standards for
welding pipelines and related facilities. The
standard includes regulation of the gas and
arc welding of piping used in the compres-
90 Double Offset Expansion Expansion
Pipe Bend Expansion Bend Square Bend U Bend sion, pumping, and transmission of crude pe-
troleum, petroleum products, and fuel gases,
Fig. 16-28 Several types of hand-fabricated branch connections and e xpansion bends. and certain distribution systems.

Pipe Welding and Shielded Metal Arc Welding Practice: Jobs 16-J1J17 (Pipe) Chapter 16483
The American Water Works Association This group has
issued standards covering the fabrication of piping for
water purification plants.
The Heating, Piping, and Air Conditioning Contractors
National Association This piping contractors association
has set up standard welding procedures for the installa-
tion of piping systems by their member contractors. The
National Certified Pipe Welding Bureau is one of several
organizations which supervises and certifies welder qual-
ification tests in a uniform manner in accordance with the
Associations standard procedures.
The American Welding Society (AWS) This organization
is responsible for a great many of the uniform practices
in the field of welding. One document that deals with the
welding of pipe and tubes is D18.1. It covers the speci-
fication for welding austenitic stainless-steel tube and
pipe systems in sanitary (hygienic) applications. Not all
pipe is used to carry products. Sometimes pipe is used
as a structural material, and the D1.1 Structural Welding
CodeSteel covers this aspect. The AWS was one of the
early pioneers in the development of uniform training and
testing practices for welders and welding operators. Today
the society is one of the outstanding authorities in all mat-
ters pertaining to welding.
These are the principal code bodies concerned with the
design, installation, and testing of piping systems. There
are a number of other groups concerned with special pur-
pose installations.
It is suggested that you obtain a copy of each of the
following publications in order to become thoroughly fa-
miliar with all of the information in regard to the common
codes and testing situations:
The American Welding Society, B1.10 Guide for the
Nondestructive Inspection of Welds, B1.11 Guide
for the Visual Inspection of Welds, B2.1 Standard
for Welding Procedure and Performance Qualifica-
tion, D18.1 Specification for Welding of Austenitic
Stainless Steel Tube and Pipe System in Sanitary
(Hygienic) Applications, and the D1.1 Structural
Welding CodeSteel.
American Petroleum Institute, Standard for Welding
Pipe Lines and Related Facilities (API Std.1104).
The American Society of Mechanical Engineers,
Section IXASME Boiler and Pressure Vessel
CodeWelding Qualifications.
Procedure and Welding Qualification
Code welding requires the setting up and acceptance of
the qualifications for welding procedures and for welders
484Chapter 16Pipe Welding and Shielded Metal Arc Welding Practice: Jobs 16-J1J17 (Pipe)
who are going to fabricate the piping installation follow-
ing the welding procedure adopted.
Procedure Qualification Tests The welding procedure
qualification is set up and approved before the start of
production welding. It is recorded on a form called a
Welding Procedure Qualification Record (WPQR).
This establishes the fact that the procedure can pro-
duce welds having suitable mechanical properties and
soundness.
The details of each qualified procedure are recorded on
a Welding Procedure Specification (WPS), and include a
record of the following:
Material for pipe and fitting
Diameter and wall thickness of the pipe
Joint design
Joint preparation, including root opening and bevel
angle if necessary
Position of welding
Welding process
Type and size of electrode or filler rod
Type of current
Current setting
Number of passes
Welding technique
Use of a backing strip if necessary
Preheat, between-pass heat, and postheat
temperatures
Special information peculiar to each job
It must be understood that the purpose of the welding
procedure is to make certain that welds made in compli-
ance with it have the potential mechanical properties to
meet its application. This is often called fitness for pur-
pose. Many codes will describe changes that may or may
not be allowed. These are welding procedure variables,
which are further defined as:
Essential variables: Those in which a change is consid-
ered to affect the mechanical properties of the weld-
ments and shall require requalification of the WPS.
Supplementary essential variables: Required for metal
for which notch-toughness tests is specified and are
in addition to the essential variables and are welding
process specific.
Nonessential variables: Those in which a change, as de-
scribed in the specific code variables, may be made in
the WPS without requalification.
The specific code being used should be consulted to de-
termine if these items are considered essential or nones-
sential variables.