Level 1 Chapter 10

Objective
 When we have completed this chapter,
you will be able to:
 Identify and explain job code specifications
 Use fit-up gauges and measuring devices
 Identify and explain distortion
 Fit up joints using plate and pipe fit-up tools
 Check for joint alignment
1.0.0 Introduction
 Joint design and setup affect the safety
and quality of completed weldment.
 Because joint design and setup are so
important, they are covered by written
codes and specifications that must be
followed.
 Special tools to measure and aid fit-up
are also available.
2.0.0 Job Code Specifications
 Whenever a bridge, building, ship or
pressure vessel is welded, the
manufacturer and the buyer must reach
agreement on how each weld will be made.
 To eliminate the need to write a new code
for each job, government agencies,
societies, and associations have developed
codes.
 These codes are used universally to
ensure safety and quality when welds are
made.
2.1.0 Governing Codes and
Standards
 A welding code or standard is a detailed
listing of the rules and principles that
apply to specific welded products.
 Codes ensure that safe and reliable
welded products will be produced and
that persons associated with the welding
operation will be safe.
2.1.0 Governing Codes and
Standards
 In addition, when codes are specified, the
use of these codes is mandated with the
force of law by one or more government
jurisdictions.
 Here are some of the more common codes
and standards:
 API 1104-Standards for Welding of Pipeline and
Related Facilities- used for pipelines
 ASME Boiler and Pressure Vessel Code –
American Society of Mechanical Engineers
 ASME B31.1, Power Piping – used for pressure
piping
 AWS D1.1 – Structural Welding Code – Steel
2.2.0 Code Changes
 Codes are periodically reviewed and
updated.
 Addendum sheets (new pages) for the
areas of the code affected by the
changes are issued.
 The ASME issues yearly addendums.
 The yearly addendum is identified by
placing the letter A in front of the year on
the cover of the code.
2.3.0 Welding Procedure
Specifications (WPS)
 A welding procedure specification is a
written set of instructions for producing
sound welds.
 Each WPS is written and tested in
accordance with a particular welding code
or specification and must be in accordance
with industry practice.
 If a weld does require a WPS, the WPS
must be followed.
 Consequences for not following a required
WPS are unsafe weldment that could
endanger life, rejection of the weldment
and lawsuits.
2.3.0 Welding Procedure
Specifications (WPS)
2.3.0 Welding Procedure
Specifications (WPS)
 The requirement for the use of a WPS is
often listed on job blueprints as a note or in
the tail of the welding symbols.
 It is the responsibility of each manufacturer
or contractor to test and qualify the WPS
before using it.
 The WPS is tested by welding test
coupons.
 Then, the coupons are tested according to
the code.
2.3.0 Welding Procedure
Specifications (WPS)
 The testing includes nondestructive
testing (NDT), tensile strength tests, and
root, face, or side bends tests.
 The results of the testing are recorded
on a procedure qualification record
(PQR).
 The WPS and PQR must be kept on file.
2.3.0 Welding Procedure
Specifications (WPS)
 Information typically found on a WPS
includes:
 Base metal-the chemical composition of the
base metal using the standard identification.
○ Example – A36 – carbon steel
 Welding process
 Filler Metal
 Type of Current
 Arc voltage and travel speed
 Joint design
 Joint preparation
 Positions of welding
3.0.0 Fit-Up Gauges and
Measuring Devices
 Before making a weld, the joint must be
fit up and checked to ensure it conforms
to the WPS.
 The most common tools used to lay out
and check joint fit-ups are straightedges,
squares, levels and Hi-lo gauges.
3.1.0 Straightedges
 Straightedges are used to mark straight
lines and check joint alignment.
 Many have calibrations along their
length for measuring.
 Straightedges, particularly longer ones,
are typically fabricated on the job from
small channel or angle iron.
3.2.0 Squares
 Two types of squares are used for
layout: pipefitter’s square and a
combination square.
 Pipefitter’s square is used to measure
angles and check squareness.
 Combination squares are smaller with
blades typically 12” or 18” long.
 They have replaceable attachments that
slide along the blade.
3.2.0 Squares
3.2.0 Squares
 Attachments include a combination 90
degree / 45 degree level head, a centering
head, and a protractor head.
 The combination attachment is used to
check and lay out 90 degree and 45
degree angles, to check level, and to
measure depth.
 The centering head is used to measure
round stock and to locate the center of
shafts or other round objects.
 The protractor is used to lay out and check
angles.
3.3.0 Levels
 Levels come in a variety of sizes and
shapes.
 Some have magnetized bases.
 Levels are used to check that layouts are
level (horizontal) and plumb (vertical).
 Levels use a bubble in a glass vial to check
level and plumb.
 Centering the bubble between the lines
marked on the vial indicates level or plumb.
 Some levels have a 45 degree vial.
3.3.0 Levels
3.4.0 Hi-Lo Gauges
 The primary purpose of a Hi-Lo gauge is
to check for pipe joint misalignment.
 The name of the gauge comes from the
relationship between the alignment of
one pipe to the other pipe, which is
called high-low.
3.4.0 Hi-Lo Gauges
3.4.1 Internal Misalignment
Checks
 To check for internal misalignment, Hi-
Lo gauges have two prongs that are
pulled tightly against the inside diameter
of the joint so that one prong is flush
with each side of the joint.
 The variation between the two stops is
read on a scale marked on the gauge.
3.4.1 Internal Misalignment
Checks
 Many HI-Lo gauges also have the
capability to check the following:
 Pipe wall thickness
 Root opening
 Weld reinforcement
4.1.0 Positioning Parts of a
Weldment
 Hydraulic jacks, chain falls, and come
alongs are used to position parts of a
weldment.
 Hydraulic Jacks
○ Never weld directly on the hydraulic jack base
or ram.
○ Monitor the jack for oil leaks.
4.1.2 Chain Hosts
 Chain hosts, also called chain falls, are
used to lift or lower weldment parts.
 Secure the chain hoist over the
weldment with an approved sling
wrapped around a structural member.
 Never hang chain hosts from any item
not designed to carry external loads.
4.1.3 Come-Alongs
 Come-alongs can be used for vertical
lifting and pulling at angles.
 More than one come-along or chain fall
can be used to precisely position a
weldment.
 Before welding, make use the welding
current will not pass through the come-
along.
Chain Hoist & Come-Alongs
4.2.0 Plate Fit-Up Tools
 The most common method of holding a
joint in place after it had been fitted up is
to tack-weld it in place.
 The most common tools for plate fit-up
are strong-backs, clips, yokes, and
wedges.
4.2.1 Strongbacks
 Strongbacks are typically made on the
job site from heavy bar stock.
 They are notched at the weld joint to
allow access to the joint so that welds
can be made without interference.
 The strongback can be on the face or
root side of the weldment.
 When tack-welding strongbacks, place
the tack welds on only one side of the
strongback, so it will be easier to
remove.
4.2.2 Clips, Yokes, and Wedges
 Clips, yokes, and wedges can be used
to align joints and then hold them in
place during the welding.
 Clips are welded to the edge of one
plate and then wedges are positioned on
the other plate and driven under the
clips to force the joint alignment.
 Yokes work in a similar manner.
4.2.4 Plate Alignment Tools
 A typical configuration of an alignment
tool consists of a yoke, threaded
adjusting rod, gap plate, and root bar.
 The alignment tool is used by straddling
the joint opening with the yoke.
 The gap plate can be changed to match
the specified root opening.
 15 minute break
4.3.0 Pipe Fit-Up Tools
 Pipe jacks and rollers are used to
support pipe for fit-up and welding.
 Pipe jacks typically have either a V-head
or roller head and a height adjustment.
 Rollers, which can be floor stand or
table models, can be adjusted
horizontally for various pipe diameters.
4.3.1 Pipe Jacks and Rollers
 Pipe jacks and rollers are used to
support pipe for fit-up and welding.
 Pipe jacks typically have either a V-head
or roller head and a height adjustment.
 Rollers can be adjusted horizontally for
various pipe diameter.
4.3.1 Pipe Jacks and Rollers
4.3.2 Chain Clamps
 Chain clamps are used to align and hold
pipe for fit-up and tacking.
 The chain, which is anchored to one
side of the clamp, is passed around the
pipe and secured.
 The slack in the chain is then removed
using a screw jack to pull the pipe tightly
against the clamp.
4.3.3 Other Pipe Alignment and
Clamping Tools
 Cage clamps are another style of clamp
that can also be used to for the same
purpose.
 Cage clamps come in a variety of styles
and sizes.
 All cage clamps must be installed
manually.
 Cage clamps are good for aligning and
holding two sections of straight pipe.
 They are of no use when a flange must be
welded.
Cage Clamp
4.3.3 Other Pipe Alignment and
Clamping Tools
 One of the devices used when welding
flanges onto pipes is a rim clamp.
 The jack screws on a rim clamp exert
pressure on specific high points so the
precise alignment can be made.
 These clamps are ideal for tasks in
which 100 percent weld and grind is
required before the clamp can released.
Rim Clamp
5.1.0 Causes of Distortion
 Distortion is the expansion and
contraction of metal as it responds to
changes in temperature.
 Distortion is caused by the nonuniform
expansion and contraction of the weld
metal and adjacent base metal during
the heating and cooling cycles of
welding.
5.1.0 Causes of Distortion
 When the base metal is heated during the
welding process, it will attempt to expand
but will be restricted by the surrounding
cooler base metal.
 Even when the weld is at room
temperature, stress equal to the strength of
the base metal will be locked in the
weldment.
 This is called residual stress.
 5.2.0 - The degree of distortion is directly
related to the stresses generated during
welding.
5.3.1 Clamping & Bracing
 Field fabricated alignment devices are
often used to hold weldments firmly in
place during the welding process.
 They must also be left in place long
enough to allow the weldment to cool to
ambient temperature.
5.3.2 Tack Welding
 A tack weld holds parts of a weldment in
proper alignment until the finish welds
are made.
 If too few tacks are made, the joint will
close up as the weld proceeds.
5.3.3 Amount of Weld Material
 The more weld metal placed in a joint,
the greater the forces of shrinkage.
 Excess reinforcement on the face of a
weld increases the forces of the weld .
 Excess face reinforcement actually
reduces the strength of a weld and is
therefore prohibited by welding codes.
 Groove welds should have a slight
reinforcement of no more than 1/8” for
butt or corner welds.
5.3.3 Amount of Weld Material
 Proper fit-up and edge preparation also
reduce the amount of weld required.
 Open-root joints should have a root
opening from 1/16” to 1/8”.
 To control melt-through, a root face of 1/16”
to 1/8” is used.
 Each side of the open-root joint is beveled
from 30 to 37 ½ degrees.
 The bevel angle must be sufficient to allow
access to the root.
5.3.4 Backing Strips on Groove
Welds
 Various forms of the backing materials
or strips can be applied to the back side
of plate weldments.
 Temporary strips typically have a groove
machined directly into them that controls
the shape and size of the penetration
material once it cools.
5.3.4 Backing Strips on Groove
Welds
 If the backing strip is designed to
become part of the permanent
weldment, it must be made of material
similar to the alloy or metal being
welded.
 When thick metal backing strips are
used on groove welds, the root opening
normally opens to ¼” and the bevel is
reduces to 22 ½ degrees.
5.3.5 Open Root Pipe Welds
 Molten metal that extends beyond the
back or opposite side of the groove is
called root reinforcement.
 When welding pipe, the amount of root
reinforcement on the inside of the pipe
must be controlled.
 Excessive root reinforcement on the
interior of the pipe interferes with the
flow in the pipe, causing turbulence and
other problems.
5.3.6 Backing Rings
 Backing rings are flat metal strips that have
been rolled to fit inside a pipe.
 They can be ordered in a variety of base
metal types to match the base metal being
welded.
 Backing rings have three or more nubs
around the outside of the ring.
 The diameter of the nub is the root opening
required for the pipe being welded.
 The nubs are removed by striking them
with a chipping hammer.
5.3.6 Backing Rings
5.3.7 Consumable Inserts on
Pipe Welds
 Consumable inserts are similar to
backing rings.
 They are completely consumed during
welding and become part of the finished
weld.
 They must match the filler metal
requirements for the weld being made.
5.3.8 Inserts on Socket Joints
 Socket joints generally are used on pipe
that is 5” or smaller in diameter.
 A socket joint uses a prefabricated fitting
containing sockets on the ends; the pipe
slips into these sockets.
 The fitting and pipe are joined using a
fillet weld.
5.3.8 Inserts on Socket Joints
 In order to eliminate stress, distortion,
and possible cracking by expansion
during heating, the end of the pipe must
not touch the bottom of the socket.
 Socket welds require a 1/16” to 1/8” gap
between the end of the pipe and the
bottom of the socket fitting.
5.3.8 Inserts on Socket Joints
 There are two ways to ensure that the
gap between the end of the pipe and the
socket fitting is maintained.
 One way is to scribe the pipe a preset
distance from the end.
 The gap is checked by measuring from
the scribed line to the socket and then
adding the socket depth.
5.3.8 Inserts on Socket Joints
 The second method of ensuring the
correct gap is to use a gap ring.
 The gap ring is placed in the bottom of
the socket and becomes a permanent
part of the joint.
 Gap rings are commonly called gap-o-
lets.
5.3.8 Inserts on Socket Joints
5.3.10 Backstep Welding
 Backstep welding is a welding technique
in which the general progression of
welding is from left to right.
 But the weld beads are deposited in
short increments from right to left.
 This technique reduces distortion by
minimizing and interrupting heat input.
5.3.10 Backstep Welding
5.3.11 Welding Sequence
 A welding sequence involves placing welds
at different points on a weldment so that
shrinkage forces in one location are
counteracted by shrinkage forces in
another location.
 A simple welding sequence is to make
short welds on alternating sides of the joint.
 Welding sequences are often performed by
two individuals welding on opposite sides
of a joint at he same time.
 This type of welding is often called buddy
welding.
 It is a very effective way to control
distortion.
5.3.12 Heat Treatments
 Distortion can be controlled by
preheating and postheating.
 Applying heat before welding is called
preheating.
 Applying heat immediately after the
welding is called postheating.
6.0.0 Checking Joint
Misalignment and Fit-Up
 The quality of joint preparation and fit-up
directly affects the quality of the
completed weld.
 By thoroughly checking the joint fit-up,
potential problems can be avoided.
 Check that the joint surfaces are free of
contamination such as grease, oil,
moisture and rust.
 If there is contamination, clean the joint
before continuing.
Summary
 It is very important to perform proper
joint fit up and alignment to ensure an
acceptable weld.
 The proper fit-up measuring devices and
tools must be used to accomplish this.
 Government agencies, professional
societies, and associations have written
guidelines for joint fit-up and alignment.
 All fit-up procedures should follow these
guidelines.
Review Questions
 Answer Review questions 1-10
 Answer Trade Terms 1-11