WELDER’S TRAINING

MANUAL

Welder’s Training Manual

Welder’s Training Manual
35 Days Training Course Program for Welder on GTAW & SMAW Process

Day Contents

1 Acquaintance and Chapter I & II

2 Chapter III

3 Chapter IV, V, & VI

4 Chapter VII, VIII, IX, X

Practical / Hands-On Training (Plate)

For fresh trainee on SMAW Process

5&6 Burning Electrode along with straight line with required current
adjustment of various DIA Electrodes. (Scrap Plate or pipe to be
used) E7018 Local Electrode to be used

7 1F Position Plate

8 2F Position Plate

9 3F Position Plate

10 1G Plate

11 2G Plate

12 3G Plate

13-14 4G Plate

Practical / Hands-On Training (Pipe)

15-16 1G Pipe Axis Horz Rotation

17-18 2G Pipe Axis Vert Fixed

19-20 5G Pipe Axis Horz Fixed

21-22 6G Pipe Axis Horz Fixed

Day Contents

Hands-On Training on GTAW (PIPE 2” x Sch. 80)

Welder’s Training Manual

23 * Introducing GTAW Process (page 17), Equipment (page 18),
Accessories and TIG Torch Assembly (page 38), Current
Adjustment for filler wire (page 29), Joint Preparation (page 35),
RHFC + Multi & Single Run Capping (page 56)

Feeding Filler Wire, Moving Paddling Torch (how to fused both

bevel)

Practicing to feed Wire & Torch Paddling (with out power

connection)

Note: * Refresh

24 To Burn filler wire on straight line on scrap plate or pipe

Practical / Hands-On Training (Pipe 2” x Sch. 80)

For fresh trainee on GTAW Process

25 1G – 2’’ Pipe

26 2G – 2’’ Pipe

27-28 5G – 2’’ Pipe

29-31 6G – 2’’ Pipe

32-34 6G – Combination on 6’’ Sch. 80 Pipe (with Multi Run Capping)

35 Final Test for X-Ray

Using combination process on 6’’ x Sch. 80 Pipe with 3 passes
Multi Run Capping

Welder’s Training Manual

Table of Contents i

Chapter I
Personal Protective Equipments for Welder 1-4

1. Welding Screen including Dark glass

2. Welding Gloves
3. Welding Jacket
4. Safety Boots
5. Safety Glasses
6. Safety Harness (While Working Above 1.5 meter)

Chapter II
Tools for Welder 5 - 12

1. Small Grinder
2. Chipping Hammer
3. Chisel
4. Half Round File
5. Wire Brush
6. Power Brush

Chapter III
Welding Processes 13 - 23

Chapter IV
Miscellaneous Explanation about Welding: 24 - 31

Weaving, Electric Current, Polarity, Filler Metals,

Power Cable, Earthing Cable, Earth Ground,
Electrode Holder & Electrode

Chapter V
Joint Types 32 - 33

Chapter VI
Joint Details 34 - 35

Chapter VII
Torch Assemble 36 - 41

Chapter VIII
Welding Defects 42 - 52

Chapter IX
Good and Bad Welding 53 - 54

Chapter X
Complete Welding Joint w/ Multi & Single Pass Capping 55 - 56

Welder’s Training Manual

Table of Contents ii

Chapter XI
Practical and Hands-On Training for SMAW 57 - 61

Chapter XII
Practical and Hands-On Training for GTAW 62 - 65

Welder’s Training Manual

 1

CHAPTER I

Personal Protective
Equipments for Welder
Chapter I. Personal Protective Equipments for Welder 2

Personal Protective Equipments for Welder

1. Welding Mask - is headgear used when performing certain types of

welding to protect the eyes, face and neck from flash burn, ultraviolet
light, sparks and heat.

2. Welding Gloves – used for the hand, to avoid directly contact with
heat or scratches.
Chapter I. Personal Protective Equipments for Welder 3

3. Welding Jacket / Apron - is an outer protective garment that

covers primarily the front of the body

4. Safety Boots - is used for feet protection from sudden impact of fallen
materials.
Chapter I. Personal Protective Equipments for Welder 4

5. Safety Glasses - used for eye protection against the fumes or other
foreign materials.

6. Safety Harness (While working above 1.5 meter) - use for the
body protection form high or above the sea level, to avoid falling direct to
the ground.
 5

CHAPTER II

TOOLS FOR WELDER

Chapter II. Tools for Welder 6

Tools for Welder

1. Small Grinder

An angle grinder is a handheld power tool used for cutting, grinding and
polishing. There are a myriad of different kinds of disks that are used for
various materials and tasks, such as cut-off disks (diamond blade), abrasive
grinding disks, sanding disks, wire brush wheels and polishing pads. Disc size
is usually measured in inches. Common disc sizes for angle grinders include 4,
4.5, 5, 6, and 7 inches.
Chapter II. Tools for Welder 7

1. Tighten the grinding disk snuggly when mounting it on the

portable disc grinder. The disk will tighten itself during normal
operation.

2. Be sure to hold the portable disc grinder firmly when the off/on
switch is turned on. The centrifugal force created by the rotating
disk will cause the portable disc grinder to move or jump.

3. For extended periods of grinding the operator may lock the off/on
switch in the on position to avoid fatigue from holding the switch on
manually.

4. When an extension cord is used with the portable disc grinder

make sure the cord is sufficiently large in size for the grinder being
used. A #14 gauge extension cord is minimum and #12 gauge is
preferred.

5. Keep the electrical and extension cords positioned away from the
grinding area. Cords are easily severed by the portable disc grinder.

6. When laying the portable disc grinder down, always position it on

the tool rest.

7. Before using the switch lock on the portable disc grinder always
check to make sure the lock is functioning properly.

8. Hold the portable disc grinder so that sparks and grit are thrown
away from the operator and others working in the area.

9. Using the portable disc grinder is hard work and causes rapid
fatigue, rest frequently and do not become exhausted to help avoid
accidents.
Chapter II. Tools for Welder 8

2. Chipping Hammer

Chipping Hammer is used to clean slug and spatter

Chapter II. Tools for Welder 9

3. Chisel

A cold chisel is a tool made of tempered steel used for cutting 'cold' metals,
meaning that they are not used in conjunction with heating torches, forges, etc.
Cold chisels are used to remove waste metal when a very smooth finish is not
required or when the work cannot be done easily with other tools, such as a
hacksaw, file, bench shears or power tools.

A hot chisel is used to cut metal that has been heated in a forge to soften the
metal.
Chapter II. Tools for Welder 10

4. Half Round File

Half round ring files taper in width and thickness, coming to a point, and
are narrower than a standard half round. Used for filing inside of rings.
Chapter II. Tools for Welder 11

5. Wire Brush

The wire brush is primarily an abrasive implement, used for cleaning rust and
removing paint. It is also used to clean surfaces and to create a better
conductive area for attaching electrical connections, such as those between a
car battery posts and their connectors, should they accumulate a build-up of
grime and dirt.
Chapter II. Tools for Welder 12

6. Power Brush / Round Wire Brush

The Power Brush / Round Wire Brush is used together with grinder for cleaning
rust and removing paint. It is also used to clean surfaces and to create a better
conductive area for attaching electrical connections, such as those between a
car battery posts and their connectors, should they accumulate a build-up of
grime and dirt.
 13

CHAPTER III

Welding Processes
Chapter III. Welding Process 14

WELDING

A joining process that produces coalescence of materials by heating to a

melting point, with or without the application of pressure and with or without the
use of filler metal.

A. Shielded Metal Arc Welding (SMAW) – An arc welding process that

produces coalescence of materials by heating them with an arc between a
covered electrode and a workpiece.; shielding is obtained from
decomposition of the electrode cover, pressure is not use, and filler metal is
obtained from electrode

B. Gas Tungsten Arc Welding (GTAW) – An arc welding process that

produces coalescence of materials by hating them with an arc between a
non-consumable tungsten electrode and a workpiece; shielding is obtained
from a gas, and filler metal may or may not be use.

C. Gas Metal Arc Welding (GMAW) – An arc welding process that

produces coalescence of metals by heating them with an arc between a
continuous filler metal electrode and a workpiece; shielding is obtained
entirely from an externally supplied gas.

D. Submerged arc Welding (SAW) – An arc welding process that produces

coalescence of metals by heating them with an arc or arcs between a bare
metal electrode or electrodes and a workpiece; the arc and molten metal
are shielded by a blanket of granular, fusible material on the workpiece;
pressure is not used, and filler metal is obtained from the electrode or
sometimes from a supplemental square.
Chapter III. Welding Process 15

WELDING PROCESSES

A. Shielded Metal Arc Welding (SMAW)

Description:

In shielded metal arc welding (SMAW), an electric arc is established

between a flux-coated consumable rod (electrode) and work piece. A gaseous
shield is provided by vaporization of the flux coating.

Process Characteristics:
 Uses a consumable rod
electrode
 Deposits slag on the weld
bead
 Provides shielding by
vaporization of the flux
coating on the electrode
 Supplies constant welding
current
 Weld appearance and
quality depend on operator
skill in maintaining a
constant arc length and
travel speed.

Applicability:

SMAW is often used to weld carbon steel, low and high alloy steel,
stainless steel, cast iron, and ductile iron. While less popular for nonferrous
materials, it can be used on nickel and copper and their alloys and, in rare
cases, on aluminum. The thickness of the material being welded is restricted on
the low end primarily by the skill of the welder, but rarely does it drop below
0.05 in (1.5 mm). No upper restriction exists: with proper joint preparation and
use of multiple passes, materials of virtually unlimited thicknesses can be
joined. Furthermore, depending on the electrode used and the skill of the
welder, SMAW can be used in any position.
Chapter III. Welding Process 16
Chapter III. Welding Process 17

Gas Tungsten Arc Welding (GTAW)

Description:

Gas tungsten arc welding (GTAW), also known as tungsten inert gas
(TIG) welding, is an arc welding process that uses a non-consumable tungsten
electrode to produce the weld. The weld area is protected from atmospheric
contamination by a shielding gas and a filler metal is normally used, though
some welds, known as autogenously welds, do not require it. A constant-
current welding power supply produces energy which is conducted across the
arc through a column of highly ionized gas and metal vapors known as plasma.

Process
Characteristics:

 Uses non-consumable
tungsten electrode
 Uses shielding gases
(Ar, He, or CO2)
 Produces very high
quality welds
 Produces no slag or
spatter
 Is ideal for thin
materials

Applicability:

Except for ASME P-No. 1

through P-No. 5A/5B/5C base
materials, all manual GTAW
shall use a high frequency
start, post-purge gas flow for
the torch, and filler metal shall be added. The GTAW process shall be used for
all passes for butt welds in piping and nozzles less than 25.4mm (1”) nominal
diameter. The GTAW process shall be used for the root pass of butt welds
without backing in piping and nozzles of 50.8 mm (2”) nominal diameter or less,
except for vent and drain piping open to the atmosphere or Category D piping.

The GTAW process shall be used for the root pass of single-sided groove
welds without backing made with stainless steel or nickel-based consumables.
Chapter III. Welding Process 18

Power Transformer/
control panel Rectifier

Power return Inverter

cable power source

Torch Power
assemblies control panel

Tungsten Power cable

electrodes*
Flow-meter
Chapter III. Welding Process 19

The tungsten must have

the correct vertex angle
to 30°

Grinding is done on a special

jig, and on a dedicated wheel
Chapter III. Welding Process 20

Submerged Arc Welding (SAW)

Description:

Submerged Arc Welding (SAW) is a common arc welding process. It requires a

continuously fed consumable solid or tubular (flux cored) electrode. The molten
weld and the arc zone are protected from atmospheric contamination by being
“submerged” under a blanket of granular fusible flux. When molten, the flux
becomes conductive, and provides a current path between the electrode and
the work.
SAW is normally operated in the automatic or mechanized mode, however,
semi-automatic (hand-held) SAW guns with pressurized or gravity flux feed
delivery are available. The process is normally limited to the 1F, 1G, or the 22F
positions (although 2G position welds have been done with a special
arrangement to support the flux). Deposition rates approaching 100 1b/h
(45kg/h) have been reported – this compares to ~ 10 1b/h (5kg/h) (max) for
shielded metal arc welding. Currents ranging from 200 to 1500 Amps are
commonly used; currents of up to 5000 Amps have been used (multiple arcs).
Single or multiple (2 to 5) electrode wire variations of the process exist. SAW
strip-cladding utilizes a flat strip electrode (e.g. 60 mm wide x 0.5 mm thick).
DC or AC power can be utilized, and combinations of DC and AC are common
on multiple electrode systems. Constant Voltage welding power supplies are
most commonly used, however Constant Current systems in combination with
a voltage sensing wire-feeder are available.

Process
Characteristics:

 Uses a consumable
wire-fed electrode

 Is shielded by a
granular flux that
partially vaporizes

 Has a slag deposit on

the weld bead

 Is capable of high
welding speeds and
deposition rates

 Produces high quality

welds on thick workpieces
Chapter III. Welding Process 21

Material Applications:

1. Carbon steels (structural and vessel construction);

2. Low alloy steels

3. Stainless Steels

4. Nickel-based alloys
5.
6. Surfacing applications (wear facing, build-up, and corrosion resistant
overlay of steels).

Limitations:

1. Limited to ferrous (steel or stainless steels) and some nickel based

alloys

2. Normally limited to the 1F, 1G, and 2F positions

3. Normally limited to long straight seams or rotated pipes or vessels

4. Flux and slag residue can present a health & safety issue

5. Requires inter-pass and post weld slag removal.

Chapter III. Welding Process 22

Gas Metal Arc Welding / Flux Cored Arc Welding

Description:

Gas metal arc welding (GMAW), sometimes referred to by its subtypes,

metal inert gas (MIG) welding or metal active gas (MAG) welding, is a semi-
automatic or automatic arc welding process in which a continuous and
consumable wire electrode and shielding gas are fed through a welding gun. A
constant voltage, direct current power source is most commonly used with
GMAW, but constant current systems, as well as alternating current, can be
used. There are four primary methods of metal transfer in GMAW, called
globular, short-circuiting, spray, and pulsed-spray, each of which has distinct
properties and corresponding advantages and limitations. A related process,
flux cored arc welding, often does not utilize a shielding gas, instead employing
a hollow electrode wire that is filled with flux on the inside.

Process
Characteristics:

 Uses a consumable
wire electrode

 Uses shielding gas

 Results in a uniform
weld bead

 Produced a slag-
free weld bead

 Is commonly used
for semi-automatic
& automatic welding
Chapter III. Welding Process 23

Applicability:

The GMAW short-circuiting (dip) mode shall not be used except for:

1. Structural attachments to the outside surface of the pipe, including seal

welds.

2. Tacking (including continuous tacks) that will be completely removed by

back gouging and back welding

3. The root pass and hot pass only for butt welds in P-No. 1 carbon steels.

4. GMAW and FCAW shall not be used for the root pass on single-sided
tee or corner joints (i.e., branch or nozzle welds).

Flux-Cored Arc Welding (FCAW).

1. The FCAW process shall not be used for the root pass on full
penetration, groove joints that are welded from one side only without
backing (backing may be used if it is removed after welding and weld
irregular profile is rectified).

2. Self-shielded FCAW shall not be used without the specific approval of

the client.
 24

CHAPTER IV

MISCELLANEOUS
EXPLATION ABOUT
WELDING
Chapter IV. Miscellaneous Explanation About Welding 25

WEAVING

Weaving is side to side motion of electrode which improves the dilution

between electrode & base metal, but care should be taken for high alloy steel
as shorter as possible.

ELECTRIC CURRENT

Electric current is the flow (movement) of electric charge. The SI unit of

electric current is the ampere, and electric current is measured using an
ammeter.

Direct current (DC or "continuous current") is the unidirectional flow of

electric charge.

Alternating current (AC) is an electric current whose magnitude and

direction vary cyclically, as opposed to direct current, whose direction
remains constant. An electric current that reverses its direction at regularly
recurring intervals.
Chapter IV. Miscellaneous Explanation About Welding 26

POLARITY
Polarity is a description of an attribute, typically a binary attribute (one with
two values), or a vector (a direction).
For example:

 An electric charge has a polarity of either positive or negative.

 A voltage has a polarity, in that it could be positive or negative (with
respect to some other voltage, such as the one at the other end of a
battery or electric circuit).
 A magnet has a polarity, in that one end is the "north" and the other is
the "south".
 The spin of an entity in quantum mechanics has a polarity - positive
or negative.
 Polarized light has waves which all line up in the same direction.

In welding aspects, Polarity is

the tendency of body to place
its axis in a certain direction in
electrode (the quality of
attraction or repulsion). They
are (+) reverse, positive; (-)
straight, negative.

N.B. If you are welding on

GTAW process power cable
connects to the (-) pole DCEN
& for SMAW process power
cable to be connected on (+)
pole DCEP. (-) & (+) POLARITY
FILLER METALS
A filler metal is a metal added in the making of a joint through welding,
brazing, or soldering. Four types of filler metals exist—covered electrodes,
bare electrode wire or rod, tubular electrode wire and welding fluxes.
Chapter IV. Miscellaneous Explanation About Welding 27

POWER CABLE

A power cable is an assembly

of two or more electrical
conductors, usually held
together with an overall
sheath. The assembly is used
for transmission of electrical
power to the electrode holder.

POWER CABLE

EARTHING CABLE
This cable usually connected
from welding machine to the
workpiece. Polarity depends
on welding process.
Sometimes, this cable is called
as return cable as well.

EARTHING CABLE
Chapter IV. Miscellaneous Explanation About Welding 28

EARTH GROUNDING

In electrical engineering, the term ground or earth

has several meanings depending on the specific
application areas. Ground is the reference point in an
electrical circuit from which other voltages are
measured, a common return path for electric current
(earth return or ground return), or a direct physical
connection to the Earth.

Electrical circuits may be connected to ground (earth) for several reasons. In

power circuits, a connection to ground is done for safety purposes to protect
people from the effects of faulty insulation on electrically powered equipment. A
connection to ground helps limit the voltage built up between power circuits and
the earth, protecting circuit insulation from damage due to excessive voltage.

ELECTRODE HOLDER ELECTRODE

A device used for mechanically
holding the electrode an
conducting current to it to
allow welding.

ELECTRODE

Filler metal in the form of a wire

or rod whether bare or covered
though current is conducted
between the electrode holder &
the arc.

ELECTRODE HOLDER
Chapter IV. Miscellaneous Explanation About Welding 29

Normally following filler metals are use for GTAW & SMAW process for various
steel to weld. Required current volts are given to burn the filler metal smoothly.

Electrodes (SMA)

Electrode Ø A V Metal
E6010 2.5 80-110 22 CS
E6010 3.2 110-140 24 CS
E7018 2.5 80-110 22 CS
E7018 3.2 10-140 24 CS
E7018 4.0 140-200 24 CS
E8018 2.5 55-110 22 LOW ALLOY
E8018 3.2 81-145 24 LOW ALLOY
E8018 4.0 110-200 24 LOW ALLOY
E308 L/H 2.5 55-85 23 SS
E308 L/H 3.2 75-110 23 SS
E308 L/H 4.0 100-155 24 SS
E316 L/H 2.5 60-90 30 SS
E316 L/H 3.2 80-125 31 SS
E316 L/H 4.0 120-170 32 SS

Filler Wire GTAW

Electrode Ø A V Metal
ER-70S-6 2.4 mm 75-130 9-11 CS
ER-308L 2.4 mm 75-115 9-12 SS
ER316L 2.4 mm 75-115 9-12 SS
ER309-L 2.4 mm 75-115 9-12 DS
Chapter IV. Miscellaneous Explanation About Welding 30

WELDING POSITIONS
Chapter IV. Miscellaneous Explanation About Welding 31
 32

CHAPTER V

JOINT TYPES
Chapter V. Joint Types 33
 34

CHAPTER VI

JOINT DETAILS
Chapter VI. Joint Details 35
 36

CHAPTER VII

TORCH ASSEMBLY
Chapter VII. Torch Assembly 37

How to Assemble Argon Torch

1. Vertex Angle of Tungsten by Grinder

2. Insert Tungsten into collet.

3. Inter collet into collet Body

4. Insert into Torch Head and tight/screw the collet body

5. Screw/Tight the ceramic/orifice cup to the body.

6. Adjust Tungsten length 5mm outer the orifice cup.

7. Screw the cap (short or long) to the Argon Torch.

N.B.: Use of short & long cup vary on the length of Tungsten
electrode.

8. Adjust the argon gas flow to the gas flow meter which connected to
argon bottle between 10 to 18 LPM (as per WPS requirements)

9. Turn the gas flow knob on to allow gas flow to the job to start welding.

10. Make sure the polarity is straight (-) on holder.

Chapter VII. Torch Assembly 38
Chapter VII. Torch Assembly 39

How do I prepare my weld joint?

1. Clean
Cleaning both the weld joint area and the filler metal is an important
preparation. Remove all oil, grease, dirt, paint, etc. The presence of
these contaminants may result in arc instability or contaminated welds.

2. Clamp
Clamping may be required if the work piece cannot be supported during
welding.

3. Tack weld
Make short 1/4 in. tack welds along the work pieces to hold them
together.

How to position TIG torch for different types of joints?

Butt welds
When welding a butt joint, center the weld pool on the
adjoining edges. When finishing, decrease the heat
(amperage) to aid in filling the crater.
Chapter VII. Torch Assembly 40

Lap joint
For a lap weld, form the weld pool so that the edge of
the overlapping piece and the flat surface of the second
piece flow together. Since the edge will melt faster, dip
the filler rod next to the edge and make sure you are
using enough filler metal to complete the joint.

T-joint

When welding a T-joint, the edge and the flat surface

are to be joined together, and the edge will melt faster.
Angle the torch to direct more heat to the flat surface
and extend the electrode beyond the cup to hold a
shorter arc. Deposit the filler rod where the edge is
melting.
Chapter VII. Torch Assembly 41

Corner joint
For a corner joint, both edges of the adjoining pieces
should be melted and the weld pool should be kept on
the joint centerline. A convex bead is necessary for this
joint, so a sufficient amount of filler metal is needed.
 42

CHAPTER VIII

WELDING DEFECTS
Chapter VIII. Welding Defects 43

WELDING DEFECTS

1. Arc Strike

2. Lamellar Tearing
Chapter VIII. Welding Defects 44

3. Crack.(HAZ crack, center line cracking. Transvers crack, crater

crack)
Chapter VIII. Welding Defects 45

4. Inadequate penetration or lack of penetration.

Incomplete root
Penetration bead

5. Incomplete fusion or lack of fusion.

Lack of sidewall fusion

(Also causing an incompletely filled
groove)

Lack of inter-run
Lack of sidewall fusion

Lack of root fusion

Chapter VIII. Welding Defects 46

6. Internal concavity or root concavity.

7. Porosity (cluster, piping, gas pore, hollow bead, wagon truck,

herring bone.

Gas Por
Surface cluster porosity

Fine cluster
Porosity
Coarse cluster porosity
 Chapter VIII. Welding Defects 47

8. Slag inclusion.

Surface breaking solid inclusion

Internal solid inclusion
causing a lack of inter-run
fusion Solid inclusion causing a
Lack of sidewall fusion

Internal solid inclusion

Solid inclusions from base metal

undercut in the root run, or hot pas (Slag traps)

9. Burn through.

Burn Through
Chapter VIII. Welding Defects 48

10. Root undercut.

Root Undercut

11. Cap undercut

Base metal, surface undercut

Base metal, “top the undercut

Chapter VIII. Welding Defects 49

12. High low or misalignment

13. Excess penetration.

Excess Penetration
 Tungsten Inclusion
Chapter VIII. Welding Defects 50

14. Tungsten inclusion.

15. Mechanical damage

Chapter VIII. Welding Defects 51

16. Spatters

Spatters

17. Incomplete Filled Groove

An incompletely filled groove

Chapter VIII. Welding Defects 52

18. Overlapped
Overlapped
 53

CHAPTER IX

GOOD AND BAD

WELDING
Chapter IX. Good and Bad Welding 54
 55

CHAPTER X

COMPLETE WELDING
JOINT WITH MULTI &
SINGLE PASS CAPPING
Chapter X. Complete Welding Joint w/ Multi & Single Pass Capping 56

What is PASS?

The weld metal deposited in one general progression along the axis of the
weld.

Single Pass Capping

4
1 - Root Pass
2 - Hot Pass
3 & 4 – Filling Passes
3 5 – Capping Pass

Multi Pass Capping

7 8
6

5 1 - Root Pass
4 2 - Hot Pass
3, 4, & 5 – Filling Passes
3 6, 7, & 8 – Capping Pass

2
1
 57

CHAPTER XI

PRACTICAL AND
HANDS-ON TRAINING
FOR SMAW
Chapter XI. Practical and Hands-On Training 58

Practical / Hands-On Training (Plate)

For fresh trainee on SMAW Process

DAY

5-6 Burning Electrode along with straight line with required current
adjustment of various DIA Electrodes. (Scrap Plate or pipe to be
used) E7018 Local Electrode to be used

7 1F Position Plate

8 2F Position Plate

9 3F Position Plate
Chapter XI. Practical and Hands-On Training 59

10 1G Plate

11 2G Plate

12 3G Plate
Chapter XI. Practical and Hands-On Training 60

13-14 4G Plate

Practical / Hands On Training (Pipe) 6” x 5ch. 40

15-16 1G Pipe Axis Horz Rotation

17-18 2G Pipe Axis Vert Fixed

Chapter XI. Practical and Hands-On Training 61

19-20 5G Pipe Axis Horz Fixed

21-22 6G Pipe Axis Horz Fixed

Chapter XI. Practical and Hands-On Training 62

CHAPTER XII

PRACTICAL AND
HANDS-ON TRAINING
FOR GTAW
Chapter XI. Practical and Hands-On Training 63

Hands-on Training on GTAW (PIPE 2” x Sch. 80)

23 * Introducing GTAW Process (page 17), Equipment (page 18),

Accessories and TIG Torch Assembly (page 38) * Current
Adjustment for filler wire (page 29), Joint Preparation (page 35),
RHFC + Multi & Single Run Capping (page 56)

Feeding Filler Wire, Moving Paddling Torch (how to fused both

bevel)

Practicing to feed Wire & Torch Paddling (with out power

connection)

Note: * Refresh

24 To Burn filler wire on straight line on scrap plate or pipe

Practical / Hands-On Training (Pipe 2” x Sch. 80)

For fresh trainee on GTAW Process

25 1G – 2’’ Pipe

26 2G – 2’’ Pipe
Chapter XI. Practical and Hands-On Training 64

27-28 5G – 2’’ Pipe

29-31 6G – 2’’ Pipe

32-34 6G – Combination on 6’’ sch. 80 Pipe (with Multi Run Capping)

Chapter XI. Practical and Hands-On Training 65

35 Final Test for X-Ray

Using combination process on 6’’ x Sch. 80 Pipe with 3 passes
Multi Run Capping