ChabotCollege

Course outline for Welding Technology 69B, Page 1

Fall 2010

ChabotCollegeFall 2010

Course Outline for Welding Technology 69B

ADVANCED PIPE WELDING**

Catalog Description:

69B - Advanced Pipe Welding3 units

(May be repeated 3 times)

Advanced theory and practical applications of pipe joint preparation and design, API (American Petroleum Institute) and AWS (American Welding Society) welding codes specifications for pipe and pipe fittings, geometric curve design for branched joint of piping systems, wire and electrodes selections, advanced welding blue print and pipe welding symbols, SMAW, GMAW, and GTAW of pipe joints, metallurgical transformation of weld Heat Affected Area (HAA), welding discontinuities and defects, destructive and non-destructive testing, and methods of inspection and testing. Prerequisite: Welding Technology 69A or equivalent. 1 hour lecture, 6 hours laboratory.

[Typical contact hours: lecture 17.5, laboratory 105]

Prerequisite Skills:

Upon entering the course, the student should be able to:

  1. identify and understand the API and AWS codes specification;
  2. convert the blueprint concepts in practical welding application;
  3. properly joint, fit up, and align pipe welding joints;
  4. perform manually and automatic pipe joint cuts using plasma, oxy-fuel and gouging equipment within manufacturing standards and specifications;
  5. employ appropriated welding techniques to weld pipes to code specification in rotated flat (1G) and horizontal (2G) position using SMAW, GMAW, and GTAW processes;
  6. perform practical performance tests in 1G and 2G using one of the three welding processes mentioned above;
  7. recognize and identify pipe welding discontinuities and defects and employ the proper method of correction;
  8. perform destructive and non-destructive welding test, evaluate and expound the results.

Expected Outcomes for Students:

  1. Upon completion of the course, the student should be able to:
  1. identify and understand the API and AWS code specifications;
  2. properly identify welding equipment and describe their applications;
  3. handle welding and shop equipment in a safe manner;
  4. correctly identify physical, mechanical, and chemical properties of industrial metals and metal alloys and their weld-ability;
  5. correctly identify electrodes, flux-core wires and welding consumables;
  6. read, understand and apply blueprints, welding symbols, and shop sketches to required welding applications;
  7. perform manually and automatic pipe joint cuts using plasma, oxy-fuel and gouging equipment within manufacturing standards and specifications;
  8. properly joint, set up and align pipe welding joints;
  9. employ appropriate welding techniques to weld pipes to code specification in 1G, 2G, 5G & 6G positions using SMAW, GMAW, and GTAW processes;
  10. perform sound pipe welding V groove open-root welds in 1G, 2G, 5G and 6G positions;
  11. perform required math calculations, which include geometry and trigonometry;
  12. perform conversions between English and metric measurements and vice versa;
  13. properly use oxy-fuel, plasma and gouging equipment and their accessories.

Course Content (Lecture):

  1. Welding power supplies and their application
  2. Pipe-welding blueprint and layout of welded joints
  3. Design, layout and execution of joints templates for branched pipe systems
  4. Open-root V groove welds on 1” to 4” inch diameter branched pipe using SMAW, GMAW and GTAW processes in 1G, 2G, 5G and 6G positions
  5. Branched pipe multi-pass welding techniques
  6. Advanced blueprint reading of pipe systems
  7. Isometric pipe system drawings and pipe run calculations
  8. API and AWS codes and welding inspection (welding procedures and welder qualification)
  9. Theory of metallurgical transformation in welds and welding heat affected area
  10. Welding related distortion and the proper appropriate control techniques
  11. Techniques applicable to pipe welding V groove open-root welds in 1G, 2G, 5G and 6G positions
  12. Welding procedure qualifications in accordance with AWS codes and standards
  13. OSHA industrial safety requirements regulations
  14. Equipment and shop maintenance
  15. Pipe welding certification preparation

Course Content (Laboratory):

  1. Select the appropriate welding power supplies selection and settings for the required application
  2. Apply advanced blueprint reading of pipe systems
  3. Execution of designed joint templates for branched pipe systems such as: reducing tee, eccentric reducer, 90 degree elbow, 60 degree elbow, 45 degree elbow, lateral run branch, etc.
  4. Apply API and AWS code requirements and welding inspection tests
  5. Welding practice on open-root grove of 1” to 4” inch diameter branched pipe using SMAW, GMAW and GTAW processes in 1G, 2G, 5G and 6G positions
  6. Performance of Multi-pass welds on pipe in 1G, 2G, 5G and 6G pipe positions
  7. Perform AWS welding performance tests in 1G, 2G, 5G and 6G pipe positions according to AWS standards
  8. Performance of destructive and nondestructive tests using plasma and fuel cuttingpractices with shop related equipment
  9. Knowledge of the welding metallurgical modification of the weld bed and its HAZ (heat affected zone)
  10. Indentify and reason related metallurgical and non-metallurgical welding discontinuities and defects, ascertaining control related techniques in order to satisfy AWS welding codes
  11. Demonstrate proper and safe techniques in using oxy-fuel, plasma cutting and gouging equipment
  12. Equipment and shop maintenance and management
  13. Proper use of welding inspection procedure and qualifications

Methods of Presentation:

  1. Lectures and discussions
  2. Destructive tests specimens models
  3. Models, laboratory studies
  4. Videos
  5. Laboratory demonstrations
  6. AWS technical testing report

Assignments and Methods of Evaluating Student Progress:

  1. Typical Assignment

Properly set up and adjust the SMAW machine, select the appropriate settings (1/8 in. diameter electrodes), select two sections of mild steel 2 inch diameter, schedule 40 pipe and perform branch pipe open-root grove welds in a fixed 5G & 6G position.

  1. Obtain two 2 inch section pipe
  2. Bevel one end on each pipe at a 45 degree manually, using plasma or oxyacetylene
  3. Obtain 6010 and 7018 electrodes of the necessary quantity and size (1/8 in.)
  4. Set the power supply on DC reverse polarity (90 to 105 amperes for 6010 and 110 to 130 amperes for 7018)
  5. Set up and align the two pipes within a 1/16-inch tolerance. Tack the two pipe with 4 tacks
  6. Set the pipes in the branched position and weld in 5G & 6G position
  7. Perform an open keyhole root pass using a 6010 rod.
  8. Chip the slag from the weld brush and inspect
  9. Perform the rest of the passes as many as necessary with 7018 electrodes
  10. Chip the slag from the weld brush and inspect
  11. Submit the welds for instructor inspection for each weld performed
  12. Practice until will produce consistently sound welds
  13. Inspect and discuss the results with your instructor
  1. Methods of Evaluating Student Progress
  1. Class participation
  2. Laboratory assignments and projects.
  3. Student laboratory written reports
  4. Homework assignments
  5. Quizzes
  6. Midterm examination
  7. Final examination

Textbook(s) (Typical):

  1. Pipe Welding Procedures, H. Rampaul, 2003*
  2. *Rationale: Techniques have not changed much in the past 10 years. This book is still the best resource on the market to date.
  3. Pipe Trades Pocket Manual, Thomas W. Frankland, 2003*
  4. *Rationale: Small, easily accessible reference manual with as current information as larger textbooks.

Special Student Materials:

  1. Welding protective clothing
  2. Welding gloves
  3. Welding goggles
  4. Welding helmet
  5. Welding safety glasses
  6. Welding jacket
  7. Welding boots
  8. Pure tungsten 3/32 rod
  9. 2% thorium oxide tungsten 3/32 rod

DR

Weld 69B course outline

Revised: Aug2009