INTRO
• JOINT DESIGN AND SETUP AFFECT THE SAFETY AND QUALITY OF A COMPLETED WELDMENT.
• ALL OF THESE ARE COVERED BY CODES AND SPECIFICATIONS THAT MUST BE FOLLOWED.
• SPECIAL TOOLS FOR FIT UP AND ALIGNMENT WILL BE DISCUSSED IN THIS UNIT.
CODE CHANGES
• CODES ARE REVIEWED AND UPDATED AS NEEDED. WHEN A CODE IS UPDATED, THE CODE CAN BE REISSUED
WITH AN UPDATED YEAR SUFFIX OR AS AN ALTERNATIVE, ADDENDUM SHEETS MAY BE ISSUED.
• CHANGES ARE TYPICALLY HIGHLIGHTED TO SHOW CHANGES.
• THE ASME UPDATES THE ENTIRE CODE EVERY _______ YEARS. AN ADDENDUM IS ISSUED ________.
• THE YEARLY ADDENDUM IS IDENTIFIED BY PLACING THE LETTER ___ IN FRONT OF THE YEAR ON THE
COVER OF THE CODE.
WPS
• A _____ IS A WRITTEN SET OF INSTRUCTIONS FOR PRODUCING SOUND WELDS.
• ALL WELDING REQUIRES THAT ACCEPTABLE INDUSTRY STANDARDS BE FOLLOWED, BUT NOT ALL WELDS
REQUIRE A WPS.
• THE REQUIREMENT FOR THE USE OF A WPS IS OFTEN LISTED ON THE _____________ AS A NOTE OR IN
THE TAIL OF THE WELDING SYMBOL.
WPS
• EACH WPS IS WRITTEN BY AN INDIVIDUAL WHO KNOWS WELDING CODES, SPECS, AND INDUSTRY
PRACTICES.
• IT THEN BECOMES THE RESPONSIBILITY OF THE CONTRACTOR TO TEST AND QUALIFY THE WPS BEFORE
USING IT.
• THE RESULTS OF TESTING ARE RECORDED ON A _______. THE WPS AND PQR MUST BE KEPT
__________.
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 OR SITE QUALITY STANDARDS.
• THE MOST COMMON TOOLS USED TO LAY OUT AND CHECK JOINT FIT UPS ARE STRAIGHTEDGES, SQUARES,
LEVELS, AND HI-LO GAUGES.
STRAIGHTEDGES
• STRAIGHTEDGES ARE USED TO SCRIBE STRAIGHT LINES AND CHECK JOINT ALIGNMENT.
• ALWAYS CHECK A STRAIGHTEDGE FOR ________________, HEAT CAN CAUSE DISTORTION AND IF
THIS HAPPENS THE STRAIGHTEDGE IS NO LONGER GOOD.
SQUARES
• TWO TYPES ARE TYPICALLY USED…..
• PIPEFITTERS SQUARES- USED TO MEASURE ANGLES AND CHECK SQUARENESS.
• COMBINATION SQUARES- TYPICALLY SMALLER, HAVE ATTACHMENTS THAT SLIDE AND LOCK ALONG A
GROOVE ON THE BLADE.
• THE ________________ IS USED TO MEASURE ROUND STOCK AND TO LOCATE THE CENTER OF
SHAFTS OR OTHER ROUND OBJECTS.
LEVELS
• LEVELS ARE USED TO CHECK THAT LAYOUTS ARE LEVEL (HORIZONTAL) AND PLUMB (VERTICAL).
• LEVELS USE A __________ IN A GLASS VIAL TO CHECK LEVEL AND PLUMB.
• THE BUBBLE MUST BE CENTERED IN THE VIAL TO ENSURE THE LEVEL IS CORRECT.
• TORPEDO LEVELS HAVE THREE VIALS: ONE TO CHECK LEVEL, ONE TO CHECK PLUMB, AND ONE TO CHECK 45
DEGREE ALIGHNMENT.
HI LO GAUGES
• THE MAIN PURPOSE OF A HI LO GAUGE IS TO CHECK FOR ______________________, ALTHOUGH
PLATE JOINT MISALIGNMENT CAN ALSO BE CHECKED.
• THE NAME COMES FROM THE RELATIONSHIP BETWEEN THE ALIGNMENT OF ONE PIPE TO THE OTHER PIPE,
WHICH IS CALLED HIGH-LOW.
FIT UP TOOLS
• MANY TOOLS HAVE BEEN DEVELOPED TO AID PLATE AND PIPE FIT UP. SOME ARE SPECIALTY TOOLS AND
OTHERS ARE COMMON HAND TOOLS.
• THE FOLLOWING ARE COMMON FIT UP TOOLS….
HYDRAULIC JACKS
• WHEN USING A HYDRAULIC JACK, NEVER WELD DIRECTLY ON THE JACK BASE OR RAM.
• ALWAYS PROTECT THE RAM FROM WELD SPLATTER.
• IF THE RAM IS OFF THE GROUND, SECURE IT WITH ROPE OR CHAIN.
CHAIN HOISTS (CHAIN FALLS)
• CHAIN HOISTS, ALSO CALLED FALLS, ARE USED TO LIFT OR LOWER WELDMENT PARTS.
• ALWAYS SECURE THE CHAIN HOISTS OVER THE WELDMENT WITH AN _______________ WRAPPED
AROUND A SECURE STRUCTURE.
• NEVER HANG CHAIN HOISTS FROM PIPING, DUCTS, CONDUIT, OR RACEWAYS.
COME-ALONGS
• COME-ALONGS CAN BE USED FOR VERTICAL LIFTING AND PULLING AT ANGLES.
PLATE ALIGNMENT TOOLS
• SPECIAL TOOLS ARE MANUFACTURED FOR ALIGNING PLATE.
• TYPICAL CONFIGURATION OF AN ALIGNMENT TOOL CONSISTS OF A YOKE, ADJUSTMENT ROD, GAP PLATE, AND
ROOT BAR.
• THE ____________ CAN BE CHANGED TO MATCH THE SPECIFIED ROOT OPENING.
PIPE FIT UP TOOLS
• PIPE JACKS AND ROLLERS ARE USED TO SUPPORT PIPE FOR FIT UP AND WELDING.
• JACK STANDS AND ROLLERS ARE NECESSARY TOOLS IN THE PIPELINE WELDING INDUSTRY.
CHAIN CLAMPS
• _________________ ARE USED TO ALIGN AND HOLD PIPE FOR FIT UP AND TACKING.
• THE CHAIN IS PASSED AROUND THE PIPE AND SECURED, THE SLACK IN THE CHAIN IS THEN REMOVED
USING A JACK SCREW TO PULL THE PIPE TIGHTLY AGAINST THE CLAMP.
• THESE CLAMPS ARE IDEAL FOR JOBS IN WHICH 100 PERCENT ________ AND _________ IS REQUIRED
BEFORE THE CLAMP CAN BE RELEASED.
WELD DISTORTION
• DISTORTION IS THE EXPANSION AND CONTRACTION OF METAL AS IT RESPONDS TO CHANGES IN
TEMPERATURE.
• DISTORTION CANT BE PREVENTED AS LONG AS THE METAL EXPERIENCES CHANGES IN TEMPS CREATED IN
THE WELDING PROCESS.
DISTORTION
• THE DEGREE OF DISTORTION IS DIRECTLY RELATED TO THE ____________ GENERATED DURING
WELDING.
• TWO OF THE BIGGEST FACTORS IN DISTORTION ARE COEFFICIENT OF THERMAL EXPANSION AND THE
SPECIFIC HEAT PER UNIT VOLUME.
• METALS WITH HIGHER VALUES FOR THESE TWO FACTORS WILL EXPERIENCE A HIGHER DEGREE OF
DISTORTION THAN THOSE WITH LOWER VALUES.
CONTROLLING DISTORTION
• DISTORTION CAN BE CONTROLLED USING VARIOUS TOOLS AND TECHNIQUES.
• IT CAN ALSO BE CONTROLLED BY USING CLAMPS AND BRACES, TACK WELDS, AND CONTROLLING THE
AMOUNT OF WELD MATERIAL.
• EXCESS FACE REINFORCEMENT ACTUALLY REDUCES THE STRENGTH OF A WELD AND IS THEREFORE
_______________ BY WELDING CODES.
JOINT FIT UP
• PROPER FIT UP AND EDGE PREPARATION ALSO REDUCE THE AMOUNT OF WELD REQUIRED.
• OPEN ROOT JOINTS SHOULD HAVE A ROOT OPENING FROM _____ TO ______ WIDE.
WELDING SEQUENCE
• A WELDING SEQUENCE INVOLVES PLACING WELDS AT DIFFERENT POINTS ON A WELDMENT SO THAT
SHRINKAGE IN ONE AREA IS COUNTERACTED BY SHRINKAGE IN ANOTHER AREA.
• WELDING SEQUENCES ARE OFTEN PERFORMED BY TWO INDIVIDUALS WELDING ON ___________ SIDES
OF A JOINT AT THE SAME TIME.
• THIS IS KNOWN AS ___________ WELDING, WHICH IS ONE OF THE BEST WAYS AT CONTROLLING
DISTORTION.