LEARNING OUTCOME #4

CLEAN ROOT PASS

CONTENTS:
1. Defects and discontinuities
2. Welding codes and standards
3. Cleaning root pass

ASSESSMENT CRITERIA:

1. Root pass is cleaned and free from defects and discontinuities.

2. Task is performed in accordance with approved WPS.

CONDITIONS: The students must be provided with the following:

4. Equipment: portable grinder
5. Tools: chipping hammer, steel brush, half-round file
6. Materials: grinding stone/disc, carbon steel plate/pipe

ASSESSMENT METHODS:
 Written Test
 Oral Questioning/Interview
 Demonstration/Role Play
 Learning Experiences

Learning Outcome 4

CLEANING ROOT PASS

Learning Activities Special Instructions

Read Information Sheet 4.2-1: This Learning Outcome deals with the
“Defects and discontinuities” development of the Institutional
Competency Evaluation Tool which
Read Information Sheet 4.2-2: trainers use in evaluating their trainees
“Welding codes and standards” after finishing a competency of the
qualification.

Go through the learning activities outlined

for you on the left column to gain the
necessary information or knowledge
before doing the tasks to practice on
performing the requirements of the
evaluation tool.

The output of this LO is a complete

Institutional Competency Evaluation
Package for one Competency of Welding.
Your output shall serve as one of your
portfolio for your Institutional
Competency Evaluation for Welding
Carbon Steel Plates and Pipes Using
SMAW.

Feel free to show your outputs to your

trainer as you accomplish them for
guidance and evaluation.

After doing all the activities for this LO,

you are ready to proceed to the next LO:
Weld Subsequently/Filling Pass
 Information Sheet 4.2-1

DEFECTS AND DISCONTINUITIES

Learning Objectives:
After reading this information sheet, you must be able to:
1. Identify defects and discontinuities.

Discontinuities
Discontinuities are interruptions in the typical structure of a material. These
interruptions may occur in the base metal, weld material or "heat affected"
zones. Discontinuities, which do not meet the requirements of the codes or
specifications used to invoke and control an inspection, are referred to as
defects.

Defects
An irregularity in the specified and expected composition of a weld that exceeds
the part design's tolerances. A defect is a rejectable discontinuity.

General Welding Discontinuities

The following discontinuities are typical of all types of welding.

Cold lap is a condition where the weld filler metal does not properly fuse with
the base metal or the previous weld pass material (inter-pass cold lap). The arc
does not melt the base metal sufficiently and causes the slightly molten puddle
to flow into the base material without bonding.
Porosity is the result of gas entrapment in the solidifying metal. Porosity can
take many shapes on a radiograph but often appears as dark round or irregular
spots or specks appearing singularly, in clusters, or in rows. Sometimes,
porosity is elongated and may appear to have a tail. This is the result of gas
attempting to escape while the metal is still in a liquid state and is called
wormhole porosity. All porosity is a void in the material and it will have a higher
radiographic density than the surrounding area.

Cluster porosity is caused when flux coated electrodes are contaminated with
moisture. The moisture turns into a gas when heated and becomes trapped in
the weld during the welding process. Cluster porosity appear just like regular
porosity in the radiograph but the indications will be grouped close together.

Slag inclusions are nonmetallic solid material entrapped in weld metal or

between weld and base metal. In a radiograph, dark, jagged asymmetrical
shapes within the weld or along the weld joint areas are indicative of slag
inclusions.
Incomplete penetration (IP) or lack of penetration (LOP) occurs when the
weld metal fails to penetrate the joint. It is one of the most objectionable weld
discontinuities. Lack of penetration allows a natural stress riser from which a
crack may propagate. The appearance on a radiograph is a dark area with well-
defined, straight edges that follows the land or root face down the center of the
weldment.

Incomplete fusion is a condition where the weld filler metal does not properly
fuse with the base metal. Appearance on radiograph: usually appears as a dark
line or lines oriented in the direction of the weld seam along the weld
preparation or joining area.

Internal concavity or suck back is a condition where the weld metal has
contracted as it cools and has been drawn up into the root of the weld. On a
radiograph it looks similar to a lack of penetration but the line has irregular
edges and it is often quite wide in the center of the weld image.
Internal or root undercut is an erosion of the base metal next to the root of the
weld. In the radiographic image it appears as a dark irregular line offset from
the centerline of the weldment. Undercutting is not as straight edged as LOP
because it does not follow a ground edge.

External or crown undercut is an erosion of the base metal next to the crown
of the weld. In the radiograph, it appears as a dark irregular line along the
outside edge of the weld area.

Offset or mismatch are terms associated with a condition where two pieces
being welded together are not properly aligned. The radiographic image shows a
noticeable difference in density between the two pieces. The difference in
density is caused by the difference in material thickness. The dark, straight line
is caused by the failure of the weld metal to fuse with the land area.
Inadequate weld reinforcement is an area of a weld where the thickness of
weld metal deposited is less than the thickness of the base material. It is very
easy to determine by radiograph if the weld has inadequate reinforcement,
because the image density in the area of suspected inadequacy will be higher
(darker) than the image density of the surrounding base material.

Excess weld reinforcement is an area of a weld that has weld metal added in
excess of that specified by engineering drawings and codes. The appearance on
a radiograph is a localized, lighter area in the weld. A visual inspection will
easily determine if the weld reinforcement is in excess of that specified by the
engineering requirements.

Cracks can be detected in a radiograph only when they are propagating in a

direction that produces a change in thickness that is parallel to the x-ray beam.
Cracks will appear as jagged and often very faint irregular lines. Cracks can
sometimes appear as "tails" on inclusions or porosity.
Under-fill - A condition in which the weld face or root surface extends below the
adjacent surface of the base metal.
 Information Sheet 4.2-2
WELDING CODES AND STANDARDS

Learning Objectives:
After reading this information sheet, you must be able to:
1. Determine the different list of welding codes and standards.

American Society of Mechanical Engineers (ASME) Codes

The American Society of Mechanical Engineers (ASME) Boiler and Pressure

Vessel Code (BPVC) covers all aspects of design and manufacture of boilers and
pressure vessels. All sections contain welding specifications, however most
relevant information is contained in the following:

Code Description

ASME BPVC Section Part C: Specifications for Welding Rods, Electrodes, and
II Filler Metals.

ASME BPVC Section

Nondestructive Examination
V

ASME BPVC Section

Welding and Brazing Qualifications
IX

ASME B16.25 Butt welding ends

American Welding Society (AWS) Standards

The American Welding Society (AWS) publishes over 240 AWS-developed codes,
recommended practices and guides which are written in accordance with
American National Standards Institute (ANSI) practices. The following is a
partial list of the more common publications:

Standard
Title
Number†

Standard symbols for welding, brazing, and non-destructive

AWS A02.4
examination

AWS A03.0 Standard welding terms and definitions

Standard
Title
Number†

Specification for carbon steel electrodes for shielded metal arc

AWS A05.1
welding

Specification for carbon steel electrodes and rods for gas

AWS A05.18
shielded arc welding

AWS B01.10 Guide for the nondestructive examination of welds

Specification for Welding Procedure and Performance

AWS B02.1
Qualification

AWS D01.1 Structural welding (steel)

AWS D01.2 Structural welding (aluminum)

AWS D01.3 Structural welding (sheet steel)

AWS D01.4 Structural welding (reinforcing steel)

AWS D01.5 Bridge welding

AWS D01.6 Structural welding (stainless steel)

AWS D01.7 Structural welding (strengthening and repair)

AWS D01.8 Structural welding seismic supplement

AWS D01.9 Structural welding (titanium)

AWS D08.1 Automotive spot welding

AWS D08.6 Automotive spot welding electrodes supplement

AWS D08.7 Automotive spot welding recommendations supplement

AWS D08.8 Automotive arc welding (steel)

AWS D08.9 Automotive spot weld testing

Standard
Title
Number†

AWS D08.14 Automotive arc welding (aluminum)

AWS D09.1 Sheet metal welding

AWS D10.10 Heating practices for pipe and tube

AWS D10.11 Root pass welding for pipe

AWS D10.12 Pipe welding (mild steel)

AWS D10.13 Tube brazing (copper)

AWS D10.18 Pipe welding (stainless steel)

AWS D11.2 Welding (cast iron)

AWS D14.1 Industrial mill crane welding

AWS D14.3 Earthmoving & agricultural equipment welding

AWS D14.4 Machinery joint welding

AWS D14.5 Press welding

AWS D14.6 Industrial mill roll surfacing

AWS D15.1 Railroad welding

AWS D15.2 Railroad welding practice supplement

AWS D16.1 Robotic arc welding safety

AWS D16.2 Robotic arc welding system installation

AWS D16.3 Robotic arc welding risk assessment

AWS D16.4 Robotic arc welder operator qualification

AWS D17.1 Aerospace fusion welding

Standard
Title
Number†

AWS D17.2 Aerospace resistance welding

AWS D18.1 Hygienic tube welding (stainless steel)

AWS D18.2 Stainless steel tube discoloration guide

AWS D18.3 Hygienic equipment welding

†
The zero after the first letter is only placed there so the table can be sorted. i.e.
D01.1 is actually D1.1).

American Petroleum Institute (API) Standards

The American Petroleum Institute (API) oldest and most successful programs is
in the development of API standards which started with its first standard in
1924. API maintains over 500 standards covering the oil and gas field. The
following is a partial list specific to welding:

Standard
Description
Number

API RP 577 Welding Inspection and Metallurgy

API 1104 Welding of pipelines and related facilities

Australian / New Zealand (AS/NZS) Standards

Standards Australia is the body responsible for the development, maintenance

and publication of Australian Standards. The following is a partial list specific
to welding:

Standard
Description
Number

AS/NZS 1554.1 Structural steel welding - Welding of steel structures

AS/NZS 1554.2 Structural steel welding - Stud welding (steel studs to steel)
Standard
Description
Number

AS/NZS 1554.3 Structural steel welding - Welding of reinforcing steel

Structural steel welding - Welding of high strength quenched

AS/NZS 1554.4
and tempered steels

Structural steel welding - Welding of steel structures subject to

AS/NZS 1554.5
high levels of fatigue loading

Structural steel welding - Welding stainless steels for structural

AS/NZS 1554.6
purposes

AS/NZS 1554.7 Structural steel welding - Welding of sheet steel structures

AS/NZS 3992 Pressure equipment - Welding and brazing qualification

Canadian Standards Association (CSA) Standards

The Canadian Standards Association (CSA) is responsible for the

development, maintenance and publication of CSA standards. The following is a
partial list specific to welding:

Standard Number Description

CAN/CSA-G401-07 Corrugated Steel Pipe Products

Welding consumables - Wire electrodes and weld deposits

CAN/CSA-ISO
for gas shielded metal arc welding of non-alloy and fine
14341:11
grain steels -

CAN/CSA-W117.2-
Safety in Welding, Cutting and Allied Processes
06 (R2011)

G40.20-04/ General Requirements for Rolled or Welded Structural

G40.21-04 (R2009) Quality Steel/ Structural Quality Steel

W178.1-08 Certification of Welding Inspection Organizations

W178.2-08 Certification of Welding Inspectors

W47.1-09 Certification of companies for fusion welding of steel

W47.2-11 Certification of companies for fusion welding of aluminum

W48-06 (R2011) Filler Metals and Allied Materials for Metal Arc Welding

Certification of companies for resistance welding of steel

W55.3-08
and aluminum

W59-13 Welded Steel Construction (Metal Arc Welding)

W59.2-M1991
Welded Aluminum Construction
(R2008)

Z662-11 Oil and Gas Pipeline Systems

British Standards (BS)

British Standards are developed, maintained and published by BSI Standards

which is UK's National Standards Body. The following is a partial list of
standards specific to welding:

Standard
Description
Number

Welding terms and symbols. Glossary for welding, brazing and

BS 499-1
thermal cutting

Welding terms and symbols. European arc welding symbols in

BS 499-2C
chart form

Specification for Class I arc welding of ferritic steel pipework for

BS 2633
carrying fluids

Specification for class II arc welding of carbon steel pipework for

BS 2971
carrying fluids

Specification for welding of steel pipelines on land and offshore -

BS 4515-1
Part 1: Carbon and carbon manganese steel pipelines

BS 4515-2 Specification for welding of steel pipelines on land and offshore.

Standard
Description
Number

Duplex stainless steel pipelines

Structural use of steel and aluminum. Recommendations for the

PD 6705-2
execution of steel bridges to BS EN 1090-2

Structural use of steel and aluminum. Recommendations for the

PD 6705-3
execution of aluminum structures to BS EN 1090-3

International Organization for Standardization (ISO) Standards

International Organization for Standardization (ISO) has developed over 18500

standards and over 1100 new standards are published every year. The following
is a partial list of the standards specific to welding:

Standard
Description
Number

Welded, brazed and soldered joints - symbolic representation on

ISO 2553
drawings (1992)

Welding consumables. Covered electrodes for manual metal arc

ISO 2560
welding of non-alloy and fine grain steels. Classification

Covered electrodes for manual arc welding of creep-resisting steels

ISO 3580
- Code of symbols for identification

Covered electrodes for manual arc welding of stainless and other

ISO 3581
similar high alloy steels - Code of symbols for identification

Quality requirements for fusion welding of metallic materials, five

ISO 3834
parts.

Welding and allied processes - Nomenclature of processes and

ISO 4063
reference numbers

Welding. Fusion-welded joints in steel, nickel, titanium and their

ISO 5817
alloys (beam welding excluded). Quality levels for imperfections

ISO 6520-1 Welding and allied processes — Classification of geometric

Standard
Description
Number

imperfections in metallic materials — Part 1: Fusion welding

Welding and allied processes — Classification of geometric

ISO 6520-2 imperfections in metallic materials — Part 2: Welding with
pressure

Welds. Working positions. Definitions of angles of slope and

ISO 6947
rotation

ISO 9606 Qualification test of welders — Fusion welding, parts 1 to 5

Welding and allied processes. Recommendations for joint

ISO 9692-1 preparation. Manual metal-arc welding, gas-shielded metal-arc
welding, gas welding, TIG welding and beam welding of steels

Welding and allied processes. Joint preparation. Submerged arc

ISO 9692-2
welding of steels

Welding and allied processes. Joint preparation. Part 3: TIG and

ISO 9692-3
MIG welding of aluminum and its alloys

Petroleum and natural gas industries - Pipeline transportation

ISO 13847
systems - Welding of pipelines

Welding - Guidance on the measurement of preheating

ISO 13916 temperature, inter-pass temperature and preheat maintenance
temperature

ISO 13918 Welding - Studs and ceramic ferrules for arc stud welding

Welding - Electron and laser-beam welded joints - Guidance on

ISO 13919-1
quality level for imperfections - Part 1: Steel

Welding - Electron and laser-beam welded joints - Guidance on

ISO 13919-2 quality level for imperfections - Part 2: Aluminum and its weldable
alloys

Welding - General tolerances for welded constructions -

ISO 13920
Dimensions for lengths and angles - Shape and position
Standard
Description
Number

ISO 14112 Gas welding equipment - Small kits for gas brazing and welding

Welding consumables — Gases and gas mixtures for fusion

ISO 14175
welding and allied processes. Replaced EN 439:1994 in Europe.

Welding consumables. Wire electrodes and deposits for gas

ISO 14341 shielded metal arc welding of non-alloy and fine grain steels.
Classification

ISO 14554 Resistance welding

ISO 14744 Electron beam welding, six parts

Specification and qualification of welding procedures for metallic

ISO 15607
materials - General rules

ISO/TR
Welding - Guidelines for a metallic material grouping system
15608

Specification and qualification of welding procedures for metallic

ISO 15609
materials - Welding procedure specification, five parts.

Specification and qualification of welding procedures for metallic

ISO 15610
materials — Qualification based on tested welding consumables

Specification and qualification of welding procedures for metallic

ISO 15611
materials — Qualification based on previous welding experience

Specification and qualification of welding procedures for metallic

ISO 15612 materials — Qualification by adoption of a standard welding
procedure

Specification and qualification of welding procedures for metallic

ISO 15613
materials — Qualification based on pre-production welding test

Specification and qualification of welding procedures for metallic

ISO 15614
materials - Welding procedure test, 13 parts.

ISO 15615 Gas welding equipment. Acetylene manifold systems for welding,
cutting and allied processes. Safety requirements in high-pressure
Standard
Description
Number

devices

Qualification testing of welders for under-water welding. Diver-

ISO 15618-1
welders for wet welding

Qualification testing of welders for under-water welding. Diver-

ISO 15618-2
welders and welding operators for dry welding

Non-destructive testing of welds. General rules for metallic

ISO 17635
materials

ISO/TR
Welding — Grouping systems for materials — European materials
20172

ISO/TR
Welding — Grouping systems for materials — American materials
20173

ISO/TR
Welding — Grouping systems for materials — Japanese materials
20174

Welding for aerospace applications. Qualification test for welders

ISO 24394
and welding operators. Fusion welding of metallic components

European Union (EU) standards

The European Committee for Standardization (ECS) had issued numerous

standards covering welding processes, which unified and replaced former
national standards. Of the former national standards, those issued
by BSI and DIN were widely used outside their countries of origin. After the
Vienna Agreement with ISO, ECS has replaced most of them with equivalent
ISO standards (EU ISO series).

Standard
Description
Number

EN 287-1 Qualification test of welders — Fusion welding — Part 1: Steels

EN 1090-1 Execution of steel structures and aluminum structures - Part 1:

Requirements for conformity assessment of structural
Standard
Description
Number

components

Execution of steel structures and aluminum structures - Part 2:

EN 1090-2
Technical requirements for steel structures

Execution of steel structures and aluminum structures - Part 3:

EN 1090-3
Technical requirements for aluminum structures

Welding — Recommendations for welding of metallic materials —

EN 1011-1
Part 1: General guidance for arc welding

Welding — Recommendations for welding of metallic materials —

EN 1011-2
Part 2: Arc welding of ferritic steels

Welding — Recommendations for welding of metallic materials —

EN 1011-3
Part 3: Arc welding of stainless steels

Welding — Recommendations for welding of metallic materials —

EN 1011-4
Part 4: Arc welding of aluminum and aluminum alloys

Welding. Recommendations for welding of metallic materials.

EN 1011-5
Welding of clad steel

Welding. Recommendations for welding of metallic materials.

EN 1011-6
Laser beam welding

Welding — Recommendations for welding of metallic materials —

EN 1011-7
Part 7: Electron beam welding

Welding. Recommendations for welding of metallic materials.

EN 1011-8
Welding of cast irons

Welding personnel. Approval testing of welding operators for

EN 1418 fusion welding and resistance weld setters for fully mechanized
and automatic welding of metallic materials

Welding. Basic welded joint details in steel. Pressurized

EN 1708-1
components.

EN 1708-2 Welding. Basic weld joint details in steel. Non-internal pressurized

Standard
Description
Number

components.

Welding. Basic weld joint details in steel. Clad, buttered and lined
EN 1708-3
pressurized components.

Eurocode 3: Design of steel structures – Part 1-8: General –

EN 1993-1-8
Design of joints

EN 13133 Brazing - Brazer approval

Welded, brazed and soldered joints – Symbolic representation on

EN 22553
drawings. (CEN version of ISO 2553)

Additional requirements for welding exist in CEN codes and standards for
specific products, like EN 12952, EN 12953, EN 13445, EN 13480, etc.

German Standards (DIN and others

NA 092 is the Standards Committee for welding and allied processes (NAS) at
DIN Deutsches Institut für Normung e. V. The following is a partial list of DIN
welding standards:

Code Description

DIN 1910-
Welding; terms dependent on materials for metal welding
100

Schweißgeeignete Feinkornbaustähle - Richtlinien für die

SEW 088 Verarbeitung besonders für das Schmelzschweißen", Stahlinstitut
VDEh

Merkblatt Metall-Schutzgasschwißen von Feinkornbaustählen", Deutscher

DVS 0916 Verband für Schweißtechnik e.V.