Course Overview:
This program ensures the students get sufficient knowledge on welding related assembly, quality assurance and code compliance with ASME, AWS, and API standards.
Attendees will acquire skills such as determination of welding processes, consumables classification, material properties comprehension, and last but not least proper quality control through inspections and welder qualification.
The course encompasses welding of the procedures which include designs of joints, fatigue, heat treatment, and the application of welding codes such as API 1104 and ASME section nine. Participants shall also obtain skills to draft welding procedure specifications (WPS) including measures of occupational health and safety standards.
This programme is useful for the people who deal with welding inspection, welding procedure qualification, and quality assurance
Course Objectives:
Upon the successful completion of this course, the participants should be able to:
- Identify the tools and techniques associated with welding-related fabrication and quality control.
- Point out practical aspects of fabrication and inspection which should be taken into consideration in the design of equipment.
- Monitor fabrication and erection plan and incorporate some quality control requirements into contractual documents.
- Achieve economical compliance with ASME, AWS, and API Standards when writing and qualifying welding and brazing procedures.
- Gain insights into ASME Code, AWS, and API Standards to facilitate interpreting, understanding, and complying with Standards.
- Review welding processes, common variables, and basic welding metallurgy.
- Find out how to qualify welders and brazers the easy way.
- Writing and qualifying welding procedures that comply with ASME Code, AWS, and API Standards with an in-depth understanding of the requirements.
- Understand and examine the requirements for welder and operator qualification in detail and in an easy way.
- Select test coupons to minimize the overall cost of qualification and writing WPSs so that optimum flexibility is achieved.
Who Should Attend?
Inspection engineers, Mechanical Engineers, Electrical Engineers, NDT personnel, quality assurance personnel, auditors, testing laboratory personnel, and maintenance personnel. Further, this course is a must for anyone involved in the inspection of welding construction, qualifying welders, brazers and operators; or other involved in writing and qualifying welding and brazing procedure specifications; those responsible for reviewing supplier procedures, auditing or reviewing in-house procedures and qualifications; and those who estimate jobs where compliance of ASME code.
Course Outlines:
Welding Processes Welding Processes
Welding Processes
- Fundamentals
- SMAW (Shielded Metal Arc)
- GTAW (Gas Tungsten Arc)
- GMAW (or MIG) (Gas Metal Arc)
- FCAW (Flux Cored Arc)
- SAW (Submerged Arc)
- Stud Welding
- OAW (Oxy-Acetylene)
- High Energy, Special and Hybrid Welding Processes
- Power Sources for Arc Welding
- Brazing and Cutting Processes
Classification of Arc Welding Consumables
- Coated Electrodes
- GMAW and GTAW Wires
- FCAW Wires
- Sub Arc Wires and Fluxes
- Neutral and Active Fluxes
- Shielding Gases
Introduction to Properties of Materials
Strength of Materials
- Material Properties
- Destructive Testing
Fatigue of Welded Structures
- Fatigue mechanisms
- Weld finish classifications
Joint Designs
- Joints
- Symbols
- Preparation
- Design for Productivity
Dissimilar Welds and Weld Overlays
Metallurgical Properties of Steel & Heat Treatment
- Metallurgical Properties of Steel
- Preheating
- Post Weld Heat Treatment (PWHT)
- Field Heat Treating Equipment
- Plans for PWHT
Welding Quality Control
- Planning for QC
- Welding Problems and Defects
- Visual Inspection
- Employment of NDT
- Welder Training & Qualification
- CSWIP vs. ASNT qualification
API 1104 and AWS D1.1: History and Structure
- Historical Development of AWS D1.1 and API 1104
- Pre-Qualification and Qualification of Welding Procedures
- The use of Pre-qualified procedures
- Base Metal Classifications to AWS and API
ASME Code, History and Structure
- Historical Development of Section IX
- Relationship of Section IX to Other Codes (ASME V111 and B31.3)
- Organization, Structure, and Mechanics of Using Section IX – Essential, Non-Essential and Supplemental Essential Variables
ASME Section IX: Base and Filler Metal Specifications
- P numbers and Base Metal Classifications
- F-numbers
- A-numbers
- SFA and Non-SFA filler metal specifications
The use of Standard Welding Procedures
ASME Section IX: Selecting and preparing the test coupon for both procedures and Welder qualifications.
- Obtaining maximum cost-effectiveness from test coupons
- Preparation and welding of the test coupon
- Recording both necessary and worthwhile data
Demonstrating code compliance
ASME Section IX: Writing Welding Procedure Specification
- Meeting code requirements
- Addressing customer requirements
- Providing direction to the welder
Sources of information for preparing intelligent and meaningful welding procedure specifications
ASME Supplemental Variables – special consideration for notch-toughness
- How welding influences toughness
- Toughness requirements of construction codes
- Measuring and recording heat input data
- Translating heat input data into useful directions for a welder
- Typical construction code requirements
Welding Safety
- Electric Shock
- Radiation
Fire and explosions
- Eye injuries
- Fume
Hearing impairment
Procedure Specification
- Use of Section IX form
- Other Formats
- Procedure qualification record forms
- Revisions to records and procedures
- Take-home test
Procedure Specification
- Use of Section IX form
- Other Formats
- Procedure qualification record forms
- Revisions to records and procedures
ASME Brazing Qualifications
- Brazing process and variables
- Differences between QW and QB Sections
Preparation of the Brazing Procedure Specification
ASME Brazing Qualifications (cont’d)
- Qualification of the brazing procedure
- Types of test
Qualification of Brazers and brazing operators