Course Overview:
This course aims at providing participants with the competency to develop and approve welding and brazing procedures in accordance with ASME, AWS and API Standards.
It includes joining processes, weld materials, joint configuration, welded assemblies and quality assurance including non-destructive testing methods and welder approval.
It is also expected that they will understand how to prepare WPS, test coupons and the general aspects of safety of environment during welding.
It provides a detailed introduction to ASME Section IX – its use and the manner in which the provisions of the code are met. Suitable for inspection engineers, welding engineers, QA/QC staff and people involved in the qualification of welding procedures.
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 plans 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 details and in an easy way.
- Select test coupons to minimize 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. Maintenance Engineers, technicians, and staff Plant engineers Operation, maintenance, inspection and repair managers, supervisors and engineers Mechanical engineers and technicians design engineers, electrical engineers and technicians, consulting engineers.
Course Outlines:
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
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
Introduction to Properties of Materials
- Strength of Materials
- Material Properties
- Destructive Testing
- Fatigue of Welded Structures
- Fatigue mechanisms
- Weld finish classifications
Joint Designs
Joint Designs
- Joints
- Symbols
- Preparation
- Design for Productivity
- Dissimilar Welds and Weld Overlays
- Metallurgical Properties of Steel & Heat Treatment
Dissimilar Welds and Weld Overlays
Metallurgical Properties of Steel & Heat Treatment
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
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
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
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
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.
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
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
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
Welding Safety
- Electric Shock
- Radiation
- Fire and explosions
- Eye injuries
- Fume
- Hearing impairment
Procedure Specification
Procedure Specification
- Use of Section IX form
- Other Formats
- Procedure qualification record forms
- Revisions to records and procedures
- Take-home test
Procedure Specification
Procedure Specification
- Use of Section IX form
- Other Formats
- Procedure qualification record forms
- Revisions to records and procedures
- Take-home test
ASME Brazing Qualifications
ASME Brazing Qualifications
- Brazing process and variables
- Differences between QW and QB Sections
- Preparation of the Brazing Procedure Specification
- Qualification of the brazing procedure
- Types of tests
- Qualification of brazers and brazing operators