Course Introduction
In today’s times of reduced manual labor onboard vessels coupled with the increasing challenges to perform maintenance tasks of equipment under tight schedules, the staff that occupies a ship must be trained in the required skills to carry out safe, efficient, and quick repair of cracked, damaged or leaking plates and pipes.
Why are there so many requirements for the marine industry and how does this “Marine Shipyard Welding and Fabrication Certification” course contribute to those? Marine welding roles require a vast array of skills and training due to the safety considerations involved in the marine industry. Failure to keep your work up to standards can not only result in monetary penalties but also jeopardize the workers and anyone else whose work depends on the structural integrity of the vessels and equipment that they operate with. This program acquaints its participants with the relevant safety precautions to be observed, the requisite knowledge of the various welding equipment, and processes. It also identifies proper electrode and welding parameters for selection, and the practical skills required to execute various repair jobs on plates and pipes.
Course Objectives
Upon completing this Marine Shipyard Welding and Fabrication Certification Course successfully, participants will be able to:
- Understand the performance and functioning of different types of welding equipment and their working principles
- Attain advanced skills in gas cutting techniques
- Recognize the dangers and observe the relevant safety precautions while performing hot work
- Acquire the necessary skill to make acceptable weld joints on steel and nonferrous plates and pipes with both, gas, and arc welding in different positions
- Gain the knowledge of correct welding electrodes and filler rod selection and parameter settings based on the material to be welded
- Acquire the skills in brazing using filler rods such as silver and bronze
- Develop the skill to be able to weld various metals such as steel, stainless steel, cast iron, and aluminum
- Familiarize themselves with the TIG and MIG welding processes and plasma cutting
Who Should Attend?
This Marine Shipyard Welding and Fabrication Certification course would be suitable for:
- Ships Fitters
- Pumpmen
- Shipyard Welder
- Repair team members
- Marine Technicians
- Marine Engineers
- Marine Crew
Course Outline
MODULE 1: MATERIAL TYPES AND CASTING DISCONTINUITIES
- Characteristics of steel, castings, and forgings
- Types of discontinuities
- ABS requirements for steel, castings, and forgings
MODULE 2: MATERIAL PROPERTIES, CHARACTERISTICS, AND TESTS
- Material property testing:
- Tensile
- Hardness
- Weld soundness testing:
- Bend
- Fillet break
- Nick break
- Toughness
- Fatigue
MODULE 3: BASIC WELDING METALLURGY
- The grain structure of steel
- Grain size and properties
- Cooling rates and structural properties
- Pre-heating and cooling
- Thermal stress relief
- Heat treatment methods
MODULE 4: WELD JOINT GEOMETRY AND WELDING TERMINOLOGY
- Overview of basic weld joints
- Weld joint parts and preparation
- Explanation of types of welds:
- Groove
- Fillet
- Spot/Seam
- Plug/Slot
- Surfacing
- Back
- Backing
- Weld application terminology
MODULE 5: WELD SYMBOL TYPES AND TEST SYMBOL TYPES
- Weld symbols
- Test symbols
- Supplementary symbols
MODULE 6: WELDING PROCESSES
- Shielded metal arc welding
- Gas metal arc welding
- Safety precautions in gas and arc welding
- Gas and arc welding gear and attachments
- Gas and arc welding processes
- Flux core arc welding
- Submerged arc welding
- Gas tungsten arc welding
- Joint preparation
- Brazing and cutting processes
MODULE 7: WELDING DISCONTINUITIES AND REPAIRS
- Surface discontinuities
- Surface discontinuity weld repairs
- Weld root discontinuities
- Root discontinuity weld repairs
- Internal discontinuities
- Internal discontinuity weld repairs
- Cracking and cracking repairs
MODULE 8: WELDING PROCEDURE QUALIFICATION
- Welder qualification documents
- Required and optional tests to be carried out
MODULE 9: WELDER PERFORMANCE QUALIFICATION
- Welder qualification assessment criteria
- Monitoring production welding
MODULE 10: WELDING STRESS CONTROL
- Heating and cooling consequences on welding stresses
- Methods of controlling welding stress
- Weld stress correction techniques
- Welding sequence best practices
MODULE 11: PIPING DRAWINGS
- Fabrication
- Welding and testing
- Installation and repair