Introduction:

Welding Technology plays a major role in all maintenance and fabrication activities in the industry. Production equipment, a highly sophisticated welding technique and qualified personnel allow processing or production of steel products for different applications within short periods. This seminar provides a much needed source of authoritative information on the complex subject of welding. It provides a comprehensive run-down of the complex science of welding- processes, selection of power sources, weld metallurgy, weldability of metals, testing and inspection techniques. The course will cover welding processes, welding consumables, design of welded joints, applied welding metallurgy and heat treating, welding quality control, non-destructive testing and major International Welding Codes and Standards such as AWS and API.

Course Objectives:

By the end of this course, delegates will 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?

Welders I & II, Fabricators, Welding Metallurgy Technicians, Welding Supervisors, Welding Sales/Service Technicians, Foreman Mechanical Maintenance, New Technologists, Engineering Technicians, Pipefitters, Weld Inspectors, Production Welders, Managers, Petroleum Engineers, Senior Welders and Operators, Production and Maintenance Staff, Inspectors, anyone who works with welding, Inspection Engineers, Mechanical Engineers, Electrical Engineers, NDT Personnel, Quality Assurance Personnel, Auditors, Testing Laboratory Personnel, and Maintenance Personnel, Qualifying Welders, Brazers and Operators, anyone 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 Outline:

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 procedure 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

• 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
• 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 tests
• Qualification of Brazers and brazing operators

COURSE LOCATIONS