The principles of welders verification of Competency

Preparation of the Principles of Welders Verification of Competency

The Preparation of the Principles of Welders Verification of Competency Course is designed to provide participants with the knowledge and skills necessary to verify and assess a welder’s competency through formal qualification processes. This course ensures that welders are capable of producing welds that meet industry standards, such as ASME (American Society of Mechanical Engineers), AWS (American Welding Society), and ISO. It focuses on preparing welding inspectors, supervisors, and engineers to evaluate welders based on performance tests and certification requirements.

Course Overview:

1- Introduction to Welder Qualification and Competency

• Purpose of Welder Verification: Ensuring that welders possess the required skills and knowledge to produce welds that comply with project specifications and industry codes.
• Importance of Competency: Competent welders reduce the likelihood of weld defects, rework, and safety risks in critical applications such as oil & gas, petrochemical, construction, shipbuilding, and manufacturing.

2- Understanding Welder Qualification Standards

• AWS and ASME Qualification Standards:
  • ASME Section IX: Qualification of welders and welding procedures for pressure vessels, boilers, and piping.
  • AWS D1.1: Structural welding code for steel, widely used in construction and infrastructure projects.
  • Other relevant standards: API 1104 (Pipeline welding), ISO 9606 (Welder qualification testing).

Key Topics Covered in the Course:

1- Welder Qualification Testing

• Qualification Process: Understanding how welders are tested and qualified for specific projects and welding processes.
  • Test joints: Preparation of test coupons for different types of welds, including butt joints, fillet welds, and pipe welds.
  • Welding positions: Testing welders in various positions such as flat, horizontal, vertical, overhead, and 6G (pipe welding).
  • Welding processes: Testing welders for different processes such as SMAW, GTAW, GMAW, FCAW, and SAW.
  • Essential Variables: Identifying key variables that affect the welder’s performance, such as welding process, materials, joint design, and welding position.
  • Witnessing and verifying the welder’s performance during the test.

2- Practical Performance Tests

• Preparation of Test Coupons: Setting up welding tests by preparing the test pieces (metal plates or pipes) according to standard configurations.
• Executing Test Welds: Observing the welder’s performance as they execute the weld according to a qualified welding procedure.
• Evaluating Test Results:
  • Visual Inspection (VT): Inspecting the weld for surface defects such as cracks, undercut, porosity, and incomplete fusion.
  • Destructive Testing: Performing mechanical tests such as bend tests, tensile tests, and impact tests to assess the weld’s mechanical properties.
  • Non-Destructive Testing (NDT): Using radiographic (RT), ultrasonic (UT), or magnetic particle testing (MT) to detect internal defects in the weld.

3- Performance Qualification Record (PQR)

• Documenting Results: Recording the welder’s test results in a Performance Qualification Record (PQR) or Welder Qualification Test Record (WQTR).
  • Essential details: Welding process, base material, filler material, joint type, position, and test results.
  • Test outcomes: Pass or fail decisions based on inspection and testing results.

4- Evaluation and Verification of Welder Competency

• Assessing Skills and Knowledge:
  • Technical knowledge: Ensuring the welder understands key concepts, such as welding parameters, joint preparation, and materials.
  • Practical skills: Evaluating the welder’s ability to perform the welds in a controlled, repeatable manner.
• Requalification:
  • When requalification is necessary due to changes in essential variables or when a welder fails a test.

5- Standards and Codes for Welder Verification

• AWS Standards:
  • AWS D1.1: Qualification requirements for structural welders.
  • AWS D1.3: Sheet steel welding qualifications.
  • AWS D1.6: Stainless steel welding qualifications.
• ASME Section IX: Guidelines for qualifying welders for pressure vessels, boilers, and piping systems.
• API 1104: Qualification standards for pipeline welding.
• ISO 9606: International standard for welder qualification testing.

6- Welder Certification

• Types of Certification:
  • Position-based certification: Certifications for welders in specific positions (1G, 2G, 3G, 4G, 5G, 6G, etc.).
  • Process-based certification: Certifications for specific welding processes (SMAW, GTAW, GMAW, etc.).
  • Material-based certification: Certifications for welding specific materials like carbon steel, stainless steel, aluminum, and others.
• Maintaining and Renewing Certification:
  • Requirements for keeping certifications valid.
  • Requalification requirements for welders after a set period or when certain variables change.

Course Learning Outcomes:

• Develop competency in verifying welders based on formal qualification tests as per AWS, ASME, and other standards.
• Understand essential and non-essential variables that affect welder qualifications and how changes in these variables may require requalification.
• Prepare and evaluate test coupons for various welding processes, positions, and materials.
• Perform visual and NDT inspections on welds to verify the quality and detect defects.
• Maintain welder qualification records (PQR/WQTR) in compliance with industry standards.
• Apply industry standards such as ASME Section IX, AWS D1.1, and others to ensure the proper verification and certification of welders.

 Target Audience:

• Welding Inspectors and Supervisors: Responsible for overseeing welding operations and ensuring that welders meet required competency levels.
• Quality Control (QC) Personnel: Ensuring that welders are properly qualified for specific welding tasks.
• Welding Engineers: Developing and approving welding procedures and overseeing welder qualifications.
• Welders: Interested in understanding the process of qualification and improving their skills to meet industry standards.

Certification:

Participants who successfully complete the course will receive a certificate of completion, demonstrating their ability to prepare, administer, and evaluate welder qualification tests and verify competency based on industry standards.