Welding Fundamentals & Processes

Module 1 – Introduction to Welding Technology

• What is welding?

• Importance of welding in oil & gas facilities

• Welding vs brazing vs soldering

• Basic welding terminology:

  • Base metal

  • Filler metal

  • Weld joint

  • Heat input

• Role of codes and standards:

  • ASME Section IX

  • Relationship with construction & inspection codes

Module 2 – Welding Joints, Positions & Symbols

• Types of weld joints:

  • Butt

  • Fillet

  • Lap

  • T-joint

• Welding positions:

  • 1G, 2G, 5G, 6G (pipe)

  • Flat, horizontal, vertical, overhead

• Welding symbols (basic):

  • Size

  • Length

  • Location

• Common mistakes in reading drawings

Module 3 – Common Welding Processes (ASME IX Focus)

• SMAW (Shielded Metal Arc Welding)

• GTAW (TIG)

• GMAW (MIG)

• FCAW

• SAW (overview)

For each process:

• How it works (simple explanation)

• Typical applications

• Advantages and limitations

• Common defects associated with each process

Module 4 – Welding Consumables & Materials

• Welding electrodes and filler metals

• Electrode classification basics

• Role of shielding gas and flux

• Base material considerations:

  • Carbon steel

  • Low alloy steel

  • Stainless steel

• Preheat and interpass temperature (intro)

ASME Section IX & Welding Qualification

Module 1 – Overview of ASME Section IX

• Purpose of ASME Section IX

• What is controlled by ASME IX:

  • Welding procedure qualification

  • Welder qualification

• What ASME IX does NOT cover

• Relationship with:

• ASME VIII

• ASME B31 codes

• API inspection codes

Module 2 – Welding Procedure Specification (WPS)

• What is a WPS?

• Essential variables (conceptual)

• Non-essential & supplementary variables (awareness)

• Typical WPS content:

  • Process

  • Material

  • Thickness range

  • Position

  • Heat input controls

• Common WPS misuse on the site

Module 3 – Procedure Qualification Record (PQR)

• What is a PQR?

• Difference between WPS and PQR

• Mechanical tests overview:

  • Tensile

  • Bend

  • Impact (awareness)

• Role of test results

• Validity and limitations of a PQR

Module 4 – Welder Performance Qualification (WPQ)

• What is a WPQ?

• Qualification ranges:

  • Thickness

  • Diameter

  • Position

• Continuity requirements

• Common qualification mistakes

• The inspector’s responsibility on site

Welding Inspection & Defect Recognition

Module 1 – Welding Inspection Stages

• Inspection before welding:

  • Material check

  • Fit-up

  • WPS availability

• Inspection during welding:

  • Parameters

  • Preheat & interpass

• Inspection after welding:

• Visual inspection

• NDT readiness

Module 2 – Welding Discontinuities & Defects

• Discontinuity vs defect

• Common welding defects:

  • Cracks

  • Lack of fusion

  • Incomplete penetration

  • Porosity

  • Undercut

  • Slag inclusion

• Typical causes and prevention

Module 3 – Visual Inspection & NDT Overview

• Visual inspection basics:

  • Lighting

  • Accessibility

  • Acceptance concept

• NDT overview:

  • PT

  • MT

  • RT

  • UT

• Choosing the right method (basic logic)

Module 4 – Practical Application & Case Discussions

• Common site welding problems

• Misinterpretation of WPS & drawings

• Case examples:

  • Rejected weld due to the wrong process

  • Welder not properly qualified

  • Cracking due to poor heat control

• Inspector–welder–engineer communication

• Final recap & Q&A