API RP-577 Welding Process, Inspection and Metallurgy

What are the Goals?

In summary, this API RP-577 Welding Process, Inspection and Metallurgy training course empowers participants with the knowledge in:

• Welding techniques, welding positions, welding consumables, weld preparation
• Basics of welding metallurgy
• Various welding inspection, NDE methods, relative merits, demerits
• Various welding codes, specifications and standards
• Evaluation of welding procedure specifications and welder’s performance qualifications acc. to ASME IX
• Evaluate the preparation of test pieces for destructive tests and verify their compliance with applicable specifications
• Various parent materials and welding consumable (acc. to ASME codes)
• Reviewing NDT reports on welding work; ensuring that NDT personnel are properly qualified, and that certification is relevant and valid for the testing performed drawings and specifications, having understanding of weld symbols
• Each of the above contents are backed up with daily Mock-Up examinations and evaluations

Who is this Training Course for?

This API RP-577 Welding Process, Inspection and Metallurgy training course is suitable to a wide range of professionals but will greatly benefit:

• Welding Engineers
• Welding Inspectors
• Welding Supervisors
• A/Q.C personnel working in the process, oil, gas, pipeline, petrochemicals, chemicals, power industry
• Those involved in the design, procurement, engineering construction, operation, maintenance and inspection of welded components and related facilities

Daily Agenda

Day One: Introduction & Scope

• Scope
• Normative References
• Terms, Definitions, and Acronyms
• Terms and Definitions
• Acronyms

Welding Inspection

• General
• Tasks Prior to Welding
• Tasks during Welding Operations
• Tasks upon Completion of Welding
• Non-Conformances and Defects
• NDE Examiner Certification
• Safety Precautions

Day Two: Welding Processes 

• General
• Shielded Metal Arc Welding (SMAW)
• Gas Tungsten Arc Welding (GTAW)
• Gas Metal Arc Welding (GMAW)
• Flux Cored Arc Welding (FCAW)
• Submerged Arc Welding (SAW)
• Stud Arc Welding (SW)
• Plasma Arc Welding (PAW)
• Electro gas Welding (EGW)

Welding Procedure

• General
• Welding Procedure Specification (WPS)
• Procedure Qualification Record (PQR)
• Reviewing a WPS and PQR
• Tube-to-Tubesheet Welding Procedures

Welding Materials

• P-Number Assignment to Base Metals
• F-Number Assignment to Filler Metals
• AWS Classification of Filler Metals
• A-Number
• Filler Metal Selection
• Consumable Storage and Handling

Day Three: Welder Qualification

• Welder Performance Qualification (WPQ)
• Reviewing a Welder Performance Qualification (WPQ)

Non-destructive Examination

• Discontinuities
• Materials Identification
• Visual Examination (VT)
• Magnetic Particle Examination (MT)
• Alternating Current Field Measurement (ACFM)
• Liquid Penetrant Examination (PT)
• Eddy Current Examination (ET)
• Radiographic Examination (RT)
• Ultrasonic Examination (UT)
• Hardness Testing
• Pressure and Leak Testing (LT)
• Weld Inspection Data Recording

Day Four: Metallurgy 

• The Structure of Metals and Alloys
• Physical Properties
• Mechanical Properties
• Preheating
• Post weld Heat Treatment
• Hardening
• Material Test Reports
• Weldability of Metals
• Weldability of high-alloy Steels

Refinery and Petrochemical Plant Welding Issues

• Hot Tapping and In-Service Welding
• Lack of Fusion with GMAW-S Welding Process
• Caustic Service

Day Five: Explanations of Annexures to this RP

• Annex A, Terminology and Symbols
• Annex B, Actions to Address Improperly Made Production Welds
• Annex C, Welding Procedure Review
• Annex D, Guide to Common Filler Metal Selection
• Annex E, Example Report of RT Results
• API 577, Exam tips, mock up Exam
• Summary & Feedback