KNEC Oriented Welding Inspector Courses

CHAPTER 01- INTRODUCTION

Welding and Its requirements

CHAPTER 02- DUTIES AND RESPONSIBILITIES

a)Main responsibilities (code compliance, workmanship control, documentation control)
b) Personal attributes (honesty, integrity, knowledge, good communicator, physical fitness, good eye sight)
c)Welding inspection (before ,during, after welding)
d)Welding inspectors equipments
e)Summary of duties (observe, record, compare)

CHAPTER 03- WELD TERMINOLOGY

a)What is weld and types of welds (butt weld, fillet weld, spot weld, edge weld, plug weld, compound weld)
b) Joint and types of joint (edge, lap, open and closed corner, tee, butt, cruciform)
c) Weld zone terminology
d) Joint design (bevel angle, included angle, root face, root gap) and weld preparation (single Vee, double Vee, single J, double J etc.)
e) Welding positions (1G, 2G, 3G, 4G, 6G, 1F, 2F, 3F, 4F etc.)

CHAPTER 04- WELDING IMPERFECTIONS

a)Cracks
b)Lamellar tearing
c)Gas cavities
d)Crater pipe
e)Solid inclusion
f)Lack of fusion
g)Weld root imperfections
h)Undercut
i)Surface and profile
j)Overlap
k) Set up irregularities l)Incomplete groove
m)Oxide root
n)Miscellaneous imperfections
o)Mechanical damage

CHAPTER 05- DESTRUCTIVE TESTING

a)Quantitative tests (tensile test, hardness test, charpy v notch impact test)
b) Qualitative tests (bent tests, macro tests, fillet fracture, nick-break tests)
c)Welding procedure qualification testing

CHAPTER 06- WELDING PROCEDURE QUALIFICATION

a)What is the test trying to show
b)Essential variable and Non essential variable
c) Additional variable
d) Preliminary welding procedure specification(PWPS)
e) Welding procedure approval record (WPAR)
f) Welding procedure specification (WPS)
g) Welder qualification

CHAPTER 07- MATERIAL INSPECTION , CODES AND STANDARDS

a)Pipe inspection (corrosion , damage, wall thickness ovality, lamination and seams)
b) Plate inspection (corrosion, mechanical damage, laps, bands and lamination)
c)Parent material imperfections
d)Difference between standard and code

CHAPTER 08- WELDING SYMBOL

a)advantage and disadvantage of symbolic representation
b) symbolic representation
c) elementary symbol
f)BS EN 22553 symbols
g)AWS welding symbols

CHAPTER 09- INTRODUCTION TO WELDING PROCESS AND CONSUMABLES

a) Classifications of welding m/c by principles (welding transformers, welding rectifiers, welding generators, alternator, inverter technology)
b) butt welding
c) fillet welding
d) welding process (SMAW AND TIG) C) Welding consumables (covered electrodes, filler wires and electrode wires, shielding gases, separately supplied fluxes, fusible

CHAPTER 10-WELD REPAIRES

a)Production repairs and in-service repairs
b)Authorization and procedure for repair
c) Removal of material and preparation for repair
d)Monitoring of repair weld
e)Testing of repair-visual and NDT
f) Weld repair and related problems

CHAPTER 11-RESIDUAL STRESS AND DISTORTION

a)Stresses (normal stress, shear stress, hoop stress)
b)Residual stress ( along the weld, through the weld, across the weld)
c) Types of distortion (angular distortion, transverse distortion, bowing distortion, longitudinal distortion)
d)distortion prevention methods
e)distortion corrective techniques

CHAPTER 12-HEAT TREATMENT

a)Why?
b) How?
c) Types of heat treatment (preheat, annealing, normalising, quench hardening, temper, stress relief)

CHAPTER 13-FOUR FACTORS AND WELD ABILITY

a)fusion
b)atmospheric protection
c)surface protection
d)adequate properties
e) steel alloying elements
f)classification of steels
g)carbon equivalent formula
h) heat input
i) weld decay

CHAPTER 14-NON DESTRUCTIVE TESTING

a) visual testing
b)magnetic particle testing
c)ultrasonic testing
d)radiographic testing
e)dye Penetrant testing
f)radiographic film inter pretation