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MODULE 1.B.1 WELDING PROCESS FAMILIARISATIO FAMILIARISATION N

WELDING PROCESS FAMILIARITY Module Reference: Distance learning 1.B.1 To take the first steps in becoming familiar with the 4 Purpose of this common welding processes specified for ASME IX module qualification and the way they are covered in API 577 Suggested learning 4 hrs time API 577, API 570(3r Edition 2009), ASME B31.3, Documents needed ASME IX

Self-test papers included

3 x 10 questions

MODULE INTRODUCTION

This module is to ensure you can recognise the main welding processes that may be specified by the welding documentation requirements of ASME IX. The API exam will include questions in which you have to assess a Weld Procedure Specification (WPS) and its corresponding Procedure Qualification Record (PQR) As the codes used for API certification are all American you need to get into the habit of using American terminology for the welding processes and the process parameters. This module will also introduce you to the API RP 577 ‘Welding In spection and Metallurgy’ in your code document package. This document has only recently been added to the API examination syllabus. As a ‘Recommended Practice’ document, it contains technical descriptions and instruction, rather than truly prescriptive requirements.

WELDING PROCESSES

There are 4 main welding processes that you have to learn about: Shielded Metal Arc Welding (SMAW) Gas Tungsten Arc Welding (GTAW) Gas Metal Arc Welding (GMAW) Submerged Arc Welding (SAW) The process (es) which will form the basis of the WPS and PQR questions in the API exam will almost certainly be chosen from these. Revised Aug 2010 for Dev 2010 exams: exams : new 570 3 rd Edition

The sample WPS and PQR forms given in the non-mandatory Appendix B of ASME IX (the form layout is not strictly within the API 570 examination syllabus, but we will discuss it later) only contains the information for qualifying these processes. It is worth bearing in mind though that API 570 Appendix C states that weld repairs may (it does not say shall) be carried out using manual welding utilising the GMAW or SMAW processes. There is a contradiction here in that GMAW is a semi-automatic process but this is best interpreted to mean is that mechanised welding is not used for repairs. API 570 also says (Section 8.1.1) that …The principles of ASME B31.3 or the code to which the piping system was built shall be followed to the extent practical for in service repairs……’ ASME B31.3 however makes reference to procedures for shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW). It also refers to some welding with consumable inserts (‘bullets’), which again indicates the use of GTAW. It is therefore safe to conclude that the main welding repairs or alterations on in-service piping are carried out by SMAW, GTAW or GMAW.

WELDING PROCESSES: SUMMARY The main welding processes mentioned in the relevant codes are: API 570 – SMAW or GMAW ASME B31.3 – SMAW or GTAW SO: You need to be familiar with these welding processes and the control documentation that goes with them As previously mentioned, Submerged Arc Welding (SAW) is also referred to in the sample documentation given in ASME IX (non-mandatory Appendix B) so it is a good idea to familiarise yourself with this process also (see API 577 section 5.6) Note that two other processes; Flux Cored Arc Welding (FCAW) and Stud Arc Welding (SW) are mentioned in API 577.You need to know what they are (see API 577 sections 5.5 and 5.7) as the exam may include general questions on them. They are unlikely to form the subject of the API exam WPS/PQR assessment question(s) Revised Aug 2010 for Dev 2010 exams: new 570 3 rd Edition

Note: Do not confuse Submerged Arc Welding (SAW) with the Stud Arc Welding (SW) abbreviation.

FIRST STEP

Click here

Review this powerpoint presentation that explains how each welding process works and their advantages/disadvantages

Re-run the presentation as required, until you are happy with the similarities and differences between the processes.

NEXT STEP Review Section 5 of API 577 noting what it says about each of the welding processes. Take note of the process diagrams showing pictorial representation of the processes and their equipment. Read what FCAW (5.5) and SW (5.7) are but mainly for interest as they are unlikely to figure much in the exam. Then try these ten simple ‘starter’ questions on welding processes (click QS). Treat them as closedbook questions, but you should aim to get them all correct

Revised Aug 2010 for Dev 2010 exams: new 570 3 rd Edition

QS

WELDING PROCESSES

An important area the main welding processes is that of weld consumables. We can break these down into the following 3 main areas: Filler (wires, rods, flux coated electrodes) Flux (granular fluxes) Gas (shielding, trailing or backing)

There are always questions in the API examination about weld consumables

NEXT STEP CLICK HERE Review this powerpoint presentation showing the basic relationship between the main welding processes and their consumables

CONSUMABLES Once you are happy with what consumables relate to what process answer these 10 consumables questions Q1 based on the presentation slides (rather than referring to the codes CLICK HERE


FINALLY Re-read this module as often as you feel necessary, until you think you understand its content

Once you have done this, proceed to this (slightly more difficult) set of self-test questions Q2. Test yourself (closedbook) checking the answers from API 577 and repeating them until you get them all correct under closed-book conditions Q2


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