API116- API 577: Supplemental Inspection Certification Program

Introduction

This course is designed to provide participants with a detailed and up-to-date overview of Welding Inspection and Metallurgy in accordance with the API 577 Standard. It covers the welding process for SMAW, GTAW, GMAW, FCAW, SAW, SW, PAW and EGW; the welding materials, P-number assignment and F-number assignment; the AWS classification, filler metal selection, consumable storage and handling; the welding procedure specification (WPS), procedure qualification record (PQR) and tube-to-tube sheet welding procedures; and the welding qualification including expiration, revocation and renewal. During this interactive course, participants will learn the welding general requirements of ASME BPVC IX; the welding procedure qualifications and welding performance qualifications; the welding data and standard welding procedure specifications (SWPSs); the nondestructive examination and welding inspection; the metallurgy and refinery and petrochemical plant welding issues; and the safety precautions and annexes of API 577.

Objectives

Upon the successful completion of this course, participants will be able to:-

• Get prepared for the next API 577 exam and have enough knowledge and skills to pass such exam in order to get the API 577 Inspector certificate
• Apply welding process for SMAW, GTAW, GMAW, FCAW, SAW, SW, PAW and EGW
• Identify welding materials including P-number assignment and F-number assignment
• Carryout AWS classification, filler metal selection, consumable storage and handling
• Employ welding procedure specification (WPS), procedure qualification record (PQR) and tube-to-tubesheet welding procedures
• Recognize welding qualification including expiration, revocation and renewal
• Discuss the welding general requirements of ASME BPVC IX as well as apply welding procedure qualifications and welding performance qualifications • Review welding data and standard welding procedure specifications (SWPSs)
• Apply nondestructive examination and welding inspection and discuss metallurgy and refinery and petrochemical plant welding issues
• Explain the safety precautions and annexes of API 577 covering technology and symbols, actions to address improperly made production welds, WPS/PQR review, etc.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This program will be highly beneficial for welding Engineers, Mechanical Supervisors, Foreman, Shop Inspectors, QA/ QC personnel, and inspection agencies including third party Inspection agencies. Welders, welding supervisors, inspectors, and NDE examiners who are seeking an understanding of welding technology and welding inspection will find the program useful. It will help the API 577 Certification exam candidates to score very well.

Course Outline

Introduction

• Welding terms and definitions
• Important points to be noted prior, during, and after welding
• Non-conformances and defects

Welding processes

• Shielded Metal Arc Welding (SMAW), Gas Tungsten Arc
• Welding (GTAW), Gas Metal Arc Welding (GMAW)
•  Flux Cored Arc Welding (FCAW), Submerged Arc Welding (SAW)

Welding procedures

• Welding Procedure Specification (WPS), Procedure
• Qualification Record (PQR), Review of WPS and PQR
• Documents, Welder Performance Qualification (WPQ)

Base Metals and consumables

• P-number, F-number and A-numbers, AWS Classification of Filler Metals, Filler Metal Selection, Consumable
• Storage and Handling

Non-destructive examination

• Common weld discontinuities, Visual Examination (VT)
• Magnetic Particle Examination (MT), Alternating Current
• Field Measurement (ACFM), Liquid Penetrant Examination (PT), Eddy Current Inspection (ET), Radiographic
• Inspection (RT), Ultrasonic Inspection (UT), Hardness
• Testing, Pressure and Leak Testing (LT)

Welding metallurgy

• The Structure of Metals and Alloys, Physical Properties
• Mechanical Properties, Preheating, Effects of welding
• Heat on the metal  structure, Post-weld Heat Treatment
• Hardening Effects, HAZ, Weldability of Steels
• Carbon equivalent formula

Refinery and petrochemical plant welding issues

• Hot Tapping and In-service Welding
• Lack of Fusion with GMAW-S Welding Process
• Practice Quiz and feedback