NEW BLENDED LEARNING PROGRAM (E-LEARNING AND IN-CLASS)
  or E-LEARNING BY THE WELDING GREEK INSTITUTE

Manufacturing Welding Engineer

The Market Needs - Purpose of Education:

The Welding Related Personnel are staff which is responsible for coordinating, monitoring, supervising, inspecting and performing welding activities.
The categories are as follow:

  • Welding Coordination Personnel
  • Welding Inspection Personnel
  • Welders

The international framework for the certification of persons allows Welding Inspectors to be certified according to the requirements of standard ISO 14731. Also one of the keys to the certification of construction companies / organizations in accordance with ISO 3834, which is the adoption of the Welding Coordinators. Finally and in accordance with standards EN 1090-2 and ISO 3834-2: 2005 § 7 regarding the Welding Personnel, the manufacturer should have necessary and sufficient staff to design, planning, execution and supervision of production at welding activities.

Access conditions:

  • Relevant Diploma from Highest Educational Institution
  • Planning and control of records
  • Codes and standards – Interpretation and use
  • Safety in inspection
  • Confirmation of parent material identity
  • Welding processes review
  • Consideration of the method of qualification of welding procedures
  • Consideration of the range of qualification of welding procedure specifications
  • Confirmation of consumables identity
  • Verification of the compliance, availability and application in production of approved Welding Procedure Specifications.
  • Verification of Welding Personnel Qualification compliance, availability, application in production, and validity
  • Verification that preheating is applied in accordance with specified procedures
  • Visual Techniques and measurement before welding to verify dimensions, fit-up, and weld preparations are in accordance with engineering drawings.
  • In-process welding surveillance to verify compliance with specified Welding Procedure Specifications
  • Post weld Visual Techniques and measurement of completed welds against specification and engineering drawing requirements
  • Verification of the compliance and completion of destructive testing where required
  • Verification of the completion and compliance of Non-destructive Testing
  • Defect identification, acceptance/rejection and cause investigation
  • Verification of compliance of documentation (ITPs, procedures, reports)
  • Verification and compliance of engineering drawings and weld symbols
  • Supervision of Certified Welding Inspectors, Certified Senior Welding Inspectors and Trainees
  • Verification that heat treatment procedures and records are in accordance with specification requirements
  • Verification and final acceptance of Certification of Compliance
  • Preparation and approval of Inspection Reports
  • Preparation and approval of Welding Procedure Specifications
  • Preparation of and approval of Welding Personnel Qualifications
  • Design and implementation of quality assurance programmes
  • Welding consumables: Compatibility, Identity verification, Delivery conditions, storage and handling of welding consumables, purchasing specifications review
  • Suitability and validity of welders' and welding operators' qualification certificates
  • Review of necessary measures and actions with respect to non-conformance and corrective actions
  • Consideration of quality records, including the preparation and maintenance of the necessary records
  • Identification of:  production plans, routing cards, weld locations in construction, non-destructive testing procedures and personnel, traceability of parent material (e.g. type, cast number)
  • Traceability for: fully mechanized and automatic welding units to specific welds, welder and welding operators to specific welds, welding procedure specifications to specific welds.
  • Qualification of the welding procedures Specifications
  • Document Reviews of the method and range of qualification, specifications and laboratory testing shall be considered.
  • Welding consumables
  • Identification of production and/or expiring dates
  • The storage and handling of welding consumables status
  • Identification and traceability
    • The identification of weld locations in construction
    • The identification of non-destructive testing procedures and personnel
    • Traceability of welder and welding operators to specific welds
    • Traceability of welding procedure specifications to specific welds.
  • Inspection and testing during welding
  • Review of suitability and validity of welders' and welding operators' qualification certificates
  • Joint preparation overview (dimensions control, shape conditions)
  • Overview of suitability of working conditions for welding, including the environment.
  • Visual inspection (for completeness of welding, weld dimensions, shape)
  • Review of non-destructive testing methods
  • Review of destructive testing methods
  • Quality Records completion of all activities required by specifications
  • Non-conformance and corrective actions after welding
  • Regarding to non-conformance and corrective actions, the necessary measures and actions (e.g. weld repairs, re-assessment of repaired welds, corrective actions) shall be considered.

The education structure:

The Welding Greek Institute (WGI) offers an innovative and specialized short-term training program, recognized and accredited by major Welding Institutes and accepted by the international market, the Manufacturing Welding Engineer.

The program will be implemented in blended learning (e-learning and in-class) or exclusively on e-learning.

The duration is 8 weeks

Teaching is divided into three (3) modules:

1.1 Quality Management Systems
1.2 Welding Technology
1.3 QC Welding Coordinator

2.1 General Introduction to Welding Inspection
2.2 Testing
2.3 Weld imperfections
2.4 Testing methods
2.5 Quality Assurance
2.6  Management of inspection function

3.1 Basic theory of structural systems
3.2 Fundamentals of the strength of materials
3.3 Joint design for Welding and Brazing
3.4 Basics of weld design
3.5 Behaviour of welded structures under different types of loading
3.6 Design of welded structures with predominantly static loading
3.7 Behaviour of welded structures under cyclic loading
3.8 Design of cyclic loaded welded structures
3.9 Design of welded pressure equipment

 

  1. QA/QC Welding Coordinator

The first chapter is titled: Quality Management Systems, entirely implemented in E-Learning platform of the Welding Greek Institute, and includes a comprehensive approach to Quality Assurance, Quality Management, Quality Control, Inspection quality system, ISO 9000 , documentation of a quality system and internal control.

The second chapter entitled Welding Technology, also implemented entirely in E-Learning platform of the Greek Institute of Welding, and includes an introduction on welding, metallurgy, materials welding, to destructive and non-destructive inspections.

The third chapter entitled: QC Welding Coordination, implemented entirely in Class and includes the introduction and analysis of an Inspection Test Plan (ITP) and a Quality Control System applied to metal construction processes. Analysis of international standards and a high quality Reference Book with all the documentation you need to know as a qualified QA / QC Welding Coordinator in construction companies for steel structures.

 

  2. Inspection & NDT

Chapter 1: General Introduction to Welding Inspection: (scope of activity, terms and definitions)

  • Common Inspection and NDT terms
  • Reference standards for terminology
  • IIW collections of terms

Chapter 2: Testing (Mechanical tests on welded joints)

Objectives in relation to welder and procedure qualification, and to service performance

Test welds; sources of test pieces

Material certificates: essential features and data

Chapter 3: Weld imperfections (Types and evaluation of imperfections)

  • Review of weld imperfections, their cause and characteristics, in particular
  1. Porosity and cavities
  2. Imperfect and profile shape
  3. Arc strikes
  4. Cracks
  5. Inclusions
  6. Lack of fusion
  7. Lack of penetration
  8. Lamellar tearing
  9. Overlap
  10. Poor surface condition
  11. Seams and laminations
  12. Spatter
  13. Undercut
  14. Classification (EN-ISO 6520)
  15. Others
  • Features of weld imperfections:
  1. volumetric form
  2. nature of surface
  3. size
  4. location
  5. orientation
  6. Significance of defects in relation to service performance
  7. Compliance with specifications
  8. Acceptance/rejection criteria


 

Chapter 4: Testing methods (VT, UT, RT, reporting etc.)

  • Role of visual and non-destructive testing methods
  • Application ranges of available methods
  • Visual Inspection
  1. Inspection tools
  2. Checking before welding
  3. Inspection during welding
  4. Testing (see EN 473 or ISO 9712) after welding
  5. Reporting results: visual testing report
  • Liquid penetrant testing
  1. Principles
  2. Technique
  3. Interpretation
  4. Application
  5. Standards
  6. Personnel competence
  • Magnetic particle testing
  1. Principles
  2. Technique
  3. Interpretation
  4. Application
  5. Standards
  6. Personnel competence
  • Radiographic testing
  1. Principles
  2. Techniques
  3. Interpretation
  4. Specialised radiographic facilities:
  5. Legislation and standards
  6. Personnel competence
  • Ultrasonic testing
  1. Principles
  2. Equipment:
  3. Thickness testing
  4. Preparation for manual testing
  5. Imperfections location
  6. Nature and size of reflectors
  7. The ultrasonic test report
  8. Interpretation
  9. Mechanised systems
  10. Scan system
  11. Standards
  12. Personnel competency

  • Eddy current testing:
  1. Principles; induction into component of eddy currents by ac magnetic field;
  2. equipment; test coil; presentation of test results
  3. Influence of materials, thickness, component geometry
  4. Interpretation of results
  5. Personnel competence
  • Leak testing:
  1. Principles and methods; vacuum box; tracer gases; instrumentation detection of leak source
  • Strain gauges:
  1. Types of gauge; application; instrumentation
  2. Interpretation of results
  • Critical review of selection of NDT methods
  • NDT methods versus:
  1. Cost, operator competence
  2. Surface-sub/surface detection
  3. Type of imperfection detected
  4. Imperfection measurement achieved
  5. Reliability of detection
  6. Limitations of materials, component size and geometry
  7. Accuracy, validity of information or data obtained
  • Logical route to selection
  • Other test methods
  1. Pressure test
  2. Component pressurization; equipment and instrumentation; proof testing X
  3. Dimensional tests:
  4. Size, tolerances; measuring instruments and devices
  • Reporting
  1. Preparation of inspection and test reports;
  2. Essential information and data; standard forms
  3. Procedure for report assessment
  4. Essential records and their maintenance


 

Chapter 5: Quality Assurance (Principles and levels)

  • Level of QA required versus product specification
  • Risk and consequences of failure
  • Product liability
  • Role of quality control and inspection in QA
  • Implementation of standards in a fabrication environment

Chapter 6: Management of inspection function

  • Management of inspection function
  • Responsibilities; organisation; personnel; personnel management discipline; motivation of subordinates; staff development; planning and scheduling of key activities records and record keeping

  3. Design of Welded Structures

3.1 Basic theory of structural systems:

  • Structural elements (cables, bars, beams, plates, slabs, shells)
  • Theory of forces
  • Combination and resolution of forces
  • Equilibrium of forces and torques
  • Bearings, constraints and basic types of connections
  • Equilibrium of structural systems
  • Statically determinate and indeterminate systems
  • Stress in structural systems resulting from external actions
  • Relationship between external loads and internal forces
  • Calculation and determination of the internal forces and moments of simple
  • statically determinate systems

3.2 Fundamentals of the strength of materials:

  • Types of stresses (normal stress, shear stress)
  • Types of deformation (axial strain, shear strain)
  • Stress-strain relationship, yielding theories
  • Elastic and plastic deformation
  • Young’s modulus, shear modulus, transverse contraction coefficient
  • Characteristic material properties
  • Different stresses resulting from internal forces and moments
  • Different types of section properties
  • Cross section variables
  • Calculation of stresses
  • Limit states of failures: ductile, brittle, fatigue, creep.

3.3 Joint design for Welding and Brazing:

  • Introduction (importance of welding joint design and groove shapes, influence on welding stresses and distortion)
  • Types of welded/brazed joints (ISO 9692, CEN, national)
  • Importance of weld joint design and groove shapes, types of welded  joints, design of welded joints
  • Classification of groove shapes (by material type, thickness, welding process, accessibility)
  • Tolerance requirements (ISO 13920)
  • Welding symbols on drawings, symbols for groove shapes
  • Symbolic representation of welded, brazed and soldered joints according to ISO 2553
  • National Standards

3.4 Basics of weld design:

  • Types of stresses in welded joints (nominal stress, hot spot stress, notch stress)
  • Stresses in butt welds, stresses in fillet welds
  • Calculation of cross section variables of welded joints
  • Determination of nominal stresses in single welded joints
  • Determination of reference values of stresses due to multi-axial stressing.
  • Determination of design resistance of arc-welded and resistance-welded joints
  • Worked examples of calculation of nominal stresses in welded joints
  • Principal stresses, nominal/normal stress, shear stress, Mohr circle
  • Stress concentration, factor-k, SCF elastic, strain concentration factor
  • Constraint factor. Stress calculation by finite elements method. Experimental elasticity: strain gauges, photo elasticity, method Moiré, holography

3.5 Behaviour of welded structures under different types of loading:

  • Static strength
  • Elevated temperature strength
  • Low-temperature strength
  • Creep resistance
  • Impact behaviour
  • Influence of notches and weld defects
  • Types of fracture (ductile fracture, fatigue fracture, brittle fracture, lamellar tearing)
  • Selection of steel quality groups, Z-quality
  • Typical data for common steels
  • Use of standards and specifications
  • Collecting and processing experimental stress/strain data

3.6 Design of welded structures with predominantly static loading:

  • Steel constructions including lightweight structures
  • Structural details
  • Use of different types of welds related to joint types
  • Use of standards and specifications
  • Worked examples

3.7 Behaviour of welded structures under cyclic loading:

  • Types and variables of cyclic loading
  • Statistical stress analysis on real structures
  • S-N diagram
  • Stress collective
  • Fatigue strength (low cycle, and others)
  • Effect of mean stress including residual stresses
  • Effect of stress range
  • Stress distribution
  • Influence of notches
  • Influence of weld imperfections
  • Fatigue improvement technique
  • Standards ISO, CEN and National
  • Palmgren-Miner rule
  • Classification of weld joints

3.8 Design of cyclic loaded welded structures:

  • Range of application: bridges, cranes, machines, ships and offshore constructions, chimneys, towers and masts, vehicles
  • Acceptance criteria
  • Dimensioning according to different standards and specifications
  • Worked examples
  • Calculation methods

3.9 Design of welded pressure equipment:

  • Construction of boilers, pressure vessels, pipelines,
  • Calculation (formulae) of the welds
  • High and low temperatures applications
  • Details of design (flanges, nozzles, shells, compensating plates etc.)
  • Use of laws and design rules, standards and specifications
  • Worked examples of construction and design
  • Standards (ISO, CEN and National)


 

The instructors of the program are Phd Engineers, industry executives, Welding Inspectors and Engineers with extensive experience. who have the appropriate background to teach such a specialized and demanding course.

At the end of each module takes place two hour e-examination.
Total e-exams: 3

  Training syllabus:

1st week - E-Learning
Quality Management Systems
Day 1: Quality Management Principles, Processes, Effectivenes and Efficiency.
Day 2: ISO 9001 analysis and implementation requirements.
Day 3: Structure of a Quality Management System, Documentation
Day 4: Auditing (Internal & External)
Day 5:  Quality Framework, European Directives, CE marking, Accreditation System, Notification.

2nd week - E-Learning
Welding Technology
Day 1: Welding Processes & Equipment
Day 2: Welding Metallurgy
Day 3: Inspection & NDT Methods
Day 4: Design & Construction
Day 5:  Management Systems implementation principles (ISO 3834 & 9001)

3rd week - Class Room or E-learning
QC Welding Coordination
Day 1: Quality Control in Welding Fabrication, Construction, Repair and Maintenance
Day 2: Inspection Test Plans
Day 3: Establish, implement and manage a documentation package
Day 4: Documentation Package & Elements
Day 5: Compliance with specific codes

4th week - E-Learning
Inspection & NDT
Day 1: General Introduction to Welding Inspection:
Day 2: Testing
Day 3: Weld imperfections
Day 4: Testing methods
Day 5: Visual Inspection

5th week - E-Learning
Inspection & NDT
Day 1: Liquid penetrant testing
Day 2: Magnetic particle testing
Day 3: Radiographic testing
Day 4: Ultrasonic testing
Day 5: Eddy current testing

6th week - E-Learning
Inspection & NDT
Day 1: Leak testing
Day 2: Other test methods
Day 3: Selection of NDT methods
Day 4: Quality Assurance
Day 5: Management of inspection function

7th week - E-Learning
Design of Welded Structures
Day 1: Basic theory of structural systems
Day 2: Fundamentals of the strength of materials
Day 3: Joint design for Welding and Brazing
Day 4: Basics of weld design
Day 5: Behaviour of welded structures under different types of loading

8th week - E-Learning
Design of Welded Structures
Day 1: Design of welded structures with predominantly static loading
Day 2: Behaviour of welded structures under cyclic loading
Day 3: Design of cyclic loaded welded structures
Day 4: Design of welded pressure equipment
Day 5: Revision in Welding Design

  E-Exams (online) - Certification WSTAR

After passing the examination, candidates will be recognized as Qualified Manufacturing Welding Engineer, absolutely fulfilling the requirements of the standards as stated in the purpose of education.

After 3 years work experience in connection with the subject or an existing service, the Qualified Manufacturing Welding Engineer will have the opportunity be certified and participate in the Registry of the Welding Greek Institute for Certified Welding Coordinators with international recognition through Accreditation ISO 17024.