Welding and Weld Repairs on Pressure Retaining Carbon Steel Materials

This 2.5 day series of presentations will focus on materials, weldability and welding consumables with respect to the fabrication of carbon steel materials. It will illustrate the concepts of hardenability and cooling rate during welding and the direct effect this can have on HICC (Hydrogen Induced Cold Cracking) in regular and sour service. The defects produced by particular welding processes will be illustrated together with repair approaches, temper beads and the influence of relevant fabrication codes.

The mysteries of a PQR vs. a WPS will be explained, NDE techniques discussed and finally an ECA (Engineering Critical Assessment) will be illustrated where, defect size, NDE evaluation techniques and material properties culminated in predicting vessel failure.

Prerequisites & Requirements: Education/ certification: There are no prerequisites qualifications for this course.

Safety: No safety equipment is required for this course.

Personal Study Material: Not required

Student Recognition: Upon completion of the course all students will receive a Certificate of Attendance. This course qualifies for .5 CEUs where applicable.

Key Topics in this course:

Section 1 Welding Process

  • Shielded Metal Arc Welding (SMAW)
  • Power Sources and equipment used in the Field (SMAW). DC and AC.
  • Flux Cored Arc Welding- Self Shielded (FCAW)
  • Power Sources and equipment for Semi Automatic Welding processes.
  • Awareness of other welding processes that could be used in the field

Section 2 Materials

  • Steel
  • Influence of Carbon and other Alloying materials
  • Hardenability
  • Influence of Welding Parameters on Hardenability
  • Post weld heat treatment PWHT. (e.g. Softening by tempering)

Section 2a Materials For pipe and pressure vessel.

Section 3 Consumables

  • General SMAW
  • SMAW Classification (CSA-AWS)
  • Why Low-Hydrogen
  • How to control Low-Hydrogen
  • General FCAW Self Shielded
  • FCAW Classification (CSA-AWS)
  • Controlled Hydrogen FCAW

Section 4 Welding Discontinuities Latent to Field welding Processes

  • Type
  • Defects produced by particular welding processes

Section 4a HICC

Section 4b Sour Service and Temper Bead

Section 5. Codes/Standards

  • What standards
  • What standards require
  • Procedure vs.Welder

5a Z662 Repairs, Pressure Test

5b Qualification of welding procedures (PQR/WPS/Welders)

  • What is a PQR and WPS
  • How to qualify
  • How to apply in the field

Section 6 NDE and Qualification of Inspection Personnel

  • Brief background of requirements.
  • Brief background of NDE type, use, advantages and disadvantages

Section 7 General Welding Repair Approach

  • Workmanship
  • Cleanliness
  • Application of knowledge at repair site. Bake out and Sour Gas.
  • Pre and post weld heat treatment and its application
  • Interpass temperatures
  • Grinding versus gouging
  • Effects of ambient temperature

Section 8 Examples of Weld Repair

  • Plus ECA

Upcoming Classes

There are no upcoming classes scheduled for this course. Please contact us to find out about when this course may be offered next.