Training and approval of welders - best practice in action

Section 2. Information, explanation and practical guidance

• Introduction
• Training objectives and typical syllabus
• The welder approval certificate
• Routes for training and qualification of welders
• Training programmes
• Practical training modules
• Further skills development
• How to get more information

Introduction

This best practice guide looks at the key issues and main concepts central to the design and implementation of training and approval-test programmes for welders. Based on TWI's established programmes, it demonstrates best practice principles in the planning and structuring of welder training.

More information on TWI programmes: Practical welder training and approval to recognised standards

Training objectives and typical syllabus

Key steps to success

TWI has around 30 welder Training programmes . Each programme - which consists of a particular group of training modules - has built-in flexibility which allows it to be readily adapted to meet the specific requirements of individual clients.

Before looking at the objectives of a training module and at a typical syllabus, it's helpful to have an overview of the main stages which make up a TWI welder training and approval programme:

• establish client needs and training objectives
• design training programme utilising appropriate modules
• recommend and agree on an appropriate welder training and approval regime
• conduct initial skills assessment to identify individuals' abilities against agreed training regime and objectives

(It is assumed that a pre-requisite will require individuals to demonstrate an acceptable degree of physical dexterity together with evidence of a recent satisfactory eyesight test)

• deliver and supervise theoretical and practical welder training programme to coincide with basic, intermediate and advance level welder skills and welder approval tests, as appropriate
• implement simulated welder approval tests to monitor individuals' practical progress and to identify/rectify any technique weaknesses
• meet client's objectives within an acceptable welder training and approval test programme duration
• investigate, rectify problem and retest when a welder approval test is rejected
• issue Welder Approval Certification authenticated by TWI

Objectives of training modules

Currently, there are about 10 discrete training modules to cover the full range of different applications. Although each module covers certain practical exercises, broadly, the object of all modules is to:

• provide attendees with appropriate knowledge to enable them to carry out welding and/or thermal cutting and/or gouging tasks in a safe and efficient manner
• provide flexibility against a broad range of practical welding exercises that may be selected as training objectives to accommodate individuals' varying skill levels
• enable the attendee to -
  
  
  • gain valuable experience across a progressive range of practical exercises exclusive to a particular welding process (or a combination of more than one welding process) representative of general welding activities, and those activities unique to specific industry sectors
    
    
  • become competent and confident to undertake welding activities within their ultimate, relevant Scope of Welder Approval
    
    
  • initially attain a Basic Level Welder Certificate authenticated by TWI
    
    
  • attain an Intermediate Level and ultimately progress to, or directly obtain, Advance Level Welder Approval Certificate authenticated by TWI
    
    
  • progress ultimately to TWI Certified Quality Welder (CQW)

Syllabus

A well-planned training syllabus absorbs all directly relevant, related subjects and ensures coverage at a depth which allows the welder to gain the necessary know-how and skills to be competent and confident in the workplace. A typical TWI training syllabus encompasses:

• welding-related health & safety issues
• welding-related terminology
• welding/cutting process equipment and fundamentals
• process advantages and limitations
• setting up and auditing equipment
• process operation problems and rectification
• identification, storage and handling of welding consumables
• shielding gas types, advantages and limitations
• process welding/cutting techniques
• process-related defects, their identification, cause and avoidance
• quality issues and conformance; weld procedures and welder approval
• control of distortion
• definition of weld symbols to BSEN 22553: 1995/ISO 2553: 1992 standard
• knowledge of internationally recognised welding approval standards
• welding considerations for materials (as appropriate)
• visual inspection of welds
• end of session, multi-choice technical questionnaire
• demonstration of practical competence

The welder approval certificate

Typical welder approval identity card and documentation, authenticated and issued by TWI Certification Ltd, is shown below. This is issued after successful completion of appropriate welder approval tests, conducted during the training programme. The corresponding practical training report is also shown.

The training report shows the four exercises - in order of increasing difficulty - within the training module applied. It also details joint configuration and welding position, as well as what the welder was tested on and where the welder was successful.

Together, these two documents provide evidence of completed training and successful approval tests undertaken by the welder.

Routes for training and qualification of welders

The following flowchart starts with an initial skill assessment. This is an essential stage in the design and implementation of a TWI welder training and approval test programme. At this point, the goal is to determine objectively an individual's existing ability and compare this with the training regime and objectives agreed with the client.

Regarding the Selected Programme and Modules boxes, the welding process, type of material, joint configuration/dimensions, welding positions and approval test details are matched to the training programme objectives. Also, the duration of the training programme is governed by the individual's start standard, measured during the initial skills assessment.

Training programmes

The following tables show the current range of training programmes available from TWI's Welder Training Centre. Programmes are grouped in the following way (programme No. in brackets):

• Welding of
  

  - C/Mn and low alloy steels (1 - 8)
  - austenitic stainless steel (9 - 14)
  - aluminium and its alloys (15, 16)

  
  
• Submerged arc welding of
  

  - C/Mn, low alloy and austenitic stainless steels (17)
  

  
  
• Civil Aviation Authority (CAA) BCAR sub-section A8-10 (18)

  - material type optional

  
  
• Oxy-acetylene gas process for C/Mn and low alloy steels

  - fusion welding (19)
  - braze welding (20)

  
  
• Oxy-acetylene gas process for brazing

  - copper (21)
  - aluminium and its alloys (22)

  
  
• Cutting/gouging processes for steel

  - oxy-fuel gas cutting (23)
  - air-arc cutting and gouging (24)
  - plasma cutting and gouging (25)

  
  
• Further skills development

  - certification in visual inspection of welds (26)
  - quality awareness for welders (27)

Each programme contains several modules, e.g. 1A, 1B, 2, 3 - as indicated in the tables. The scope of each module is shown in the next section of this guide.

Although every programme has been optimised to meet typical, average requirements, each can easily be adapted by, for example, changing the mix of modules in order to satisfy any very specific needs a client may have.

Welder Training Centre Welding process versus training modules exclusive to C/Mn & low alloy steels Programme No.1 Programme No.2 Programme No.3 Programme No.4 Programme No.5 Programme No.6 Programme No.7 Programme No.8 MMA MAG FCAW (gas shielded) MMA root & FCAW fill FCAW (self shielded) TIG TIG root & MMA fill Oxy-acetylene gas 1A 1A 1A - 1A 1A - 1A 1B 1B 1B - 1B 1B - - 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 4 - 4 4 4 - - - Welding process versus training modules exclusive to austenitic stainless steel and similar Programme No.9 Programme No.10 Programme No.11 Programme No.12 Programme No.13 Programme No.14 TIG MAG MMA FCAW MMA root & FCAW fill TIG root & MMA fill 1A 1A 1A 1A - - 1B 1B 1B 1B - - 2 2 2 2 2 2 3 - 3 - - 3 Welding process versus training modules exclusive to aluminium and aluminium alloys Programme No.15 Programme No.16 TIG MIG 1A 1A 1B 1B 2 2 3 - Copyright © 2002, TWI Ltd

Welder Training Centre Submerged arc welding process - C/Mn, low alloy & austenitic stainless steel Programme No.17 Selected exercises from relevant modules Civil Aviation Authority (CAA) BCAR Sub-section A8-10 Programme No.18 Note: Welding process optional, however, usually TIG. Materials and figure adopted to accommodate industry requirement 5 Oxy-acetylene gas welding process training modules Programme No.19 Programme No.20 Fusion welding C/Mn & low alloy steels Braze welding C/Mn & low alloy steels 1A 6A 2 6B 3 - Oxy-acetylene gas process training modules Programme No.21 Programme No.22 Brazing copper Brazing aluminium and aluminium alloys 6A 6A 6B 6B Oxy-fuel gas cutting process training modules for steel Programme No.23 7A 7B Copyright © 2002, TWI Ltd

Welder Training Centre Air arc cutting & gouging for steel Programme No.24 8 Plasma cutting & gouging for steel Programme No.25 9 Optional further skills development Programme No.26 TWI's standard WIS1 course CSWIP 3.0 Visual Welding Inspection - Training & Examination Package Note: Successful completion of programme 26 for welders who hold current approvals will provide the necessary elements for those seeking certified quality welder status Copyright © 2002, TWI Ltd

Practical training modules

As mentioned previously, each training programme contains a particular set of modules. The following training report sheets are included to show the various practical exercises within each module.

Further skills development

TWI offers additional training for welders which goes beyond that covered in the modules previously described. There are two courses:

• Certification in visual inspection of welds - for welders, operators, line inspectors and foremen
  
  
• Quality awareness for welders - for craftsmen welders who hold approvals to either ASME IX, BS EN 287, CAA BCAR A8-10 or BS 4872

Both courses are summarised below:

CSWIP 3.0 Visual Welding Inspection - Training & Examination Package WIS1 Course content Visual inspection procedures; relevant codes of practice, terms and definitions; welding processes and typical welding defects; weld measurements; typical documentation and requirements; practical inspection and reporting; end of course assessment for TWI's Certificate of Competence. Suitable for Welders, operators, line inspectors and foremen who undertake visual examination of welded joints; quality control staff associated with welding; all staff who need basic training in welding inspection coupled with a qualification in this field. Objectives identify various weld imperfections (defects) understand the relevant welding technology related to visual inspection understand the need for documentation in welding be aware of codes and standards related to inspection requirements carry out inspection of parent materials and consumables carry out visual inspection of welds, report on them and assess their compliance with specified acceptance levels Successful completion of this course and the end-of-course assessment leads to award of TWI's Certificate of Competence in Visual Inspection of Welds. In addition, candidates are also able to enrol for CSWIP 3.0 Visual Welding Inspector.

Apart from the above two courses, TWI provides a large range of training programmes for welding personnel seeking to broaden their skills and know-how - for example:

Courses on welding engineering

Courses on non-destructive testing

How to get more information

TWI has invaluable experience in the design and successful delivery of wide-ranging welder training and approval test programmes throughout the UK, Europe, India, Asia, the USA, the Middle-East and the Far-East.

In its role of improving the skill and competence of welders, TWI's Welder Training Centre serves many industrial sectors and runs courses at its Abington headquarters, at Middlesbrough (TWI North) and at the client's facilities.

If you would like further information on any aspect of welder training and approval, or weld procedure development and approval, please contact:

Colin Eileens
Programme Manager
Welder Training
TWI Ltd
Granta Park
Great Abington
Cambridge CB21 6AL (previously CB1 6AL), UK

Tel: +44 (0) 1223 899000
Fax: +44 (0) 1223 891630
E-mail: colin.eileens@twi.co.uk

Copyright © 2005 TWI Ltd