TWI Training and Examination Services - Power Plant Maintenance
Welding Inspection and Quality Control
The courses and examinations are aimed at general maintenance and cover thermal, hydro and CCGT plants.
CSWIP 3.0 Visual Welding Inspector WIS1
Duration
2 day course, ½ day exam
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.
CSWIP 3.1 Welding Inspector WIS5
Duration
4½ day course, ½ day exam
The duties and responsibilities of a welding inspector; fusion welding processes; typical weld defects; types of steel; carbon-manganese, low alloy and stainless steels; hardening of steels; weldability; heat treatment; parent metal defects; visual inspection; testing parent metals and welds; destructive tests; NDT techniques; welder and procedure approval; codes and standards; outline of safe working practices; practice in examination questions; continuous and end-of-course assessment.
CSWIP 3.2 Senior Welding Inspector WIS10
Duration
4½ day course, ½ day exam
Function and responsibilities of a senior welding inspector; defects in welds; weld symbol interpretation; interpretation of NDT reports; documentation of welding; approval and certification procedures; general principles of supervision; case studies; planning; organisation; interpretation of fracture surfaces; auditing; practice in typical examination questions; course assessments.
Welding Inspection Refresher Training Modules WIS2-WIS4
(AWS to CSWIP) or (CSWIP 10 year renewals 3.1/3.2) or (CSWIP 3.0 refresher) or BGAS to CSWIP 3.1
Duration
- 1 day - Practical
- 1 day - Application
The training modules have been set up to provide training and instruction in the requirements for the various bridging examinations available.
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Plant Inspection Management
CSWIP Plant Inspector - Level 1 PL11 - PL22
Duration
This course is conducted in two separate one-week (5 days) modules with CSWIP examinations at the end of each respective week.
Course dates
Week 1
14 - 18 March 2005
Week 2
21 - 25 March 2005
Course Content - Week 1 PL11
Roles and duties of the Plant Inspector; QA/inspection in context; inspection safety; basic inspection skills; legislation, rules, regulations; inspection of materials; visual examination of welds; inspection and NDT; introduction to corrosion.
Course Content - Week 2 PL12
Roles and duties of the Plant Inspector; the use of codes and standards; inspection of welding; inspection of pressure vessels; inspection of pipework systems; inspection of storage tanks; inspection of paint systems; inspection of rubber/GRP linings; introduction to risk-based inspection; inspection reporting.
CSWIP Plant Inspector - Level 2 PL21-PL22
Duration
This course is conducted in two separate one-week (5 days) modules with CSWIP examinations at the end of each respective week.
Legislative aspects; written schemes of examination; visual inspection and inspection technologies; condition monitoring and risk-based inspection; materials and basic metallurgy; cladding and coatings technology; welding technology and defects; pressure equipment certification (International requirements); corrosion, erosion and basic defect behaviour, including creep and fatigue mechanisms; plant systems and components, including safety-relief valves; codes and specifications; quality assurance requirements; health, safety and environment.
Risk-based Inspection and Maintenance (RBI/RBM) ATC115
Duration
2½ day course
Course dates
5 - 7 April 2005
2 - 4 May 2005
1 - 3 August 2005
The course is aimed at inspection, maintenance and engineering staff who are likely to participate in RBI assessment projects on pressure systems, pipelines, boilers and storage tanks and who are likely to lead RBI assessment teams. The topics include: an overview of RBI; reasons for implementing RBI; the benefits of using RBI; the practical implementation of RBI; planning successful RBI implementation projects; practical likelihood and consequence analysis; preparing inspection plans and optimising maintenance and inspection intervals; implementing risk mitigation actions; detailed RBI assessment software exercises.
Fitness-for-Service (FFS) Assessment ATC116
Duration
3 day course
A course covering the latest technologies for making repair, replace, re-rate and re-design decisions. This course covers Level 1 and Level 2 FFS assessments and is aimed at plant inspectors, inspection and other plant engineers responsible for managing the integrity of ageing process equipment, pipelines, boilers and storage tanks. A working knowledge of pressure equipment design codes and handbook stress analysis is recommended. The topics include: introduction to FFS; FFS assessment procedures; introduction to damage mechanisms; brittle fracture; general metal loss; localised metal loss; pitting; blisters and laminations; weld misalignment and shell distortion; crack-like flaws; creep; fired damage.
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Non-destructive Testing (NDT)
Appreciation of NDT Techniques NDT1
Duration
3 day course
NDT methods with demonstrations; surface methods; magnetic particle and penetrant testing; methods for internal examinations; X- and gamma radiography, ultrasonic flaw detection; advantages and limitations of NDT methods; NDT equipment and accessories; choice and applications of methods in relation to materials and requirements, defect types, position and weld geometry; ideal informational course for managers, supervisors, administrators and technicians.
Radiographic Interpretation - Principles NDT2A
Duration
4½ day course
Course dates
21 - 25 February 2005
4 - 8 April 2005
4 - 8 July 2005
12 - 16 September 2005
Designed for personnel responsible for judging the quality of radiographs and reaching informed decisions regarding the identity and extent of the defects revealed.
Radiographic Interpretation - Light & Dense Metal Welds NDT2B
Duration
5 day course
Weld defects and their components; viewing conditions; identification of radiographs; spurious indications; appreciation of radiographic principles and parameters of interpretation; standards for radiographic practice, interpretation tutorial; acceptance criteria. It is required that course members have knowledge of radiographic theory.
Magnetic Particle Testing NDT30M
Duration
4 day course
Principles of magnetism, magnetic fields; induction; permeability and reluctance; magnetisation; lines of force, methods of testing, interpretation of indications; demagnetisation; practical exercises; methods of assessing sensitivity; instruction writing. During the Level 2 instruction writing and application, students requiring only Level 1 training will carry out practical applications to written instructions.
Penetrant Testing NDT30P
Duration
4 day course
Materials, methods, compatibility of materials, equipment and safety aspects; practical exercises; methods of assessing sensitivity. During the Level 2 instruction writing and application, students requiring only Level 1 training will carry out practical applications to written instructions.
Ultrasonic Testing NDT4
Duration
9 day course plus exam (exam duration is dependent upon type of examination taken)
Welding processes and weld defects; basic principles of ultrasonics; the flaw detector; practical exercises on test specimens containing simulated flaws; examination of parent plate, butt welds; instruction writing.
Ultrasonic Testing - Thickness Measurement NDT4T
Duration
5 day course, 1 - 2 day(s) exam
Principles of ultrasonics; properties of sound; waves, frequencies, sound beam, attenuation; thickness gauges and flaw detectors, ultrasonic compression probes; calibration blocks, calibration, sensitivity, sizing techniques; practical exercises on various test specimens; testing of parent plates; lamination and thickness measurement; report and instruction writing.
Supervised Practical Ultrasonic Testing NDT47
Duration
4½ day course
A course designed for practical testing of specimens of various configurations - plates, pipes, nozzles, nodes and on forged components or structures. Specimens for practical work cover all joint configurations. Designed for the experienced participants who wish to undertake practical testing of all weld configurations and samples under supervision.Eddy Current Testing NDT31
Duration
9½ day course plus exam
Basic electrical theory, principles of eddy currents, types of circuit, test coils, factors influencing impedance; low and high frequency testing, amplitude and phase sensitive methods; analysis of impedance diagrams; practical applications; technique preparation.
ASNT Level III Refresher Courses NDT35
Duration
Basic
4 day course
Ultrasonic
3 day course
Magnetic Particle
2 day courses
Radiography
3 day course
Liquid Penetrant
2 day course
These ASNT refresher courses use material produced by ASNT and review each attendee's understanding of the Level III body of knowledge for the specified NDT method. ACCP Level III examinations will be arranged immediately following each course.
Materials Weldability
C-Mn & Low Alloy Steels WTC84F
Duration
1 day course
Structure of metals; basic phase diagrams; influence of alloying elements; properties of welded joints; weldability of steels - mild and low alloy; use of carbon equivalent formulae; metallurgical defects; cracking mechanisms and control; effects of preheat and/or postweld heat treatment.
Stainless Steels WTC84S
Duration
1 day course
Basic metallurgy and properties of stainless steel; corrosion and oxidation resistance; weldability of highly corrosion resistant grades (duplex, superduplex and high alloy austenitics); weldability of conventional stainless steels (austenitic, ferritic and martensitic); avoidance of weld defects; use of Schaeffler diagram for dissimilar joints; measurements of ferrite levels and ferrite number (FN); weld overlaying and welding clad steels; degradation of stainless steels (pitting, crevice corrosion and stress corrosion cracking); practical considerations for welding stainless steels.
Ni-base Alloys WTC84N
Duration
1 day course
Basic metallurgy and properties of nickel and its alloys; effects of alloying elements; age hardening; high temperature and corrosive environment performance; weldability; consumable design and selection; appropriate welding processes; preparation for welding.
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Welding Procedures and Approvals
Formulating Weld Procedures to:
Duration
1 day course for each of the following
- BS EN 288 (ref WTC90)
- ASME IX (ref WTC91)
Establishing the basic data required; evaluation of process parameters; selection of joint design; influence of material type; choice of consumables; building up a weld procedure, avoiding errors and omissions.
The course provides in logical sequence all the basic information required to produce a welding procedure, correct formulation of which is crucially important in the production of sound acceptable joints.
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General Technology
Essentials of Welding Design WTC100
Duration
2 day course
The welded joint; terminology; steps of successful design; features of welding processes; edge preparations; weld symbols; residential stress and distortion; defects; weldability; strength of welded joints; calculation of weld size for static loading; material selection and process control to avoid brittle fracture; design exercises; assessment of the relative fatigue life of welds; fatigue life improvement methods.
This course reviews the terminology and explains concisely the basic principles of effective welding design. It is regularly updated in line with current technology and needs.
Introduction to Welding & Non-destructive Testing WTC17
Duration
4½ day course
Terminology; review of commonly used welding processes and NDT methods; features and control of welding processes; use and control of consumables; approval testing; inspection procedures and techniques; welding imperfections and their causes and interpretation; comparative studies in practical application of welding and NDT; hands-on experience of welding and NDT.
Structural Integrity Assessment ATC65
Duration
2½ day course
Failure case studies; fitness-for-purpose concept; materials issues; introduction to fracture mechanics; inspection; fatigue design of welded structures; BS 7910 creep and fatigue assessment procedures; fracture assessment to BS 7910 (Levels 1, 2 and 3); current and future developments; software for structural integrity assessment.
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Diploma in Inspection Methodology
Lectures: 27 weeks; Study: 5 weeks; Examinations: 5 weeks
Duration
- Foundation - 4 weeks
- Metallurgy - 4 weeks
- Basic inspection methods - 6 weeks
- Volumetric and advanced inspection methods - 6 weeks
- In-service inspection - 7 weeks
Foundation Module
Introduction to NDT; introduction to welding inspection (CSWIP 3.0); Quality Assurance; practical welding.
Metallurgy
Materials technology; materials behaviour; corrosion.
Basic Inspection Methods
Penetrant inspection; magnetic particle inspection; visual inspection; welding inspection; eddy current inspection.
Volumetric and Advanced Inspection Methods
Radiographic inspection; ultrasonic inspection; advanced welding inspection; advanced NDT methods (ACFM, phased array, TOFD, long range UT).
In-service Inspection
Plant inspection 1 and 2; risk-based inspection; in-service NDT; tank assessment.
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International Institute of Welding/European Welding Federation Specialist Diploma
Welding Processes and Equipment - Foundation WPE1
Duration
5 day course
Modules cover a range of common welding processes. In addition, two complementary modules in advanced welding processes, and practical welding technology are provided to cover other aspects of joining and welding.
Advanced Welding Processes AWP
Duration
5 day course
This module provides an overview of the more unusual welding and joining methods such as power beams, friction welding etc and should be taken in conjunction with module WPEI for those who wish to gain a credit in welding processes and equipment.
Materials and Their Behaviour MAB1
Duration
5 day course
The module provides personnel with knowledge to join a range of materials and methods of avoiding problems. Modules include materials science and technology and an understanding of characteristics of materials, ranging from steels to titanium and other alloys.
Design and Construction DAC1
Duration
5 day course
The module concentrates on welding and fabrication issues such as design principles, fracture mechanics, behaviour of welded structures in service, fatigue and brittle fracture, engineering critical assessment and thermodynamically loaded structures as well as the practicalities of construction of a variety of products.
Practical Welding Technology PWT
Duration
5 day course
Follows IIW Guidelines for practical training in MMA, TIG, MIG/MAG and oxyfuel gas cutting and welding processes. The module provides supervised project work at varying levels to suit the background experience of course members.
Fabrication and Application FAA1
Duration
5 day course
This subject is offered as a final module only. Subjects included are quality assurance and quality control in welding, welding procedure requirements, approval testing, welder performance testing, calibration, economics, repairs and case studies.
Gas Turbine courses
These two modules deal with the life management and repair of gas turbine hot section components. The knowledge gained will enable the operator to make informed decisions regarding run, repair or replace advice.
Module 1 - Life Management
Duration
5 day course
Introduction to the issues of hot section life management (operator's considerations); materials and components (superalloys and coatings); component design (expected design lives and how to design them); degradation of components and materials; Equivalent Operating Hours (EOHs).
Module 2 - Inspection and Repair
Duration
5 day course
Maintenance inspections (factors affecting maintenance planning, types of inspection); destructive and non-destructive inspection (limits and advantages of these approaches); typical hot section component repair considerations (nozzles, blades, rotors, combustor and transition pieces, coatings).
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