Cswip

CERTIFICATION SCHEME FOR WELDING AND INSPECTION PERSONNEL
DOCUMENT No. CSWIP-WCO-18-06
Provisional Document Requirements for the Certification of Welding Co-ordinators in accordance with ISO 14731:2006 and ISO 3834:2005
Part 1: Structural steel sector 1st Edition January 2008
Issued under the authority of the Governing Board for Certification All correspondence should be addressed to: TWI Certification Ltd Granta Park, Great Abington, Cambridge CB21 6AL, UK Telephone: +44 (0) 1223 899000 Telefax: +44 (0) 1223 894219 Email: twicertification@twi.co.uk Website: www.iso3834.org
CSWIP is administered by TWI Certification Ltd
Copyright 2008, TWI Certification Ltd
FOREWORD The Certification Scheme for Personnel (CSWIP) is a comprehensive scheme which provides for the examination and certification of individuals seeking to demonstrate knowledge and/or competence in their field of operation. The scope of CSWIP includes, among others, Welding Inspectors, Welding Supervisors, Welding Instructors, Cathodic Inspection personnel, Bolting Technicians, Plant Inspectors, Underwater Inspection personnel, Plastics Welders and NDT personnel. CSWIP is managed by the Certification Management Board, which acts as the Governing Board for the certification body, TWI Certification Ltd, in keeping with the requirements of the industries served by the scheme. The Certification Management Board, in turn, appoints specialist Management Committees to oversee specific parts of the scheme. All CSWIP Boards and Committees comprise member representatives of relevant industrial and other interests.
ACCESS TO CERTIFICATION
Access to certification schemes is not improperly restricted. The sole criteria for certification are given in this document (and any subsequent amendments) and no other criteria will be applied. Certification is not conditional on the candidate applying for other services or membership from TWI Certification Ltd, its parent, or any other group or associations.
1
1.1
GENERAL
Background ISO 14371:2006(1) (first published as BS EN 719) requires people with welding responsibilities (Welding Co-ordinators) in a manufacturing organisation to be competent to discharge the responsibilities that have been allocated to them. Reference is made in the standard to IIW (formerly EWF) qualifications as being one way of demonstrating the required breadth of knowledge required to underpin competence. However, it is recognised, that some welding co-ordination functions may not require the full breadth of knowledge provided by the IIW qualifications. An alternative method of demonstrating appropriate knowledge is therefore desirable. Another important point is that IIW qualifications, in themselves, do not give any indication of job competence. They are like a university degree in that they are valid for the life of the holder and indicate that, at a particular point in time, the person passed an examination on a body of knowledge. It is therefore appropriate, in the current context, to offer a certification scheme not only to confirm familiarity with a specific body of knowledge but also to provide assurance that the person is competent to perform a job related to that knowledge. This implies that the person will have had a significant period of experience relevant to the job function for which certification is sought.
1.2
Certification of welding co-ordinators This document describes a process for the evaluation and certification of Welding Coordinators in the structural fabrication sector in accordance with the individual applicants specific job function and meeting the requirements of ISO 14731:2006 and Parts 2 and 3 of ISO 3834:2005(2). Furthermore, in the context of structural fabrication, both these standards will be a requirement of the proposed new series of European Standards, EN 1090. The appointment of Welding Co-ordinators and Responsible Welding Co-ordinators in accordance with ISO 14731:2006 is the responsibility of the manufacturer. However, the current certification scheme provides manufacturers with a sound and convincing basis for making such appointments and will facilitate compliance with the relevant part of ISO 3834:2005.
1 Copyright 2008, TWI Certification Ltd
ISO 14731:2006 gives guidance on the knowledge requirements for Responsible Welding Co-ordinators, and requires them to be allocated to one of the groups listed below. The manufacturer must appoint at least one Responsible Welding Co-ordinator. a) Comprehensive level (C) - personnel with comprehensive technical knowledge, where full technical knowledge is required, for the planning, executing , supervising and testing of all tasks and responsibilities in welding fabrication. b) Specific level (S) - personnel with specific technical knowledge, where the level of technical knowledge needs to be sufficient for the planning, executing, supervising and testing of the tasks and responsibilities in welding fabrication within a selective or limited technical field. c) Basic level (B) - personnel with basic technical knowledge, where the level of technical knowledge needs to be sufficient for the planning, executing, supervising and testing of the tasks and responsibilities within a limited technical field, involving only simple welded constructions. The Standard gives non-mandatory references to the International Institute of Welding qualifications. Such qualifications provide one way of demonstrating that the technical knowledge requirements have been met but acceptable national qualifications may be used. In order to satisfy ISO 14731:2006, Responsible Welding Co-ordinators and Welding Coordinators must also demonstrate competence in relation to the tasks and responsibilities that have been allocated to them by their employer. Achieving certification under the current scheme is therefore a two step process: Stage 1: Demonstrating both the core and specific knowledge as defined in Appendix 2 Part A and Part B; and Stage 2: successfully undergoing a professional interview which would normally be conducted as part of the ISO 3834 assessment of the employing organisation. 1.3 1.3.1 Application for training and assessment Stage 1 Applicants are required to provide an authenticated CV and to carry out a self-assessment against the core knowledge syllabus at the applicable level, see Appendix 2 Part A. Forms for this will be provided on request. It is envisaged that most applicants will then be required to attend training in order to prepare them for the examination covering both the core knowledge in all four main modules and the specific knowledge as described in Appendix 2 Part B. The examination will consist of four papers (one in each of the main modules) each containing 50 multiple choice questions and with a duration of one hour. During this examination candidates will be permitted to make reference to a data book provided by the Examiner. A two hour case study will also be required. Those who pass the examination will be deemed to have satisfied the knowledge requirements (core and specific) of this document and will be issued with a statement to this effect. The statement provides satisfactory evidence of achievement for entry into Stage 2 (see below) providing that it is no more than five years old at the point of application for Stage 2. Those who are unsuccessful will be required to attend further training before proceeding. Resit examinations are not available at this stage. However, credits will be awarded for passed modules.
1.3.2
Stage 2 Having successfully completed Stage 1, candidates can apply to be assessed for competence in relation to their specific job function for a specific employer. The assessment is conducted via a professional interview usually as part of an ISO 3834 audit of the employing organisation. Information on the job function, experience, etc, is required in advance of the interview. Successful completion of Stage 2 leads to the issue of a CSWIP certificate, see below. In the event of a false statement being discovered on forms or on CVs any examination or assessment undertaken will be declared null and void. A certificate is automatically invalidated if there are any outstanding fees in respects of that certificate.
CATEGORIES OF CERTIFICATION
Using the levels as defined in 1.2 above, candidates may apply for one of the three following certification categories: Certified Welding Co-ordinator (Comprehensive Level Knowledge) Certified Welding Co-ordinator (Specific Level Knowledge) Certified Welding Co-ordinator (Basic Level Knowledge).
Further categorisation for each Certified Welding Co-ordinator is available and will be stated on the certificate: Steel bridges (Standard(s) to be specified, eg BS 5400 Part 6); or Steel buildings (Standard(s) to be specified, eg BS 5950 Part 2, NSSS, etc) or Both of the above.
The certificate will also include a reference to the employer and to the job specification under which the candidates was assessed.
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3.1
CERTIFICATION
Results notices All candidates will be sent separate results notices for Stage 1 and Stage 2. This notice will also be sent to the organisation paying the examination fee, if not paid by the candidate.
3.2
Successful candidates Stage 2 Two copies of a certificate of proficiency and an ID card will be issued to the sponsoring organisation or person that pays the fees. Duplicate certificates to replace those lost or destroyed will be issued only after extensive enquiries.
3.3
Unsuccessful candidates Stage 2 Candidates who fail to obtain a certificate may attempt one Stage 2 re-assessment, see Appendix 1. The re-assessment must be completed within one year of the initial assessment. The re-assessment may not be taken within 30 days of the assessment. Failure in the re-assessment will result in the candidate being required to undergo further specified training.
3.4
Period of Validity The certificate is valid for three years from the date of completion of the successful initial evaluation and may be renewed for a further three years on application, provided evidence is produced in accordance with Clause 3.5.1. Certificates are only valid provided: a) they are within date; b) they are on standard cream CSWIP paper bearing the CSWIP logo in black on gold signed by an officer of CSWIP and embossed with the CSWIP stamp; c) they have been signed by the individual to whom the certificate is awarded; d) they are accompanied by a valid official CSWIP identity card; and e) the holders job specification does not change significantly. Note: It is the manufacturers responsibility to ensure that the scope of proficiency as defined in the holders certificate matches the job responsibilities that have been allocated to the holder by the manufacturer. A significant mismatch would require re-assessment and recertification. Photocopies are unauthorised by CSWIP and should only be used for internal administrative purposes.
3.5 3.5.1
Renewal Three year renewal document review In order for the certificate to be renewed after three years, the holder has to demonstrate that they have maintained their competence by: i) providing evidence of continuous work activity as a welding co-ordinator at the appropriate level for which certification was awarded providing evidence that the holder has kept up to date in relevant welding technology, see Appendix 4.
ii)
Requests for the appropriate documentation should be made to TWI Certification Ltd at the address given at the end of this document. Renewal must take place not later than 21 days after the date of expiry. It is the certificate holders responsibility to ensure that renewal takes place at the appropriate time. Only under extreme circumstances will certificates be renewed up to a maximum of six calendar months from the date of expiry shown on the certificate and late renewal will be subject to a special fee. 3.5.2 Six year renewal document review plus re-assessment Certificates are renewed before six years from initial assessment (or from a previous six year renewal) by the holder successfully completing a re-assessment prior to the expiry of the certificate in addition to the renewal procedure given in Clause 3.5.1. Requests for the appropriate documentation should be made to TWI Certification Ltd at the address below. 3.6 Complaints and Appeals An aggrieved party in a dispute which considers itself to have reasonable grounds for questioning the competence of a CSWIP qualified person may petition the Governing Board for invalidation of the certificate. Such a petition must be accompanied by all relevant facts, and if in the opinion of the board an adequate case has been presented, a full investigation of the circumstances under dispute will be initiated. Appeals against failure to certify or against invalidation may be made by the holder upon application in writing to the Governing Board.
RECORDS
TWI Certification Ltd maintains records of successful and unsuccessful candidates. These records are accessible to the Governing Board or its nominees at all reasonable times.
REFERENCES
1. 2. BS EN ISO 14731:2006 Welding co-ordination Tasks and Responsibilities BS EN ISO 3834:2005 Quality requirements for fusion welding
ADDRESSES For further information contact: TWI Certification Ltd Granta Park Great Abington Cambridge CB21 6AL Tel 01223 899000 Fax: 01223 894219 Email: twicertification@twi.co.uk www.iso3834.org
Appendix 1 Evaluation Process STAGE 1 1.1 Personal Evaluation A company and/or an individual has decided to pursue certification. It is considered beneficial for individuals to receive the support of their companies in working towards this certification. However, individuals can pursue certification on their own behalf. This may be reduced if the candidate presents specific welding qualifications at the appropriate level. This would include products, material type(s), thicknesses and welding processes. Experience requirements are given in Appendix 3. NOTES DETAILED PROCEDURE
1.2
Potential candidates ensure they have the required minimum appropriate experience requirements. The potential candidates and/or their company decide on the knowledge level required to fulfil the applicants work scope: Comprehensive, Specific or Basic. Potential candidates review their experience and knowledge against the requirements for certification as a Welding Co-ordinator.
1.3
This is the point at which candidates decide which level they require (Comprehensive, Specific or Basic) for their work in order to comply with EN 1090, see Appendix 2.
1.4
There are two parts to the knowledge requirement, (a) core knowledge and, (b) specific knowledge, see Appendix 2. Experience requirements are given in Appendix 3.
All candidates have to demonstrate familiarity with the core knowledge at the appropriate level. In addition to this, familiarity must be demonstrated with the product specific knowledge that applies: bridges, buildings, or both. Details of the knowledge requirements may be found in Appendix 2.
2 2.1
External Review If they consider themselves suitable, potential candidates submit an initial fee and details of their knowledge, qualifications and experience for review. A standard application form is available. Candidates would need to provide an authenticated CV (using existing TWI forms), evidence of relevant qualifications and training, examples of reports and documents they have prepared during the course of their work (eg WPSs, method statements, quality plans, etc), and a self-assessment against the applicable core syllabus, see Appendix 2A.
STAGE
NOTES
DETAILED PROCEDURE
2.2 2.3
The application is reviewed. Result of review The candidate is given the result of the review. It is possible that a further review(s) will be necessary in order to give a candidate the best opportunity to provide correct and full information.
The review is be carried out by TWI staff with the help of trained reviewers. Successful candidates will be required to undergo a short course of refresher training. In exceptional circumstances, candidates may be allowed direct entry to the examination. In other cases, candidates will be given specific advice on how to proceed.
3 3.1 4 4.1
Training Candidates undergo training as applicable. Knowledge examination (Stage 1) Where a candidate has undergone any required training and is deemed in the external review to have sufficient experience and knowledge for the certification applied for he/she may proceed to the knowledge examination. Competence assessment (Stage 2) Following success at Stage 1 the candidate proceeds to Stage 2. Certification Following success in Stage 2, a Welding Co-ordinator certificate is issued at the applicable level and in the applicable categories. See Clauses 2 and 3. The certificate will include a reference to the employer and the job specification. Certificates have a validity period of three years, see Clause 3.4 and 3.5 See Clause 1.3.2. The candidates competence in accordance with his/her specific job function is assessed, usually as part of an ISO 3834 assessment of the employing organisation. See clause 1.3.1. See Clause 1.3.1. The examination covers the knowledge described in Appendix 2A and 2B.
6 5.1
Appendix 2
Part A Core Knowledge

Module 1: Welding Processes and Equipment
1.3 Electrotechnics, a review

Objective (all levels): Understand (gain knowledge to understand in general) the basics of electricity in relation to the requirements of welding technology and appreciate the key electronic components used in welding power sources. Scope: Basics of electricity and electronics (define current, voltage and resistance) Ohm's Law Parallel and serial circuits Direct current (DC), polarity, alternating current (AC). Magnetism in welding Capacity, condenser Transformer, and rectifying bridge (half wave and full wave rectification) Transistor, thyristor, Inductance, inductors Hazard Health and safety Expected Result for C: 1. Define and explain the effect of current, voltage and electrical resistance in welding. 2. Detail the functions of the most important components of welding power sources. 3. Discuss competently the differences between DC and AC current. 4. Interpret and apply knowledge of electricity and electronics to welding applications. Expected Result for S: 1. Define and explain the effect of current, voltage and electrical resistance in welding. 2. Detail the functions of the most important components of welding power sources. 3. Discuss competently the differences between DC and AC current. 4. Interpret and apply knowledge of electricity and electronics to welding applications. Expected Result for B: 1. Outline the relation between current, voltage and electrical resistance, and also define each electrical parameter. 2. Outline the major functions of the most important components of welding power sources. 3. Describe the major differences between DC and AC current and give examples of their individual application to different welding processes. 4. Demonstrate and apply knowledge related to electricity and electronics in welding applications.
Key:
C = Comprehensive Level S = Specific Level B = Basic Level
Note: Applicants are not expected to have a 100% knowledge of all the areas listed.
Number relates to Section in the IIW Guideline Personnel with Responsibility for Welding Coordination
1.5 Power sources for arc welding

Objective (all levels): Understand in detail (gain knowledge to understand in general/having a outline working knowledge) the characteristics and main components of arc welding power sources. Scope: Power source classification, types and characteristics (static and generators, and each sub-group) Power source electrical characteristics (static and dynamic) Relationship between static characteristic and welding process Control of the electrical static characteristic (flat and drooping) Arc stability for the main processes (MMA, TIG, MIG/MAG, SAW, PAW) The operation working point Inverter technology Stability of processes in AC and DC AC (sine wave and square wave) and DC power sources Open circuit voltage, short circuit current, power factor of transformers Duty cycle of a power source and typical values for the most common arc welding processes. Voltage losses, relationship between welding current value and cable section Arc striking methods and devices, slope up and down, pre- and post-flow Current and voltage setting (electromagnetic and electronic devices) Standards related with welding power sources and their requirements Expected Result for C: 1. Explain each type of arc welding power source for both AC and DC including the most common devices used. 2. Detail for each type of welding power source the static and dynamic electrical characteristics, operation point and control of arc stability. 3. Explain the meaning of open circuit voltage, short circuit current, duty cycle of a power source, voltage losses, and welding current to cable cross section relationship. 4. Explain the differences of the above characteristics for each type of power source and welding process. 5. Recognise the various functions and switches on different power sources and their effects. Expected Result for S: 1. Explain each type of arc welding power source for both AC and DC including the most common devices used. 2. For each type of welding power source detail the static and dynamic electrical characteristics, operation point and control of arc stability. 3. Explain the meaning of open circuit voltage, arc voltage short circuit current, duty cycle of a power source, voltage losses, and welding current to cable cross section relationship. 4. Explain the differences of the above characteristics for each type of power source and welding process for a specific application. 5. Recognise the various functions and switches on different power sources and their effects. Expected Result for B: 1. Outline how each type of welding power source works (AC and DC) including the most common devices used. 2. Describe for each type of arc welding power source the static characteristic, operation point and control of arc stability. 3. Outline the meaning of open circuit voltage, arc voltage short circuit current, duty cycle of a power source, voltage losses, and current to cable section relationship. 4. Be able select the appropriate power sources for a given welding process. 5. Recognise the various settings and switches on different power sources and their effects. Key: C = Comprehensive Level S = Specific Level B = Basic Level
1.8 MIG/MAG and Flux Cored Arc Welding

Objective (all levels): Understand in detail/gain knowledge to understand in general/explain MIG/MAG and Flux Cored Arc welding fundamentals, including equipment, applications, procedures and common problems Scope: Power source characteristics for conventional process and CPU controlled power sources Effect of current type and polarity Equipment and accessories: torches, wire feeders, hose assembly, control panel Metal transfer modes (dip, globular, spray, pulsed and rotating), and their application Welding parameters and settings: current, voltage, travel speed, gas flow rate, etc. Consumables: shielding gases, filler materials (solid and flux cored wires), and their combinations Joint preparation: typical joint design for welding, fit-up, cleaning Welding procedures Standards for filler materials, and gases Welding applications, typical problems and how to solve them Health and safety specific to the process. Expected Result for C: 1. Explain in detail the principles of MIG/MAG and Flux Cored Arc welding including metal transfer modes and their applications. 2. Explain the selection of appropriate type of current, polarity and electrode according to application. 3. Detail the range of application, appropriate joint preparations and potential problems to be overcome. 4. Detail appropriate welding parameters for particular applications. 5. Define potential hazards and methods of safe handling and working. 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Interpret appropriate standards 8. Explain selection of consumables. 9. Recognise the various settings and switches on different MIG/MAG and Flux Cored power sources and effects. Expected Result for S: 1. Explain and compare in detail the principles of MIG/MAG and Flux Cored Arc welding including metal transfer modes and their applications. 2. Compare the selection of appropriate type of current, polarity and electrode according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome. 4. Identify appropriate welding parameters for particular applications. 5. Define potential hazards and methods of safe handling and working. 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Interpret appropriate standards 8. Explain selection of consumables. Recognise the various settings and switches on different MIG/MAG and Flux Cored power sources and effects. Expected Result for B: 1. Describe and compare the principles of MIG/MAG and Flux Cored Arc welding including metal transfer modes and their applications. 2. Identify the most common applications for each type of current, polarity and electrode. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome. 4. Identify an appropriate range of welding parameters for particular applications. 5. Describe potential hazards and methods of safe handling and working. 6. Outline the various functions of the main components of the equipment and accessories. 7. Demonstrate the use of appropriate standards 8. Give examples on how consumables should be selected.
Key:
1.9 MMA Welding Objective (all levels): Understand in detail/gain knowledge to understand in general/explain MMA welding fundamentals, including equipment, applications, procedures and common problems
Scope: Process principles and arc characteristics Effect of current type and polarity Power source characteristics applicable to MMA (open circuit voltage, static and dynamic characteristics, types of current, arc striking methods) Equipment and accessories Process application range, typical problems and how to solve them Covered electrodes (functions of the coating and rod, types of electrodes, slag-metal and gas-metal covered reactions) Production of electrodes (how, typical defects) Handling and storage of electrodes (storage environment, redrying) Electrode classification (International and national standards) Selection of covered electrodes for applications. Welding parameters: current, voltage, run out length, etc Joint preparation: typical joint design for welding, fit-up, cleaning, welding position Relationship between electrode diameter and current range, rod material, electrode length and welding position Welding procedures Special techniques (gravity welding, vertical down welding, on-site welding)
Health and safety specific to this process

Expected Result for C: 1. Explain in detail the principles of MMA welding including special techniques, arc striking methods and their applications. 2. Explain the selection of the appropriate type of current, polarity and electrode according to application. 3. Detail the range of application, appropriate joint preparations and potential problems to be overcome. 4. Detail appropriate welding parameters for particular applications. 5. Define potential hazards and methods of safe handling and working. 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Explain the handling and storage of the various types of electrodes. 8. Interpret appropriate standards. 9. Identify the influence of electrode coating on droplet transfer and weld metal properties. 10. Recognise the various functions and switches on different MMA power sources and their effects. Expected Result for S: 1. Explain in detail the principles of MMA welding including with particular emphasis on special techniques, arc striking methods and their applications. 2. Explain the selection of the appropriate type of current, polarity and electrode according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome. 4. Identify appropriate welding parameters for particular applications. 5. Define potential hazards and methods of safe handling and working. 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Explain the handling, control and storage of the various types of electrodes. 8. Interpret appropriate standards. 9. Identify the influence of electrode coating on droplet transfer and weld metal properties. Expected Result for B: 1. Describe the principles of MMA welding 2. Describe how to select the appropriate type of current, polarity and electrode according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome. 4. Identify an appropriate range of welding parameters for particular applications. 5. Describe potential hazards and methods of safe handling and working. 6. Outline the purpose and functions of each component of the equipment and accessories. 7. Describe the appropriate methods of handling, control and storage of the various types of electrodes. 8. Demonstrate the use of appropriate standards. 9. Describe the influence of electrode coating on droplet transfer and weld metal properties.
Key:
1.10 Submerged-Arc Welding

Objective (all levels): Understand in detail/get a complete knowledge/explain SAW welding fundamentals,
including equipment, applications, procedures and common problems.

Scope: SAW process principles and arc characteristics Effect of current type and polarity Power source characteristics applicable to SAW (open circuit voltage, static and dynamic characteristics, types of current, arc striking methods) Equipment and accessories Process application range, typical problems and how to solve them Consumables (functions of the flux and wire -solid or flux cored-, types of flux and wire, wire-flux combination, slagmetal and gas-metal reactions) Production of consumables (how, typical defects) Handling and storage of consumables (storage environment, re-drying) Consumable classification (International and national standards) Welding parameters: current, voltage, travel speed, type of flux and particle size, stick-out, etc Joint preparation: typical joint design for welding, fit-up, cleaning Relationship between the wire-flux combination and the characteristics of deposited material Welding procedures Single-wire and multi -wire techniques Special techniques (iron-powder addition, cold and hot wire addition) Health and safety specific to SAW process Expected Result for C: 1. Explain in detail the principles of SAW process including arc striking methods, special techniques and their applications. 2. Explain the selection of appropriate type of current, polarity and consumable according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome. 4. Identify appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Explain slag-metal/gas-metal reactions and their influence on weld metal properties 7. Interpret appropriate standards. 8. Define potential hazards and methods of safe handling and working. Expected Result for S: 1. Explain in detail the principles of SAW process including arc striking methods, special techniques and their applications. 2. Explain the selection of appropriate type of current, polarity and consumable according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome. 4. Identify appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Explain slag-metal/gas-metal reactions and their influence on weld metal properties. 7. Interpret appropriate standards. 8. Define potential hazards and methods of safe handling and working. Expected Result for B: 1. Explain the principle of the SAW process including arc striking methods, special techniques and their applications. 2. Explain the criteria for evaluating the applicable welding parameters. 3. Identify the application range, joint edge preparation and potential problems to overcome. 4. Clarify the procedures for the set-up of power sources. 5. Explain the criteria for the selection of flux-wire combinations. 6. Interpret appropriate standards and welding procedures. 7. Define welding instructions for welders and operators. 8. Define potential hazards and methods of safe handling and working.
Key:
1.13 Cutting and other edge preparation processes

Objective (all levels): Understand in detail/get a complete knowledge/explain/interpret the basic principles and the field of application of the most common cutting and edge preparation processes used in weld construction, including equipment, procedures and common problems. Scope: Survey of edge preparation processes Mechanical cutting Principles of flame and flame powder cutting, equipment, applications and auxiliaries Flame cutting parameters, edge quality, oxygen purity grades Materials suitable for flame cutting Basic principles of the various arc cutting processes (arc-air, carbon and metal-arc, oxy-arc cutting, gouging with carbon electrode) equipment and auxiliaries Materials suitable for arc-cutting, applications, cutting parameters for each process Fundamentals of plasma cutting, equipment and auxiliaries Materials suitable for plasma cutting, applications, cutting parameters, cutting gases Plasma cutting special applications (under water cutting, cutting with water vortex) Fundamentals of laser cutting, equipment, parameters, applications Fundamentals of arc gouging and flame gouging, parameters and applications Appropriate national and international standards for each process Health and safety Expected Result for C: 1. Explain in detail the principles of: mechanical, flame, arc, plasma, electron beam, laser, and water jet cutting. 2. Explain the influence of each parameter for the above mentioned processes on the edge surface quality. 3. Detail the range of applications for: flame, arc, plasma, electron beam, and water jet cutting. 4. Define potential risks, hazards and methods of safe handling and working. Expected Result for S: 1. Explain in detail the principles of: mechanical, flame, arc, plasma, electron beam, laser, and water jet cutting. 2. Explain the influence of each parameter for the above mentioned processes on the edge surface quality. 3. Identify the range of applications for: flame, arc, plasma, electron beam, and water jet cutting. 4. Identify potential risks, hazards and methods of safe handling and working. Expected Result for B: 1. Explain the principles of: mechanical, flame, arc, plasma, electron beam, laser, and water jet cutting. 2. Identify the characteristic parameters for the above mentioned processes 3. Make a comparison among different edge preparation processes, considering technical and economic aspects. 4. Evaluate potential risks and hazards related with edge preparation processes. Key: C = Comprehensive Level S = Specific Level B = Basic Level
Module 2 Materials and their Behaviour during Welding
2.1 Manufacture and designation of steels

Objective (all levels): Understand/describe the principles of iron metallurgy, steel making and designation of steels. Scope: Introduction to metallurgy of steel making Steel making processes Special treatments Deoxidation Designation of steels Defects in steels Expected Result for C: 1. Explain the various steel making processes. 2. Detail the reasons for and principles of special treatments in steel making. 3. Explain the different methods of deoxidation 4. Explain potential defects, their cause and elimination. 5. Explain the designation of steels. Expected Result for S: 1. Explain the various steel making processes. 2. Detail the reasons for and principles of special treatments in steel making. 3. Explain the different methods of deoxidation 4. Explain potential defects, their cause and elimination. 5. Explain the designation of steels Expected Result for B: 1. Explain the various steel making processes. 2. Explain the special treatments in steel making. 3. Explain the different methods of deoxidation. 4. Explain potential defects, their cause and elimination. 5. Explain the designation of steels.
Key:
2.2 Testing Materials and the weld joint

Objective (all levels): Understand/name the fundamental aspects of testing materials with particular reference to weldment test pieces. Scope: Review of destructive testing Testing welded joints (technological specimen) Destructive testing. Tensile and bend tests Impact tests (ductile and brittle fracture, transition temperature) Hardness tests Fatigue tests Overview on related standards Expected Result for C: 1. Discuss the reasons for destructive testing and the limitations of the data generated. 2. Describe in detail each of the major testing methods and the parameters to be measured. 3. Predict when and why special testing should be specified. 4. Show competence in carrying out testing to a given schedule. Expected Result for S: 1. Discuss the objectives of each destructive test and the limitations of the data generated 2. Describe in detail each of the major testing methods and the parameters to be measured 3. Predict when and why special testing should be specified 4. Show competence in carrying out testing to a given schedule. Expected Result for B: 1. Discuss the objectives of each destructive test and the limitations of the data generated. 2. Describe each of the major testing methods and the parameters to be measured. 3. Predict when and why special testing should be specified. 4. Show competence in carrying out testing to a given schedule. Key: C = Comprehensive Level S = Specific Level B = Basic Level
2.5 Iron Carbon Alloys

Objective (all levels): Understand/name the principles of alloying iron with carbon, the crystalline structures developed under equilibrium and non-equilibrium conditions and their representation in phase and transformation diagrams. Scope: Equilibrium and non equilibrium transformations Time-temperature-transformation (TTT) diagrams Different types of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) Influence of alloying elements Carbide forming elements Control of toughness t8/5 concept Expected Result for C: 1. Interpret the reasons for different structures under equilibrium and non-equilibrium conditions. 2. Explain the use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) to show the development of particular steel microstructures. 3. Predict the changes that strengthen structure caused by alloying additions with reference to TTT diagrams. 4. Detail hardening mechanisms with reference to the microstructure developed. 5. Interpret the relationship between microstructure and toughness. Expected Result for S: 1. Interpret the reasons for different structures under equilibrium and non-equilibrium conditions. 2. Explain the use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) to show the development of particular steel microstructures. 3. Predict the changes that strengthen structure caused by alloying additions with reference to TTT diagrams. 4. Detail hardening mechanisms with reference to the microstructure developed. 5. Interpret the relationship between microstructure and toughness. Expected Result for B: 1. Interpret the reasons for different structures under equilibrium and non-equilibrium conditions. 2. Explain the use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) to show the development of particular steel microstructures. 3. Identify the changes that strengthen structure caused by alloying additions with reference to TTT diagrams. 4. Describe hardening mechanisms with reference to the microstructure developed. 5. Interpret the relationship between microstructure and toughness. Key: C = Comprehensive Level S = Specific Level B = Basic Level
2.7 Structure of the welded joint

Objective (all levels): Understand in detail/get a complete knowledge/explain the formation of the different metallurgical structures within a weldment. Scope:
Thermal field Equations for the heat distribution Heat input and efficiency of heat input Peak temperature Cooling rate and thermal cycle Dilution Weld metal Solidification of weld pool Structure of the weld Fusion line Heat-affected zone (HAZ) Microstructure of HAZ Grain growth and grain refinement Relationship grain size toughness (equations from regression) Transition temperature Weldability (definitions) Single and multi -pass welding Expected Result for C: 1. Explain the temperature distribution in welds and the microstructure formed as a result. 2. Interpret the effects of heat input, cooling rate and multi- pass operation on weld metal solidification and the microstructure formed. 3. Explain the effects of the weld protection, the type of consumables on the microstructure of the weld metal and on it properties. 4. Detail areas of HAZ, the reasons for grain, size and microstructure changes and their effects on properties. 5. Discuss the various aspects of weldability. 6. Deduce the microstructural and weldability changes induced by dilution. Expected Result for S: 1. Explain the temperature distribution in welds and the microstructure formed as a result for a single pass weld versus a multi-pass weld. 2. Interpret the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and the microstructure formed for a single pass weld versus a multi-pass weld. 3. Explain the effects of the weld protection, the type of consumables on the microstructure of the weld metal and on it properties for a single pass weld versus a multi-pass weld. 4. Detail areas of HAZ, the reasons for grain, size and microstructure changes and their effects on properties for a single pass weld versus a multi-pass weld. 5. Discuss the various aspects of weldability 6. Deduce the microstructural and weldability changes induced by dilution. Expected Result for B: 1. Explain the temperature distribution in welds and the microstructure formed as a result for a single pass weld versus a multi-pass weld. 2. Interpret the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and the microstructure formed for a single pass weld versus a multi-pass weld. 3. Explain the effects of the weld protection, the type of consumables on the microstructure of the weld metal and on it properties for a single pass weld versus a multi -pass weld. 4. Draw areas of HAZ, the reasons for grain size and microstructure changes and their effects on properties for a single pass weld versus a multi-pass weld. 5. Discuss the various aspects of weldability.
Key:
Module 3 Construction and Design
3.1 Basic theory of structural systems

Objective (all levels): Understand the effect of external loads on structures, the types of structural systems and the relationship between external loads and internal forces. Scope: 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 Expected Result for C and S: 1. Explain the composition of forces. 2. Explain the resolution of forces. 3. Define the conditions of equilibrium. 4. Explain the equilibrium of structural systems. 5. Explain bearings, constraints and the basic types of connections. 6. Explain the difference between a statically determinate and a statically indeterminate system. 7. Determine the internal forces and moments of simple statically determinate systems. 8. Explain and sketch the shearing force and bending moment diagram of simple statically determinate systems. Expected Result for B: 1. Understand in general the composition of forces. 2. Understand in general the resolution of forces. 3. Name the conditions of equilibrium. 4. Understand in general the equilibrium of structural systems. 5. Name bearings, constraints and the basic types of connections.
Key:
3.2 Fundamentals of the strength of materials

Objective (all levels): Understand the principles governing the behaviour of metallic structures under loading.
Scope: Types of stresses (normal stress, shear stress) Types of deformation (axial strain, shear strain) Stress-strain relationship, yielding theories Elastic and plastic deformation Youngs modulus, shear modulus, transverse contraction coefficient Characteristic material properties Different stresses resulting from internal forces and moments Different types of section properties Calculation of section properties Calculation of stresses Expected Result for C and S: 1. Explain the different types of stresses (normal stress, shear stress). 2. Explain the different types of deformation (axial strain, shear strain etc.). 3. Explain the stress-strain relationships. 4. Deduce Youngs modulus; shear modulus and transverse contraction coefficient from the stress-strain relationships. 5. Explain the determination of characteristic material properties. 6. Explain the stresses resulting from internal forces and moments. 7. Calculate the different types of section properties. 8. Calculate nominal stresses in sections. Expected Result for B: 1. Understand in general the different types of stresses (normal stress, shear stresses). 2. Understand in general the different types of deformation (axial strain, shear strain etc.). 3. Understand in general the stress-strain relationships. 4. Understand in general the stresses resulting from internal forces and moments.
3.3* Welded Joint design

Objectives (all levels): Design and draw weld details related to a given material, wall thickness, accessibility, loading, welding process, welding position, NDT, available equipment, tolerances.
Scope: Introduction (importance of welding joint design and grove shapes, influence on welding stresses and distortion) Types of welded joints (ISO 9692 series) 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 Expected Result for C, S and B: 1. Classify different types of welded joints. 2. Design a weld according to the given conditions. 3. Detail and use appropriate weld symbols. 4. Explain the symbolic representation of welded, brazed and soldered joints on drawings. Key: C = Comprehensive Level S = Specific Level B = Basic Level
3.4 Basics of weld design

Objectives (all levels): Understand the relationship between external loads on structures, internal forces and the stresses induced with especially with regard to welds.
Scope: Types of stresses in welded joints (nominal stress, hot spot stress, notch stress) Stresses in butt welds, stresses in fillet welds Calculation of section properties 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
Expected Result for C and S: 1. Explain the different types of stresses in welded joints (nominal stress, hot spot stress, notch stress) 2. Calculate in detail simple welded joints (internal forces). 3. Calculate the values of cross sections for welded joints. 4. Calculate nominal stresses in welds. 5. Calculate combined stresses in welds (superposition). Expected Result for B: 1. Understand in general the different types of stresses in welded joints (nominal stress, hot spot stress, notch stress). 2. Understand simple welded joints (internal forces). 3. Understand cross sections for welded joints.
3.5* Behaviour of welded structures under different types of loading

Objectives (all levels): Understand the different types of loading and the influence of ambient conditions on structures.
Scope: Static strength Low-temperature strength Impact behaviour Influence of notches and weld defects Types of fracture (ductile fracture, fatigue fracture, brittle fracture, lamellar tearing) Selection of steel quality groups Typical data for common steels Use of standards and specifications
Expected Result for C: 1. Explain the requirements according to different types of loading and temperatures. 2. Determine materials which meet strength/temperature requirements. 3. Select appropriate materials according to specific applications. 4. Explain different types of fracture (ductile fracture, fatigue fracture, brittle fracture, lamellar tearing). Expected Result for S: 1. Explain the requirements according to different types of loading and temperatures. 2. Select appropriate materials according to specific applications. 3. Explain different types of fracture (ductile fracture, fatigue fracture, brittle fracture, lamellar tearing). Expected Result for B: 1. Understand the requirements for the construction according to different types of loading and temperatures. 2. Identify globally groups of materials which meet strength / temperature requirements. 3. Identify the various types of facture.
Key:
3.6 Design of welded structures with predominantly static loading

Objectives (all levels): Be able to design and calculate joints and all relevant details of welded metallic structures. Scope: Steel constructions including lightweight structures Structural details eg (stiffeners, knots, columns, base- and cap-plates, reinforced structures, supports, framecorners, frame structures, trusses, nodal joints, weld connections, braces / bracing, lattice work structures, etc) Use of different types of welds related to joint types Use of standards and specifications Worked examples Expected Result for C: 1. Competently design different connection zones. 2. Calculate appropriate weld geometry. 3. Calculate the relevant weld stresses. 4. Outline stresses in frames. 5. Nominate the stresses in welds in frames. 6. Detailed knowledge of advantage and disadvantage of different types of welds. Expected Result for S: 1. Design different connection zones. 2. Outline stresses in frames. 3. Nominate the stresses in welds in frames. 4. Explain the advantage and disadvantage of different types of welds. Expected Result for B: 1. Identify different connection zones. 2. Read and understand appropriate weld geometry. 3. Outline stresses in structural details. 4. Global knowledge of advantage and disadvantage of different types of welds. Key: C = Comprehensive Level S = Specific Level B = Basic Level
3.7 Behaviour of welded structures under dynamic loading

Objectives (all levels): Understand the development of fatigue, calculation of load cycles, the influence of notches and their avoidance. Scope: Types of cyclic loading Statistical stress analysis on real structures S-N diagram Stress collective Fatigue strength (low cycle, and others) Effect of mean stress Effect of stress range Stress distribution Influence of notches Influence of weld defects Fatigue improvement technique (needle peening, TIG dressing, burr grinding, hammering, stress relieving, etc) Standards Palmgren-Miner rule Classification of weld joints Expected Result for C: 1. Draw and use an S-N diagram. 2. Describe methods of counting load cycles. 3. Calculate the stress ratio. 4. Detail the influence of notches and weld defects. 5. Explain the methods for improving fatigue performance. Expected Result for S: 1. Draw and use an S-N diagram. 2. Detail the influence of notches and weld defects. 3. Describe the methods applied to welds for improved fatigue performance. Expected Result for B: 1. Understand an S-N diagram. 2. Name the influence of notches and weld defects. 3. Name possible modifications to welds for improved performance. Key: C = Comprehensive Level S = Specific Level B = Basic Level
3.8 Design of dynamically loaded welded structures

Objectives (all levels): Understand the different design details and notch classes in the range of application.
Scope: Range of application: bridges, cranes, towers and masts, etc Acceptance criteria Use of standards and specifications Worked examples
Expected Result for C: 1. Design welded joints in accordance with given details. 2. Interpret the influence of notch effects on the classification of welded joints. 3. Interpret appropriate standards. 4. Compare details in different standards and classify them. Expected Result for S: 1. Design welded joints in accordance with given details. 2. Explain the influence of notch effects on the classification of welded joints. 3. Compare details in different standards and classify them. Expected Result for B: 1. Recognise welded joints in accordance with given details. 2. Know the influence of notch effects and stresses on the classification of welded joints.
3.11 Reinforcing-steel welded joints (optional)

Objectives (all levels): Understand the principles of choice of joints and their design.
Scope: Reinforcing-steel types, properties Direct and indirect loading Types of joints used (lap, cruciform) Calculation Weldability with respect to weld joint strength Preheating in respect to bar diameter Application of welding processes Standards and specifications (ISO 17660 series and National Standards)
Expected Result for C and S: 1. Explain the basics of the different joints in full. 2. Differentiate between load bearing and non-load bearing joints. 3. Detail applicable processes. 4. Determine the length of weld with respect to diameter. 5. Deduce the required preheating temperature. Expected Result for B: 1. Outline the basics of the different joints in full. 2. Recognise between load bearing and non-load bearing joints. 3. Classify applicable welding processes. 4. Outline the length of weld with respect to diameter. 5. Understand the application of preheat.
Key:
Module 4: Fabrication, Applications Engineering
4.1 Introduction to quality assurance in welded fabrication

Objective (all levels): Understand in detail/get a complete knowledge/explain the principles of quality assurance and quality control and recognise the related standards and their application to welded fabrication as a special process. Scope: Concept of quality assurance and quality control (including analysis, continuous improvement) Weldability Quality manual Quality plan Audit of plant Personnel and equipment Maintenance Inspection Activities of the welding engineer/technologist/specialist/practitioner in the different functions in industry Standards (QMS guidebook, ISO 9000 series, ISO 3834, national and international standards) Expected Result for C and S: 1. Explain the principles of quality assurance, quality control and inspection systems and their usage for welded fabrication. 2. Be capable of writing quality control procedures and quality plans for welded fabrication. 3. Explain in detail the purpose of an audit of plant. 4. Be capable of carrying out audits of welding related plant, personnel, equipment and product. 5. Interpret appropriate standards (e.g. ISO 9000, and ISO 3834 series). 6. Explain in detail the main factors related to personnel and equipment, which influence the quality in a welded fabrication. 7. Explain the role of the Welding Engineer in the fabrication industry. Expected Result for B: 1. Explain the main differences between quality assurance, quality control and inspection systems and their usage for welded fabrication. 2. Be capable of writing quality control procedures. 3. Interpret appropriate standards (e.g. ISO 9000, and ISO 3834 series). 4. Know the basic factors related to personnel and equipment, which influence the quality in a welded fabrication. 5. Explain the role of the Welding Specialist in the fabrication industry. Key: C = Comprehensive Level S = Specific Level B = Basic Level
4.2 Quality control during manufacture

Objective (all levels): Understand in detail/get a complete knowledge/explain the requirements and function of Quality Control during manufacture. Explain the standards related to welders/operators and welding procedure qualification including traceability, need for calibration and monitoring of welding parameters. Scope: Documentation to national, regional and international standards, e.g. WPS Advantages to the quality of welded constructions Welding sequence Welding coordination and inspection personnel; qualification tasks and responsibilities (ISO 14731, ISO 9712, and National standards) Procedure qualification (as described in ISO 15607) and National standards Welding procedure specification (WPS) - how to create and develop Welder qualification (ISO 9606 series, EN 287-1, and National standards) Welding operator qualification (EN 1418, ISO and National standards) Traceability (materials identification, welder/operator, procedures, certificates) Possible methods of monitoring, control and storage of fabrication data Calibration and validation of measuring equipment Expected Result for C:
1. Explain in detail the main purpose of a WPS/WPQR/pWPS and the main advantages to the quality of welded fabrication. 2. Compile and review detailed WPSs for welded components in accordance with national and international standards. 3. Interpret the standard for the qualification of a WPS, determine the main variables for a particular WPS qualification and its range of qualification. 4. Explain in detail the main purpose of a welder qualification and the main advantages to the quality of welded fabrication. 5. Interpret the standard for a welder qualification, determine the main variables for a particular welder qualification and its range of qualification. 6. Explain the main purpose of a welding operator qualification and the main advantages to the quality of welded fabrication. 7. Interpret the standard for a welding operator qualification, determine the main variables for a particular welding operator qualification and its range of qualification. 8. Detail the traceability requirements for materials procedures and certificates. 9. Detail methods available for the monitoring and storage of fabrication data. 10. Detail the calibration requirements of measuring equipment explaining why they are needed. 11. Explain in detail the tasks and responsibilities of the welding coordination personnel. 12.Explain in detail the tasks and responsibilities of the different inspection personnel Expected Result for S: 1. Explain the main purpose of a WPS/WPQR/pWPS and the advantages to the quality of welded fabrication. 2. Compile and review WPSs for welded components in accordance with national and international standards. 3. Interpret the standard for the qualification of a WPS, determine the main variables for a particular WPS qualification and its range of qualification in accordance with National and/or International standards. 4. Explain the main purpose of a welder qualification and the main advantages to the quality of welded fabrication. 5. Interpret the standard for a welder qualification, determine the main variables for a particular welder qualification and its range of qualification. 6. Explain the main purpose of a welding operator qualification and the main advantages to the quality of welded fabrication. 7. Interpret the standard for a welding operator qualification, determine the main variables for a particular welding operator qualification and its range of qualification. 8. Define the traceability requirements for materials procedures and certificates and give examples. 9. Give examples of methods available for the monitoring and storage of fabrication data. 10. Recognise the equipment and instruments needing calibration and explain why. 11. Explain the tasks and responsibilities of the welding coordination personnel. 12. Explain the tasks and responsibilities of the different inspection personnel
Expected Result for B: 1. Explain the main purpose of a WPS/WPQR/pWPS and the advantages to the quality of welded fabrication. 2. Compile and review WPSs for welded components in accordance with national and international standards. 3. Interpret the standard for the qualification of a WPS, determine the main variables for a particular WPS qualification and its range of qualification in accordance with National and/or International standards. 4. Explain the main purpose of a welder qualification and the main advantages to the quality of welded fabrication. 5. Interpret the standard for a welder qualification, determine the main variables for a particular welder qualification and its range of qualification. 6. Explain the main purpose of a welding operator qualification and the main advantages to the quality of welded fabrication. 7. Interpret the standard for a welding operator qualification, determine the main variables for a particular welding operator qualification and its range of qualification. 8. Define the traceability requirements for materials procedures and certificates and give examples. 9. Give examples of methods available for the monitoring and storage of fabrication data. 10. Know the equipment and instruments needing calibration
Key:
4.3 Residual Stresses and Distortion

Objective (all levels): Understand in detail/get a complete knowledge/explain the main factors affecting welding stress and distortion in welded fabrications and how these effects can be measured and minimised. Scope: Influencing factors Thermal data of the materials Origin of the residual stresses and deformation Magnitude of longitudinal and transverse shrinkage stresses Relationship between heat input, shrinkage stresses and distortion Methods of residual stress measurement Welding sequence techniques Effects of residual stresses on the behaviour of the structure in service Methods of reducing residual stresses or distortion Correction and removal of welding deformation (pressing, rolling, local heating, etc.) Examples of control of distortion Expected Result for C: 1. Explain in detail the origin, influencing factors and magnitude of residual stress and distortion in welded fabrications. 2. Predict quantitatively contraction and distortion in joints and structures. 3. Produce detailed procedures to minimise distortion and stress. 4. Explain how residual stresses may affect the behaviour of a structure in service. Expected Result for S: 1. Explain in detail the origin, influencing factors and magnitude of residual stress and distortion in welded fabrications. 2. Predict quantitatively contraction and distortion in joints and structures. 3. Develop procedures to minimise distortion and stress. 4. Explain how residual stresses may affect the behaviour of a structure in service. Expected Result for B: 1. Explain in general terms the origin, influencing factors and magnitude of residual stress and distortion in welded fabrications. 2. Predict qualitatively contraction and distortion in joints and structures. 3. Develop procedures to minimise distortion and stress. 4. Describe how residual stresses may affect the behaviour of a structure in service. Key: C = Comprehensive Level S = Specific Level B = Basic Level
4.5 Health and Safety

Objective (all levels): Understand detail/get a complete knowledge/explain the health and safety hazards associated with welding and fabrication processes, including techniques to minimise them. Scope: Introduction to health and safety requirements Survey of safety and environmental aspects, risk assessment Hazards of electric power Electro-magnetic fields Connecting of equipment Problems with shielding gases Radiation and eye protection Welding fume emission Exposure limits MAC and OEL values Ventilation and fume extraction Ergonomics Determination of acceptable emissions Tests for measuring emissions Noise levels and ear protection Special risks for automated processes Standards and regulations Expected Result for C: 1. Explain the risks associated with welding from electricity, gases, fumes, fire, radiation and noise. 2. Interpret Health and Safety regulations with respect to the above hazards. 3. Deduce from measurements the risk associated with welding operations. 4. Produce safe working procedures to ensure the requirements are met. 5. Perform measurements of welding hazards. Expected Result for S: 1. Explain the risk factors associated with welding from electricity, gases, fumes, fire, radiation and noise. 2. Interpret Health and Safety regulations with respect to the above hazards. 3. Select the appropriate methods to reduce each type of welding risk factors. 4. Produce safe working procedures to ensure the requirements are met. 5. Perform measurements of welding hazards. Expected Result for B: 1. Explain the risk factors associated with welding from electricity, gases, fumes, fire, radiation and noise. 2. Interpret Health and Safety regulations with respect to the above hazards. 3. Select the appropriate methods to reduce each type of welding risk factors. 4. Describe safe working procedures to ensure the requirements are met. 5. Know how to measure welding hazards. Key: C = Comprehensive Level S = Specific Level B = Basic Level
4.6 Measurement, Control and Recording in Welding

Objective (all levels): Understand/know/name the requirements for measurement, control and recording during welding and allied operations. Scope: Methods of measurement (electrical parameters, gas flow rate, temperature, velocity) Instruments (types, measuring applications) Temperatures (ISO 13916), humidity, wind Cooling time e.g. t 8/5 Welding parameters (voltage, current, speed, gas flow rate, etc.) Control in heat treatment (heating and cooling rate, CR ISO 17663) Calibration and validation of equipment (ISO 17662) Expected Result for C and S: 1. Explain the methods of measurement used in the control of welding and allied operations. 2. Detail working procedures for the measurement of welding parameters. 3. Detail working procedures for the measurement and control of heat treatment operations. 4. Detail procedures for the calibration, validation and monitoring of welding operations. Expected Result for B: 1. Describe the methods of measurement used in the control of welding and allied operations. 2. Explain working procedures for the measurement of welding parameters. 3. Explain working procedures for the measurement and control of heat treatment operations. 4. Explain procedures for the calibration, validation and monitoring of welding operations. Key: C = Comprehensive Level S = Specific Level B = Basic Level Note: Applicants are not expected to have a 100% knowledge of all the areas listed.
4.7 Non Destructive Testing

Objective (all levels): Understand in detail/understand/explain/describe the use of Non Destructive Testing as applied to welding fabrications. Scope: Types of weld imperfections (IIW-designations classification according to ISO standards) Acceptance criteria (e.g. ISO 5817, ISO10042, and EN 12062) Fundamentals of NDT methods (visual, dye penetrant, magnetic particle, eddy current, acoustic emission, radiography, ultrasonic, etc.) Field of application and limitations Design in respect of NDT Calibration Interpretation (IIW Radiographic reference) Recording of data Correct selection of the NDT methods versus application (eg CEN/TR 15135) Qualification and certification of NDT personnel NDT procedures Automation of NDT (computer aid evaluation, etc) Use of standards and specifications Health and safety aspects Expected Result for C: 1. Explain the modes of operation of the principal NDT methods, their advantages and disadvantages when applied to welded fabrications. 2. Explain weld imperfections, their causes and avoidance and methods of detection. 3. Interpret acceptance standards for weld imperfections. 4. Understand of the principles of NDT interpretation. 5. Detail weld configurations and design to allow adequate application of NDT methods. 6. Interpret the qualification of NDT personnel. 7. Recognise safety aspects Expected Result for S: 1. Explain the modes of operation of the principal NDT methods, their advantages and disadvantages when applied to welded fabrications. 2. Identify weld imperfections, their causes and avoidance and methods of detection. 3. Interpret acceptance standards for weld imperfections. 4. Identify the principles of NDT interpretation. 5. Select weld configurations and design to allow adequate application of NDT methods. 6. Interpret the qualification of NDT personnel. 7. Recognise safety aspects Expected Result for B: 1. Know the modes of operation of the principal NDT methods, their advantages and disadvantages when applied to welded fabrications. 2. Identify weld imperfections, their causes and avoidance and methods of detection. 3. Interpret acceptance standards for weld imperfections. 4. Identify the principles of NDT interpretation. 5. Select weld configurations and design to allow adequate application of NDT methods. 6. Identify the qualification of NDT personnel. 7. Recognise safety aspects Note: Welding coordination personnel may need qualifications according to ISO 9712. In this guideline a part of that education is covered already.
Key:
4.8 Economics
Objective (all levels): Understand in detail/understand/know/interpret the economics of welding operations applied to welded fabrications. Scope: Analysis of welding costs Deposition rate Costs of labour Costs of welding consumables Costs of equipment Return on investment Costs of energy Welders duty cycle Calculation of welding costs Cost awareness (of labour, consumables, equipment, gases, energy, etc) The application of software, calculation programmes Measures for decreasing welding costs Mechanisation Automation Robotics Expected Result for C: 1. Explain in detail the make up of costs associated with welding. 2. Calculate the cost of welding operations. 3. Devise welding and handling procedures including mechanisation and automation to minimise production costs. 4. Operate software packages used in weld cost calculations. Expected Result for S: 1. Explain the elements of costs associated with welding. 2. Calculate the cost of welding operations. 3. Select welding and handling procedures including mechanisation and automation to minimise production costs. 4. Operate software packages used in weld cost calculations. Expected Result for B: 1. Describe the elements of costs associated with welding. 2. Know about the costs of welding operations. 3. Select welding and handling procedures including mechanisation and automation to minimise production costs. Key: C = Comprehensive Level S = Specific Level B = Basic Level
4.9 Repair Welding Applied to Structural Steels

Objective (all levels): Understand in detail/understand/name the problems of repair welding both for in-manufacture and in-service situations. Scope: Welding repair procedure specification Welding repair plan Welding repair procedure qualification NDT of the weld repair Special precautions Expected Result for C: 1. Explain in detail the problems of making repair welds. 2. Predict the possible hazards likely to occur in making repair welds particularly for in-service repairs. 3. Detail comprehensive procedures to be applied to weld repairs. 4. Specify the procedural and operator qualifications to be applied to repair welds. Expected Result for S: 1. Explain the problems and implications of making repair welds. 2. Predict the possible hazards likely to occur in making repair welds particularly for in-service repairs. 3. Develop procedures to be applied to weld repairs. 4. Specify the procedural and operator qualifications to be applied to repair welds. Expected Result for B: 1. Explain the problems and implications of making repair welds. 2. Predict the possible hazards likely to occur in making repair welds particularly for in-service repairs. 3. Understand procedures to be applied to weld repairs. 4. Specify the procedural and operator qualifications to be applied to repair welds. Key: C = Comprehensive Level S = Specific Level B = Basic Level
Appendix 2
Part B Specific Knowledge
Applicants would be expected to have a detailed knowledge of the areas that apply to their field of work in the structural steel sector. Level 1 - Primary application standards, eg: BS 5400: Part 6 Steel, concrete and composite bridge Part 6 Specification for Materials and workmanship, Steel BS 5950: Part 2 Structural use of steelwork in building Part 2: Specification for materials, fabrication and reception rolled and welded sections. Highways Agency Specification of Highway Works Network Rail Section 90 PR EN 1090-1 Steel and aluminium structural components Part 1: General delivery conditions PR EN 1090-2 Execution of steel structures and aluminium structures Part 2: Technical requirements for the execution of steel structures
Level 2 - Standards referred to in the primary application standards Level 1 documents that directly affect welding, eg: EN 1011-1 Welding Recommendations for welding of metallic materials, Part 1: General guidance for arc welding EN 1011-2 Welding Recommendations for welding of metallic materials Part 2: Arc welding of ferritic steels BS EN ISO 15614-1 Specification and qualification of welding procedures for metallic materials welding procedure test Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys EN 287-1 Qualification test of welders - fusion welding - Part 1: Steels. BS EN 100251 Hot rolled products of structural steels Part 1: General technical delivery conditions. BS PD CEN ISO/TR 15608 Welding Guidelines for a metallic materials grouping system.
Level 3 Standards supporting Level 1 and 2 standards, eg ones covering non destructive testing and destructive testing, etc.
Appendix 3 Experience Requirements In order to satisfy the experience requirements, the applicant must: 1. Have obtained a minimum of four years experience in the six year period prior to certification which demonstrates successful application of his/her welding technology knowledge at appropriate level applied for (i.e. Comprehensive, Specific or Basic). Provide evidence of scope of experience in accordance with ISO 14731 at the appropriate level. The list below is intended as a guide only and other activities may be acceptable. It is the applicants responsibility to give an accurate account of his/her scope of responsibilities and activities in the application.
2.
Review of requirements Product standard to be used together with any supplementary requirements Capability of the manufacturer to meet the prescribed requirements Technical Review Parent material(s) specification and welded joint properties Joint location with relation to the design requirements Quality and acceptance requirements for welds Location, accessibility and sequence of welds, including accessibility for inspection and nodestructive testing Other welding requirements, e.g. batch testing of consumables, ferrite content of weld metal, ageing, hydrogen content, permanent backing, use of peening, surface finish, weld profile Dimensions and details of joint preparation and completed weld Sub-contracting - With regard to sub-contracting, the suitability of any sub-contractor for welding fabrication shall be considered Welding personnel - With regard to welding personnel, the qualification of welders and welding operators, brazers and brazing operators shall be considered Equipment The suitability of welding and associated equipment Auxiliaries and equipment supply, identification and handling Personal protective equipment and other safety equipment, directly associated with the applicable manufacturing process Equipment maintenance Equipment verification and validation Production planning Reference to the appropriate procedure specifications for welding and allied processes Sequence in which the welds are to be made Environmental conditions (e.g. protection from wind, temperature and rain) Allocation of qualified personnel Equipment for preheating and post-heat treatment, including temperature indicators Arrangement for any production test. Qualification of the welding procedures With regard to the qualification of the welding procedures, the method and range of qualification shall be considered Welding procedure specifications With regard to welding procedure specifications, the range of qualification shall be considered Work instructions With regard to work instructions, the issuing and use of work instructions shall be considered Welding consumables Compatibility Delivery conditions Any supplementary requirements in the welding consumable purchasing specifications, including the type of welding consumable inspection document The storage and handling of welding consumables
Materials Any supplementary requirements in the material purchasing specifications, including the type of inspection document for the material The storage and handling of parent material traceability Inspection and testing before welding The suitability and validity of welders' and welding operators' qualification certificates The suitability of the welding procedure specification The identity of the parent material The identity of welding consumables Joint preparation (e.g. shape and dimensions) Fit-up, jigging and tacking Any special requirements in the welding procedure specification (e.g. prevention of distortion) The suitability of working conditions for welding, including the environment. Inspection and testing during welding Essential welding parameters (e.g. welding current, arc voltage and travel speed) The preheating/interpass temperature The cleaning and shape of runs and layers of weld metal Back gouging The welding sequence The correct use and handling of welding consumables Control of distortion Any intermediate examination (e.g. checking dimensions) Inspection and testing after welding The use of visual inspection (for completeness of welding, weld dimensions, shape) The use of non-destructive testing The use of destructive testing The form, shape, tolerance and dimensions of the construction The results and records of post-operations (e.g. post-weld heat treatment, ageing) Post-weld heat treatment With regard to post-weld heat treatment, performance in accordance with the specification shall be considered Non-conformance and corrective actions With regard 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 Calibration and validation of measuring, inspection and testing equipment With regard to the calibration and validation of measuring, inspection and testing equipment, the necessary methods and actions shall be considered Identification and traceability The identification of production plans The identification of routing cards The identification of weld locations in construction The identification of non-destructive testing procedures and personnel The identification of the welding consumable (e.g. designation, trade name, manufacturer of consumables and batch or cast numbers) The identification and/or traceability of parent material (e.g. type, cast number) The identification of the location of repairs The identification of the location of temporary attachments Traceability for fully mechanized and automatic welding units to specific welds Traceability of welder and welding operators to specific welds Traceability of welding procedure specifications to specific welds. Quality records With regard to quality records, the preparation and maintenance of the necessary records (including subcontracted activities) shall be considered.
Appendix 4
Maintaining and developing knowledge
Applicants and existing certified persons are required to demonstrate that they are maintaining and updating their knowledge relevant to the areas in which they practice for example by implementing a personal scheme for professional development. This is an important feature of certification because a persons capability is dependent on the knowledge base from which he/she operates. Technology does not stand still and therefore the individuals knowledge base must be continuously developed and refined during his/her working career in order to remain competent. In order to satisfy this requirement applicants and certified persons will be required to describe their method of keeping up to date. This is usually accomplished in partnership with the employer. Evidence of participation in relevant activities; for example, training courses, seminars, committee work, etc, will be required.

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CERTIFICATION SCHEME FOR WELDING AND INSPECTION PERSONNEL

DOCUMENT No. CSWIP-WCO-18-06

CSWIP is administered by TWI Certification Ltd

Copyright 2008, TWI Certification Ltd

2 Copyright 2008, TWI Certification Ltd

3 Copyright 2008, TWI Certification Ltd

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Part A Core Knowledge

1.3 Electrotechnics, a review

C = Comprehensive Level S = Specific Level B = Basic Level

1.5 Power sources for arc welding

1.8 MIG/MAG and Flux Cored Arc Welding

C = Comprehensive Level S = Specific Level B = Basic Level

Health and safety specific to this process

C = Comprehensive Level S = Specific Level B = Basic Level

1.10 Submerged-Arc Welding

including equipment, applications, procedures and common problems.

C = Comprehensive Level S = Specific Level B = Basic Level

1.13 Cutting and other edge preparation processes

Module 2 Materials and their Behaviour during Welding

2.1 Manufacture and designation of steels

C = Comprehensive Level S = Specific Level B = Basic Level

2.2 Testing Materials and the weld joint

2.5 Iron Carbon Alloys

2.7 Structure of the welded joint

C = Comprehensive Level S = Specific Level B = Basic Level

Module 3 Construction and Design

3.1 Basic theory of structural systems

C = Comprehensive Level S = Specific Level B = Basic Level

3.2 Fundamentals of the strength of materials

3.3* Welded Joint design

3.4 Basics of weld design

3.5* Behaviour of welded structures under different types of loading

C = Comprehensive Level S = Specific Level B = Basic Level

3.6 Design of welded structures with predominantly static loading

3.7 Behaviour of welded structures under dynamic loading

3.8 Design of dynamically loaded welded structures

3.11 Reinforcing-steel welded joints (optional)

C = Comprehensive Level S = Specific Level B = Basic Level

Module 4: Fabrication, Applications Engineering

4.1 Introduction to quality assurance in welded fabrication

4.2 Quality control during manufacture

C = Comprehensive Level S = Specific Level B = Basic Level

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4.3 Residual Stresses and Distortion

4.5 Health and Safety

4.6 Measurement, Control and Recording in Welding

4.7 Non Destructive Testing

C = Comprehensive Level S = Specific Level B = Basic Level

4.9 Repair Welding Applied to Structural Steels

Part B Specific Knowledge

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Maintaining and developing knowledge

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