Welders Training Program to qualify for IBR

Eligibility
Minimum 10th Pass; Basic English vocabulary advantageous.
General Industrial Knowledge:

1 Understanding simple instructions in regional language / English. 2 Reading and using a ruler / measuring tape in inch / metric and understanding simple sketches of weld joints etc. 3 Basic idea of good housekeeping practice during welding. 4 Should know the hazards and precautions to be followed in case of Manual Arc Welding. 5 Should know the P.P.Es to be used for Welding. 6 Knowledge on safe working practices during welding to prevent accident. 7 Knowledge of basic first aid relating to injuries common in welding processes.
Technical Knowledge requirement:

1 Knowledge of basic welding terms and definitions. 2 Principle of gas welding and cutting. 3 Principles of MMAW process. 4 Knowledge of basics of weld joint fit-up. 5 Knowledge of tack welding. 6 Knowledge of welding parameters for different plate thickness and electrode size. 7 Should be conversant with A.C. and D.C. welding machine. 8 Knowledge of general weld defects. Practical knowledge for MMAW Basic Level (MMAW-B): 1 Set up of hand welding and cutting equipment and adjustment of pressure valves. 2 Fit up of holder and earth cables to welding power sources.
3 Surfacing on a M.S. plate by depositing a metal pad with 3 layers using 4mm or 5mm dia size electrodes in flat position. The weld pad area to be fixed as 200mm x 100mm. While welding the pad, welder should ensure that 1/3rd portion of the weld run falls on the preceding run and cater groove, if any may be filled up. The weld pad should be free from porosity and inclusion and of uniform width.

4 Should be able to prepare Fillet Welds T-joint in Flat, Horizontal, Vertical and Overhead positions (Thickness > 3mm and t>8mm). 5 Should be able to prepare Fillet Weld corner joint (t>3) in Horizontal position. 6 Should be able to prepare Fillet Weld, Tube to plate (t>3, D40) in O.H. position. 7 Should be able to prepare Fillet Weld, Tube to plate t>3, D>150 and t>3, 40D80 in Vertical position. 8 Should be able to prepare butt welds in down hand position on 10 mm plate. 9 Should be able to gas cut and grind plates required for subject joints and also for 20-25 mm plate thickness. 10 Should be able to identify the electrodes being used by them.

Training program
For welders with experience 0 to 3 years
Period : 7 weeks ( 350 Hrs.) MMAW Section
I Classroom 1. Exercise on measuring Simple objects With Scale and draw sketches of simple weld joints. 2. Lectures on safe working practices during welding including good housekeeping. 3. Lectures on hazards in welding specifically for MMAW and Gas welding and Cutting Process and precautions to be taken including use of P.P.Es. 4. Lectures on first aid with reference to burns ,cuts, electric shocks and eye injuries. Practical Training Exercises: Set up of hand welding and cutting equipment and adjustment of pressure values. Acquaintances with welding and cutting equipment . Exercise on fit up of holder and earth cables on welding equipments and acquaintance of polarity on D.C welding equipments. Practice striking the arc on plates by MMAW process and set arc length. Practice laying beads on plates and achieve full control of slag and weld metal. II Classroom 1. Lectures on set up of gas welding /cutting equipment and MMAW equipment. 2. Lectures on welding position and weld joints. 3. Lectures on Principles of MMAW process. 4. Lectures on types of A.C and D.C Welding machines. Practical Training Exercises: Practice unlimited straight bead on plates in Flat , Horizontal and Vertical positions(t>3mm)by using electrodes of 3.15mm and 4.0mm.The running beads should be correct length ,width and profile. Practice laying running beads with weaving technique in Flat position using electrodes of 3.15 mmand4.0mmplats(t>3mm) with craters properly filled up and without excessive deposit of metals at the point of re-striking the arc. Practice both straight and weave beads as stated above of longer lengths on all directions. Should practice surfacing on a M>S>plate by depositing metal pad with 3 layers using 4mmor5mmdia size electrodes in flat position .The weld pad area to be fixed as 200mm X 100mm.While welding the pad ,welder should ensure that

1/3rd portion of the weld pad should be free from porosity and incision and of uniform width.

III Classroom 1. Lectures on principles of gas welding. 2. Lectures on welding equipment for MMAW process. Practical Training Exercises: Practice welding Fillet welds T-joint in Flat position(t>3mm). Practice welding Fillet weld T-joint in Horizontal position (t>mm, t>8mm). Practice welding Fillet weld T-joint in vertical upward position(t>3mm). Practice welding Fillet weld T-joint in vertical Downward position(t>3mm) Should practice gas welding on sheet metals. IV Classroom 1. Lectures on principles of gas cutting. 2. Lecture on welding of corner joints and butt joints. Practical Training Exercises: Practice gas cutting of plates of different thickness (10mm thick and 20-25mm thick). Practice bevel cutting of plates for edge preparations. Should practice straight-line cutting and Circular cutting of plates using Pug Cutting machine. Practice welding Fillet weld T-joints in Overhead position(t>8mm). Practice welding Fillet weld corner joint (t>mm) in Horizontal position. Practice welding Fillet weld corner joint (t>mm) in vertical upward position. Practice preparation of butt weld in flat position on 10mm thick plate. V Classroom 1. Lectures on weld joint fit up and tack welding. 2. Lectures on weld defects. Practical Training Exercises: Practice welding Fillet Weld, Tube to Plate joint in Horizontal vertical fixed position (t>mm, D40mm). Practice welding Fillet Weld ,Tube to Plate joint in Vertical Upward fixed position(t>3mm,D150mm).

VI Classroom 1. Revision of all theory modules covered in previous weeks. 2. Brief question and answer session on all theory modules covered during previous weeks. Practical Training Exercises: Practice welding Fillet Weld , Tube to Plate joint in vertical Upwards fixed position(t>3mm,40D80mm). Practice welding Fillet Weld, Tube to Plate joint in horizontal Overhead Fixed position(t>3mm,D40mm). Mock practical tests as per requirements stipulated in Certification tests.

Test conducted
MMAW (For Fillet weld Joints in C.S. plate) a. Macro Examination: 2 test pieces. b. Fillet Weld Fracture Test: 3 test pieces. 3F (PF) & 4F (PD) Thickness = 6 mm 100x125 mm

VII Classroom 1. Lectures on brazing and braze welding. 2. Lecture on welding and cutting terms and definitions. 3. Lecture on knowledge of different manual arc welding machines and their Features. 4. Lectures on knowledge of edge preparation and joint fit-up for different joints. Practical Training Exercises: Practice brazing of M.S. sheets (3.15mm thick) - Fillet joint and Lap joint in flat position . Practice brazing of Copper or brass sheets (1.6 - 2.5mm thick) in flat position . Practice braze (bronze) welding of Fillet joint of M.S. sheet (size: 150 x 50 >< 3.15mm thick.) in flat position . Practice gas cutting of plates - 10mm and 20 - 25mm thick in straight lines and with circular profile . Know different arc welding machines, their controls and other accessories required for welding . Should practice set up and connection of AC. and D.C. welding sets and do simple troubleshooting . Should be able to lay beads on plates with E 7018 (Low Hydrogen electrodes) of' sizes 2.5mm, 3.15mm and 4.0mm by setting proper current and voltage .

Should be able to lay beads with stringer technique as well as weave bead technique . Should practice corner weld in flat position . Should practice fillet weld with single run in flat position on 10mm thick plate . Should practice fillet weld with multi run in flat position on 10mm thick plate . Should practice welding of fillet joint in Horizontal - Vertical position by" depositing a single run fillet of 6mm size using 4mm<p and 5mm<p electrodes. Should practice welding of multi run fillet joint in 3 runs with 4mm electrical in Horizontal-Vertical position. Should practice laying of bead welds on Vertical-Up and Vertical-Down position using 3.15mmq,4mmq and 5mmq electrodes. VIII Classroom 1. Lectures on basic knowledge of other fusion welding processes and special cutting processes-Plasma cutting. 2. Lectures on knowledge of different welding electrodes and their specifications. 3. Lectures on knowledge of parameter used for different type and sizes of electrodes for different welding position. 4. Lectures on knowledge of weld cleaning technique for elimination of slag, porosity and other defects during welding. Practical Training Exercises: Should practice fillet welds in single run in Vertical Up position as follows: Tee and Lap joint to be prepared on 10mm thick plate - 6.3mm fillet to be made with 4 mm electrodes . Should practice fillet welds in multi run in Vertical Up position as follows: Tee and Lap joint to be prepared on 10mm or higher thickness plates - 10mm fillet to be made with 1st run by 4mmcp electrodes and second run by 5mmcp electrodes . Should practice corner welds in Vertical Down position with 3. 15mmcp and 4mmcp electrodes - Throat thickness = 0.75 of thickness of plate . Should practice butt welds of Single 'V' butt joint on 10mm or thicker plate in Vertical Up position as per following sequence: - Welding to be completed in 3 runs - first run using 3.15mmcp electrodes - second and third runs using 4mmcp electrodes. IX Classroom 1. Lectures on knowledge of problems associated with welding in Carbon steel materials. 2. Lectures on different welding position as per ISO and AWS nomenclature. 3. Lectures on welding procedure, specification and certification.

4. Revision of all theory modules covered in previous weeks. Brief question and answer session all theory modules covered during previous weeks. 5. Lecture on weld defects-their causes and prevention. Practical Training Exercises: Practice Bead welds and prepare reinforcing pad in H-V position where deposition is to be done using 3.15mmq> and 4mmq> electrodes . Practice Butt Weld on 10mm thick plate on Single 'V' Butt joint in Flat position. Built up to be done with approximately 4 straight beads deposited without weaving. First run to be deposited with 3.15mmq> electrodes and subsequent runs with 4mmq> electrodes . Practice Butt welds in O.H. position by striking the arc with 3.15mmq> and 4mmq> electrodes . Practice Fillet welds as Tee-Joint and Lap Joint in O.H. position with single run 5mm Fillet to be made with 4mmq> electrodes . Practice Fillet welds as Tee-Joint and Lap Joint in O.H. position by multi run 10mm Fillet to be made in 3 runs using 4mmq> electrodes . Practice Butt Weld of Single 'V. Butt joint on 10mm or thicker plate in O.H. position with multi run as per following sequence: - First run deposited by straight bead with 3.15mmq> electrodes. - Second run deposited by weave bead with 3.15mmq> electrodes. - Final run deposited by weave bead with 4mmq> electrodes . Mock tests to train the welders for certification tests.

Tests conducted
MMAW (For Butt Joints in C.S. plate) MMAW (Radiographic) (For Butt Joints in C.S. plate) a. Root Bend Tests 2 Nos. b. Face Bend Tests 2 Nos. a. Radiographic Examination. b. Root Bend Tests 2 Nos. c. Face Bend Tests 2 Nos. 3G (PF) & 4G (PE) Thickness = 16 20 mm 200x225 mm (Preferable 300x250 mm)

3G (PF) & 4G (PE)

Thickness = 16 20 mm 200x225 mm (Preferable 300x250 mm)

GTAW Section
X Classroom 1. Lectures on basic principles of GTAW process. Its relative advantages and disadvantages. 2. Lectures on other equipment for GTAW process.

3. Lectures on basic of power source and other equipment for GTAW process. 4. Lectures on basic of High Frequency devices being used in GTAW process. 5. 5. Lectures on different types of Tungsten electrodes being used in GTAW process, Preparation of the electrodes and applicability of different electrodes for welding of different types of materials. 6. Lectures on Argon gas cylinders, regulators , and flow meters. 7. Lectures on edge preparation in pipes and setting of pipes. Practical Training Exercises: Should be able to set up GTAW power source GTAW Torch Other GTAW welding equipments Should be able to do grinding of tungsten electrodes to proper angles . Should be able to set up Argon Cylinders, regulators and flow meters . Should be able to do gas cutting and beveling of pipes . Should be able to prepare fillet welds in C. S. Plate (3 to 4mm) in Flat position Horizontal position Vertical up position. Overhead position. XI Classroom 1. Lectures on joint position for different weld joints. 2. Lectures on setting of pipes in different pipe positions. 3. Lectures on different techniques being adopted in pipe welding by GTAW process. 4. Lectures on different techniques being used for Carbon Steel and Stainless Steel. 5. Lectures on potential hazards encountered in GTAW process and how to avoid them. 6. Lectures on different types of GTAW filler wires being used for Carbon Steel and Stainless Steel. Practical Training Exercises: Should be able to prepare fillet joints in S.S. Sheet (0.5 to 2mm) in all positions . Should be able to prepare butt joints in S.S. Sheet (0.5 to 2mm) in all positions . Should be able to prepare fillet welds in C.S. tube to plate in all positions. XII Classroom 1. Lectures on basic knowledge of different Carbon Steel and Stainless Steel material.

2. Lectures on basic knowledge of Weld defects that occurs in GTAW process. 3. Lectures on safety precaution to be adopted for GTAW process. 4. Lectures on welding cleaning technique of contact faces to eliminate porosity, slag and other defects during welding. 5. Lectures on technique of grinding of tungsten electrodes and their applications. Practical Training Exercises: Should be able to prepare butt joints in Carbon Steel pipe (114.3mm 0.0. x 810mm thick.) in Horizontal and Vertical positions (Radiographic quality). -with root run by GTAW process. -Filler runs to be completed with MMAW process . Should be able to prepare butt joints on S.S. pipe (50mm 0.0. x 2-3mm thick.) - In Horizontal position. - In Vertical position.

Tests Conducted
Courses GTAW - Butt Weld on C.S. plate Or - Butt Weld on C.S. pipe - Root by GTAW and subsequent runs by MMAW GTAW Fillet Weld on S.S 304 plate Tests Conducted a. Radiographic Examination. b. Root Bend Tests 2 Nos. a. Radiographic Examination. b. Root Bend Tests 2 Nos. Visual Examination Position of Welding 3G (PF) Size Size of each coupon: 300mm long x 150mm width x 5mm thick. 114.3 O.D (100mm NB) x 4 to 5 mm thickness Thickness = 2 to 3 mm

5G (PF) 2F (PF) & 4F (PD)

Training program
For welders with experience 3 to 6 years For welders having completed training modules I to XII
Period 3 Weeks (150 Hrs.) MMAW Section
XIII Classroom 1. Lectures on different welding power sources that are used in welding industries. 2. Knowledge of different welding position with respect to pipe. 3. Lectures on head cutting and edge preparation and setting of pipe. 4. Knowledge of different electrodes being used in pipe welding. Practical Training Exercises: . Should gain knowledge of gas cutting of pipes of different thicknesses using different sizes of gas cutting nozzles . Should be able to make the edge preparation of pipes by grinding and filing and should prepare the pipe by setting proper root gap and root face and included angle . Should be able to identify D.C. Welding power sources and should know their features. Should know about polarity of the welding machine and which polarity is to be chosen for which type of electrodes . Should be able to lay beads on plates with E 7018 (Low Hydrogen electrodes) of sizes 2.5mm, 3.15mm and 4.0mm by setting proper current and voltage . Should be able to lay beads with stringer technique as well as weave bead technique . Should be conversant with minor troubleshooting in different D.C. Power sources . Should know about uphill technique and downhill technique of welding in pipes. XIV Classroom 1. Lectures on knowledge of tacking of pipes 2. Lectures on knowledge of joint preparation and welding techniques for pipe welding

3. Lectures on knowledge of different carbon and low alloy steels that are welded and basic idea of weld ability. 4. Knowledge of different electrodes being used in pipe welding. Practical Training Exercises: Should expertise manipulation of electrodes in Flat(1G)and vertically fixed (2G) position in pipe 6O.D.(168.3mm O.D x 10-12mm thick). Should be conversant with proper technique and manipulation of electrodes with multi runs of radiographic quality. Should know and exercise how the root run is to be laid by proper crater filling . Should exercise manipulation of electrodes in Horizontally Fixed (5G) and 45 inclined position (6G) in pipes. Pipe size: 6" 0.0. (168.3mm 0.0. x 10/12 mm thick) . Should know the technique of uphill welding in 5G and 68 positions. Should know the progression of welding in 5G & 6G positions . Should learn the technique of downhill welding of pipes in 6G position . Should know and exercise how the root run is to be laid by proper crater filling and then how the subsequent passes are to be laid in multi-run welding of radiographic quality. XV Classroom 1. Lectures on knowledge of important Nation/international standards on pipes. 2. Lectures on knowledge of welding Procedure Specification (WPS). 3. Knowledge of special consumables for pipe welding and parameters for different technique. 4. Knowledge of the causes of weld defects in pipe welding and how to avoid/rectify them. Practical Training Exercises: Should practice and prepare butt welds in pipes in 5G and 6G position by uphill technique and downhill technique. Should have a basic idea of how to examine a weld join after welding by visual examination a) For root pass: i) Check whether penetration is satisfactory. ii) Check whether there is any burn through or there is any root concavity and see if excess penetration at the root is there. b) For hot pass: i) Check whether proper cleaning of root is done. ii) Check whether any under fill in root pass has been covered. Should gain knowledge of checking the root run in pipe by Dye-Reentrant process.

Should gain basic idea as to weld different joints in pipes as per given Welding Procedure Specification (WPS). Should acquire basic idea of manipulation of electrodes during different runs in pipe welding.

Tests conducted
MMAW (For Butt Joints on C.S. pipe) a. Radiographic Examination. b. Root Bend Tests 2 Nos. c. Face Bend Tests 2 Nos. 5G (PF) & 6G (HL045) D = 125 150 mm Total Length = 200-225 mm Thickness = 10-12 mm

GTAW Section
XVI Classroom 1. Lectures on basic knowledge of Carbon Steel and Stainless Steel materials their properties, characteristics and weld ability. 2. Lectures on basic knowledge of shielding gas used for GTAW process. 3. Lectures on different national and international standers used in GTAW process. Practical Training Exercises: Should learn how to attach the regulator to the cylinders and how to open it. Should learn how to set the flow meters. Should learn how to fit the argon torch and should know to set the polarity in the D.C. Welding machine . Should be able to produce butt welds in Horizontal (5G) and inclined at 45 (6G) position on C.S. tubes (100 to 125mm 0.0. x 8-10mm thick) with root run by GTAW and filler and final runs by MMAW process. The weld should be radiographic quality. Minimum 2 to 3 test pieces are to be welded. XVII Classroom 1. Lectures on basics if special GTAW processes-Pulsed TIG and mechanised TIG. 2. Lectures on classification of different GTAW filler wires for C.S and .S.S. Practical Training Exercises: Should be able to produce butt welds in branch connection (set on) on tube to tube joints for C.S. and S.S . Should be able to produce butt joints on S.S. pipe ( Dia = 40 to 80mm x 5mm thick) by full GTAW process of radiographic quality.

Tests Conducted
GTAW - Butt Weld on Carbon Steel plate Or - Butt Weld on Carbon Steel pipe GTAW Butt Weld on S.S. 304 pipe a. Radiographic Examination. b. Root Bend Tests. a. Radiographic Examination. b. Root Bend Tests. Radiographic Examination. 4G (PE) Size of each coupon: 300mm long x 150mm width x 5mm thick. 114.3 O.D (100mm NB) x 4 to 5mm thick. 88.9 O.D x 4 to 5 mm thick.

6G (H-L045) 6G (H-L045)

End of Training Program Terms and Conditions :

The training program is designed for IBR qualification Total Training program 500 Hrs. All certification/qualification cost to the student/customer. Every Welder will be allotted min. 25 Hrs. practice on CS Wave Virtual Welding Trainer to develop/enhance skill of hand.