Industrial Welder Level 3

Rev. September 2008

Industrial Welder Level 3

1 Rev. September 2008

Industrial Welder

Unit: A6 Pre-Interprovincial Review Level: Three Duration: 30 hours Theory: Instructor’s discretion Practical: Instructor’s discretion Overview: This unit offers apprentices a systematic review of skills and knowledge required to pass the Interprovincial “Red Seal” Examination. It provides the connections between on-the-job learning and the content of in-school technical training. The unit includes pertinent information about the significance of “Red Seal” IP certification and the main features of the IP exam. No testing is prescribed for this instructional unit; a Pass grade will be awarded for participation in this unit. Percent of Objectives and Content: Unit Mark (%)

1. Describe the significance, format, and general content of Interprovincial “Red Seal” Examinations. a. Scope and aims of “Red Seal” system; value of certification b. Obligations and entitlements of candidates for IP certification

• Relevance of IP Examination to current, accepted trade practices; industry-based national validation of test items

• Supplementals Policy (retesting) by the Apprenticeship Branch • Confidentiality of examination content; the certified journeyperson’s own stake in examination security

(value of credential) • Limitations on use of calculators (cannot be programmable)

c. Multiple-choice (four-option) item format; “Red Seal” and Apprenticeship Branch standards for acceptable test items (e.g. no “trick”-type questions; specifications for use of metric/imperial units)

d. Important government materials relevant to the IP Examination for apprentice industrial mechanics (millwrights) • National Occupational Analysis (NOA); prescribed scope of the skills and knowledge which comprise

the trade • NOA “Pie-chart” and its relationship to content distribution of IP Examination items • Manitoba Apprentice Portfolio, especially the NOA-based Practical Record Book and task and subtask

checklists

2. Identify resources, strategies, and other key considerations for maximizing successful completion of written exams used in certifying tradespeople. a. Personal preparedness b. Proper rest and nutrition, eye-testing c. Making room for a personal study regimen d. Focused reflection on prior test taking e. Self-assessment and a Personal Study Plan

• Preliminary self-assessment of individual strengths and weaknesses in trade-related skills and knowledge; usefulness of old tests; usefulness of Apprenticeship Portfolio checklists and reflection on the in-school and on-the-job components of the Apprenticeship Program

• Use(s) of approved textbooks, chapter tests, study guides, and note taking in preparing for an examination • Study groups; perils and possibilities • Formulation of a personal study plan, including an approximate timetable, which describes and schedules a course of action for

reviewing all relevant material(s) and for strengthening areas of deficient skills and knowledge


3. Review program content a. Safety, Tools, Weld Faults and OAW

• Trade Safety Awareness (ATQ Board Standard) • Orientation and safety • Oxy-fuel Welding, brazing and cutting • Introduction to GMAW, FCAW and SAW Processes • Trade Problems • Pre IP review

b. SMAW One • Introduction to SMAW • SMAW welds on 3/8” mild steel plate

c. SMAW TWO • Metallurgy I • SMAW welds on mild steel and stainless steel

d. GTAW One • GTAW process • GTAW welds on mild steel • GTAW and GMAW Welds on Aluminum • GMAW, SMAW, FCAW and MCAW Welds on Mild Steel Pipe

e. Pattern Development and Drawing Interpretation • Introduction to pattern development and geometric construction • Layout • Welding Symbols • Estimating

f. SMAW Three • Stainless steels and nickel alloys and clad steels • SMAW welds on mild steel pipe and oxy-fuel cutting on mild steel • GTAW 2 welds on mild steel plate and pipe

g. Drawing interpretation • Introduction to drawing interpretation • Structural drawings • Piping drawings • Pressure Vessel Drawings

h. Trade Science • Testing • Metallurgy • Heat Treatment • Codes and Standards

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Industrial Welder

Unit: E4 Estimating Level: Three Duration: 7 hours Theory: 7 hours Practical: 0 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of estimating. Percent of Objectives and Content: Unit Mark (%)

1. Convert angular (degree) measurements to linear dimensions. 15% a. Converting angular measurements to linear measurements. b. Units of angular measurement. c. Arc length. d. The right triangle.

• Pythagorean theorem • Ratio • Trigonometry

e. Trigonometry tables.

2. Calculate the cost of steel sections given the price per unit weight. 15% a. Calculating the cost of steel. b. Designations of various structural shapes.

• Angle • Tee • Channel • Zee • Standard S-Beam (I-Beam) • Wide-Flange Beam • Rectangular and square bar • Round bar and half round bar • Hexagon bar • Hollow structural steel (HSS)

3. Estimate the total costs for a given project. 70%

a. Estimating b. Generating the estimate and quote.

• Generate an estimate sheet • Develop your quote on a recapitulation sheet


Industrial Welder

Unit: F1 Stainless Steel, Nickel Alloys and Clad Steels Level: Three Duration: 8 hours Theory: 8 hours Practical: 0 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of stainless steels and welding procedures. Percent of Objectives and Content: Unit Mark (%)

1. Describe the characteristics of Stainless Steel. 10% a. Effects of Alloying Elements

• Chromium • Nickel • Manganese • Molybdenum • Carbon • Silicon

b. Properties of Stainless Steel • Thermal conductivity • Thermal expansion • Oxidation resistance

c. Weldability of Stainless Steel • Common grades of stainless steel are generally welded using:

- GMAW - GTAW - FCAW - SMAW - SAW - PAW (Plasma Arc Welding)

2. Describe the major types of Stainless Steel. 10%

a. Identify major alloying elements, AISI classifications and atomic structures • Austenitic • Atomic structure of austenitic stainless steel • Ferritic • Martensitic • Duplex • Precipitation hardening

3. Identify carbide precipitation and list ways of overcoming this problem. 10%

a. Limit the carbon content b. Add stabilizers c. Controlled heating and cooling d. Welding procedures


4. Identify major types of stainless steel filler metals. 10% a. Stainless steel SMAW electrodes b. Stainless steel GMAW, GTAW, PAW and SAW filler metals c. Stainless steel FCAW and flux cored GTAW filler metals d. Stainless steel consumable inserts

5. Describe handling procedures and preparation for welding stainless steel. 10%

a. Precautions for handling and storing stainless steel b. Preparation of stainless steel for welding c. Welding austenitic stainless steels d. Welding ferritic stainless steels e. Welding martensitic stainless steels

6. Describe nickel and its alloys. 10%

a. Types of nickel and nickel alloys. • Commercially pure nickel • Low carbon nickel • Monel alloys • Inconel alloys • Incoloy alloys • Nichrome alloys • Nimonic alloys • Hastelloy alloys

b. Chemical composition of selected nickel alloys c. Cryogenic applications

7. Describe the ability to locate and select appropriate filler metals in CSA specifications. 10%

a. Nickel and nickel alloy filler metals • Nickel and nickel alloy SMAW electrodes • Nickel and nickel alloy bare electrodes and rods

b. Selection of filler metals for nickel and nickel alloys 8. Explain welding procedures for nickel alloys and clad steel. 10%

a. Joint design b. Joint and surface preparation c. Preheat requirements d. Welding procedures:

• SMAW procedures • GMAW procedures • GTAW procedures • SAW procedures

9. Identify common weld faults with nickel and nickel alloys. 10%

a. Spatter b. Porosity c. Cracking

10. Describe clad steels and list their advantages. 10%

a. Clad steels • Bonding process

- Co-rolling - Welding - Casting - Explosive bonding - Furnace brazing

• Cladding thickness • Types of cladding • Types of backing steels

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Industrial Welder

Unit: F2 SMAW Welds on Mild Steel Pipe and Oxy-fuel Cutting on Mild Steel Level: Three Duration: 128 hours

Theory: 10 hours

Practical: 118 hours

Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of SMAW welds on mild steel and oxy-fuel cutting on mild steel. Percent of Objectives and Content: Unit Mark (%)

1. Identify SMAW welds on mild steel pipe. 20% 2. Prepare, fit-up and tack weld pipe for SMAW: 40%

a. SMAW on pipe • Preparation • Fit up and tacking procedure

b. Feathering tack welds • Results of proper tack feathering

c. Pipe welding positions • Pipe groove weld positions • Pipe fillet weld positions

d. Groove welds on pipe in the 2G and 5G positions e. Groove welds on pipe in the 5G position using a downhand weld progression

3. Perform SMAW groove welds in the 1G, 2G, 45º overhead, 4G and 4GF positions and perform

oxyfuel gas cutting. 40% a. Demonstrate the ability to weld in the 1G position on 9.6 mm (3/8”) mild steel using 3.2 mm

(1/8”) E41010 or E41011 for the root pass and 2.5 mm (3/32”) E48018 for each subsequent pass • Groove welds in the 1G position

b. Demonstrate the ability to weld in the 2G position on 9.6 mm (3/8”) mild steel using 3.2 mm (1/8”) E41010 or E41011 for the root pass and the 1st fill pass and the 2.5 mm (3/32”) E48018 for each subsequent pass • Groove welds in the 2G position

c. Demonstrate the ability to weld butt joints in the 45 degree overhead position on 9.6 mm (3/8”) mild steel using 3.2 mm (1/8”) E41010 or E41011 for the root pass and the 1st fill pass and 2.5 mm (3/32”) E48018 for each subsequent pass • Groove welds in the 45º overhead position

d. Demonstrate the ability to weld butt joints in the 4G position on 9.6 mm (3/8”) mild steel using 3.2 mm (1/8”) E41010 or E41011 for the root pass and 2.5 mm (3/32”) E48018 for each subsequent pass • Groove welds in the 4G position

e. Demonstrate the ability to weld butt joints in the 4GF position on mild steel plate according to CSA standard W47.1 • Groove welds in the 4GF position

f. Perform Oxyfuel gas bevel cutting on available mild steel • Oxyfuel cutting

d. Pierce and cut a wide flange structural shape opening in mild steel plate ***


Industrial Welder

Unit: F3 GTAW 2 Welds on Mild and Stainless Steel Plate and Pipe Level: Three Duration: 18 hours Theory: 15 hours Practical: 3 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with the knowledge and understanding of GTAW welds on mild and stainless steel plate and pipe. Percent of Objectives and Content: Unit Mark (%)

1. Identify GTAW welds on pipe 20% 2. Perform GTAW welds on pipe. 40% 3. Perform GTAW groove welds in the 1G, 2G and 3G positions; groove welds on pipe in the

2G and 5G position using stainless steel filler metal and groove welds on pipe in the 6G position using carbon steel filler metal. 40% a. Demonstrate the ability to weld in the 1G position on 6.5 mm (1/4”) mild steel plate.

• Exercise: 1G Welds on mild steel plate - Dip technique - Continuous feed technique - Suck-back - Fill and cap pass techniques

b. Demonstrate the ability to weld in the 2G position on 6.4 mm (1/4”) mild steel plate • Exercise: 2G Welds on mild steel plate

- Root bead using dip technique - Root bead using continuous feed technique - Fill and cap passes

c. Demonstrate the ability to weld in the 3G position on 6.4 mm (1/4”) mild steel plate. • Exercise: 3G Welds on mild steel plate

- Root bead dip technique - Root bead continuous feed technique - Filler rod positioning for the root bead - Fill pass and cap

d. Prepare and fit-up pipe for GTAW. • Pipe fit up • Tack welding procedure • Tack weld length and preparation

e. Demonstrate the ability to weld in the 2G position on available mild steel pipe using stainless steel filler metals. • Exercise: 2 G welds on mild steel pipe

f. Demonstrate the ability to weld in the 5G position on available mild steel pipe using stainless steel filler metals. • 5G Welds on mild steel pipe

g. Demonstrate the ability to weld in the 6G position on available mild steel pipe using carbon steel filler metals. • Exercise: 6G Welds on mild steel pipe

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Industrial Welder

Unit: G1 Introduction to Drawing Interpretation Level: Three Duration: 12 hours Theory: 12 hours Practical: 0 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with an introduction to drawing interpretation. Percent of Objectives and Content: Unit Mark (%)

1. Read and interpret drawings. 20% a. Purpose of drawings:

• Drawings and blueprints • Computer aided drafting • Specifications • The five divisions of blueprints

- Architectural drawings - Structural drawings - Mechanical drawings - Electrical drawings - Landscaping drawings

2. Identify elements and information found on drawings: 20%

a. Three basic elements of drawings: • Lines • Dimensions • Notes or specifications • Types of lines:

- Object lines - Hidden lines - Section lines - Centrelines - Extension and dimension lines - Terminals - Leader lines - Cutting plane lines and viewing plane lines - Short break lines - Long break lines - Phantom lines

b. Placement of dimensions • Notes and specifications

c. General layout of drawings


3. Interpret symbols, views and sections used on drawings: 20% a. Symbols:

• Corrections or revisions on prints • Symbols for detail drawings

b. Views: • Auxiliary view • Developed view • Revolved view • Untrue projection

c. Sections: • Full section • Half section • Offset section • Revolved section • Aligned section

4. Recognize and interpret abbreviations used on drawings. 20% 5. Identify site plans, benchmarks and orientation. 20%

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Industrial Welder

Unit: G2 Structural Drawings Level: Three Duration: 14 hours Theory: 14 hours Practical: 0 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with and introduction to structural drawings. Percent of Objectives and Content: Unit Mark (%)

1. Identify structural shapes and how they are specified. 20% a. Structural shapes:

• S shape • W shape • Welded wide flange beams • C shapes and MC shapes • L shapes • T shapes • Z shapes • HSS (Hollow structural section) square • HSS (Hollow structural section) round • Steel bar shapes

2. Identify types of structural drawings: 20% a. Engineering drawings:

• Perspective drawing • Site plan • Foundation plan • Framing plan • Elevations • Sections

b. Shop drawings: • Detail drawing • Assembly drawing • Detail assembly drawing

3. Obtain dimensions and other information from drawings. 20%

a. Dimensioning systems • Fractional system • Decimal system • Combined fractional and decimal system • Dual system • Metric system

b. Dimensioning methods • Baseline and conventional dimensioning


• Degree and angular dimensioning • Bevel and chamfer dimensioning • Drilled hole dimensioning • Tolerance dimensioning • Arrowless dimensioning • Tabular dimensioning • Radius, curve and arc dimensioning

c. Steel detailing terms • Gauge and pitch • Spread • Cope • Block • Bevels • Mitre joints • Right and lefts

4. Reference the bill of materials for drawings. 20%

a. Written information on drawings • Title block • Bill of materials • Bill of materials headings:

- Item number - Part number - Quantity - Description - Material - Weight

5. Interpretation of drawings. 20%

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Industrial Welder

Unit: G3 Piping Drawings Level: Three Duration: 16 hours Theory: 10 hours Practical: 6 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with and introduction to piping drawings. Percent of Objectives and Content: Unit Mark (%)

1. Define and explain the purpose of a spool sheet: 30% a. Spool sheet b. Pipe and common pipe materials

• Carbon steel pipe • Stainless steel pipe • Alloy steel pipe • Cast iron pipe • Copper tubing

2. Identify single line and double line drawings: 10%

a. Single line drawings b. Double line drawing

3. Interpret symbols that represent individual components on a spool sheet. 10%

a. Pipe fittings b. Pipe fitting symbols

• Advantages of a welded joint

4. Interpret relative position and orientation of piping systems from an isometric drawing. 10% a. Isometric piping drawings b. Isometric piping drawing procedures c. Isometric piping dimensioning

5. Interpret component sizes in a piping system from a spool sheet. 10%

a. Dimensioning welded pipe fittings • 90º Short radius elbow • 90º Long radius elbow • 90º Long radius elbow with long tangent on one end • 45º Elbow • Short radius return bend • Long radius return bend • Straight tee • Reducing tee • Straight cross • Reducing cross


• Reducing elbow • Lateral • Concentric reducer • Eccentric reducer • Welded outlet (weldolet)

6. Draw sketches of piping assemblies in schematic form from an isometric drawing. 15%

a. Interpreting piping assembly drawing views • Isometric view

b. Pipe coming toward you c. Pipe going away from you d. Pipes running on diagonals

7. Compile a material list for a simple piping system: 15% a. List of materials for piping systems

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Industrial Welder Unit: G4 Pressure Vessel Drawings Level: Three Duration: 16 hours Theory: 16 hours Practical: 0 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with and introduction to pressure vessel drawings. Percent of Objectives and Content: Unit Mark (%)

1. Identify external and internal vessel components. 40% a. Pressure vessels b. Pressure vessel orientation

• Shell of a vessel • Welds on a pressure vessel • Head of a vessel • Straight flange

c. External vessel attachments • Skirt • Base plate and anchor bolts • Saddles and wear plates • Supporting spherical vessels • Nozzles • Concentric and tangential connections • Nozzle projections • Internal projections • Reinforcing pads • Manways and davits • Bootlegs • Bridles and instrumentation • Platforms and ladders • Pipe supports and pipe guides • Clips, brackets and insulation rings • Lifting lugs • Vessel nameplate

d. Internal vessel attachments • Trays

- Bubble cap trays - Valve trays

• Baffles • Weirs • Downcomers • Demisters (mist extractors or mist eliminators) • Vortex breakers


2. Interpret pressure vessel drawings. 30% a. Title block b. Bill of materials, views and details c. Recycle cylinder vessel drawings

3. Identify material compositions as per code requirements on mill certification. 30%

a. Quality control system b. Six-step process to identify material composition

• Engineering • Purchasing • Receiving • Quality control • Fabrication • Quality assurance

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Industrial Welder

Unit: H1 Testing Level: Three Duration: 10 hours Theory: 8 hours Practical: 2 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with an introduction to non- destructive testing and destructive testing. Percent of Objectives and Content: Unit Mark (%)

1. Identify various non-destructive tests. 5%

a. Radiography • Sources of radiation • X-ray machines • Gamma ray sources • Producing a radiograph • Quality of the radiograph • Plaque-type penetrameters • Wire-type penetrameters • Film identification • Radiation hazards

b. Ultrasonic inspection • Flaw detection

c. Magnetic particle testing • Methods of magnetization • Magnetizing currents and particles

d. Liquid penetrant testing • Testing procedure

2. Describe visual inspection techniques. 5%

a. Visual inspection • Visual inspection

- Visual inspection before welding - Visual inspection during welding - After welding

3. Describe hydrostatic testing. 10%

a. Setting up for testing b. Testing c. Pneumatic testing

4. Identify types of destructive testing. 15% a. Destructive tests that prove weld integrity


• Guided bend testing • Nick break testing • Microscopic testing (including macroscopic examination)

b. Destructive tests that determine mechanical properties • Tensile testing • Charpy and Izod testing (impact testing) • Hardness testing

- Rockwell and Brinell test procedures c. Destructive tests that establish the expected minimum service life of the material

• Fatigue testing - Typical fatigue test results data sheet - Test conclusion

• Creep testing

5. Describe the advantages and disadvantages of destructive testing methods. 15% a. Suitability of destructive tests b. Advantages and disadvantages of destructive testing methods

• Guided bend testing • Nick break testing • Microscopic testing (including macroscopic examination) • Tensile testing • Charpy and Izod testing (Impact testing) • Hardness testing • Fatigue testing • Creep testing

6. Describe methods of conducting guided bend tests and the test results required of a

sound weld. 25% a. Guided bend tests b. Guided bend test acceptance standards

7. Describe tensile testing and the results of a tensile test. 25% a. Tensile testing

• Stress • Strain • ASTM standard 0.505” tensile specimen • Tensile test procedure • Definitions of terms used on stress/strain diagrams:

- Elastic deformation - Plastic deformation - Yield point - Ultimate tensile strength - Fracture point

• Ductility • Conclusion

- Hardness testing o The brinell hardness test and equipment o Rockwell test and equipment

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Industrial Welder Unit: H2 Metallurgy Level: Three Duration: 7 hours Theory: 7 hours Practical: 0 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with an introduction to metallurgy. Percent of Objectives and Content: Unit Mark (%)

1. Describe grain structure of metals, pure iron, slowly cooled carbon steels and 25% rapidly cooled carbon steels. a. Definition of terms related to the grain structure of steel:

• Austenite • Cementite • Ferrite • Martensite • Micrograph • Pearlite • Critical temperature range

b. The composition of steel

2. Describe dendritic grain growth. 25% a. Definition of terms related to dendrite formation b. Dendrite formation

3. Identify space lattice types in metals. 15%

a. Definition of terms related to space lattice types b. Space lattice types

• Allotropy

4. Identify changes in grain structure that result from welding. 25% a. Definition of terms related to welding metallurgy:

• Columnar grains • Critical range

b. Welding metallurgy • Quench rate of the weld • Affect of welding on the grain structure of the HAZ

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Industrial Welder

Unit: H3 Heat Treatment Level: Three Duration: 7 hours Theory: 5 hours Practical: 2 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with an introduction to heat treatment. Percent of Objectives and Content: Unit Mark (%)

1. Define heat affected zones in metals. 15% a. Heat affected zone b. HAZ grain structure of single pass and multi-pass welds c. Achieving an acceptable HAZ

2. Explain the difference between heat and temperature. 15% a. Temperature b. Heat

• Conversion factors - Selecting a fuel gas based on heat and temperature

3. Explain the three forms of heat transfer. 15%

a. Heat transfer • Radiation • Convection • Conduction

4. Describe the effects of expansion and contraction. 15%

a. Expansion and contraction from welding b. Free or volumetric expansion and contraction c. Restrained expansion and free contraction d. Restrained expansion and contraction e. Using expansion and contraction

• Using dimensional upset

5. Describe the purpose and effects of preheating and postheating. 15% a. Preheating

• Purposes of preheating • Effects of preheating • Preheat temperature

b. Postheating • Purpose of postheating • Postheating temperatures • Rate of heating and cooling


6. Define stress relieving, normalizing, annealing, hardening, tempering and quenching and their effects on mechanical properties. 15%

a. Postweld heat treatments b. Higher temperature heat treatments

• Normalizing - Local normalizing

• Annealing c. Hardening through heat treatment

• Flame hardening (steels over 0.35% Carbon) • Induction hardening

d. Lower temperature heat treatments • Stress relieving • Tempering

7. Describe the principle of temperature indicating crayons and other temperature indicating

devices. 10% a. Temperature-indicating devices

• Temperature-indicating crayons and pellets • Pyrometers and thermocouples

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Industrial Welder

Unit: H4 Codes and Standards Level: Three Duration: 7 hours Theory: 7 hours Practical: 0 hours Overview: This unit of instruction is designed to provide the Industrial Welder Apprentice with an introduction to codes and standards. Percent of Objectives and Content: Unit Mark (%)

1. Define the terms code, standard and specification. 15% a. Purpose of codes, standards and specifications

• Terms: - Codes - Standards - Specifications

b. Organizations that produce codes, standards and specifications • Historical development of codes, standards and specifications

- Codes and standards development for boilers and pressure vessels - Codes and standards development for welded structures

2. Identify the advantages of standardization. 15%

a. Compatibility and standardization b. Product quality and reliability c. Simplification of product design:

3. Identify agencies that set codes and standards. 15%

a. Standards Council of Canada b. American National Standards Institute (ANSI) c. Codes and standards related to welding d. CSA

4. Identify codes that govern welding in Canada for a) structural steel, b) boilers and pressure vessels, c) piping systems, d) pipelines and transmission systems and e) storage tanks. 15%

a. Codes and standards related to structural steel construction • CSA International W47.1 Certification of companies for fusion welding of steel structures

b. Table of contents c. Scope d. Jurisdiction e. Administration f. Welding Procedure Qualification g. Areas of interest to welders


h. CSA International CSA W59 welded steel construction (Metal Arc Welding) i. Codes and standards related to boilers and pressure vessels j. ASME boiler and pressure vessel code k. Specifications for welding rods, electrodes and filler metals

5. Describe a welding procedure qualification. 20% 6. Describe a welder performance qualification. 20%

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Industrial Welder Level 3

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Transcript of Industrial Welder Level 3