The Advanced Quality Centre (AQC) in Coimbatore is committed to maintaining the highest welding standards and ensuring that every welder meets rigorous industry requirements. This qualification program aims to verify and certify the competency of welders for welding blocks used in various critical applications, ensuring adherence to safety and quality standards.

Objective of Welder Qualification

The main objectives of this qualification program are:

  • To evaluate the welding skills and knowledge of welders.
  • To ensure the ability to produce welds that meet defined industry codes and standards.
  • To certify welders for specific welding processes, materials, and positions for block welding applications.

Scope

This qualification covers the following aspects:

  • Welding Processes: Manual Metal Arc Welding (SMAW), Gas Tungsten Arc Welding (TIG), Metal Inert Gas Welding (MIG), and Flux-Cored Arc Welding (FCAW).
  • Material Types: Mild steel, stainless steel, alloy steel, and other ferrous and non-ferrous materials.
  • Welding Positions: Flat (1G), Horizontal (2G), Vertical (3G), and Overhead (4G).
  • Application: Blocks for structural, mechanical, and industrial applications.
  • Qualification Levels: Welder qualification for multiple skill levels (e.g., Welder, Senior Welder, and Welding Supervisor).

Welder Qualification Procedure

The qualification process includes a series of steps to assess a welder’s ability to perform welding tasks in real-world conditions.

Step 1: Initial Welder Evaluation

  • Welder’s Experience and Background: Collect information on previous welding experience and prior certifications.
  • Health and Safety Briefing: Ensure that the welder understands safety protocols and is fit to work in a welding environment.

 

Step 2: Welder Test Procedure

The test involves several critical phases:

  • Material Preparation: Select the appropriate block materials for the test. This includes ensuring materials are free of contaminants (rust, dirt, oil) and properly aligned.
  • Welding Process Setup: The welder will use the selected welding process (e.g., TIG, MIG) to fabricate a test weld on the blocks. The machine settings (e.g., voltage, amperage) must align with the specified Welding Procedure Specification (WPS).
  • Welding Positions: The welder will perform the test in the positions as specified (Flat, Horizontal, Vertical, Overhead).

Step 3: Post-Weld Inspection

Once the welding is completed, a detailed inspection will be performed:

  • Visual Inspection: Check for defects such as cracks, undercuts, porosity, and incomplete fusion.
  • Non-Destructive Testing (NDT): Depending on the requirements, perform tests like ultrasonic testing (UT), X-ray inspection, or dye penetrant testing (DPT) to ensure weld integrity.
  • Destructive Testing (If Applicable): Include tensile testing, bend tests, or macro etch testing for more comprehensive results.

Step 4: Documentation

  • Qualification Records: Upon successful completion of the test, a welder qualification record (WQR) will be issued. This includes details of the welder, welding process, test results, and the scope of qualification.
  • Certification: A certificate will be issued to the welder, indicating the specific processes, materials, and positions they are qualified for.

Welder Test Requirements

  • Test Coupon Specifications:
  • Material Type: Mild Steel (IS2062), Stainless Steel (AISI 304, 316), or Alloy Steel (as per requirement).
  • Thickness: 6mm to 50mm depending on the block size and application.
  • Size of Test Coupon: Typically 150mm x 150mm x thickness of the block material.
Welding Parameters:
  • Electrode/Consumable Selection: Choose electrodes, filler wires, or rods that match the material grade.
  • Preheat/Interpass Temperature: Preheat requirements depending on material thickness and type.
  • Welding Speed/Heat Input: Controlled to prevent defects such as burn-through or warping.
  • Test Positions: Conduct tests in Flat (1G), Horizontal (2G), Vertical (3G), and Overhead (4G) positions to ensure versatility.

Safety Requirements

Personal Protective Equipment (PPE):

  • Safety goggles, welding helmets, gloves, fire-resistant jackets, and boots.
  • Adequate ventilation for proper fume extraction.
  • Fire prevention measures such as fire extinguishers and fire blankets.

Welding Environment:

  • Clean, dry, and well-lit work areas.
  • Proper grounding of welding machines.
  • Availability of first-aid kits and trained personnel for emergencies.

Post-Qualification Requirements

Maintenance of Qualification:

  • Welders must undergo periodic audits and performance evaluations.
  • Requalification may be necessary for changes in material types, welding processes, or equipment.

In cases where the welder has not been active in welding for a period, a requalification process will be required.

Certification and Record-Keeping

  • Qualification Validity: Welder certification is valid for 2-3 years, after which recertification or requalification may be required.
  • Documentation Retention: Qualification records are stored for future reference, ensuring traceability for quality control purposes
  • Issuance of Certificates: Upon successful qualification, a certificate with the welder’s unique ID, process, materials, and test position will be provided

Conclusion

AQC’s Welder Qualification Program ensures that every welder is fully equipped to handle high-quality welding operations for blocks, meeting international standards. The rigorous testing and qualification process uphold the integrity and safety of welded products, giving clients confidence in the quality and reliability of welded structures.

 

FOR MORE INFORMATION AND TRAINING:

  • Contact ADVANCED QUALITY CNTRE (AQC)
  • Mail ID : [email protected]
  • Contact: 8668082413
  • Visit as : https://aqcinspection.com/
  • Address: 100 ft road, Gandhipuram, Coimbatore.

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