Professional Welder III
PWIII is designed specifically for the student who already has previous welder training to at least the level of structural certification. This program will allow the student to progress from structural welding to pipe / boiler tube welding. It is structured using 14 individual modules for a total of 632 clock hours of training. During the program students will master pipe / boiler tube welding with the SMAW and GTAW processes.
In addition to the hands-on craft training, students will also complete modules in welding metallurgy, non-destructive examination, QA/QC, and resume building / interview skills.
Module 16: Shielded Metal Arc Welding (SMAW) – Part 3, 6” pipe
Description: Shielded Metal Arc Welding – Part 3, 6” pipe is designed to introduce the student to the world of pipe welding. The first section of this module focuses on training students to deposit open root groove welds using the 1/8” E6010 electrode followed by 1/8” E7018 fill and cap passes. Students will train on 3/8” carbon steel plate in the 2G, 3G, and 4G positions passing a visual examination and guided bend test for each. Students will then transition to self paced practice on 6” sch. 80 carbon steel pipe and will begin a number of proficiency tests designed to train the student in depositing sound, visually acceptable open root groove welds in the 2G, 5G (vertical up and downhill root progression), 6G, and 6G-restricted positions. Students will also build on previously learned skills in welding symbols and blueprint reading through the use of drawings provided for each proficiency test. The proper navigation and compliance with a WPS (Welding Procedure Specification) will also be reinforced throughout this module. Culmination of the module will be successful completion of (1) each of a 6” sch. 80 2G, 5G, and 6G ASME Section IX pipe test. Each test coupon must pass a visual examination as well as guided bend testing.
Objective: Upon successful completion of module 16 the student will be able to perform the following; describe the basic theory for the use of groove welds in piping systems, identify the parts of a pipe groove weld, understand how to visually inspect a pipe groove weld (root and cap), and proficiently deposit sound, visually acceptable groove welds in the 2G, 5G, and 6G positions using 1/8” E6010 root electrode and 1/8” E7018 fill and cap electrode.
Duration: 2 weeks, 80 clock hours
Module 17: Shielded Metal Arc Welding (SMAW) – Part 4, 2” pipe
Description: Shielded Metal Arc Welding – Part 4, 2” pipe is designed to increase the student’s skill level on pipe by transitioning from training on 6” sch. 80 to 2” sch. 80. Students will begin self paced practice on 2” sch. 80 carbon steel pipe and will begin a number of proficiency tests designed to train the student in depositing sound, visually acceptable open root groove welds in the 2G, 5G (vertical up and downhill root progression), 6G, and 6G-restricted positions. Students will also build on previously learned skills in welding symbols and blueprint reading through the use of drawings provided for each proficiency test. The proper navigation and compliance with a WPS (Welding Procedure Specification) will also be reinforced throughout this module. Culmination of the module will be successful completion of (1) each of a 2” sch. 80 2G, 5G, and 6G ASME Section IX pipe test. Each test coupon must pass a visual examination as well as guided bend testing.
Objective: Upon successful completion of module 17 the student will be able to proficiently deposit sound, visually acceptable groove welds in the 2G, 5G, and 6G positions using 3/32” E6010 root electrode and 3/32” E7018 fill and cap electrode.
Duration: 2 weeks, 80 clock hours
Module 18: Non-Destructive Examination – Part 1, VT, PT & MT
Description: Non-Destructive Examination - Part 1 is a fundamental course that introduces welding students to the broad field of NDE. The module uses an excellent training course developed by the American Welding Society titled “The Science of Non-Destructive Testing”. In Part 1, students will gain a fundamental understanding of the science and application of visual examination (VT), liquid penetrant examination (PT), and magnetic particle examination (MT). Topics will include common weld discontinuities and their causes, as well as the role of vision, capillary action, and magnetism. Students will also gain an understanding of what weld discontinuities can be identified with each method and how each method is applied in various construction codes and standards.
Objective: Upon successful completion of module 18 and a 75% minimum passing grade of the written examination, the student will have a fundamental understanding of both the science and application of VT, PT, and MT.
Duration: 8 clock hours
Module 19: Shielded Metal Arc Welding (SMAW) – Part 5, 1” socket weld pipe
Description: Shielded Metal Arc Welding – Part 5, 1” socket weld pipe is designed to train students on how to fit and weld these very common but often improperly performed joint designs. Students will begin self paced socket weld practice using 1” carbon steel pipe and 3000# class carbon steel fittings completing joints in the 2F, 5F, 4F, and 4F restricted positions. Training will help students develop the skills necessary for depositing smooth, consistent, properly sized socket welds. Additional skills covered will include how to properly gap, fit, and tack a socket weld joint as well as how to properly excavate a socket weld without damaging pipe and / or fitting as is often necessary in plant maintenance applications. Students will also build on previously learned skills in welding symbols and blueprint reading through the use of drawings provided for each proficiency test. The proper navigation and compliance with a WPS (Welding Procedure Specification) will also be reinforced throughout this module. Culmination of module 19 will be successful completion of (1) carbon steel pressure vessel fabricated from multiple pipe and fitting sizes combining both groove and socket welds in various positions welded with the SMAW process and tested to 1,000 psi.
Objective: Upon successful completion of module 19 the student will be able to properly fit and proficiently deposit smooth, consistent, properly sized socket welds in the 2F, 5F, 4F and 4F restricted positions using 3/32” E7018 electrodes.
Duration: 1 week, 40 clock hours
Module 20: Gas Tungsten Arc Welding (GTAW) – Part 1, basic
Description: Gas Tungsten Arc Welding – Part 1, basic, is designed to introduce the student to the foundational principals of the GTAW process and begin building hands on proficiency with the use of ER70 series filler wire. Students will learn a brief history of the process, gain an understanding of the theory behind how it works, and learn about the equipment and consumables used for GTAW. This training will include the different types of power sources as well as the AWS classification system for GTAW electrodes and rods. Once these topics are covered the student will begin self paced practice on a number of proficiency tests designed to train the student in techniques such as proper arc starting, re-starts, overlapping beads, and 2F, 3F, and 4F fillet welds on carbon steel plate. Students will be introduced to the concept of a WPS (Welding Procedure Specification), what its purpose is, what it contains, and how to navigate it. Culmination of the module will be a final project fabricated from a drawing containing fillet welds in the 2F, 3F, and 4F positions.
Objective: Upon successful completion of module 20, a 75% minimum passing grade of the written examination, and a passing visual examination on each of the proficiency tests the student will be able to perform the following; describe the basic theory behind GTAW, identify equipment and consumables used for the process, perform basic troubleshooting and safety inspections of the equipment, and proficiently deposit smooth, consistent, properly sized fillet welds in the 2G, 3G, and 4G positions using ER70 series filler wire on carbon steel plate.
Duration: 2 weeks, 80 clock hours
Module 21: Combination Gas Tungsten Arc Welding (GTAW) / Shielded Metal Arc Welding (SMAW) – Part 1, 6” pipe
Description: Combination GTAW / SMAW – Part 1, 6” pipe is designed to introduce the student to the world of pipe welding. The first section of this module focuses on training students to deposit open root groove weld roots and hot passes with the GTAW process using the 1/8” ER70S-2 filler wire followed by 1/8” E7018 fill and cap passes. Students will train on 3/8” carbon steel plate in the 2G, 3G, and 4G positions passing a visual examination and guided bend test for each. Students will then transition to self paced practice on 6” sch. 80 carbon steel pipe and will begin a number of proficiency tests designed to train the student in depositing sound, visually acceptable open root groove welds in the 2G, 5G, 6G, and 6G-restricted positions. Students will also build on previously learned skills in welding symbols and blueprint reading through the use of drawings provided for each proficiency test. The proper navigation and compliance with a WPS (Welding Procedure Specification) will also be reinforced throughout this module. Culmination of the module will be successful completion of (1) each of a 6” sch. 80 2G, 5G, and 6G ASME Section IX pipe test. Each test coupon must pass a visual examination as well as guided bend testing.
Objective: Upon successful completion of module 21 the student will be able to perform the following; describe the basic theory for the use of groove welds in piping systems, identify the parts of a pipe groove weld, understand how to visually inspect a pipe groove weld (root and cap), and proficiently deposit sound, visually acceptable groove welds in the 2G, 5G, and 6G positions using 1/8” ER70S-2 filler wire for root and hot passes and 1/8” E7018 for fill and cap passes.
Duration: 2 weeks, 80 clock hours
Module 22: Combination Gas Tungsten Arc Welding (GTAW) / Shielded Metal Arc Welding (SMAW) – Part 2, 2” pipe
Description: Combination GTAW / SMAW – Part 2, 2” pipe is designed to increase the student’s skill level on pipe by transitioning from training on 6” sch. 80 to 2” sch. XXH. Students will begin self paced practice on 2” sch. XXH carbon steel pipe and will begin a number of proficiency tests designed to train the student in depositing sound, visually acceptable open root groove welds in the 2G, 5G, 6G, and 6G-restricted positions. Students will also build on previously learned skills in welding symbols and blueprint reading through the use of drawings provided for each proficiency test. The proper navigation and compliance with a WPS (Welding Procedure Specification) will also be reinforced throughout this module. Culmination of the module will be successful completion of (1) each of a 2” sch. XXH 2G, 5G, and 6G ASME Section IX pipe test. Each test coupon must pass a visual examination as well as guided bend testing.
Objective: Upon successful completion of module 22 the student will be able to proficiently deposit sound, visually acceptable groove welds in the 2G, 5G, and 6G positions using 3/32” and / or 1/8” ER70S-2 filler wire for root and hot passes and 3/32” and / or E7018 for fill and cap passes.
Duration: 2 weeks, 80 clock hours
Module 23: Quality Assurance / Quality Control
Description: Module 23 is designed to introduce the student to the concept of Quality Assurance / Quality Control, the purpose and application of it in the welding industry and why as a welder it is important to have a basic understanding of how a QA/QC program works. Students will learn the structure of a typical ASME code shop QC Manual discussing topics such as drawing and specification control, material control, welding control, non-conformities, inspection, non-destructive examination, heat treatment, calibration, Authorized Inspector, and repairs and alterations. For each topic, real world examples from industry will be shared with students to help them begin to see the connection between QA/QC requirements and what takes place in the field or on the shop floor. Even though the material used is primarily from the perspective an ASME code boiler and pressure vessel shop, the QA/QC concepts learned are applied in other codes and standards as well.
Objective: Upon successful completion of module 23 and a 75% minimum passing grade of the written examination, the student will have a foundational understanding of QA/QC, the structure of a typical ASME QC Manual, and the ability to make the connection between real world industry scenarios and QA/QC requirements.
Duration: 8 clock hours
Module 24: Gas Tungsten Arc Welding (GTAW) – Part 2, 2” pipe
Description: GTAW – Part 2, 2” pipe is designed to increase the student’s skill level with the GTAW process on pipe by transitioning from training on 6” and 2” root and hot passes to depositing root, hot, fill, and cap passes on 2” sch. 80. Students will begin self paced practice on 2” sch. 80 carbon steel pipe and will begin a number of proficiency tests designed to train the student in depositing sound, visually acceptable open root groove welds in the 2G, 5G, 6G, and 6G-restricted positions. Students will also build on previously learned skills in welding symbols and blueprint reading through the use of drawings provided for each proficiency test. The proper navigation and compliance with a WPS (Welding Procedure Specification) will also be reinforced throughout this module. Culmination of the module will be successful completion of (1) each of a 2” sch. 80 2G, 5G, and 6G ASME Section IX pipe test. Each test coupon must pass a visual examination as well as guided bend testing.
Objective: Upon successful completion of module 24 the student will be able to proficiently deposit sound, visually acceptable groove welds in the 2G, 5G, and 6G positions using 3/32” and 1/8” ER70S-2 filler wire for root, hot, fill, and cap passes.
Duration: 1 week, 40 clock hours
Module 25: Non-Destructive Examination – Part 2 of 2, RT & UT
Description: Non-Destructive Examination - Part 2 builds on the student’s previously learned NDE knowledge gained in Part 1 by introducing two additional NDE processes. Like Part 1, this module also uses the American Welding Society’s “The Science of Non-Destructive Testing”. In Part 2, students will gain a fundamental understanding of the science and application of radiographic examination (RT) and ultrasonic examination (UT). Topics will include common weld discontinuities and their causes, as well as the role of radiation and sound in NDE. Students will also gain an understanding of what weld discontinuities can be identified with each method and how each method is applied in various construction codes and standards.
Objective: Upon successful completion of module 25 and a 75% minimum passing grade of the written examination, the student will have a fundamental understanding of both the science and application of RT and UT.
Duration: 8 clock hours
Module 26: Gas Tungsten Arc Welding (GTAW) – Part 3, 1” socket weld pipe
Description: Gas Tungsten Arc Welding – Part 3, 1” socket weld pipe is designed to train students on how to fit and weld these very common but often improperly performed joint designs. Students will begin self paced socket weld practice using 1” carbon steel pipe and 3000# class carbon steel fittings completing joints in the 2F, 5F, 4F, and 4F-R (restricted) positions. Training will help students develop the skills necessary for depositing smooth, consistent, properly sized socket welds. Additional skills covered will include how to properly gap, fit, and tack a socket weld joint as well as how to properly excavate a socket weld without damaging pipe and / or fitting as is often necessary in plant maintenance applications. Students will also build upon previously learned skills in welding symbols and blueprint reading through the use of drawings provided for each proficiency test. The proper navigation and compliance with a WPS (Welding Procedure Specification) will also be reinforced throughout this module. Culmination of module 26 will be successful completion of (1) carbon steel pressure vessel fabricated from multiple pipe and fitting sizes combining both groove and socket welds in various positions welded with the GTAW process and tested to 1,000 psi.
Objective: Upon successful completion of module 26 the student will be able to properly fit and proficiently deposit smooth, consistent, properly sized socket welds in the 2F, 5F, 4F and 4F restricted positions using 1/8” ER70S-2 filler wire.
Duration: 1 week, 40 clock hours
Module 27: Resume Building and Interview Skills
Description: The purpose of Module 27 Resume Building and Interview Skills is to ensure that as the student leaves NNEWI to enter the workforce they are adequately prepared with a solid resume and a sound understanding of what potential employers are looking for during a job interview. NNEWI staff will assist the student in generating a resume outlining their relevant skills, experiences, and education and ensure that the student leaves with a digitally saved copy so they can make their own changes / additions for future employment opportunities. NNEWI staff will also work with the student to ensure that they have an understanding of what some key points are that employers look for during a job interview.
Objective: Upon successful completion of module 27 the student will have a resume (paper and digital copy) ready for submission to potential employers as well as a solid understanding of what potential employers are looking for during a job interview.
Duration: 8 clock hours
Module 28: Gas Tungsten Arc Welding (GTAW) – Part 4, 6” sch. 10 stainless steel pipe
Description: GTAW – Part 4, 6” sch. 10 stainless steel pipe is designed to increase the student’s skill level with the GTAW process on pipe by transitioning from training on 6” and 2” carbon steel to 6” sch. 10 stainless steel. Students will begin self paced practice on 6” sch. 10 stainless steel pipe with a number of proficiency tests designed to train the student in depositing sound, visually acceptable open root groove welds in the 2G, 5G, and 6G positions with argon backing gas. Students will also build on previously learned skills in welding symbols and blueprint reading through the use of drawings provided for each proficiency test. The proper navigation and compliance with a WPS (Welding Procedure Specification) will also be reinforced throughout this module. Culmination of the module will be successful completion of (1) each of a 6” sch. 10 2G, 5G, and 6G ASME Section IX pipe test. Each test coupon must pass a visual examination as well as guided bend testing.
Objective: Upon successful completion of module 28 the student will be able to proficiently deposit sound, visually acceptable groove welds in the 2G, 5G, and 6G positions using 3/32” and 1/8” ER316L filler wire for root, hot, fill, and cap passes.
Duration: 1 week, 40 clock hours
Module 29: Gas Tungsten Arc Welding (GTAW) – Part 5, 2” sch. 10 stainless steel pipe
Description: GTAW – Part 5, 2” sch. 10 stainless steel pipe is designed to increase the student’s skill level with the GTAW process on pipe yet again by transitioning from training on 6” sch. 10 stainless steel to 2” sch. 10 stainless steel. Students will begin self paced practice on 2” sch. 10 stainless steel pipe with a number of proficiency tests designed to train the student in depositing sound, visually acceptable open root and fused root groove welds in the 2G, 5G, and 6G positions with argon backing gas. Students will also build on previously learned skills in welding symbols and blueprint reading through the use of drawings provided for each proficiency test. The proper navigation and compliance with a WPS (Welding Procedure Specification) will also be reinforced throughout this module. Culmination of the module will be successful completion of (1) each of a 2” sch. 10 2G, 5G, and 6G ASME Section IX pipe test. Each test coupon must pass a visual examination as well as guided bend testing.
Objective: Upon successful completion of module 29 the student will be able to proficiently deposit sound, visually acceptable groove welds in the 2G, 5G, and 6G positions using 3/32” and 1/8” ER316L filler wire for root, hot, fill, and cap passes.
Duration: 1 week, 40 clock hours