Transmission and Distribution Course

A welding inspection course for Pipeline Construction and In-Service welding leading to a Certified Pipeline Welding Inspector’s certificate, (CPWI).

“Welding Inspection for Transmission and Distribution Pipelines” is taught by Mr. John Wormeli who has over 40 years of welding engineering and non-destructive testing experience on pipelines, pressure vessels and piping systems.  John graduated from LeTourneau, Longview, Texas, with a Bachelor of Science degree in Welding Engineering.  He worked for ACF Industries for 5 years and Atlantic Richfield for 13 years, prior to forming the National Welding Inspection School and his consulting business.

This program presents the codes and standards used in the construction of pipelines and distribution systems in the oil and gas industry.  Successful completion of this program leads to a Certificate for Pipeline Welding Inspection (CPWI) from the National Welding Inspection School.  Successful completion includes a passing score of 80% or greater on the 100 question open-book examination.  A calculator will be required for this program.

Course Curriculum

The latest editions of the following codes and standards presented in the program are listed:

API 1104, Welding of Pipelines and Related Facilities
Appendix B, API 1104, In-Service Welding
ASME B31.4, Liquid Transportation Systems for Hydrocarbons
ASME B31.8, Gas Transmission and Distribution Systems
API 5L, Specification for Line Pipe
DOT Part 192, Transportation of Natural and Other Gas by Pipeline
DOT Part 195, Transportation of Hazardous Liquids by Pipeline
Specifications for Electrodes and Filler Metals

Additional topics presented in this program include:

Preparation of Welding Procedures
Welder Qualification
Visual Welding Inspection
Pipe Inspection
Weld Joint Designs
Preheat Considerations
Electrode Selection
Weld Passes and effect on Properties
Removal of Arc Burns
Weld Repair Techniques
Weld Toughness (CVN Testing)
Weld and Heat-Affected Zone Hardness
Formulas for Welding Inspection
Weld Defects and Causes
Effect of Magnetism on Weld Quality
Measurement of Welding Parameters

First Day

The first day begins with an introduction and scope of the 2 ½ day program.  Definitions of pipeline terminology and mechanical testing activities are presented.  A detailed presentation of API 1104 including welding procedure development, welder qualification, visual inspection criteria and related examples are covered this first full day.

Second Day

The second day includes detailed presentations of ASME B. 31.4 and ASME B31.8, for Liquid and Gas Pipelines respectively.  In-Service Welding is presented in depth to assure all attendees are aware of the need for safe and proper procedures when welding on loaded, pressurized pipelines.  The details of Appendix B, API 1104, including the proper method for welding procedure development and welder qualification are discussed.

Note: In the late fall of 2011or early spring of 2012, the attendees will observe actual welding of split sleeves on loaded (water flowing) pipe in the new Burton Training Facility.  Classes will be offered specifically which cover all aspects of In-Service welding with various welding processes (SMAW, GMAW and FCAW) and heat inputs for various wall thicknesses.

Also covered on this second day is the “Inspection of Pipe” using API 5L as the foundation for the acceptance criteria.  Inspection items which will be covered for the welding inspector are the dimensional tolerances and what inspection tools are to be used to determine compliance to the pipe manufacturing tolerances. The effect of magnetism on pipe ends in relation to welding of the root pass will be covered and shown on PowerPoint slides and weld cross-sections.  The carbon equivalent of the pipe is discussed in the context of potential hardness and possible cracking. Preheat requirements are discussed in the event the carbon equivalent is higher than industry accepted values.

Welding electrode selection and the electrode classification system is presented this second day  to provide the attendees with the reasons for selecting the electrodes and/or filler metals for the procedure which will assure the  deposited weld metal strength meets or exceeds the strength requirements of the pipe material.  Other properties such as impact strength (CVN testing) and the very important hardness values of the weld and HAZ are discussed for both new construction and In-Service welds.

Weld Defects and Related cross-sections are presented on the second day also to assist in learning the specific pipeline weld defects and causes for these defects.

A 100 Question Open Book Examination will be handed out at the end of the Second Day to be turned in the next morning. A calculator is required in class and during exam).

Third Day

The class begins with each attendee turning in their completed test. The remainder of the program includes a presentation on the “Elements Of Inspection”. This three hour presentation uses PowerPoint to make relevant comments on all aspects of field weld inspection, from the pipe gang through the firing line to repairs and tie-ins.

Every inspection item which has some impact on the final weld quality is addressed in this presentation.  This is a very practical and important part of the program and includes pipe dimensional inspection activities including measuring for diameter and straightness compliance, measuring for magnetism on pipe ends, measuring  welding parameters to assure conformance to an approved procedure, and finally, inspecting the completed weld for visual compliance to API 1104 and company requirements.

Note: In the late fall of 2011 or early spring of 2012, the attendees will be required to go into the welding shop/laboratory (as part of their examination score) to conduct the measurements of pipe and welds, including wall thicknesses using ultrasonic thickness gages, magnetism using various gaussmeters, measuring various pipe diameters up to 42” using “Pi” tapes to determine potential “Hi-Lo” problems during alignment, visually inspect pipe welds on different pipe diameters for visual defects per API 1104 along with measuring welding parameters using various amperage and voltage meters. Shop personnel will be on-hand to assist the attendees in learning the proper use of the measuring equipment which is expected in the field.

At the completion of the program, the certificates, laminated certification cards, and letter of attendance stating completion of the program is issued to all attendees who have passed the exam. A score of 80% is required for passing.

Note: Classes are from 8:00 - 5:00 for the first and second day.  Class is completed by Noon on the third day. Schedule your travel plans accordingly.