Course assess conditions

1. A minimum of a mechanical trade qualification at NZQA Level 4 (trade certificate), or an equivalent qualification and/or experience acceptable to CBIP.
2. This course requires proficiency in the comprehension and writing of English as used in the engineering industry, and basic mathematics.

The course format is a combination of self-study, online lectures, and assignments on the HERA e-Learning website.

The course has a comprehensive syllabus and the online format requires commitment. While it is possible to do the lectures in out-of-work hours, a structured approach of watching the lectures at the scheduled times offers the best chance of success.

Following each lecture, there is a self-study assignment to be completed on the HERA e-Learning website.

The lectures are held each day from 10am to noon, and are available to students to watch again later if required.

To take the examination students must have attended (watched) the online lectures and completed the corresponding self-study assignments on the HERA e-Learning website, and completed one-day of practical training on the visual examination of welds.

Certificate

All students who complete the course will receive a Certificate of Achievement confirming they have met the requirements of attending the lectures, completing the home assignments and the practical one-day training, and the examination of the HERA course Welding Engineering for Safety Inspections of Cable Logging Yarders.

Examination is mandatory to achieve the Certificate.

Scope of the course

1. Introduction to welding technology (1-hour webinar)

• Definitions, terminology
• Details of welds, joint design
• Welding processes: GMAW, FCAW, GTAW, MMAW. Application, advantages, and limitations for the construction and maintenance of mechanical plant

2. Welding standards (1-hour webinar)

• Applicable standards for the construction and maintenance of mechanical plants e.g. AS/NZS 1554 Part 1, 4, and 5, and overseas standards e.g. AWS.
• AS/NZS 1554.1 “prequalified” steels as used in mechanical plant
• “Non-prequalified” steels e.g. bolts, shafts, hydraulic cylinders
• Manufacturer’s specifications

3. Welding metallurgy (1-hour webinar)

• The concept of weldability (hydrogen-induced cracking, heat input, cooling rate, preheat, post-weld heat treatment)
• Materials of construction (properties, grades, specs and weldability):
  • Mild (carbon-manganese) steels
  • High strength Q&T steels and
  • Heat-treatable steels

4. Failure mechanisms in welds (1-hour webinar)

• Typical causes of damage: overload, high and low cycle fatigue
• Cracking mechanisms in welds (crack initiation and propagation, material properties, metallurgical and geometrical notches, critical locations)

5. Welding procedures and welder qualification (1-hour webinar)

• Qualification of welding procedures to AS/NZS 1554.1
• Selection of welding consumables
• Welders’ qualification

6. Weld defects and acceptance criteria (1-hour webinar)

• Weld imperfections (faults, defects)
• Weld imperfections: acceptance levels to AS/NZS 1554 Part 1 and 5

7. Inspection of welds on mechanical plant (1-hour webinar)

• Applicable inspection and Non-destructive Examination methods
• Visual testing of welded joints
• Inspection before, during and after welding
• In-service inspection
• Inspection and test plans

8. Repair welding (1-hour webinar)

• Planning, practicality (site conditions), limitations
• Repair procedures
• Identifying the material
• Selecting the type of welding to be carried out
• Preparing the material for welding, checking base metal soundness
• Repair of materials that have previously been weld-repaired
• Repair welding and fatigue

9. Practical inspection (one-day in-class training)

• Practical visual testing of welded joints to AS/NZS ISO 17637
• Assessment of sample welds
• Reporting visual examination results

Course dates:

1. Introduction to welding technology (1-hour webinar) 7 October 2022
2. Welding standard 9 October 2022
3. Welding metallurgy 14 October 2022
4. Failure mechanisms in welds 16 October 2022
5. Welding procedures and welder qualification 21 October 2022
6. Weld defects and acceptance criteria 23 October 2022
7. Inspection of welds on mechanical plant 28 October 2022
8. Repair welding 30 October 2022

Practical inspection (one-day in-class training at HERA)

Venue HERA House, 17-19 Gladding Place, Manukau, Auckland

The date TBC

All prices include GST.