“What You Need to Know About In-Service Welding Design, Implementation, Inspection & Testing, Regulation & Compliance”

Course Description
This training will address in-service welding onto gas and liquid pipelines under both typical and nontypical conditions. It describes the concerns, design implementation, inspection, and testing of in-service welds with particular emphasis on regulation/compliance review, recommended practices and case studies. In addition to the lecture portion, the course is designed to enable participants to successfully run PRCI Thermal Analysis Model for Hot Tap® Welding software and interpret the results.

The first portion of the course provides participants with an understanding of the factors that contribute to burnthrough or cracking. Participants will also learn the highlights of various technical resources that supplement the PRCI Thermal Analysis Model for Hot Tap® Welding program to provide a more comprehensive body of technical information pertaining to welding onto operating pipelines. 

Course Outline

Introduction
Arc Welding Overview

• Common Arc Welding Processes

Shielded Metal-Arc Welding (SMAW)

• SMAW Electrode Definition

Gas Metal Arc Welding (GMAW)

• GMAW Electrode Definitions
• GMAW Transfer Modes

Flux-Cored Arc Welding (FCAW)

• FCAW Electrode Definitions

Gas Tungsten Arc Welding (GTAW)

Burnthrough

• Factors Influencing Burnthrough
  • Pipeline Factors
  • Welding Factors
• Determining Burnthrough Risk
  • Thermal Analysis Models
  • Experimental Trials
  • Thermo-Mechanical Burnthrough Model
• Burnthrough Demonstrations
• Summary

Hydrogen Cracking

• Background
  • Weld Defects
  • Recent Significant Incidents
• Hydrogen Cracking Requirements
  • Tensile Stress
  • Crack Susceptible Microstructure
  • Welding Metallurgy 101
  • Hydrogen
• Hydrogen Demonstration
• Prevention of Hydrogen Cracking
• Summary

In-Service Welding Applications

• Full-encirclement Repair Sleeves
  • Type A and Type B Sleeves
  • Compression Sleeves
• Hot-tapped Branch Connections
• Weld Deposition Repairs
• General Design and Installation Practices
• Code Specific Requirements

Developing In-Service Welding Procedures

• Welding Procedure Organization
• Welding Procedure Qualification
• Procedure Options
  • Heat Input Control or Temper Bead Procedures
  • Preheat
• Inservice Welding Procedure Development and Guidance
  • EWI and DNV/Kiefner Approach
• Procedure Selection Examples
  • Battelle and PRCI Model
  • In-Service Welding Procedure Selection Guidance

What the Applicable Codes and Standards Say About In-Service Welding

• Intent of In-Service Procedure and Welder Qualification
• History of API In-Service Welding Codes
  • API 1107 to API 1104 Annex B 21st Edition
• Other Industry Codes Requirements for Inservice Welding
  • 4 2016, B31.8 2018 and PCC2 2018 and CSA Z66215
• Summary

Things To Do Before You In-Service Weld

• Welder/Procedure Qualification Approaches
• Heat input monitoring
• Pre-weld Inspection
• Pre-weld Field Guidance
  • Operating Conditions
  • Chemical Composition Determination
  • Low-hydrogen Welding Practices
• Preheat Methods
• Other Inservice Welding Concerns

Things To Do After You Perform An In-Service Weld

• Nondestructive Testing Methods for In-Service Welds
  • Common Testing Methods
  • Code Requirements for NDE
• Inspection Delay Time
• Fillet Weld Size Requirement
• Pressure Testing of Branch Connections
• Confirmation Coupons

Lessons To Be Learned and Simplified Approach to In-Service Weld

• Previously Reported Incidents
• Previously Unreported Incidents
• Five General Rules of Thumb
• Summary

The Role of PRCI Thermal Analysis Model for Hot Tap® Welding In Developing And Selecting Welding Procedures For Use On Pressurized Pipes

• History of Weld Cooling Rate Prediction
  • Battelle Model
  • EWI Heat Sink Capacity Measurement
  • PRCI Ho-tTap Model
• Procedure Development
  • Case 1 and Case 2
• Doing “What-if” Scenarios and Sensitivity Analyses
• Operating the PRCI Thermal Analysis Model for Hot Tap® Welding
• Interpreting the PRCI Thermal Analysis Model for Hot Tap® Welding software results
• Sources of Error and Conservatism

Provided

• Certificate of completion with 12 PDHs.
• Course notes provided electronically

Instructor Bio

Mr.  Matt Boring, Principal Engineer and Welding Group Lead at DNV

Matt is a registered Professional Welding Engineer in the State of Ohio as well as an AWS Certified Welding Engineer and AWS Certified Welding Inspector a pipeline welding engineer who is primarily involved in new pipeline construction including engineering critical assessments (ECA) as well as pipeline rehabilitation including in-service welding or hot-tap welding.  He started his career with EWI where he was responsible for a wide range of welding research projects for the pipeline, offshore structures, pressure vessel and nuclear industries. Mr. Boring joined Kiefner and Associates in 2012 where he continued his focus on welding research while expanding into the areas of code compliance and failure investigations of pipeline and associated components. More recently he joined the Incident Investigation Group at DNV where he continues to support the pipeline industry by providing a range of consulting services ranging from new construction, fitness for service, pipeline rehabilitation, and integrity.

Throughout his career, Mr. Boring has been heavily involved in oil and gas industry code development including membership and holding offices to several of the industry welding qualification codes. These memberships include being an API 1104 Committee voting member, ASME Section IX Committee member, ASME Section IX Sub-group member on welding qualifications, ASME PCC-2 Committee member and ASME PCC-2 Repair and Testing Subcommittee member. Mr. Boring is currently the co-chair of API 1104 Annex B Sub-committee which oversees the API 1104 in-service welding requirements and the chair of the ASME PCC-2 Welded Repair Sub-group.

Feedback

“Awesome and informative class. Thank you!”

“Great content. Learned a lot and was able to confirm or enhance knowledge I already had.”

“An expert on the subject.”

“Matt is clear and concise. He is a great presenter.”

“Handouts were very useful. Provided valuable information.”

“The videos were great!”

“Very knowledgeable and engaging instructor.”

“It was an overall good presentation. Good slides, instructor was very knowledgeable on subject matter.”

“The content was very informative and tailored to the audience’s needs” (company-specific webinar)

Very knowledgeable on the topic, obviously.  Deep dive into the fundamentals of the topic of welding and how to identify and minimize issues with cracking.”

“Instructor was very knowledgeable of the topics covered.”

“The in-service training provided a practical approach to welding based on science, experimentation, and field experience.”

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