Certification for Welding Lifting Lugs

DAVID CROSBY from Quantec Solutions outlines their two day course, the Certificate of Completion & Welding Procedure Qualification.

WELDING lifting lugs onto wear components is by its nature a high risk activity. There have been a number of incidents in recent history where welds have failed as a result of poor welding practices. This is not an acceptable situation.

One result has been industry seeking training that will enable their existing welders to hold an appropriate skill level, without being impractical in terms of cost or implementation time. Quantec Solutions has developed such training based on AS 1554 and AS 1796.

Quantec Solutions can now train and assess your staff to a welding procedure specific to welding lifting lugs as required within your obligations as an employer.

To support this training, Quantec Solutions has developed two standard welding procedures for the welding of lifting lugs in a wide range of applications, including:

• Jaw faces
• Mantles
• Concaves
• Wear plates

The course is carried out over two days optimising the training, and will assess and confirm that your staff can weld lifting lugs competently.

The training result is a “Certificate of Completion” – Welding Lifting Lugs’ & 2 x Welding Procedure Qualifications.

The ‘Welding Lifting Lugs’ course includes:

• Two lifting lug weld procedures using either 3.2mm or 4.0mm 312 electrodes
• Two weld procedure qualifications
• ‘Certificate of Completion – Welding Lifting Lugs’
• Certificate will include Photo Evidence of
  • Personnel Photo Identification of Welder
  • Photo of Welding Lifting Lug Test Coupon Results
• Formal dye penetrate and break test of welded lug
• Certificate will include test plate identification number, and certificate number
• Records stored for 25 years

COURSE OUTLINE

Day One
Safety – Two hours

• Welding safety requirements as per AS 1674 Parts 1 and 2
• Category welding environment A,B,C
• Hot work permit and PPE requirements
• Equipment safety
• Emergency response

Theory

• Welding fundamentals
• Welding positions
• Electrode selection, i.e. 4816, 309 or 312
• Lifting lug specifications

Practical

• Fillet welding in all positions, i.e. 1f, 2f, 3f and 4f
• All welding on Day 1 utilises low hydrogen electrodes

Assessment includes written safety test and visual assessment of fillet welds based on the requirements of AS 1554.1. SP

Day Two
Theory – Two hours

• Types of wear liners
• Carbon equivalent calculations
• Heat input calculations
• Electrode selection for the material type
• Understand lifting lug welding procedure
• Correct lug selection for the specific application

Practical – Six hours

• Practice welding of lifting lugs in all positions using 309 or 312 electrodes
• Lug welding examination on a mantle
• Assessment to the welding qualification procedure

The practical examination is visually assessed as per AS 1554.1 SP. Welds are then tested by dye penetrate prior to mechanical testing.

REFERENCES – AUSTRALIAN STANDARDS
AS 1988.1: 2006, Welding of ferrous castings – Steel castings
AS 1554.1 SP: 2004, Structural steel welding – Welding of steel structures
AS 1796: 2001, Certification of welders & welding supervisors
AS 1674.1 : 1997 , Safety in welding and allied processes – Fire precautions
AS 1674.2 – 2007, Safety in Welding & allied processes – Electrical

TRAINING COURSE AT QUANTEC SOLUTIONS
Location: Champion Road, Newport (EDI Rail Site)
Date: 25/06/2009 and 26/06/2009
Cost: $880 plus $137.50 resources (lunch provided)
BYO: Personal welding helmets & PPE

Bookings: Nicole Saliba – 03 9619 7833
Maximum 10 people per session

Location map and accommodation information is available on request.

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