Welding education and WRI
The need for a systematic procedure for imparting knowledge and training in welding cannot be overemphasized. Blossoming from a skill and an art, to a science and technology, embracing multiple disciplines, and shining as a major manufacturing tool, WELDING, today enjoys a pride of place in the industry. Both the conventional and advanced welding processes are finding increasing application in Indian Industry, according due recognition to the varied needs of the Indian industries, the National Committee on Science & Technology recommended in 1972, the establishment of Research & Development facilities in welding science & technology in the country. The Govt. of India approved the recommendation for establishing the Welding Research Institute, as an adjunct to Bharat Heavy Electricals Limited’s (BHEL) manufacturing unit at Tiruchirappalli. The Welding Research Institute (WRI) was thus founded in November 1, 1975 with the active support of the Government of India through its designated agency, the BHEL, and with the technical and financial assistance under the United Nation Development Program (UNDP) through the United Nations Industrial Development Organization (UNIDO).
Education, Training & Certification
Besides application oriented research, Human Resource Development was one of the key areas identified during the establishment of this Institute. Accordingly, programmes for training and certifying welding and NDT personnel at four different levels has been developed taking into consideration the needs of the various fabricating industries. Broadly, the institute conducts various training programmes under the following categories:
- Training of welders for skill development
- Training and certifying of welders to National / International standards
- Training of technicians / supervisors
- Training of Engineers
Under each of these training programmes, different modules have been developed catering to the fabrication needs of the industry and in addition, training is also offered at customer works on case- to- case basis.
Training of Welders for Skill Development
WRI has a state-of-the-art welder training facility, equipped with the Inverter-based power sources, fume extraction devices and infrastructural facility to train about 50 welders at any given time, and even double it running two shifts. The availability of this unique facility helps welders from within the country and abroad to come for the training and get qualified, thereby enhancing their skill and employability potential.
One of the cornerstones of training programs is the acceptance of WRI training by various national and International certifying bodies like Central Boilers Board, American Welding Society (AWS), Welding Technology Institute of Australia (WTIA), etc. Apart from enhancing the skills of the candidate, the Institute also links with organisations, so as to help them in getting a suitable employment in the industry on their own merit. Training of sponsored welders in special materials and processes are also imparted to meet specific demands of the industry on a case –to-case basis viz. welding of titanium tubes for the shipping industry, Welding of Al & its, etc., for Automotive and Space applications. The special feature of these programmes is that while the welder is given ample opportunity to develop his skill by welding practically, theoretical inputs on the DOs and DONTs in welding are also given during classroom sessions. A comprehensive book on welding has been brought out by the institute and is given to all the welders as reading/reference material. This book describes pictorially the various nuances of welding viz. welding process, consumables selection, joint design, defects, welder qualification, safety, etc. and is easily grasped by the participant to enhance his / her knowledge in welding processes, consumables and joint selection, defects, qualification and safety aspects. Welder training by WRI is the most sought after and remains its crowning jewel.
Training of Technicians / Supervisors
Welding Research Institute has over the years, been conducting training programmes in welding and Inspection including Non-Destructive Testing for the technicians and supervisors. These programmes enhance and improve the testing and interpretation skills of the technicians so that they are better placed in the industry with regard to NDT techniques, welding processes and quality control.
Certification programmes up to ASNT Level II in various non-destructive testing methods are conducted at the Institute. These certification programmes are so designed that the candidates gets hands-on experience in the field of Non destructive testing and practical welding so that on completion the individual would be in a position to take up jobs as Inspectors/Instructors in the fabricating industry.
Training of Fresh Engineers
An eight-week module tailor-made by WRI for fresh engineers is ideally suited for fresh graduate engineers who desire to make a career in welding. The programme is so designed that it covers the entire gamut of welding technology consisting of materials, their weldability, various processes, design aspects in welding, distortion and its control, testing techniques both destructive and non-destructive, codes, selection of consumables, etc. Apart from classroom sessions, the candidate is required to undergo practical training in welding and testing so that he is in a position to appreciate the rigors of welding.
Training for Practicing Engineers
Short term programmes on specific topics such as design and distortion, materials and their weldability, welding and inspection, pipe welding and certification programmes for welding inspectors, etc. are conducted at the Institute for experienced and practicing welding personnel. These programmes are more focused and would normally involve discussions and experience sharing sessions so that all the participants are benefited by the interactions. WRI has so far conducted around 370 such short-term programmes to date to both National and International customers.
Package Programs
These programs, designed to meet specific customer requirements, are conducted at customers works so that greater number of participants could be benefited. The duration and design of these programmes are done after discussion with the customers. The lack of practical training is adequately supplemented by numerous case studies and examples for the benefit of the participants. WRI also conducts specific programmes designed to meet the requirements of the customers based on a ‘Weld- Audit’ conducted at the customers’ works.
Industry-Institute Interaction
WRI is supporting a post-graduate certification program along with PSG College of Technology, Coimbatore, on Welding & Quality Engineering. While the theoretical sessions are conducted jointly with the support of PSG College of Technology, Coimbatore, the practical sessions and ‘on the job’ training are realized at WRI / BHEL, Tiruchirappalli. To make the students industry ready, they are also trained & qualified to Level II in the four standard NDT techniques (LPI, MPI, RT & UT). This helps to enhance their employability potential, to cater to the demands of a globalized economy, and the increased need for certified welding professionals as per international standards. Over these seven years, this unique venture between the educational institute and a research organization primarily dedicated to welding has emerged an excellent example of industry-academia partnership. The curriculum is designed such that young engineering graduates with advanced welding engineering concepts and their applications can be readily employed in fabricating industries to take up responsible positions. The success of the programme can be seen in the consistent placement records of such certified professionals in the industry.
WRI has successfully used its unique positioning as an application-oriented research Institute to spread its knowledge in the field of welding in over four decades to establish itself as a premier world-class Institute benefitting thousands of skilled personnel in Welding Engineering. It is true that one out of five welding professionals in the country has undergone some training in WRI. That just shows the task cut out for the future!
[Contributed by Welding Research Institute BHEL, Trichy]
