SMAW L3

Copyright © DSD 2012

Department of Skills Development (DSD)

Federal Government Administrative Centre

62530 PUTRAJAYA, MALAYSIA

STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN

(NATIONAL OCCUPATIONAL SKILL STANDARD)

STANDARD PRACTICE, STANDARD CONTENT

&

CURICULUM of COMPETENCY UNIT

FOR

SHIELDED METAL ARC WELDING (SMAW) PROCESS

(PROSES KIMPALAN ARKA KEPINGAN LOGAM)

LEVEL 3

(TAHAP 3)

First Publish 2012

All rights reserved

No part of this publication may be produced, stored in data base, retrieval system, or in any form by any means, electronic, mechanical, photocopying, recording or otherwise without prior written permission from

Department of Skills Development (DSD)

STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN (NATIONAL OCCUPATIONAL SKILL STANDARD)

STANDARD PRACTICE, STANDARD CONTENT &

CURICULUM of COMPETENCY UNIT FOR

SHIELDED METAL ARC WELDING (SMAW) PROCESS (PROSES KIMPALAN ARKA KEPINGAN LOGAM)

LEVEL 3

(TAHAP 3)

Jabatan Pembangunan Kemahiran

Kementerian Sumber Manusia, Malaysia

Contents STANDARD PRACTICE ............................................................................................................................................................ 3

1. INTRODUCTION ......................................................................................................................................................... 3 Pre-requisite ......................................................................................................................................................................... 4 2. OCCUPATIONAL STRUCTURE ................................................................................................................................. 5 Fig. 1.0 Occupational Profile Chart for Shielded Metal Arc Welding (SMAW) Process (Level 3) personnel ........................ 5 Fig. 1.1 Occupational Area Analysis for Shielded Metal Arc Welding (SMAW) Process (Level 3) personnel ...................... 5 3. DEFINITION OF COMPETENCY LEVEL .................................................................................................................... 6 4. MALAYSIAN SKILL CERTIFICATION ......................................................................................................................... 7 Training delivery ................................................................................................................................................................... 7 5. JOB COMPETENCIES ................................................................................................................................................ 7 6. WORKING CONDITIONS ........................................................................................................................................... 7 7. EMPLOYMENT PROSPECTS .................................................................................................................................... 7 Malaysian Market ................................................................................................................................................................. 7 International Market .............................................................................................................................................................. 8 8. TRAINING, INDUSTRIAL/PROFESSIONAL RECOGNITION, OTHER QUALIFICATIONS AND ADVANCEMENT .. 8 9. SOURCES OF ADDITIONAL INFORMATION ............................................................................................................ 9 Local ..................................................................................................................................................................................... 9 International .......................................................................................................................................................................... 9 10. VALIDATION ........................................................................................................................................................ 11 11. ENDORSEMENT .................................................................................................................................................. 11 12. ACKNOWLEDGEMENT ....................................................................................................................................... 11 13. COMMITTEE MEMBERS FOR DEVELOPMENT OF STANDARD PRACTICE (SP), JOB PROFILE CHART (JPC), COMPETENCY PROFILE (CP) AND CURRICULUM OF COMPETENCY UNIT (CoCu) ...................................... 12

STANDARD CONTENT...........................................................................................................................................................13 COMPETENCY PROFILE CHART (CPC)...............................................................................................................................14 COMPETENCY PROFILE (CP)...............................................................................................................................................15 CURRICULUM of COMPETENCY UNIT (CoCU)....................................................................................................................32 SHIELDED METAL ARC WELDING (SMAW) FOR FILLET WELD 1F, 2F, 3F, 4F, BUTT WELD 1G AND 2G......................33 SHIELDED METAL ARC WELDING (SMAW) FOR 3G AND 4G.............................................................................................57 SHIELDED METAL ARC WELDING (SMAW) FOR 5G AND 6G (UP-HILL AND DOWN-HILL).............................................79 SHIELDED METAL ARC WELDING (SMAW) 6GR ..............................................................................................................100 SUBMERGED ARC WELDING (SAW) 1G ...........................................................................................................................120 TRAINING HOUR SUMMARY ..............................................................................................................................................141

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STANDARD PRACTICE

NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR; SHIELDED METAL ARC WELDING (SMAW) PROCESS

LEVEL 3

1. INTRODUCTION

Welding is a fabrication or sculptural process that joins materials, usually metals (such as steel, aluminium, brass, stainless steel etc.) or thermoplastics (plastic or polymer), by causing coalescence to form a permanent bond. The fabrication or sculptural process refers to building metal structures by cutting, bending, and assembling. They apply heat to metal pieces, melting and fusing them. They may work in a manual mode or in a semiautomatic mode, using machinery such as a wire feeder to help them perform tasks. In the domain of welding, arc welding is part of the welding types. Arc welding is a type of welding that uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. They can use either direct or alternating current and consumable or non- consumable electrode. The welding region is usually protected by some type of shielding gas, vapour, and/ or slag. Shielded Metal Arc Welding (SMAW), are one of the many processes in arc welding. Shielded Metal Arc Welding (SMAW), also known as Manual Metal Arc (MMA) welding, flux shielded arc welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode coated in flux to lay the weld. An electric current, in the form of either alternating current or direct current from a welding power supply, is used to form an electric arc between the electrode and the metals to be joined. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination. A person who is competent in Shielded Metal Arc Welding (SMAW) Process (Level 3) is an individual who is trained and qualified in compliance to codes, standards and requirements. This NOSS document shows the structured career path of Shielded Metal Arc Welding (SMAW) Process (Level 3) personnel. It provides structured set of activities that enables a person who aspires to achieve competency in this particular occupation, ultimately enhancing him or her on a career in the welding industry.

Standard Practice and Standard Content are part of NOSS document. The job areas being develop are based on the Occupational Area Analysis (OAA). This document covers the competency standard of Shielded Metal Arc Welding (SMAW) Process (Level 3) that is currently gaining priority in the welding industry. The panel of experts had concluded that this job area starts from tier 3 due to requirement of significant range of varied work activities and performed in a variety of context, most of which are complex and non-routine. There is considerable responsibility and autonomy and control or guidance of others is often required. Where by some of the activities are non-routine and required individual responsibility and autonomy. To produce skilled workers in this industry, the needs for structured training are essential.

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Pre-requisite Based on the workshop findings, it was decided that the minimum requirement for those interested to enrol this course are as follows: • 16 years of age or above • Good eyesight. • Medically and physically fit. • Able to read, write and perform simple calculation. These pre-requisite is in line with minimum requirements set by Construction Industry development Board (CIDB) and Department of Occupational Safety and Health (DOSH). With respect to the regulating bodies, the role is as follows: Construction Industry development Board (CIDB) As welding is an essential aspect of within the construction industry, the Board has taken the functions related to welding practices performed within the construction industry. Thus, functions of the Board as laid down under subsection 4 (1) of Act 520 are as follows: • To promote and stimulate the development, improvement and expansion of construction industry; • To advise and make recommendations to the Federal Government and the State Governments on

matters affecting or connected with the construction industry; • To promote, stimulate and undertake research into any matter related to the construction industry; • To promote, stimulate and assist in the export of service related to the construction industry; • To provide consultancy and advisory services with respect to the construction industry; • To promote quality assurance in the construction industry; • To initiate and maintain the construction industry information systems; • To encourage the standardisation and improvement of construction techniques and materials; • To provide, promote, review and coordinate training programmed organized by the public and

private construction training centres for skilled construction workers and construction site supervisors;

• To accredit and register contractors and to cancel, suspend or reinstate the registration of any registered contractor; and

• To accredit and certify skilled construction workers and construction site supervisors. Department of Occupational Safety and Health (DOSH) As a regulatory body which enforces the occupational safety and health aspects in Malaysia, the role of DOSH is to study and review the policies and legislations of occupational safety and health. This in particular is enforced in risky occupations such as in the welding industry. The following acts are been enforced by DOSH: a) Occupational Safety and Health Act 1994 and its regulations. b) Factories and Machinery Act 1967 and its regulations. c) Part of Petroleum Act 1984 (Safety Measures) and its regulations. d) Guidelines, codes of practice, circulars. With regard to the respective acts, DOSH comes forward to apply the functions as to: • Conduct research and technical analysis on issues related to occupational safety and health at the

workplace. • Carry out promotional and publicity programs to employers, workers and the general public to foster

and increase the awareness of occupational safety and health. • Carry out promotional and publicity programs to employers, workers and the general public to foster

and increase the awareness of occupational safety and health. • Become a secretariat for the National Council regarding occupational safety and health

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2. OCCUPATIONAL STRUCTURE

Shielded Metal Arc Welding (SMAW) Process (Level 3) weldercomes under the sub-sector Welding Process and Fabrication. Fig. 1.0 and 1.1 show the structured career path and area of Shielded Metal Arc Welding (SMAW) Process (Level 3) personnel.

SECTOR MACHINERY AND EQUIPMENT

SUB SECTOR WELDING TECHNOLOGY AND FABRICATION

JOB AREA ARC WELDING

JOB SUB AREA

SHIELDED METAL ARC WELDING

(SMAW)

GAS METAL ARC WELDING (GMAW)

GAS TUNGSTEN ARC WELDING

(GTAW)

FLUX CORED ARC WELDING (FCAW)

JOB LEVEL WELDING ENGINEER

L5 L4 WELDING COORDINATOR

L3 SMAW WELDER GMAW WELDER GTAW WELDER FCAW WELDER

L2 N/A

L1 N/A

Fig. 1.0 Occupational Profile Chart for Shielded Metal Arc Welding (SMAW) Process (Level 3) personnel

SECTOR MACHINERY AND EQUIPMENT

SUB SECTOR

WELDING TECHNOLOGY AND FABRICATION

JOB AREA

ARC WELDING

JOB SUB AREA


(SMAW)

GAS METAL ARC WELDING (GMAW)

GAS TUNGSTEN ARC WELDING (GTAW)

FLUX CORED ARC WELDING (FCAW)

JOB LEVEL WELDING ENGINEERING

L5 L4 WELDING COORDINATION

L3 SMAW PROCESS

GMAW PROCESS

GTAW PROCESS

FCAW PROCESS

L2 N/A

L1 N/A

Fig. 1.1 Occupational Area Analysis for Shielded Metal Arc Welding (SMAW) Process (Level 3) personnel

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3. DEFINITION OF COMPETENCY LEVEL

The NOSS is developed for various occupational areas. Candidates for certification must be assessed and trained at certain levels to substantiate competencies. Below is a guideline of each NOSS Level as defined by the Department of Skills Development, Ministry of Human Resources, Malaysia.

Malaysia Skills Certificate Level 1: Competent in performing a range of varied (Operation and Production Level) work activities, most of which are routine and predictable.

Malaysia Skills Certificate Level 2: Competent in performing a significant range (Operation and Production Level) of varied work activities, performed in a variety of contexts.

Some of the activities are non-routine and required individual responsibility and autonomy.

Malaysia Skills Certificate Level 3: Competent in performing a broad range of (Supervisory Level) varied work activities, performed in a variety of contexts,

most of which are complex and non-routine. There is considerable responsibility and autonomy and control or guidance of others is often required.

Malaysia Skills Diploma Level 4: Competent in performing a broad range of (Executive Level) complex technical or professional work activities performed

in a wide variety of contexts and with a substantial degree of personal responsibility and autonomy. Responsibility for the work of others and allocation of resources is often present.

Malaysia Skills Advanced Diploma Competent in applying a significant range of Level 5: (Managerial Level) fundamental principles and complex techniques across a

wide and often unpredictable variety of contexts. Very substantial personal autonomy and often significant responsibility for the work of others and for the allocation of substantial resources features strongly, as do personal accountabilities for analysis, diagnosis, planning, execution and evaluation.

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4. MALAYSIAN SKILL CERTIFICATION

Candidates after being assessed and verified and fulfilled Malaysian Skill Certification requirements shall be awarded with Sijil Kemahiran Malaysia (SKM) for Level 3.

Training delivery - Delivery in Bahasa Malaysia and/or English (especially for welding terminology)

5. JOB COMPETENCIES

Shielded Metal Arc Welding (SMAW) Process (Level 3) welders are competent in performing welding in accordance to Welding Qualification Test (WQT) as follows: • Shielded Metal Arc Welding (SMAW) For Fillet All Position, 1G And 2G • Shielded Metal Arc Welding (SMAW) For 3G And 4G • Shielded Metal Arc Welding (SMAW) For 5G And 6G

Optionally, the Shielded Metal Arc Welding (SMAW) Process (Level 3) personnel are competent in performing the following elective competencies:-

• Shielded Metal Arc Welding (SMAW) 6GR • Submerged Arc Welding (SAW) 1G

6. WORKING CONDITIONS

The Shielded Metal Arc Welding (SMAW) Process welder should be able to concentrate on detailed work for long periods and be able to bend, stoop, and weld in awkward positions. They may work outdoors, and must wear special clothing—safety shoes, gloves, and goggles, face shields or hoods, dust mask—to protect from the intense ultra violet (UV) rays created by arcs, hazardous fumes, and spark burns (spatters). Where ever applicable, the individual must obtain Permit To Work (PTW) from employers to ensure safe working condition. In order to be employed at work, the individual need to be qualified by the employer via Welder Qualification Test (WQT). Good eyesight is needed for visual inspection to check welding condition.

7. EMPLOYMENT PROSPECTS

Malaysian Market Ahead of 2011, the drive for Malaysian welding industries will be mainly driven by foreign investors and Government Link Company’s (GLC’s). This will eventually creates competition among service providers and contractors in providing competent welders, inspectors and all other related personnel. Thus, the welding industries in Malaysia are poised to grow in the near future. With the Government encouraging foreign investment, the country is set to become a manufacturing and construction hub in the region.

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Nevertheless current practice shows appointments of competent welders within construction domain are dominantly appointed on project basis. This resulted in most competent welder’s personnel within the construction domain to practice freelancing. With the growth of the welding industry in Malaysia the number of competent coded welders is greatly in demand, however the current volume of the welders is shortage to support the industry. Hence, this National Occupational Skill Standard (NOSS) was developed as reference to train and qualify welders to meet the growing industrial needs. The sectors in the industry which required welding expertise with respect to employment opportunities are:

• Oil and Gas • Boilers and Pressure vessels • Shipbuilding • Construction / Infrastructure • Power industry • Heavy equipment • Industrial machinery • Aerospace • Automotive • Vocational training

International Market This NOSS was developed taking into consideration of international standards and requirements. As such welders who have been trained and qualified would have better opportunities entering into the international market. For example, there is a high demand of competent coded welder in the Middle Eastern and African countries as well as Asian countries like Turkmenistan, Azerbaijan, etc due to its rapid industrial development. The most widely used international standards for welder’s certification are as follows:

• American Society of Mechanical Engineers (ASME) • American Welding Society (AWS) • American Petroleum Institute (API) • British Standard European Norm (BSEN) • International Standards Organisation (ISO).

8. TRAINING, INDUSTRIAL/PROFESSIONAL RECOGNITION, OTHER QUALIFICATIONS AND ADVANCEMENT

As for career advancement, most competent welders learn their craft on the job. They usually begin as qualified welders and gradually learn their new skills as they gain experience. Further certification may increase their chances of career advancement. Thus with additional formal training/education and certification, this experience competent welders can advance to become a certified welding inspector and welding engineer.

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9. SOURCES OF ADDITIONAL INFORMATION Local

• Construction Industry development Board (CIDB) Tingkat 7, Grand Seasons Avenue, 72, Jalan Pahang, 53000 Kuala Lumpur Tel: 603-2617 0200 Fax: 603-2617 0220 Email: [email protected] Web: http://www.cidb.gov.my

• Department of Occupational Safety and Health (DOSH) Ministry of Human Resource, Level 2, 3 & 4, Block D3, Complex D Federal Government Administrative Centre 62530 W. P. Putrajaya Tel: 603 - 8886 5000 Fax: 603 - 8889 2443 Email: [email protected] Web: http://www.dosh.gov.my

• Department of Standards Malaysia (Standards Malaysia) Century Square, Level 1 & 2, Block 2300, Jalan Usahawan, 63000 Cyberjaya, Selangor Darul Ehsan, Malaysia Tel: 603-8318 0002 Fax: 603-8319 3131 Email: [email protected] Web: http://www.standardsmalaysia.gov.my

• SIRIM Berhad

No. 1, Persiaran Dato' Menteri, Seksyen 2, Peti Surat 7035, 40700 Shah Alam Selangor Darul Ehsan Tel: 603-55446000 Fax: 603-55108095 Email: [email protected] Web: http://www.sirim.my

International • American Society of Mechanical Engineers (ASME)

Three Park Avenue New York, NY 10016-5990 United States of America Tel: 973-882-1170 Fax: 973-882-1717 Email: [email protected] Web: http://www.asme.org

• American Petroleum Institute (API)

1220 L Street, NW Washington, DC 20005-4070 United States of America Tel: 202-682-8000 Fax: - Email: - Web: http://www.api.org

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• American Welding Society (AWS) 550 N.W. LeJeune Road, Miami, Florida 33126 United States of America Tel: 800-443-9353 Fax: - Email: - Web:http://awsnow.org

• American National Standard Institute (ANSI) 1899 L Street, NW, 11th Floor Washington, DC, 20036 United States of America Tel: 202-293-8020 Fax: 202-293-9287 Email: - Web:http://www.ansi.org/

• American Society for Testing and Materials (ASTM) 100 Barr Harbor Drive, West Conshohocken, Pennsylvania, United States of America Tel: 610-832-9500 Fax: 610-832-9555 Email: - Web: http://www.astm.org

• British Standards International (BSI) Group 389 Chiswick High Road, London, W4 4AL, United Kingdom Tel: 44-20-8996-9001 Fax: 44-20-8996-7001 Email: [email protected] Web: http://www.bsigroup.com

• International Organization for Standardization ISO Central Secretariat, 1, ch. de la Voie-Creuse, CP 56, CH-1211, Geneva 20, Switzerland Tel: 41-22-749 01 11 Fax: 41-22-733 34 30 E-mail: [email protected] Web: http://www.iso.org

• International Labour Organisation (ILO) 4 route des, Morillons, CH-1211,Geneva 22, Switzerland Tel: 41-22-799-6111 Fax: 41-22-798-8685 Website: www.ilo.org E-mail: [email protected]

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10. VALIDATION

This Standard has been circulated to the respective industry for two weeks for validation and feedback. The list of companies that have received the draft are as follow; i) ii) iii) This Standard has been checked by the Standard Technical Evaluation Committee (STEC), DSD and validated by the members of Skills Development Advisory Committee (SDAC) on …………………………….. The SDAC members as listed below have agreed in consensus to this standard;

5th of September 2012

i. En. Abd. Halim Bin Hasan

JPK Cawangan Cyberjaya, Suite 0-10, 4803, Bangunan CDB Perdana Persiaran Flora, 63000 Cyberjaya. Selangor Darul Ehsan

ii. En. Mohd Darus Bin Taib TWI Training & Certification (S.E. Asia) Sdn. Bhd, No 8, Jalan TSB 10, Sungai Buloh Industrial Park, 47000 Sungai Buloh, Selangor Darul Ehsan.

iii. En. Dawot Bin Hussin

Malaysian Welding & Joining Society (MWJS), Lot 10-20, Jalan Beremban 15/12, Seksyen 15, 40300 Shah Alam, Selangor

11. ENDORSEMENT The National Skills Development Board (MPKK), Ministry of Human Resources has agreed and endorsed this Standard on ………………………………….

12. ACKNOWLEDGEMENT The Director General of DSD would like to express sincere appreciation to the team of experts invited and their respective organisations involved during development of this standard for their contribution, perseverance and support until completion. Their experience and technical assistance has enhanced the capabilities of the document in hopes of alleviating the methodology and process of the NOSS development. The Director General of DSD also wishes to applaud the support and participation of all the organizations involved, especially TWI Training & Certification (S.E. Asia) Sdn. Bhd, Malaysian Welding & Joining Society (MWJS) whose major contributions and dedicated efforts were essential to the successful completion of this standard. Not forget, great appreciation go to the rest of the development committee members staffs and their beloved families that help, shared their experience and concern from time to time during the standard development. Their kindness and understanding kept the standard development team spirited and aspired Above all, very much thankful to the Great God Almighty for carrying the team through all the difficulties in the completion and preparation of this standard.

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13. COMMITTEE MEMBERS FOR DEVELOPMENT OF STANDARD PRACTICE (SP), JOB PROFILE CHART (JPC), COMPETENCY PROFILE (CP) AND CURRICULUM OF COMPETENCY UNIT (CoCU)

SHIELDED METAL ARC WELDING (SMAW) PROCESS LEVEL 3

PANEL EXPERTS

1 En. Mohd Herman Bin Rosli Johor State Occupational Safety and Health officer Department of Occupational Safety and Health (DOSH)

2 En. Mansor Bin Ibrahim Technical Instructor Malaysia Marine And Heavy Engineering Sdn Bhd (MMHE)

3 En. Awaldin Bin Mohd Arif Managing Director Industrial Testing & engineering Inspection Sdn Bhd

4 En. Azaddin Bin A. Aziz QA/QC and HSE Senior Manager 1 Sime Darby Engineering Sdn Bhd

5 En. Lokman Bin Zakaria QA and Risk Manager MISC Sdn Bhd,

6 En. Hamzah Bin Mohamed Kasa Training Manager Welding Inspection TWI Training & Certification (S.E. Asia) Sdn. Bhd,

7 En. Mohd Salleh Bin Mohd Noh Branch Manager TWI-ABM Training & Certification (Johor) Sdn. Bhd,

8 En. Zahidi Bin Zainuddin Welding Operations Officer Akademi Binaan Malaysia, CIDB

9 En. Wan Yusof Bin Wan Hasan Welding Operations Officer Akademi Binaan Malaysia, CIDB

10 En. Mohd Ali Bin Moh Salleh Welding Specialist Time Temasek Sdn Bhd

12 En. Mohd Sufie Bin Mohamed Welding Specialist Time Temasek Sdn Bhd

13 En. Mohd Ali Man Shah Bin Abu Samah

Welding Specialist Time Temasek Sdn Bhd

FACILITATORS

1 En. Syed Mahathir Bin Syed Azman Shah

Assistant Director JPK, Cyberjaya, Selangor

2 En. Ahmad Azran Bin Ranaai Assistant Director JPK, Cyberjaya, Selangor

3 Tn. Hj. Razalee Bin Che Ros Senior Skills Development Officer JPK, Cyberjaya, Selangor

4 En. Mohd Lutfi Bin Mohd Darjak Senior Skills Development Officer JPK, Cyberjaya, Selangor

STANDARD CONTENT

NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR;



LEVEL 3

(TAHAP 3)

13

COMPETENCY PROFILE CHART (CPC) SECTOR MACHINERY AND EQUIPMENT

SUB SECTOR WELDING TECHNOLOGY AND FABRICATION

JOB AREA SHIELDED METAL ARC WELDING (SMAW)

JOB LEVEL LEVEL 3 JOB AREA CODE

COMPETENCY

COMPETENCY UNIT

CORE


(SMAW) FOR FILLET WELD 1F, 2F, 3F, 4F, BUTT WELD 1G AND

2G

SHIELDED METAL ARC WELDING (SMAW) FOR

3G AND 4G

SHIELDED METAL ARC WELDING (SMAW) FOR

5G AND 6G (UP-HILL AND DOWN-HILL)

MC‐024‐3:2012‐C01 MC‐024‐3:2012‐C02 MC‐024‐3:2012‐C03

ELECTIVE

SHIELDED METAL

ARC WELDING (SMAW) 6GR

SUBMERGED ARC WELDING (SAW) 1G

MC‐024‐3:2012‐E01 MC‐024‐3:2012‐E02

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COMPETENCY PROFILE (CP)

Sub Sector WELDING TECHNOLOGY AND FABRICATION

Job Area SHIELDED METAL ARC WELDING (SMAW)

Level THREE (3)

CU Title CU Code CU Descriptor Work Activity Performance Criteria SHIELDED METAL ARC WELDING (SMAW) FOR FILLET WELD 1F, 2F, 3F, 4F, BUTT WELD 1G AND 2G

MC‐024‐3:2012‐C01

Shielded Metal Arc Welding (SMAW) For Fillet Weld 1F, 2F, 3F, 4F, Butt Weld 1G and 2G describes the competency of a welder to perform SMAW process in specified positions on carbon steel, stainless steel according to established welding procedure specification (WPS) and work instruction. The person who is competent in performing Shielded Metal Arc Welding (SMAW) For Fillet weld 1F, 2F, 3F, 4F, Butt Weld 1G and 2G will be able to Carry out safety assessment at work area; Comply to work instruction and relevant welding procedure specification (WPS); Verify based metal used; Verify consumable as specified; Check SMAW equipment and accessories functionality; Perform SMAW process; Perform visual inspection and specimen test (destructive test); Carry out back gouging and grinding as required in accordance with test specimen

1. Carry out safety assessment at work area

2. Comply to work instruction and relevant Welding Procedure Specification (WPS)

3. Verify base metal

1.1 Safety hazard checked against safety checklist and legislative requirement

nal 1.2 Relevant persoprotective equipment (PPE) acquired as per Standard Operating Procedure (SOP)

1.3 Hotwork permit secured as per SOP

2.1 Work instruction andWPS obtained from supervisor/ client’s representative

2.2 WPS content checked and confirmed against applicable code, standard and pecification s

3.1 Type of base metal

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CU Title CU Code CU Descriptor Work Activity

16

Performance Criteria (plate and pipe); and Compile work completion checklist.

material used

4. Verify consumable as specified

5. Check SMAW equipment and accessories functionality

6. Perform SMAW process

material confirmedagainst WPS and

tificate

ed

mill cer

4.1 Classification of electrode checked against WPS and

ill certificate m

5.1 Welding machine calibration status confirmed valid as

r pe certification5.2 Cable connections

P secured as per SO5.3 Welding

accessories ondition cc onfirm

functional

6.1 Joint configuration checked against WPS Jig and fixtures set-up checked and work piece secured

6.2

in 1F, 2F, 3F, 4F, 1G and 2G positioCleanliness and preheating

ns6.3

conducted as per WPS

6.4 Welding in

17

CU Title CU Code CU Descriptor Work Activity Performance Criteria

7. Perform visual inspection and specimen test (destructive test)

accordance to WPrequirement Interpass cleaning

S

7.4 e

e

7.5

6.5 carried out as per WPS

ut c6.6 apping as per WPS Weldment

rried

Carry o

7.1 cleanliness ca out as per work instruction Weldment profile checked against acceptance and

7.2

rejection criteria of applicable code in WPS Weldment test specimen cut tapplicable cod

7.3 o the e

standard and specification requirements Weld test coupon bend test or fracturtest carried out inaccordance toapplicable cod

the,

standard andspecification requirements Bend test result


8. Carry out back gouging, grinding and back welding as required in accordance with test specimen

9. Compile work

completion checklist

checked against acceptance and rejection criteria of the applicable codein WPS for 1G and 2G Fracture test result checked against acceptance and rejection criteria of he applica

7.6

t

t ble code in WPS for 1F, 2F, 3Fand 4F

8.1 Air arc gouging carried out when required

8.2 Grinding carried ouas required

Work comple checklist recorded

9.1 tion

as per work instruction

SHIELDED METAARC WELDING (SMAW) F

18

L

OR 3G AND 4G

3:2012‐C02 1.

assessment at work area

MC‐024‐ Shielded Metal Arc Welding (SMAW) For 3G And 4G describes the competency of a welder to perform SMAW process in specified positions on carbon steel, stainless steel according to established welding procedure specification (WPS) and work instruction. The person who is competent in

Carry out safety

1.1

checklist and legislative requirement Relevant personal protective

Safety hazard checked safety

1.2

equipment (PPE) acquired as per

CU Title CU Code CU Descriptor Work Activity Performance Criteria performing Shielded Metal Arc Welding (SMAW) For 3G And 4G will be able to Carry out safety assessment at work area; Comply to work instruction and relevant welding procedure specification (WPS); Verify based metal used; Verify consumable as specified; Check SMAW equipment and accessories functionality; Perform SMAW process; Perform visual inspection and specimen test (destructive test); Carry out back gouging and grinding as required in accordance with test specimen (plate); a

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nd Compile work completion checklist.

2. nt

Specification (WPS)

ble as

5. nd

functionality

OP

ed

Comply to work instruction and relevaWelding Procedure

3. tal aterial used

erify con

Verify base mem

4. sumapecified

Check SMAW equipment aaccessories

Vs

SOP 1.3 Hotwork permit

secured as per SOP Work instruction andWPS obtained

2.1

from supervisor/ client’s representative

2.2 WPS ontc ent checked and confirmed as per SOP

ype of base m ta3.1 e l material confirmed against WPS and mill certificate Classification of

T

4.1 electrode checked against WPS and mill certificate

5.1 Welding machine calibration status confirmed valid as per certification Cable connections ecured as

5.2 per S

5.3 Welding accessories condition confirm

s

20


SMAW process

7.

(destructive test)

6. Perform

Perform visual inspection and specimen test

functional Joint configuration checked against

6.1

WPS 6.2 Jig and fixtures set

up checked and work piece secured

-

in 3G and 4G positions Cleanliness an6.3 d preheating conducted as required per WPS

6.4 Welding in accordance to WPeq iremen

Stsr u

6.5 Interpass cleaning carried out as per WPS

ping6.6 Carry out cap as per WPS Weldment cleanliness carried out as per work

7.1

instruction 7.2 Weldment profile

checked against acceptance and rejection criterapplicable cod

ia of e in

WPS


8.

e

7.3

e

Carry out back gouging, grinding and back welding as equired in accordar nc

with test specimen

9. Compile work completion checklist

Weldment test specimen cut to the applicable code standard and specification requirements Weld test coup

r7.4 on

bend test or f acturtest carried out in accordance to the applicable code, standard and specification requirements

en7.5 d test result checked against acceptance and rejection criteria of

B

the applicable code in WPS for 3G and G 4

8.1 Air arc gouging

carried out when required Grinding carried out 8.2 as required

9.1 Work completion checklist recorded as per work instruction

21

22

CU Title CU Code CU Descriptor Work Activity orPerf mance Criteria SHIELDED METAL ARC WELDING (SMAW) FOR 5G AND 6G (UP-HILL AND DOWN-HILL)

MC‐024‐3:2012‐C03

SMAW process; Perform visual inspection and specimen test (destructive test); and Compile work completion checklist.


2. Comply to work instruction and relevant

e

ble as

1.1

2.2

Shielded Metal Arc Welding (SMAW) For 5G And 6G describes the competency of a welder to perform SMAW process in specified positions on carbon steel, stainless steel according to established welding procedure specification (WPS) and work instruction. The person who is competent in performing Shielded Metal Arc Welding (SMAW) For 5G And 6G will be able to Carry out safety assessment at work area; Comply to work instruction and relevant welding procedure specification (WPS); Verify based metal used; Verify consumable as specified; Check SMAW equipment and accessories functionality; Perform

Welding ProcedurSpecification (WPS)

3. erify base metal material used

V

4. Verify consumaspecified

Safety hazard checked safety checklist and legislative requirement

1.2 Relevant personal protective equipment (PPE) acquired as per SOP


2.1 Work instruction andWPS obtained

m supefro rvisor/ client’s representative WPS content checked and confirmed as p

OP er

3

S

.1 Type of base metal material confirmed against WPS and

tificate mill cer C4.1

against WPS a d mill certificate

lassification of electrode checked

n

23


5. Check SMAW equipment and accessories


s

d

6.6

functionality

5.1 Welding machine

calibration status ed confirm valid a

per certification 5.2 Cable connection

secured as per Ss OP

5.3 Welding accessories condition confirmed functional

6.1 Joint configuration checked against WPS

6.2 Jig and fixtures set-up checked and work piece securein 5G and 6G positions Cleanliness and 6.3 preheating conducted as

d prequire er WPS 6.4 Welding in

accordance to WPSrequirements

nin6.5 Interpass clea g carried out as per WPS Carry out capping as per WPS

24

CU Title CU Code CU Descriptor Work Activity Performance Criteria 7. Perform visual

spection and pecimen test destructive test)

. ile work

7.3 he

7.4

7.5 inst

8.1

ins(

8 Comp

7.1 Weldment cleanliness carried out as per work instruction

7.2 Weldment prochecked again

file st

acceptance and rejection criteria of applicable code in WPS Weldment test specimen cut to tapplicable codstandard and

e

specification requirements Weld test coupon bend test or fracture test carried out in accordance to the applicable code, standard and specification requirements Bend test result checked agaacceptance and rejection criteria of the applicable code in WPS for 5G and 6G Work completion

25

CU Title CU Code CU Descriptor Work Activity Performance Criteria completion checklist checklist recorded

as per work instruction

SHIELDED METAL ARC WELDING (SMAW) 6GR

MC‐024‐3:2012‐E01

acSMAW

(destrcompl

1. Valid certification or minimum six (6) months experience in pipe welding using Shielded Metal Arc Welding (SMAW) process with evidence of competency in 5G or 6G position.


S)

al

4. ble as

d

Shielded Metal Arc Welding (SMAW) For 6GR describes the competency of a welder to perform SMAW process in specified positions on carbon steel, according to established welding procedure specification (WPS) and work instruction. The person who is competent in performing Shielded Metal Arc Welding (SMAW) For 6GR will be able to Carry out safety assessment at work area; Comply to work instruction and relevant welding procedure specification (WPS); Verify based metal used;

e

Verify consumabl as specified; Check SMAW equipment and

cessories functionality; Perform process; Perform visual

inspection and specimen test uctive test); and Compile work etion checklist.

CU Pre-requisite:

2. Comply to work instruction and relevant Welding Procedure Specification (WP

3. e metaterial used

Verify consumaspecified

Verify basm

1.1

checklist and legislative equirement

Safety hazard checked safety

r 1.2 Relevant personal

protective equipment (PPE) acquired as per SOP


nstr2.1 uction anWPS obtained from supervisor/ client’s representative

ontent

Work i

2.2 WPS cchecked and confirmed as per SOP

f base m ta3.1 e l material confirmed against WPS and mill certificate

f

Type o

4.1 Classification oelectrode checked

CU Title CU Code CU Descriptor Work Activity P oerf rmance Criteria

26

5. Check SMAW


7. Perform visual

ed

d

6.5

equipment and accessories functionality

against WPS and mill certificate

5.1 Welding machine tioncalibra status

confirmed valid aper certification

5.2 Cable connections

s

secured as per SOP5.3 Welding

accessories condition confirmfunctional Joint configuration checked against

6.1

WPS 6.2 Jig and fixtures set-

up checked and work piece securein 6GR position Cleanliness and

ting 6.3

conducted as required per WPS Welding in

W

prehea

6.4 accordance to PSrequirements Interpass cleaning carried out as per WPS

7.1 Weldment


27

inspection and specimen test (destructive test)


7.3 he

7.4

7.5

acceptance and rejection criteria of the applicable code in WPS for 6GR

8.1 Work completion checklist recorded as per work

cleanliness carried out as per work instruction

7.2 Weldment prochecked again

file st

acceptance and rejection criteria of applicable code in WPS Weldment test specimen cut to tapplicable codstandard and

e

specification requirements Weld test coupon bend test or fracture test carried out in accordance to the

ble code, applicaast ndard and

specification requirements Bend test result checked against

CU Title CU Code CU Descriptor

28

Work Activity Performance Criteria instruction

SUBMERGED ARC WELDING (SAW) 1G

MC‐024‐3:2012‐E02

Submerged Arc Welding (SAW) 1G describes the competency of a machine operator to perform SAW process in 1G position on carbon steel according to established welding procedure specification (WPS) and work instruction. The person who is competent in Operate Submerged Arc Welding (SAW) 1G will be able to Carry out safety assessment at work area; Comply to work instruction and relevant welding procedure specification (WPS); Carry out safety assessment at work area; Verify based metal used; Verify consumable as specified; Check SAW equipment and accessories functionality; Operate SAW process Machine; Perform visual inspection and specimen test (destructive test); and Compile work completion checklist. CU Pre-requisite:

1. Valid certification or minimum three (3) months experience in Shielded Metal Arc Welding (SMAW) process with evidence of competency in minimum 1F or 1G position.


2. Comply to work instruction and relevant welding procedure specification (WPS)

3. Check SAW equipment and accessories functionality

1.1 Safety hazard checked safety checklist and legislative requirement Relevant personalprotective equipment (PPE

1.2

) acquired as per SOP

1.3 Hotwork permit secured as per SOP Work instruction andWPS obtained

2.1

from supervisor/ client’s representative

2.2 WPS content

checked and confirmed as per SOP

3.1 Welding machine calibration status

r confi med valid asper certification Cable connections

as3.2

secured per SOP 3.3 Welding

accessories condition confirmed

29


4. Verify based metal material used


6. Operate SAW process

functional Wire feeder unctionality

3.4

condition confirmeas per manufacturer’s operating man

fd

l

r

ual

4.1 Type of based metaverified against

WPS and mill certificate Type of flux confirmed as per WPS

5.1

5.2 Classification of wires checked against WPS an

fille

d manufacturer’s data sheet Joint configuration checked as per

6.1

WPS 6.2 Jig and fixtures

(roller and track)set-up checked work piece secu

and red

in 1G position 6.3 Cleanliness and

preheating conducted as

30


7. Perform visual inspection and specimen test (destructive test)

required as per WPS Welding in 6.4 accordance to WPS requirements

6.5 Interpass cleaning carried out as per WPS

6.6 Air arc back gougicarried out as per

ng

t

7.2

WPS6.7 Back Grinding

carried out as per WPS Back welding carried out as per

6.8

6.9 Defective profile rectified and accepted as per te

WPS

sspecimen requirements and WPS Weldment cleanliness carried

7.1

out as per work instruction Weldment profile checked againsacceptance anrejection criter

t d ia of

applicable code in

31




WPS Weldment test specimen cut to theapplicable code standard and specification requirements

up

7.3

8.1

required 8.2 Grinding carried out

as required

9.1 Work completion checklist record as per work instruction

7.4 Weld test co on bend test or fracture test carried out in accordance to the applicable code, standard and pecification s

requirements 7.5 Bend test result

checked against acceptance and rejection criteria of he applict able code in WPS for 1G Air arc gouging carried out when

CURRICULUM of COMPETENCY UNIT (CoCU)

FOR;

NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR;



LEVEL 3

(TAHAP 3)

32




Competency Unit Title SHIELDED METAL ARC WELDING (SMAW) FOR FILLET WELD 1F, 2F, 3F, 4F, BUTT WELD 1G AND 2G

Learning Outcomes

The person who is competent in this CU shall be able to perform shielded metal arc welding (SMAW) for fillet weld 1F, 2F, 3F, 4F, butt weld 1G and 2G positions on carbon steel or stainless steel material. Upon completion of this competency unit, trainees will be able to:-

1. Carry out safety assessment at work area 2. Comply to work instruction and relevant Welding Procedure Specification (WPS) 3. Verify base metal material used 4. Verify consumable as specified 5. Check SMAW equipment and accessories functionality 6. Perform SMAW process 7. Perform visual inspection and testing(destructive test) 8. Carry out back gouging, grinding and back welding as required in accordance with test specimen 9. Compile work completion checklist

Competency Unit ID MC-024-3:2012-C01 Level 3 Training

Duration 580 Hours Credit Values 58

Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental

Training Hours

Delivery Mode Assessment Criteria


Safety induction in accordance to Occupational Safety and Health Act (OSHA), Factory and Machinery Act, Regulation, Guideline and Code of Practice which covers: 1 Hazard

identification,

1 Demonstrate safe working habit and consciousness in workshop

2 Adhere to worksite safety requirement, regulations

3 Alert in ensuring safe working environment

24 1 Lecture 2 Group Discussion

1 Welding hazards identified which includes:

1.1 Safety hazard 1.2 Health hazard 1.3 Environmental

hazard 2 Welding risk

assessment conducted

33

34


Training Hours

Delivery Mode As essment Criteria s

risk assessment and risk control (HIRARC)

1.1 Safety hazard and protection

1.1.1 Slipping or tripping, floor protection

1.1.2 Fire and explosion hazard

1.1.2.1 Fire/ spark/ heat protection

1.1.2.2 Fire extinguisher type

1.1.2.3 Elements of fire

1.1.2.4 Flammable hazard (ex: painting, oil, gas, etc)

1.1.2.5 Fire watcher

1.1.3 Working at height

1.1.4 Pressure system

1.1.5 Eye injuries 1.2 Health hazard

and protection 1.2.1 Ergonomic in

4 Responsible and accountable in performing welding task

5 Transparent in reporting to relevant authority

6 Ensure housekeeping

7 Ensure proper PPE worn at work site

3 Proper protection addressed according to risk assessment result which covers:

3.1 Safety hazard protection

3.2 Health hazard protection

3.3 Environmental hazard protection

4 Welding risk control carried out which covers:

4.1 Procedure to obtain Permit To Work (PTW)

4.2 Lock out, tack out (LOTO)

4.3 Welding area emergency response plan (ERP)

4.4 First aid treatment procedure conducted such as:

4.4.1 Cardio Pulmonary Resuscitation (CPR)


Training Delivery Assess nt Criteria Hours Mode

35

me welding activities - body posture

1.2.2 Welding fumes, gases and protection

1.2.3 Welder health condition

1.2.4 Personnel Protective Equipment (PPE)

1.2.5 Arc burn (Intense ultraviolet radiation)

1.3 Environmental hazard

1.3.1 Adequate access and emergency escape route

1.3.2 Confined space 1.3.3 Extreme

temperature (Hotwork/ coldwork)

1.3.4 Adequate lighting

1.3.5 Falling objects 1.3.6 Radiation /

ultraviolet protection

4.4.2 Minor cut injuries

4.4.3 Bone fracture first aid treatment


Training Delivery Assessment Criteria Hours Mode

36

1.3.7 Noise hazard 1.3.7.1 Noise

exposure 1.3.7.2 Noise

protection 1.3.8 Electrical

hazard 1.3.8.1 Electrical

protection 1.3.8.2 Electrical

shock 2 Safety operating

procedure 2.1 Procedure to

obtain Permit To Work (PTW)


2.3 First aid treatment procedure



2.3.3 Bone fracture first aid treatment

2.3.4 Emergency response plan (ERP)



37

1 Identify welding hazards which covers:


hazard 2 Conduct welding

risk assessment to address proper protection within work area which covers:




3 Carry out welding risk control by:

3.1 Execute procedure to obtain Permit To Work (PTW)

3.2 Execute lock out, tack out (LOTO) procedure

3.3 Identify welding area emergency response plan (ERP)

3.4 Able to conduct

24 1 Case study 2 Observation


Training Delivery Assessment Criteria Hours Modefirst aid treatment procedure such as:


3.4.2 Minor cut injuries 3.4.3 Bone fracture first

aid treatment 2. Comply to

work instruction and relevant Welding Procedure Specification (WPS)

1 Welding terminology

2 Welding drawing and symbol

3 WPS content 4 Procedure

Qualification Record (PQR)

5 Welding codes and standards

6 Joint design 7 Material type

and grade (eg. material mill certificate)

8 Welding position 8.1 For fillet weld -

1F, 2F, 3F, 4F 8.2 For butt weld -

1G, 2G 9 Preheat

requirement 10 Post-weld heat

1 Meticulous in interpreting WPS content

2 Refer to superior for any uncertainties

3 Conform to WPS requirements


1 Welding terminology described

2 Welding drawing and symbol interpreted

3 WPS content interpreted

4 Procedure Qualification Record (PQR) familiarised

5 Code and standard complied

6 Joint design interpreted

7 Type of material identified

8 Welding position interpreted

9 Reheat requirement

38

Work Activities Rela ted Knowledge Related Skills Attitude / Safety / Environmental

Training Delivery Assessment Criteria Hours Mode treatment (PWHT) requirement

11 SMAW process 12 Consumable

specification, classification and type

13 Electrical characteristics - ampere, volt, polarity, travel speed

14 Welding parameters table

15 Role of Destructive Testing (DT) assessment

16 Role of Non-Destructive Testing (NDT)

identified 10 PWHT

requirement identified

11 SMAW process determined

12 Consumable specification, classification and type identified

13 Electrical characteristics identified

14 Welding parameter table interpreted

1 Describe welding terminology

2 Interpret welding drawing and symbol

3 Interpret WPS content

4 Familiarise Procedure Qualification


39



40

Record (PQR) 5 Comply to

welding codes and standards

6 Able to interpret joint design

7 Able to identify type of material

8 Able to interpret welding position

8.1. For fillet weld - 1F, 2F, 3F, 4F

8.2. For butt weld - 1G, 2G

9 Able to identify preheat requirement

10 Able to identify PWHT requirement

11 Able to determine SMAW process

12 Able to identify consumable specification, classification and type

13 Able to identify electrical characteristics - ampere, volt, polarity, travel speed


Training Delivery Assessment Criteria Hours Mode14 Interpret welding

parameter table 3. Verify base

metal material used

1 Carbon Steel and Stainless Steel material

1.1 Material mill certificate

1.1.1 Material standard

1.1.2 Heat number 1.1.3 Chemical

composition 1.1.4 Mechanical

properties 1.1.5 Material form -

plate and pipe 1.1.6 Material size 2 Material physical

condition (eg. Dent, rust, ovality, etc)

1 Meticulous in verifying based metal material in accordance to material mill certificate


1 Carbon steel / stainless steel material confirmed to relevant WPS

2 Content of material mill certificate affirmed

3 Material condition confirmed

1 Confirm carbon steel / stainless steel material to relevant WPS

1.1 Affirm content of material mill certificate such as:

1.1.1 Material standard 1.1.2 Heat number


41


Training Delivery Assessment Criteria Hours Mode1.1.3 Chemical



plate and pipe 1.1.6 Material size 2 Confirm material

physical condition (eg. Dent, rust, ovality, etc)


1 Electrode specification/ classification

1.1 Core wire 1.2 Electrode size 1.3 Flux coating

(basic, rutile and cellulose)

2 Electrode handling / baking procedure

3 Electrode baking oven

4 Electrode holding oven

1 Cautious practice when handling hot electrode from baking oven

8 1 Lecture 1 Electrode specification/ classification confirmed

2 Electrode handling/baking procedure carried out if required

3 Oven temperature for electrode baking setup if required

4 Temperature for holding oven setup if required

1 Confirm electrode specification/ classification such as:

4.1 Core wire 4.2 Electrode size

8 1 Demonstration 2 Observation 3 Case study

42


Training Delivery Assessment Criteria Hours Mode4.3 Flux coating


2 Carry out electrode handling/baking procedure if required

3 Setting up oven temperature for baking

4 Setting up temperature for holding oven


1 SMAW welding machine (electrical driven transformer)

1.1 Power supply switch

1.2 Power source cable

1.3 Earth cable 1.4 Electrical driven

transformer 2 SMAW welding

machine (engine driven)

2.1 Diesel engine 2.2 Electric

generator set 2.3 Earth cable

1 Ensure welding machine validity is within calibration period

2 Ensure welding machine in functioning and safe operating condition


1 SMAW welding machine functionality affirmed

2 Complete welding accessories installed to welding machine

3 Relevant welding PPE worn

4 Complete and proper welding tools ensured

5 Status of welding machine calibration confirmed

43


Training Delivery As essment Criteria Hours Mode

44

s

3 Accessories: 3.1 Welding cable 3.2 Electrode holder 3.3 Work cable 3.4 Work Clamp 3.5 Heating torch

with propane gas / heating element

3.6 Clampmeter/ tongmeter

3.7 Contactless pyrometer

3.8 Temperature indicating crayon/ chalk

3.9 Cutting lens goggle

3.10 Welding shield 3.11 Welding gauntlet 3.12 Visor / face

shield 4 Marking tools

and hand tools: 4.1 Marking chalk 4.2 Steel ruler 4.3 Center punch 4.4 L square 4.5 Chisel 4.6 Chalk line 4.7 Chipping

hammer 4.8 Portable grinding

6 Machine arc stability assured


Training Delivery Assessment Criteria Hours Modemachine

4.9 Grinding disc as per specification

4.10 Wire brush/ power brush

4.11 Type of files 4.12 Ball peen

hammer 4.13 Brush/broom 5 Electrode quiver 6 Status of

welding Machine calibration

7 Welding arc stability

1 Use relevant PPE 2 Affirm SMAW

welding machine functionality

3 Assure complete welding accessories installed to welding machine

4 Ensure complete and proper welding tools for use

5 Confirm status of welding machine calibration

6 Acquire welding


45


Training Delivery Mode Assess nt Criteria Hours me

arc stability 6. Perform

SMAW process

1 Joint Configuration 2 Joint preparation

marking and cutting 2.1 Mechanical

cutting 2.2 Oxy-acetylene

gas cutting 2.3 Plasma cutting 3 Check Angle (included

angle & bevel angle 4 Root face 5 Root gap /opening 6 Fit-up / jig & fixture

setup 7 Tack weld 8 Surface cleaning 9 Welding position - 1F,

2F, 3F, 4F, 1G and 2G

10 Operation of SMAW machine

11 Arc blow effect 12 Welding parameter

setting 13 Root pass /

penetration 14 Root pass cleaning 15 Hot pass 16 Hot pass cleaning 17 Interpass 18 Interpass cleaning

1 Ensure PPE in good usage condition

2 Ensure PPE are worn accordingly

3 Cautious when dispensing hot electrode butt

4 Ensure glove free from oil base and any moisture during electrode handling

5 Electrode to be handled according to manufacturer recommendation

6 Ensure proper welding environment condition (eg. under shade from rain and barricade from heavy wind, etc)

7 Ensure grinding work are carried out safely


1 Joint configuration identified

2 Weld joint marking and cutting prepared

3 Angle check carried out

4 Root face identified

5 Root gap /opening identified

6 Fit-up / jig & fixture set up

7 SMAW machine operated

8 Arc striking test performed

9 Tack weld carried out

10 Surface cleaning carried out

11 Welding performed in position - 1F, 2F, 3F, 4F, 1G and 2G

46

47

Work Activities Rela ed Kt nowledge Related Skills Attitude / Safety / Environmental

Training Hours

Delivery Mode As ment Criteria sess

19 Capping 20 Weldment cleaning 21 Welding machine shut

down procedure 22 Good housekeeping

12 Pre-heating carried out as required

13 Welding parameters set

14 Root pass / penetration carried out

15 Root pass cleaning executed

16 Hot pass carried out

17 Hot pass cleaning executed

18 Interpass carried out

19 Interpass cleaning executed

20 Capping executed

21 Weldment cleaning carried out

22 Post-heating carried out as required

23 Attitude/ Safety/ Environmental requirement

1 Identify joint configuration

2 Prepare weld joint 2.1 Carry out

mechanical cutting

2.2 Carry out oxy-acetylene gas cutting

2.3 Carry out plasma cutting

3 Carry out check Angle (included angle & bevel angle)

4 Identify root face 5 Identify root gap

/opening 6 Setup fit-up / jig &

fixture 7 Operate SMAW

machine 8 Carry out arc

striking test run to obtain arc stability

9 Carry out tack weld

256 1 Demonstration 2 Observation 3 Project


Training Delivery Assess Hours Mode

48

ment Criteria

10 Carry out surface cleaning

11 Setup welding position - 1F, 2F, 3F, 4F, 1G and 2G

12 Carry out pre-heating as required

13 Set welding parameters

14 Carry out root pass / penetration

15 Execute root pass cleaning

16 Carry out hot pass 17 Execute hot pass

cleaning 18 Carry out

interpass 19 Execute interpass

cleaning 20 Execute capping 21 Carry out

weldment cleaning

22 Carry out post-heating as required

23 Carry out welding machine shut down procedure

24 Carry out

carried out during performing SMAW process

24 Welding machine shut down procedure executed

25 Housekeeping carried out

Work Activities Rel ledge ated Know Related Skills Attitude / Safety / Environmental

Training Delivery Mode Assess Hours ment Criteria

housekeeping 7. Perform

visual inspection and testing (destructive test)

1 Welding inspection kit

2 Root inspection 3 Weldment profile 4 Type of welding

defects and causes such as:

4.1 Irregular weld profile

4.2 Incomplete penetration

4.3 Undercut 4.4 Arc strike 4.5 Spatter 4.6 Crack 4.7 Slag inclusion 4.8 Porosity 4.9 Overlap 4.10 Lack of fusion

(surface) 4.11 Under fill 4.12 Burn-through 4.13 Misalignment

(linear & angular)

4.14 Throat thickness (fillet)

4.15 Unequal leg length (fillet)

4.16 Concavity (fillet) 4.17 Convexity (fillet)

1 Meticulous in checking visual inspection

2 Inquisitive in seeking advice to confirm acceptance & rejection criteria from superior

3 Open to comments on weld imperfection

4 Ensure safety when performing nick break test and bend test


1 Relevant welding inspection tools selected

2 Root penetration checked

3 Weldment profile for butt weld and fillet weld checked

4 Type of surface defect Identified

5 Welding specimen visual and testing carried out

6 Penetrant test for fillet weld conducted

7 Acceptance & rejection criteria confirmed

49


Training Delivery Assessment Criteria Hours Mode5 Welding

specimen test 5.1 For fillet weld : -

nick break test, fracture test, macro examination

5.2 For butt weld - root bend (RB), face bend (FB), side bend test (SB)

6 Penetrant test (PT)

7 Acceptance & rejection criteria according to code

1 Select relevant welding inspection tools

2 Check root penetration for butt weld only

3 Check weldment profile for butt weld and fillet weld

4 Identify type of surface defect

5 Carry out welding specimen test


50


Training Delivery Assessment Criteria Hours Mode5.1 For fillet weld : -

nick break test, facture test, macro examination

5.2 For butt weld - root bend (RB), face bend (FB), side bend test (SB)

6 Conduct penetrant test for fillet weld

7 Seek advice on acceptance & rejection criteria from superior


1 Gouging technique

2 Grinding technique

3 Surface inspection and testing (PT/MT)

4 Back welding 5 Weldment

cleaning

1 Conform to WPS repair procedure

2 Perform gouging, grinding and back welding with care

3 Practice housekeeping

4 1 Lecture

1 Gouging technique applied to test specimen

2 Grinding technique applied to test specimen

3 Back welding technique applied to test specimen

4 Weldment cleaning applied to test

1 Apply gouging technique where applicable (exclude stainless steel)


51


Training Delivery Assess Hours Mode ment Criteria

2 Apply grinding technique

3 Apply back welding

4 Apply weldment cleaning

specimen


1 Welding checklist

2 Work completion hand over

1 Precise in filling welding checklist

2 Integrity in compiling report


1 Welding checklist fill up complete

2 Report compile and submitted to superior for hand over

1 Fill-up welding checklist

2 Compile and submit report to superior

4 1 Observation 2 Case study

52

Employability Skills

53

Core Abilities Social Skills 1.01 Identify and gather information 1.02 Document information, procedures or processes 1.11 Apply thinking skills and creativity 2.01 Interpret and follow manuals, instructions and SOP’s 2.03 Communicate clearly 2.04 Prepare brief reports and checklists using standard forms 2.05 Read/interpret flowcharts and pictorial information 2.11 Convey information and ideas to people 3.01 Apply cultural requirements to the workplace 3.02 Demonstrate integrity and apply ethical practices 3.03 Accept responsibility for own work and work area 3.04 Seek and act constructively upon feedback about performance 3.05 Demonstrate safety skills 3.06 Respond appropriately to people and situations 3.07 Resolve interpersonal conflicts 3.13 Develop and maintain team harmony and resolve conflicts 3.15 Liase to achieve identified outcomes 3.16 Identify and assess client/customer needs 5.01 Implement project/work plans 5.02 Inspect and monitor work done and/or in progress 4.01 Organize own work activities 4.02 Set and revise own objectives and goals 4.03 Organize and maintain own workplace 4.04 Apply problem solving strategies 4.05 Demonstrate initiative and flexibility 6.01 Understand systems 6.02 Comply with and follow chain of command 6.03 Identify and highlight problems 6.05 Analyse technical systems 6.06 Monitor and correct performance of systems 6.07 Develop and maintain networks

1 Communication Skills 2 Interpersonal Skills 3 Learning Skills 4 Multitasking and prioritizing 5 Self-discipline 6 Teamwork

Tools, Equipment and Materials (TEM) ITEMS RATIO (TEM : Trainees) 1 Welding procedure specification (WPS) 2 Procedure Qualification Record (PQR) 3 Code and standard (AWS D1.1) 4 Code and standard (ASME IX) 5 Permit To Work (PTW) form 6 Base metal plate: plate 6mm to 12mm (minimum range) 7 Base metal pipe: 4"to 6" NPS schedule 40 (minimum range) 8 Safety shoe 9 Coverall 10 Leather gloves 11 Fire extinguisher 12 Muffler / ear plug 13 First aid kit 14 Hazard signage 15 Material mill certificate 16 Material standard 17 Welding electrode (2.5mm - 4.0mm) 18 Electrode baking oven 19 Electrode holding oven 20 SMAW welding machine and accessories 21 Marking tools and hand tools 22 Electrode quiver 23 Welding inspection kit 24 Welding bay c/w accessories (eg. Power supply, lighting, welding curtain,

fume extractor, welding table with positioner, etc) 25 Jig & fixture fit-up clamp 26 Hydraulic press

1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 5 1 : 1 1 : 15 1 : 15 1 : 1 1 : 1 As required 1 : 15 1 : 15 1 : 1 1 : 1 1 : 1 1 : 15

1 : 1 1 : 5 1 : 15

54

ITEMS RATIO (TEM : Trainees) 27 Guided bend test jig 28 High speed cutting machine 29 Spark lighter 30 Plasma cutting (for stainless steel) 31 Oxy-acetylene gas cutting (manual) and accessories with flash back

arrester 32 Oxy-acetylene gas cutting machine (semi-auto) and accessories with flash

back arrester 33 Oxy-acetylene pipe cutting machine and accessories with flash back

arrester 34 Band saw machine 35 Power saw machine 36 Gouging torch and accessories 37 Air compressor and receiver 38 Welding checklist 39 Macro test equipment (cutter, polisher and etching acid) and accessories

1 : 15 1 : 15 1 : 1 1 : 15 1 : 15

1 : 15

1 : 15

1 : 15 1 : 15 1 : 5 1 : 2 1 : 1 1 : 15

55

56

References

REFERENCES

1 Sacks & Bohnart,2007,Welding Principles & Practices,3rd edition, 1221, Avenue of the Americas, New York, NY 10020 USA, Mc Graw Hill, ISBN: 978-0077238773

2 James F. Lincoln, Arc Welding Foundation, 2002, The Procedure Handbook of Arc Welding, 14th Edition, 22801 St. Clair Avenue, Cleveland, Ohio, 44117 USA, Lincoln Electric Company, ISBN: 978- 9993897302

3 Robert L. O'Brien, 1997, Jefferson's Welding Encyclopaedia, 18th Edition, 550 N.W. Lejeune Road, Miami, Florida, 33126 USA, American Welding Society, ISBN: 978-0871715067

4 Joseph W. Giachino, William, Weeks, 1985, Welding Skills & Practices, 6th edition, Western Michigan University, Kalmazoo, Michigan, Chicago, 60637, USA, American Technical Society, ISBN:978-0826930019

5 Griffin, Roden, Briggs, 1985, Pipe Welding Techniques, 4th edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-0827322486 6 Ivan H. Griffin, Edward M. Roden and Charles W. Briggs, 1984, Basic Arc Welding 4th edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-

0827321311 7 ASM International, 1983, Metal Reference Book, 2nd edition, Material Park, Ohio, 44073 USA, American Society For Metals, ISBN:978-0871701565 8 Gower A. Kennedy, 1982, Welding Technology - Student's Manual, 2nd edition, Indianapolis, USA, A Howard W. Sams Book, Bobbs- Merill Educational

Publishing, ISBN:978-0672971099 9 Gower A. Kennedy, 1982, Welding Technology, 2nd edition, Lethbridge Community College, Alberta, New York, USA, Howard W. Sams & Son Inc., ISBN: 978-

0672979903 10 Frank R. Schell, 1977, Welding Procedures: Electric Arc, 1st edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-0827316034 11 Giachino, Weeks, Johnson, 1974, Welding Technology, 2nd edition, Chicago, 60637 USA, American Technical Society, ISBN: 978-0826930637




Competency Unit Title SHIELDED METAL ARC WELDING (SMAW) FOR 3G AND 4G

Learning Outcomes

The person who is competent in this CU shall be able to perform shielded metal arc welding (SMAW) for 3G and 4G positions on carbon steel or stainless steel material. Upon completion of this competency unit, trainees will be able to:-

1. Carry out safety assessment at work area 2. Comply to work instruction and relevant Welding Procedure Specification (WPS) 3. Verify base metal material used 4. Verify consumable as specified 5. Check SMAW equipment and accessories functionality 6. Perform SMAW process 7. Perform visual inspection and testing (destructive test) 8. Carry out back gouging, grinding and back welding as required in accordance with test specimen 9. Compile work completion checklist




Training Hours




identification, risk assessment and



3 Alert in ensuring safe working




hazard

2 Welding risk assessment conducted

57

58

Work Activities Rel ated Knowledge Related Skills Attitude / Safety / Environmental

Training Hours


risk control (HIRARC)








1.1.2.5 Fire watcher 1.1.3 Working at height 1.1.4 Pressure system 1.1.5 Eye injuries 1.2 Health hazard and

protection 1.2.1 Ergonomic in

welding activities - body posture



environment 4 Responsible

and accountable in performing welding task




3 Proper protection

addressed according to risk assessment result which covers:










4.4.2 Minor cut

Work Activities Rel tea dge d Knowle Related Skills Attitude / Safety / Environmental

Training Delivery Asses Hours Mode

59

sment Criteria 1.2.4 Personnel

Protective Equipment (PPE)






1.3.4 Adequate lighting 1.3.5 Falling objects 1.3.6 Radiation /




protection 1.3.8 Electrical hazard 1.3.8.1 Electrical



procedure

injuries 4.4.3 Bone fracture

first aid treatment


Training Delivery Assessment Criteria Hours Mode2.1 Procedure to obtain

Permit To Work (PTW)





aid treatment 2.3.4 Emergency

response plan (ERP)



hazard

2 Conduct welding risk assessment to address proper protection within work area which covers:


24 1 Demonstration 2 Observation

60


Training Delivery Assessment Criteria Hours Mode2.2 Health hazard

protection 2.3 Environmental

hazard protection





3.4 Able to conduct first aid treatment procedure such as:




work instruction and relevant

1 Welding terminology 2 Welding drawing

and symbol 3 WPS content


2 Refer to



2 Welding drawing

61


Training Delivery Ass Hours Mode

62

essment Criteria

Welding Procedure Specification (WPS)

4 Procedure Qualification Record (PQR)


6 Joint design 7 Material type and

grade (eg. material mill certificate)

8 Welding position 8.1 For butt weld - 3G,

4G 9 Preheat


treatment (PWHT) requirement






16 Role of Non-

superior for any uncertainties


and symbol interpreted







9 Reheat requirement identified

10 PWHT requirement identified






Training Delivery Assessment Criteria Hours Mode Destructive Testing (NDT)




4 Familiarise Procedure Qualification Record (PQR)

5 Comply to welding codes and standards




8.1 For butt weld - 3G, 4G





63


Training Delivery Assessment Criteria Hours Mode12 Able to identify

consumable specification, classification and type


14 Interpret welding parameter table

3. Verify base metal material used



1.1.1 Material standard 1.1.2 Heat number 1.1.3 Chemical


Properties 1.1.5 Material form -

plate 1.1.6 Material size 2 Material physical







1 Confirm carbon steel / stainless


64


Training Delivery Assessment Criteria Hours Modesteel material to relevant WPS





plate 1.1.6 Material size 2 Confirm material




1.2 Core wire 1.3 Electrode size 1.4 Flux coating (basic,

rutile and cellulose) 2 Electrode handling /

baking procedure 3 Electrode baking

oven 4 Electrode holding

oven





4 Temperature for holding oven setup

65


Training Delivery Mode Ass nt Criteria Hours essme








if required




1.2 Power source cable 1.3 Earth cable 1.4 Electrical driven

transformer 2 SMAW welding machine

(engine driven) 2.1 Diesel engine







4 Complete and proper welding tools

66



67

essme t n Criteria 2.2 Generator set 2.3 Earth cable

3 Accessories: 3.1 Welding cable 3.2 Electrode holder 3.3 Work cable 3.4 Work Clamp 3.5 Heating torch with

propane gas / heating element




3.9 Cutting lense goggle

3.10 Welding shield 3.11 Welding gauntlet

4 Marking tools and hand tools:

4.1 Marking chalk 4.2 Steel ruler 4.3 Center punch 4.4 L square 4.5 Chisel 4.6 Chalk line 4.7 Chipping hammer 4.8 Portable grinding

machine 4.9 Grinding disc as

ensured 5 Status of welding

machine calibration confirmed



Training Delivery Assessment Criteria Hours Modeper type of material

4.10 Wire brush/ power brush

4.11 Type of files 4.12 Ball peen hammer 4.13 Brush/broom

5 Electrode quiver 6 Status of welding

Machine calibration 7 Machine arc stability 1 Affirm SMAW

welding machine (electrical driven transformer) functionality


3 Use relevant PPE for welding



6 Assure machine arc stability

24

6. Perform 1 Joint Configuration 1 Ensure PPE in 40 1 Lecture 1 Joint configuration

68

69


Training Hours

Delivery Mode Assessme t Cn riteria

SMAW process

2 Joint preparation marking and cutting

2.1 Mechanical cutting 2.2 Oxy-acetylene gas

cutting 2.3 Plasma cutting

3 Check Angle (included angle & bevel angle

4 Root face 5 Root gap /opening 6 Fit-up / jig & fixture setup 7 Tack weld 8 Surface cleaning 9 Welding position - 3G

and 4G 10 Operation of SMAW

machine 11 Arc blow effect 12 Parameter setting 13 Root pass / penetration 14 Root pass cleaning 15 Hot pass 16 Hot pass cleaning 17 Interpass 18 Interpass cleaning 19 Capping 20 Weldment cleaning 21 Welding machine shut


good usage condition







8 Ensure usage of gauntlet for 4G

2 Group Discussion identified 2 Weld joint marking

and cutting prepared


4 Root face identified 5 Root gap /opening

identified 6 Fit-up / jig & fixture

set up 7 SMAW machine

operated 8 Arc striking test

performed 9 Tack weld carried

out 10 Surface cleaning

carried out 11 Welding performed

in position - 3G and 4G





16 Hot pass carried out 17 Hot pass cleaning




Training Delivery Mode Hours

70

Assessment Criteria 2 Prepare weld joint

2.1 Carry out mechanical cutting



3 Carry out check Angle (included angle & bevel angle








11 Setup welding position - 3G and 4G


position

3 Project execute 18 Interpass carried

out 19 Interpass cleaning

executed 20 Capping executed 21 Weldment cleaning

carried out 22 Post-heating carried

out as required 23 Attitude/ Safety/

Environmental requirement carried out during performing SMAW process




Training Delivery Assessment Criteria Hours Mode13 Set the

parameters 14 Carry out root

pass / penetration 15 Execute root pass

cleaning 16 Carry out hot pass 17 Execute hot pass

cleaning 18 Carry out

interpass 19 Execute interpass


weldment cleaning 22 Carry out post-

heating as required


24 Carry out housekeeping

7. Perform visual inspection and testing (destructive test)

1 Welding inspection kit 2 Root inspection 3 Weldment profile 4 Type of welding defect

and causes such as: 4.1 Irregular weld profile 4.2 Incomplete

penetration


2 Inquisitive in seeking advice to confirm acceptance & rejection criteria




3 Weldment profile for butt weld checked

71



4.3 Undercut 4.4 Arc strike 4.5 Spatter 4.6 Crack 4.7 Slag inclusion 4.8 Porosity 4.9 Overlap 4.10 Lack of fusion

(surface) 4.11 Underfill 4.12 Burn-through 4.13 Misalignment (linear

& angular) 5 Welding specimen test

5.1 For butt weld - root bend (RB), face bend (FB), side bend test


from superior 3 Open to

comments on weld imperfection

4 Ensure safety when performing bend test






3 Check weldment profile for butt weld



72


Training Delivery Assessment Criteria Hours Mode5 Carry out welding

specimen test 5.1 For butt weld -

root bend (RB), face bend (FB), side bend test



1 Gouging technique 2 Grinding technique 3 Surface inspection and

testing (PT/MT) 4 Back welding 5 Weldment cleaning


2 Perform gouging and grinding with care


4 1 Lecture 1 Gouging technique applied to test specimen



4 Weldment cleaning applied to test specimen



3 Apply back welding 4 Apply weldment

cleaning


9. Compile work completion

1 Welding checklist 2 Work completion hand

over




2 Report compile and

73


Training Delivery Mode Ass Hours essment Criteria

checklist 1 Fill-up welding checklist




submitted to superior for hand over


Core Abilities Social Skills 1.01 Identify and gather information 1.02 Document information, procedures or processes 1.11 Apply thinking skills and creativity 2.01 Interpret and follow manuals, instructions and SOP’s 2.03 Communicate clearly 2.04 Prepare brief reports and checklists using standard forms 2.05 Read/interpret flowcharts and pictorial information 2.11 Convey information and ideas to people 3.01 Apply cultural requirements to the workplace 3.02 Demonstrate integrity and apply ethical practices 3.03 Accept responsibility for own work and work area 3.04 Seek and act constructively upon feedback about performance 3.05 Demonstrate safety skills 3.06 Respond appropriately to people and situations 3.07 Resolve interpersonal conflicts 3.13 Develop and maintain team harmony and resolve conflicts 3.15 Liase to achieve identified outcomes 3.16 Identify and assess client/customer needs 5.01 Implement project/work plans 5.02 Inspect and monitor work done and/or in progress 4.01 Organize own work activities 4.02 Set and revise own objectives and goals 4.03 Organize and maintain own workplace 4.04 Apply problem solving strategies

1 Communication Skills 2 Interpersonal Skills 3 Learning Skills 4 Multitasking and prioritizing 5 Self-discipline 6 Teamwork

74

Core Abilities Social Skills 4.05 Demonstrate initiative and flexibility 6.01 Understand systems 6.02 Comply with and follow chain of command 6.03 Identify and highlight problems 6.05 Analyse technical systems 6.06 Monitor and correct performance of systems 6.07 Develop and maintain networks

75

Tools, Equipment and Materials (TEM)

ITEMS RATIO (TEM : Trainees) 1. Welding procedure specification (WPS) 2. Procedure Qualification Record (PQR) 3. Code and standard (ASME IX) 4. Permit To Work (PTW) form 5. Base metal plate: plate 6mm to 12mm (minimum range) 6. Safety shoe 7. Coverall 8. Leather gloves 9. Fire extinguisher 10. Muffler / ear plug 11. First aid kit 12. Hazard signage 13. Material mill certificate 14. Material standard 15. Welding electrode (2.5mm - 4.0mm) 16. Electrode baking oven 17. Electrode holding oven 18. SMAW welding machine (electrical driven transformer) and accessories 19. Marking tools and hand tools 20. Electrode quiver 21. Welding inspection kit 22. Welding bay c/w accessories (eg. Power supply, lighting, welding curtain,

fume extractor, welding table with positioner, etc) 23. Jig & fixture fit-up clamp 24. Hydraulic press 25. Guided bend test jig 26. High speed cutting machine

1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 5 1 : 1 1 : 15 1 : 15 1 : 1 1 : 1 As required 1 : 15 1 : 15 1 : 1 1 : 1 1 : 1 1 : 15 1 : 1 1 : 5 1 : 15 1 : 15 1 : 15

76

I EMT RATIO (TEM : Trainees) S 27. Spark lighter 28. Oxy-acetylene gas cutting (manual) and accessories with flash back

arrester 29. Oxy-acetylene gas cutting machine (semi-auto) and accessories with flash

back arrester 30. Oxy-acetylene pipe cutting machine and accessories with flash back

arrester 31. Band saw machine 32. Power saw machine 33. Gouging torch and accessories 34. Air compressor and receiver 35. Welding checklist

1 : 1 1 : 15 1 : 15 1 : 15 1 : 15 1 : 15 1 : 5 1 : 2 1 : 1

77

78

References

REFERENCES












Competency Unit Title SHIELDED METAL ARC WELDING (SMAW) FOR 5G AND 6G (UP-HILL AND DOWN-HILL)

Learning Outcomes

The person who is competent in this CU shall be able to perform shielded metal arc welding (SMAW) for 5G and 6G (up-hill and down-hill) positions on carbon steel or stainless steel material. Upon completion of this competency unit, trainees will be able to:-

1. Carry out safety assessment at work area 2. Comply to work instruction and relevant Welding Procedure Specification (WPS) 3. Verify base metal material used 4. Verify consumable as specified 5. Check SMAW equipment and accessories functionality 6. Perform SMAW process 7. Perform visual inspection and testing (destructive test) 8. Compile work completion checklist




Training Hours




identification, risk assessment and



3 Alert in ensuring safe






3 Proper protection

79

80


Training Hours


risk control (HIRARC)













working environment

4 Responsible and accountable in performing welding task















4.4.3 Bone fracture first aid

Work Activities Rel tea dge d Knowle Related Skills Attitude / Safety / Environmental


81

ment Criteria














procedure

treatment


Training Delivery Assessment Criteria Hours Mode2.1 Procedure to obtain







response plan (ERP)






2.2 Health hazard


82


Training Delivery Assessment Criteria Hours Modeprotection










work instruction and relevant Welding

1 Welding terminology

2 Welding drawing and symbol

3 WPS content


2 Refer to superior for any





83


Training Delivery Hours Mode

84

Assessment Criteria Procedure Specification (WPS)

4 Procedure Qualification Record (PQR)




8 Welding position 8.1 For butt weld - 5G,

6G 9 Preheat








16 Role of Non-

uncertainties 3 Conform to

WPS requirements



6 Joint design interpreted 7 Type of material

identified 8 Welding position

interpreted 9 Reheat requirement

identified 10 PWHT requirement

identified 11 SMAW process

determined 12 Consumable

specification, classification and type identified




Training Delivery Assessment Criteria Hours Mode Destructive Testing (NDT)









1.1 For butt weld - 5G, 6G





85


Training Delivery Assessment Criteria Hours Mode12 Able to identify

consumable specification, classification and type









pipe 1.1.6 Material size 2 Material physical







1 Confirm carbon steel / stainless


86


Training Delivery Assessment Criteria Hours Modesteel material to relevant WPS





pipe 1.1.6 Material size 2 Confirm material








oven





4 Temperature for holding oven setup

87


Training Delivery Mode Ass nt Criteria Hours essme








if required




1.2 Power source cable 1.3 Earth cable 1.4 Electrical driven









4 Complete and proper welding tools

88



89

essme t n Criteria 2.1 Diesel engine 2.2 Electric generator

set 2.3 Earth cable 3 Accessories: 3.1 Welding cable 3.2 Electrode holder 3.3 Work cable 3.4 Work Clamp 3.5 Heating torch with





3.9 Cutting lens goggle 3.10 Welding shield 3.11 Welding gauntlet 4 Marking tools and

hand tools: 4.1 Marking chalk 4.2 Steel ruler 4.3 Center punch 4.4 L square 4.5 Chisel 4.6 Chalk line 4.7 Chipping hammer 4.8 Portable grinding

machine

ensured 5 Status of welding

machine calibration confirmed



Training Delivery Assessment Criteria Hours Mode4.9 Grinding disc as per

specification 4.10 Wire brush/ power

brush 4.11 Type of files 4.12 Ball peen hammer 4.13 Brush/broom 5 Electrode quiver 6 Status of welding

Machine calibration 7 Welding arc stability 1 Affirm SMAW

welding machine functionality




5 Assure welding arc stability



1 Joint Configuration 2 Joint preparation

marking and cutting 2.1 Mechanical cutting


2 Ensure PPE are



2 Weld joint marking and cutting

90



91

essme t Cn riteria 2.2 Oxy-acetylene gas

cutting 2.3 Plasma cutting

3 Check Angle (included angle & bevel angle

4 Root face 5 Root gap /opening 6 Fit-up / jig & fixture

setup 7 Tack weld 8 Surface cleaning 9 Welding position - 5G

and 6G 10 Operation of SMAW

machine 11 Arc blow effect 12 Parameter setting 13 Root pass / penetration 14 Root pass cleaning 15 Hot pass 16 Hot pass cleaning 17 Interpass 18 Interpass cleaning 19 Capping 20 Weldment cleaning 21 Gouging technique

(carbon steel only) 22 Grinding technique 23 Surface inspection and

testing (PT/MT) 24 Back welding/ back filled 25 Welding machine shut

down procedure

worn accordingly






prepared 3 Angle check carried

out 4 Root face identified 5 Root gap /opening

identified 6 Fit-up / jig & fixture

set up 7 SMAW machine

operated 8 Arc striking test

performed 9 Tack weld carried

out 10 Surface cleaning

carried out 11 Welding performed

in position - 5G and 6G





16 Hot pass carried out 17 Hot pass cleaning

executed 18 Interpass carried

out

Work Activities Related Knowledge Related Skills Attitude / Safety / Training Environmental Hours


26 Good housekeeping 19 Interpass cleaning executed

20 Capping executed 21 Weldment cleaning

carried out 22 Post-heating carried

out as required 23 Attitude/ Safety/






mechanical cutting











11 Setup welding position - 5G and


92

Work Activities Related Knowledge Rela et d Skills Attitude / Safety / Environmental

Training Delivery Assessment Criteria Hours Mode6G


13 Set the parameters

14 Carry out root pass / penetration


16 Carry out hot pass

17 Execute hot pass cleaning

18 Carry out interpass

19 Execute interpass cleaning

20 Execute capping 21 Carry out

weldment cleaning

22 Carry out post-heating as required



7. Perform visual

1 Welding inspection kit 2 Root inspection

1 Meticulous in checking visual


1 Relevant welding inspection tools

93


Training Delivery Assess Hours Mode ment Criteria inspection and testing (destructive test)

3 Weldment profile 4 Type of welding defect

and causes such as: 4.1 Irregular weld

profile 4.2 Incomplete

penetration 4.3 Undercut 4.4 Arc strike 4.5 Spatter 4.6 Crack 4.7 Slag inclusion 4.8 Porosity 4.9 Overlap 4.10 Lack of fusion





inspection 2 Inquisitive in

seeking advice to confirm acceptance & rejection criteria from superior



selected 2 Root penetration

checked 3 Weldment profile

for butt weld checked





2 Check root


94


Training Delivery Assessment Criteria Hours Modepenetration for butt weld only








over






1 Fill-up welding checklist



95



1. Communication Skills 2. Interpersonal Skills 3. Learning Skills 4. Multitasking and prioritizing 5. Self-discipline 6. Teamwork

96

Tools, Equipment and Materials (TEM) ITEMS RATIO (TEM : Trainees)

1. Welding procedure specification (WPS) 2. Procedure Qualification Record (PQR) 3. Code and standard (ASME IX) 4. Code and standard (API 1104) 5. Code and standard (AWS D1.1) 6. Code and standard (ISO) 7. Permit To Work (PTW) form 8. Base metal pipe: 6"to 8" NPS schedule 80 (minimum range) 9. Safety shoe 10. Coverall 11. Leather gloves 12. Fire extinguisher 13. Muffler / ear plug 14. First aid kit 15. Hazard signage 16. Material mill certificate 17. Material standard 18. Welding electrode (2.5mm - 4.0mm) 19. Electrode baking oven 20. Electrode holding oven 21. SMAW welding machine (electrical driven transformer) and accessories 22. Marking tools and hand tools 23. Electrode quiver 24. Welding inspection kit 25. Welding bay c/w accessories (eg. Power supply, lighting, welding curtain,

fume extractor, welding table with positioner, etc) 26. Jig & fixture fit-up clamp

1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 1 1 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 5 1 : 1 1 : 15 1 : 15 1 : 1 1 : 1 As required 1 : 15 1 : 15 1 : 1 1 : 1 1 : 1 1 : 15 1 : 1 1 : 5

97

I EMT RATIO (TEM : Trainees) S 27. Hydraulic press 28. Guided bend test jig 29. High speed cutting machine 30. Spark lighter 31. Oxy-acetylene gas cutting (manual) and accessories with flash back




1 : 15 1 : 15 1 : 15 1 : 1 1 : 15 1 : 15 1 : 15 1 : 15 1 : 15 1 : 5 1 : 2 1 : 1

98

99

References

REFERENCES












Competency Unit Title SHIELDED METAL ARC WELDING (SMAW) 6GR

Learning Outcomes

The person who is competent in this CU shall be able to perform shielded metal arc welding (SMAW) 6GR positions on carbon steel material. Upon completion of this competency unit, trainees will be able to:-

1. Carry out safety assessment at work area 2. Comply to work instruction and relevant Welding Procedure Specification (WPS) 3. Verify base metal material used 4. Verify consumable as specified 5. Check SMAW equipment and accessories functionality 6. Perform SMAW process 7. Perform visual inspection and testing (destructive test) 8. Compile work completion checklist

Competency Unit ID MC-024-3:2012-E01 Level 3 Training



Training Hours



Safety induction in accordance to Occupational Safety and Health Act (OSHA), Factory and Machinery Act, Regulation, Guideline and Code of Practice which covers: 1 Hazard identification,

risk assessment and risk control (HIRARC)

1.1 Safety hazard and



3 Alert in ensuring safe working environment

4 Responsible and

24 1 Lecture 2 Group

Discussion





3 Proper protection

100

101


Training Hours


protection 1.1.1 Slipping or tripping,

floor protection 1.1.2 Fire and explosion

hazard 1.1.2.1 Fire/ spark/

heat protection 1.1.2.2 Fire

extinguisher type

1.1.2.3 Elements of fire 1.1.2.4 Flammable

hazard (ex: painting, oil, gas, etc)







1.2.5 Arc burn (Intense

accountable in performing welding task













4.4.1 Cardio Pulmonary Resuscitatio



102

me nt Criteria

ultraviolet radiation) 1.3 Environmental

hazard 1.3.1 Adequate access

and emergency escape route




ultraviolet protection 1.3.7 Noise hazard 1.3.7.1 Noise exposure 1.3.7.2 Noise


protection 1.3.8.2 Electrical shock 2 Safety operating

procedure 2.1 Procedure to obtain




2.3.1 Cardio Pulmonary Resuscitation

n (CPR) 4.4.2 Minor cut

injuries 4.4.3 Bone

fracture first aid treatment

Work Activities Rel t wa ed Kno ledge Related Skills Attitude / Safety / Environmental

Training Delivery Assessment Criteria Hours Mode(CPR)



response plan (ERP)

1. Identify welding hazards which covers:









3.2 Execute lock out,

24 1 Case study 2. Observation

103


Training Delivery Assessment Criteria Hours Modetack out (LOTO) procedure







1 Welding terminology 2 Welding drawing and

symbol 3 WPS content 4 Procedure





8 Welding position 8.1 For butt weld - 6GR 9 Preheat requirement 10 Post-weld heat





Discussion









104


Training Delivery Hours Mode Assessment Criteria


















5 Comply to welding codes and


105


Training Delivery Assessment Criteria Hours Modestandards




8.1 For butt weld - 6GR








1 Carbon Steel material

1.1 Material mill

1 Meticulous in verifying based metal material in

4 1 Lecture 2 Group

Discussion

1 Carbon steel material confirmed to

106

Work Activities Re lated Knowledge Related Skills Attitude / Safety / Environmental

Training Delivery As Hours Mode sessment Criteria

certificate 1.1.1 Material standard 1.1.2 Heat number 1.1.3 Chemical



pipes of dissimilar thicknesses with restricted ring plate

1.1.6 Material size 2 Material physical


accordance to material mill certificate

relevant WPS 2 Content of

material mill certificate affirmed


1 Confirm carbon steel material to relevant WPS





pipes of dissimilar thicknesses with restricted ring plate


107


Training Delivery Assessment Criteria Hours Mode1.1.6 Materials sizes 2 Confirm material








oven





4 Temperature for holding oven setup if required



rutile and cellulose) 2 Carry out electrode

handling/baking procedure if required

3 Setting up oven temperature for


108


Training Delivery Assessment Criteria Hours Modebaking




1.1 Power supply switch 1.2 Power source cable 1.3 Earth cable 1.4 Electrical driven



2.1 Diesel engine 2.2 Electric generator

set 2.3 Earth cable 3 Accessories: 3.1 Welding cable 3.2 Electrode holder 3.3 Work cable 3.4 Work Clamp 3.5 Heating torch with




3.8 Temperature




Discussion







109


Training Delivery Assessment Criteria Hours Modeindicating crayon/ chalk

3.9 Cutting lens goggle 3.10 Welding shield 3.11 Welding gauntlet 4 Marking tools and


machine 4.9 Grinding disc as per

specification 4.10 Wire brush/ power

brush 4.11 Type of files 4.12 Ball peen hammer 4.13 Brush/broom 5 Electrode quiver 6 Status of welding

Machine calibration 7 Arc stability

technique

1 Affirm SMAW welding machine functionality

2 Assure complete


110


Training Delivery Assessment Criteria Hours Modewelding accessories installed to welding machine



5 Assure welding arc stability


1 Joint Configuration 2 Joint preparation marking

and cutting 2.1 Mechanical cutting 2.2 Oxy-acetylene gas

cutting 3 Check Angle (included

angle & bevel angle 4 Root face 5 Root gap /opening 6 Fit-up / jig & fixture setup 7 Tack weld 8 Surface cleaning 9 Welding position - 6GR 10 Operation of SMAW

machine 11 Arc blow effect 12 Parameter setting 13 Root pass / penetration 14 Root pass cleaning






6 Ensure proper welding


Discussion




4 Root face identified

5 Root gap /opening identified

6 Fit-up / jig & fixture set up

7 SMAW machine operated

8 Arc striking test performed

9 Tack weld

111

112

Work Activities Rela ed Kt nowledge Related Skills Attitude / Safety / Environmental

Training Hours

Delivery Mode Ass essment Criteria

15 Hot pass 16 Hot pass cleaning 17 Interpass 18 Interpass cleaning 19 Capping 20 Weldment cleaning 21 Gouging technique 22 Grinding technique 23 Surface inspection and

testing (PT/MT) 24 Back welding/ back filled 25 Welding machine shut


environment condition (eg. under shade from rain and barricade from heavy wind, etc)


carried out 10 Surface cleaning

carried out 11 Welding

performed in position – 6GR





16 Hot pass carried out

17 Hot pass cleaning execute

18 Interpass carried out

19 Interpass cleaning executed

20 Capping executed

21 Weldment cleaning carried out

22 Post-heating carried out as



mechanical cutting 2.2 Carry out oxy-

acetylene gas cutting








113

Ass nt Criteria essme



9 Carry out tack weld 10 Carry out surface

cleaning 11 Setup welding

position – 6GR 12 Carry out pre-

heating as required 13 Set welding

parameters 14 Carry out root pass

/ penetration 15 Execute root pass

cleaning 16 Carry out hot pass 17 Execute hot pass

cleaning 18 Carry out interpass 19 Execute interpass

cleaning 20 Execute capping 21 Carry out weldment

cleaning 22 Carry out post-

heating as required 23 Carry out welding

machine shut down procedure


required 23 Attitude/ Safety/





Training Delivery Mode Assess Hours ment Criteria


1 Welding inspection kit 2 Root inspection 3 Weldment profile 4 Type of welding defect

and causes such as: 4.1 Irregular weld profile 4.2 Incomplete

penetration 4.3 Undercut 4.4 Arc strike 4.5 Spatter 4.6 Crack 4.7 Slag inclusion 4.8 Porosity 4.9 Overlap 4.10 Lack of fusion










Discussion








2 Check root


114


Training Delivery Assessment Criteria Hours Modepenetration for butt weld only








over



4 1 Lecture 2 Group

Discussion



1 Fill-up welding checklist 2 Compile and submit

report to superior


115

Employability Skills Core Abilities Social Skills 1.01 Identify and gather information 1.02 Document information, procedures or processes 1.11 Apply thinking skills and creativity 2.01 Interpret and follow manuals, instructions and SOP’s 2.03 Communicate clearly 2.04 Prepare brief reports and checklists using standard forms 2.05 Read/interpret flowcharts and pictorial information 2.11 Convey information and ideas to people 3.01 Apply cultural requirements to the workplace 3.02 Demonstrate integrity and apply ethical practices 3.03 Accept responsibility for own work and work area 3.04 Seek and act constructively upon feedback about performance 3.05 Demonstrate safety skills 3.06 Respond appropriately to people and situations 3.07 Resolve interpersonal conflicts 3.13 Develop and maintain team harmony and resolve conflicts 3.15 Liase to achieve identified outcomes 3.16 Identify and assess client/customer needs 5.01 Implement project/work plans 5.02 Inspect and monitor work done and/or in progress 4.01 Organize own work activities 4.02 Set and revise own objectives and goals 4.03 Organize and maintain own workplace 4.04 Apply problem solving strategies 4.05 Demonstrate initiative and flexibility 6.01 Understand systems 6.02 Comply with and follow chain of command 6.03 Identify and highlight problems 6.05 Analyse technical systems 6.06 Monitor and correct performance of systems 6.07 Develop and maintain networks


116


1. Welding procedure specification (WPS) 2. Procedure Qualification Record (PQR) 3. Code and standard (AWS D1.1) 4. Permit To Work (PTW) form 5. Base metal pipe dissimilar thickness 8" schedule 80 and schedule 120, with

restricted ring 6mm thickness 6. Safety shoe 7. Coverall 8. Leather gloves 9. Fire extinguisher 10. Muffler / ear plug 11. First aid kit 12. Hazard signage 13. Material mill certificate 14. Material standard 15. Welding electrode (2.5mm - 4.0mm) 16. Electrode baking oven 17. Electrode holding oven 18. SMAW welding machine (electrical driven transformer) and accessories 19. Marking tools and hand tools 20. Electrode quiver 21. Welding inspection kit 22. Welding bay c/w accessories (eg. Power supply, lighting, welding curtain,

fume extractor, welding table with positioner, etc) 23. Jig & fixture fit-up clamp 24. Hydraulic press 25. Guided bend test jig

1 : 1 1 : 1 1 : 1 1 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 5 1 : 1 1 : 15 1 : 15 1 : 1 1 : 1 As required 1 : 15 1 : 15 1 : 1 1 : 1 1 : 1 1 : 15 1 : 1 1 : 5 1 : 15 1 : 15

117

I EMT RATIO (TEM : Trainees) S 26. High speed cutting machine 27. Spark lighter 28. Oxy-acetylene gas cutting (manual) and accessories with flash back




1 : 15 1 : 1 1 : 15 1 : 15 1 : 15 1 : 15 1 : 15 1 : 5 1 : 2 1 : 1

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References

REFERENCES












Competency Unit Title SUBMERGED ARC WELDING (SAW) 1G

Learning Outcomes

The person who is competent in this CU shall be able to operate submerged arc welding (SAW) 1G position on carbon steel material. Upon completion of this competency unit, trainees will be able to:-

1. Carry out safety assessment at work area 2. Comply to work instruction and relevant Welding Procedure Specification (WPS) 3. Check SAW equipment and accessories functionality 4. Verify base metal material used 5. Verify consumable as specified 6. Operate SAW process 7. Perform visual inspection and testing (destructive test) 8. Carry out back gouging, grinding and back welding as required in accordance with test specimen 9. Compile work completion checklist

Competency Unit ID MC-024-3:2012-E02 Level 3 Training Duration 248 Hours Credit Values 25


Training Hours




identification, risk assessment and risk control (HIRARC)



3 Alert in ensuring safe working


Discussion



hazard

2 Welding risk assessment conducted

120

121


Training Hours







1.1.2.3 Elements of fire 1.1.2.4 Flammable

hazard (ex: painting, oil, gas, etc)







environment 4 Responsible

and accountable in performing welding task




3 Proper protection











4.4.2 Minor cut


Training Delivery Asses Hours Mode

122

sment Criteria 1.2.5 Arc burn (Intense

ultraviolet radiation) 1.3 Environmental

hazard 1.3.1 Adequate access

and emergency escape route





1.3.7 Noise hazard 1.3.7.1 Noise exposure 1.3.7.2 Noise


protection 1.3.8.2 Electrical shock 2 Safety operating

procedure 2.1 Procedure to obtain



2.3 First aid treatment

injuries 4.4.3 Bone fracture

first aid treatment


Training Delivery Assessment Criteria Hours Modeprocedure




response plan (ERP)

1. Identify welding hazards which covers:








3.1 Execute procedure


123


Training Delivery Assessment Criteria Hours Modeto obtain Permit To Work (PTW)








1 Welding terminology 2 Welding drawing

and symbol 3 WPS content 4 Procedure









Discussion



3 WPS content interpreted 4 Procedure Qualification

Record (PQR) familiarised


6 Joint design interpreted 7 Type of material

identified

124


Training Delivery Assessment Criteria Hours Mode 8 Welding position 8.1 For butt weld – 1G 9 Preheat requirement 10 Post-weld heat


















4 Familiarise


125



126

Procedure Qualification Record (PQR)





8.1 For butt weld – 1G 9 Able to identify

preheat requirement





14 Interpret welding


Training Delivery Hours

Mode Assessment Criteria

parameter table 3. Check SAW

equipment and accessories functionality

1 SAW welding machine (electrical driven transformer)

1.1 Power supply switch 1.2 Power source cable 1.3 Earth cable 1.4 Electrical driven

transformer 2 SAW welding


2.1 Diesel engine 2.2 Generator set 2.3 Earth cable 3 Accessories: 3.1 Welding cable 3.2 Flux hopper 3.3 Slide rail 3.4 Electrode wire spool 3.5 Electrode wire reel 3.6 Carriage control unit

(including control guide)

3.7 Work cable 3.8 Work clamp 3.9 Heating torch with



3.11 Contactless



4 1 Lecture 2 Group

Discussion

1 SAW welding machine functionality affirmed






127


Training Delivery Assessment Criteria Hours Modepyrometer


3.13 Cutting lens goggle 3.14 Welding shield 4 Marking tools and


machine 4.9 Grinding disc as per

type of material 4.10 Wire brush/ power

brush 4.11 Type of files 4.12 Ball peen hammer 4.13 Brush/broom 5 Status of welding

Machine calibration 6 Machine arc stability

1 Affirm SAW welding machine functionality

2 Assure complete welding


128


Training Delivery Assessment Criteria Hours Modeaccessories installed to welding machine

3 Use relevant PPE for welding



6 Assure machine arc stability


1 Carbon Steel material





plate and large diameter pipe

1.1.6 Material size 2 Material physical



4 1 Lecture 2 Group

Discussion

1 Carbon steel material confirmed to relevant WPS



1 Confirm carbon 8 1 Demonstration

129


Training Delivery Assessment Criteria Hours Modesteel / stainless steel material to relevant WPS





plate and large diameter pipe

1.1.6 Material size 2 Confirm material


Observation



1.1 Wire electrode 1.2 Wire electrode size 1.3 Flux (fused or

agglomerated and granulated)

2 Wire Electrode handling

3 Flux handling/baking procedure



2 Flux handling/baking procedure carried out

3 Oven temperature setup for flux baking requirement

130


Training Delivery Mode Assessment Criteria Hours

4 Flux baking oven 1 Confirm electrode

specification/ classification such as:

1.1 Wire electrode 1.2 Wire electrode

size 1.3 Flux (fused or

agglomerated and granulated)

2 Carry out flux handling/baking procedure

3 Setting up oven temperature for flux baking


6. Operate SAW process

1 Joint configuration 2 Joint preparation

marking and cutting 2.1 Mechanical cutting 2.2 Oxy-acetylene gas

cutting 3 Check Angle

(included angle & bevel angle)

4 Root face 5 Fit-up / jig & fixture

setup 6 Tack weld 7 Surface cleaning 8 Welding position -





5 Electrode to be


Discussion



3 Angle check carried out 4 Root face identified 5 Root gap /opening

identified 6 Fit-up / jig & fixture set

up 7 SAW machine operated 8 Arc striking test

performed 9 Tack weld carried out 10 Surface cleaning

131



132

Assessme tn Criteria 1G plate

9 Operation of SAW machine

10 Arc blow effect 11 Parameter setting 12 Root pass 13 Hot pass 14 Hot pass cleaning 15 Interpass 16 Interpass cleaning 17 Capping 18 Weldment cleaning 19 Root pass back

gouging 20 Root pass back

grinding 21 Root pass back

welding 22 Post-Weld Heat

Treatment (PWHT) 23 Welding machine

shut down procedure

24 Good housekeeping

handled according to manufacturer recommendation



carried out 11 Welding performed in

position - 1G 12 Pre-heating carried out

as required 13 Welding parameters set 14 Root pass / penetration

carried out 15 Root pass cleaning

executed 16 Hot pass carried out 17 Hot pass cleaning

executed 18 Interpass carried out 19 Interpass cleaning

executed 20 Capping executed 21 Weldment cleaning

carried out 22 Root pass back gouging

carried out 23 Root pass back grinding

carried out 24 Root pass back welding

carried out 25 Defective profile rectified 26 Post-heating carried out

as required 27 Attitude/ Safety/

Environmental requirement carried out during operating SAW process



mechanical cutting 2.2 Carry out oxy-

acetylene gas cutting




133

Assessment Criteria 3 Carry out check

Angle (included angle & bevel angle)

4 Identify root face 5 Setup fit-up / jig &

fixture 6 Prepare start and

stop running plate 7 Operate SAW





11 Setup welding position - 1G plate


13 Set the parameters

14 Carry out root pass


16 Carry out hot pass 17 Execute hot pass

cleaning 18 Carry out interpas




Training Delivery Assessment Criteria Hours Mode19 Execute interpass


weldment cleaning 22 Carry out root

pass back gouging 23 Carry out root

pass back grinding 24 Carry out root

pass back welding 25 Carry out welding

machine shut down procedure



1 Welding inspection kit

2 Root inspection 3 Weldment profile 4 Type of welding

defect and causes such as:

4.1 Irregular weld profile 4.2 Incomplete

penetration 4.3 Undercut 4.4 Arc strike 4.5 Spatter 4.6 Crack 4.7 Slag inclusion 4.8 Porosity






Discussion






6 Acceptance & rejection criteria

134



4.9 Overlap 4.10 Lack of fusion


& angular) 4.14 Throat thickness

(fillet) 4.15 Unequal leg length

(fillet) 4.16 Concavity (fillet) 4.17 Convexity (fillet) 5 Welding specimen

test 5.1 For butt weld - root

bend (RB), face bend (FB), side bend test


confirmed






135


Training Delivery Assessment Criteria Hours Mode5 Carry out welding

specimen test 5.1 For butt weld - root

bend (RB), face bend (FB), side bend test



1 Gouging technique 2 Grinding technique 3 Surface inspection and

testing (PT/MT) 4 Back welding 5 Weldment cleaning


2 Perform gouging and grinding with care


4 1 Lecture 1 Gouging technique applied to test specimen



4 Weldment cleaning applied to test specimen



3 Apply back welding 4 Apply weldment

cleaning




over



4 1 Lecture 2 Group

Discussion



1 Fill-up welding checklist 2 Compile and submit

report to superior


136




137


1. Welding procedure specification (WPS) 2. Procedure Qualification Record (PQR) 3. Code and standard (ASME IX, AWS, API, ISO, etc.) 4. Permit To Work (PTW) form 5. Base metal - plate (9mm and above) 6. Safety shoe 7. Coverall 8. Leather gloves 9. Fire extinguisher 10. Muffler / ear plug 11. First aid kit 12. Hazard signage 13. Material mill certificate 14. Material standard 15. Welding electrode wire 16. Flux baking oven 17. SAW welding machine (electrical driven transformer) and accessories 18. Marking tools and hand tools 19. Welding inspection kit 20. Welding bay c/w accessories (eg. Power supply, lighting, welding curtain,

fume extractor, welding table with positioner, etc) 21. Jig & fixture fit-up clamp 22. Hydraulic press 23. Guided bend test jig 24. High speed cutting machine 25. Spark lighter 26. Oxy-acetylene gas cutting (manual) and accessories with flash back

1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 1 1 : 5 1 : 1 1 : 15 1 : 15 1 : 1 As required 1 : 15 1 : 1 1 : 1 1 : 15

1 : 1 1 : 5 1 : 15 1 : 15 1 : 15 1 : 1

138

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27. Oxy-acetylene gas cutting machine (semi-auto) and accessories with flash back arrester

28. Oxy-acetylene pipe cutting machine and accessories with flash back arrester

29. Band saw machine 30. Power saw machine 31. Gouging torch and accessories 32. Air compressor and receiver 33. Welding checklist

1 : 15

1 : 15

1 : 15 1 : 15 1 : 15 1 : 5 1 : 2 1 : 1

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140

References

REFERENCES









Training Hour Summary

SECTOR : MACHINERY AND EQUIPMENT SUB SECTOR : WELDING TECHNOLOGY AND FABRICATION JOB AREA : SHIELDED METAL ARC WELDING (SMAW) JOB LEVEL : THREE (3)

CU ID Competency Unit

Training Hour

MC‐024‐3:2012‐C01

SHIELDED METAL ARC WELDING (SMAW) FOR FILLET WELD 1F, 2F, 3F, 4F, BUTT WELD 1G AND 2G 580

MC‐024‐3:2012‐C02

SHIELDED METAL ARC WELDING (SMAW) FOR 3G AND 4G 652

MC‐024‐3:2012‐C03

SHIELDED METAL ARC WELDING (SMAW) FOR 5G AND 6G (UP-HILL AND DOWN-HILL) 636

MC‐024‐3:2012‐E01 SHIELDED METAL ARC WELDING (SMAW) 6GR 460MC‐024‐3:2012‐E02 SUBMERGED ARC WELDING (SAW) 1G 248 Total Training Program Hours 2576

141

SMAW L3

Documents

definition of competency

occupational structure

occupational profile

occupational area analysis

copyright dsd

malaysian skill certification

malaysian market

international market