CURRICULUM of COMPETENCY UNIT (CoCU)

Sub SectorWELDING TECHNOLOGY AND FABRICATION

Job AreaSHIELDED METAL ARC WELDING (SMAW)

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

Learning OutcomesThe 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 area2.Comply to work instruction and relevant Welding Procedure Specification (WPS)3.Verify base metal material used4.Verify consumable as specified5.Check SMAW equipment and accessories functionality6.Perform SMAW process7.Perform visual inspection and testing (destructive test)8.Compile work completion checklist

Competency Unit IDMC-024-3:2012-C03Level3Training Duration 636 HoursCredit Values64

Work ActivitiesRelated KnowledgeRelated SkillsAttitude / Safety / EnvironmentalTraining HoursDelivery ModeAssessment Criteria

1. Carry out safety assessment at work area

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 protection1.1.1 Slipping or tripping, floor protection1.1.2 Fire and explosion hazard1.1.2.1 Fire/ spark/ heat protection1.1.2.2 Fire extinguisher type1.1.2.3 Elements of fire1.1.2.4 Flammable hazard (ex: painting, oil, gas, etc) 1.1.2.5 Fire watcher1.1.3 Working at height1.1.4 Pressure system1.1.5 Eye injuries1.2 Health hazard and protection1.2.1 Ergonomic in welding activities - body posture1.2.2 Welding fumes, gases and protection1.2.3 Welder health condition1.2.4 Personnel Protective Equipment (PPE)1.2.5 Arc burn (Intense ultraviolet radiation)1.3 Environmental hazard1.3.1 Adequate access and emergency escape route1.3.2 Confined space1.3.3 Extreme temperature (Hotwork/ coldwork)1.3.4 Adequate lighting1.3.5 Falling objects1.3.6 Radiation / ultraviolet protection1.3.7 Noise hazard1.3.7.1 Noise exposure 1.3.7.2 Noise protection1.3.8 Electrical hazard1.3.8.1 Electrical protection1.3.8.2 Electrical shock2 Safety operating procedure2.1 Procedure to obtain Permit To Work (PTW)2.2 Lock out, tack out (LOTO)2.3 First aid treatment procedure2.3.1 Cardio Pulmonary Resuscitation (CPR)2.3.2 Minor cut injuries2.3.3 Bone fracture first aid treatment2.3.4 Emergency response plan (ERP)1 Demonstrate safe working habit and consciousness in workshop2 Adhere to worksite safety requirement, regulations 3 Alert in ensuring safe working environment 4 Responsible and accountable in performing welding task5 Transparent in reporting to relevant authority6 Ensure housekeeping7 Ensure proper PPE worn at work site241 Lecture2 Group Discussion1 Welding hazards identified which includes:1.1 Safety hazard1.2 Health hazard 1.3 Environmental hazard2 Welding risk assessment conducted3 Proper protection addressed according to risk assessment result which covers:3.1 Safety hazard protection3.2 Health hazard protection3.3 Environmental hazard protection4 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)4.4.2 Minor cut injuries4.4.3 Bone fracture first aid treatment

i. 1 Identify welding hazards which covers:1.1 Safety hazard1.2 Health hazard 1.3 Environmental hazard2 Conduct welding risk assessment to address proper protection within work area which covers:2.1 Safety hazard protection2.2 Health hazard protection2.3 Environmental hazard protection3 Carry out welding risk control by:3.1 Execute procedure to obtain Permit To Work (PTW)3.2 Execute lock out, tack out (LOTO) procedure3.3 Identify welding area emergency response plan (ERP)3.4 Able to conduct first aid treatment procedure such as:3.4.1 Cardio Pulmonary Resuscitation (CPR)3.4.2 Minor cut injuries3.4.3 Bone fracture first aid treatment241 Case study2 Observation

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

1 Welding terminology 2 Welding drawing and symbol3 WPS content4 Procedure Qualification Record (PQR) 5 Welding codes and standards 6 Joint design7 Material type and grade (eg. material mill certificate)8 Welding position8.1 For butt weld - 5G, 6G9 Preheat requirement10 Post-weld heat treatment (PWHT) requirement11 SMAW process12 Consumable specification, classification and type13 Electrical characteristics - ampere, volt, polarity, travel speed14 Welding parameters table15 Role of Destructive Testing (DT) assessment16 Role of Non-Destructive Testing (NDT)1 Meticulous in interpreting WPS content2 Refer to superior for any uncertainties3 Conform to WPS requirements301 Lecture2 Group Discussion

1 Welding terminology described2 Welding drawing and symbol interpreted3 WPS content interpreted4 Procedure Qualification Record (PQR) familiarised 5 Code and standard complied6 Joint design interpreted 7 Type of material identified8 Welding position interpreted 9 Reheat requirement identified10 PWHT requirement identified11 SMAW process determined12 Consumable specification, classification and type identified 13 Electrical characteristics identified14 Welding parameter table interpreted

ii. 1 Describe welding terminology2 Interpret welding drawing and symbol3 Interpret WPS content 4 Familiarise Procedure Qualification Record (PQR) 5 Comply to welding codes and standards 6 Able to interpret joint design7 Able to identify type of material8 Able to interpret welding position1.1 For butt weld - 5G, 6G9 Able to identify preheat requirement10 Able to identify PWHT requirement11 Able to determine SMAW process 12 Able to identify consumable specification, classification and type13 Able to identify electrical characteristics - ampere, volt, polarity, travel speed14 Interpret welding parameter table101 Case study2 Observation

3. Verify base metal material used

1 Carbon Steel and Stainless Steel material1.1 Material mill certificate1.1.1 Material standard1.1.2 Heat number1.1.3 Chemical composition1.1.4 Mechanical properties1.1.5 Material form - pipe1.1.6 Material size2 Material physical condition (eg. Dent, rust, ovality, etc)1 Meticulous in verifying based metal material in accordance to material mill certificate41 Lecture2 Group Discussion

1 Carbon steel / stainless steel material confirmed to relevant WPS2 Content of material mill certificate affirmed3 Material condition confirmed

i. 1 Confirm carbon steel / stainless steel material to relevant WPS1.1 Affirm content of material mill certificate such as:1.1.1 Material standard1.1.2 Heat number1.1.3 Chemical composition1.1.4 Mechanical Properties1.1.5 Material form - pipe1.1.6 Material size2 Confirm material physical condition (eg. Dent, rust, ovality, etc)81 Demonstration2 Observation

4. Verify consumable as specified1 Electrode specification/ classification1.1 Core wire1.2 Electrode size1.3 Flux coating (basic, rutile and cellulose)2 Electrode handling / baking procedure3 Electrode baking oven4 Electrode holding oven1 Cautious practice when handling hot electrode from baking oven81 Lecture1 Electrode specification/ classification confirmed2 Electrode handling/baking procedure carried out if required3 Oven temperature for electrode baking setup if required4 Temperature for holding oven setup if required

i. 1 Confirm electrode specification/ classification such as:1.1 Core wire1.2 Electrode size1.3 Flux coating (basic, rutile and cellulose)2 Carry out electrode handling/baking procedure if required3 Setting up oven temperature for baking4 Setting up temperature for holding oven81 Demonstration2 Observation3 Case study

5. Check SMAW equipment and accessories functionality

1 SMAW welding machine (electrical driven transformer)1.1 Power supply switch1.2 Power source cable1.3 Earth cable1.4 Electrical driven transformer2 SMAW welding machine (engine driven)2.1 Diesel engine2.2 Electric generator set2.3 Earth cable3 Accessories:3.1 Welding cable3.2 Electrode holder3.3 Work cable3.4 Work Clamp3.5 Heating torch with propane gas / heating element3.6 Clampmeter/ tongmeter3.7 Contactless pyrometer3.8 Temperature indicating crayon/ chalk3.9 Cutting lens goggle3.10 Welding shield3.11 Welding gauntlet4 Marking tools and hand tools:4.1 Marking chalk4.2 Steel ruler4.3 Center punch4.4 L square4.5 Chisel4.6 Chalk line4.7 Chipping hammer4.8 Portable grinding machine4.9 Grinding disc as per specification4.10 Wire brush/ power brush4.11 Type of files4.12 Ball peen hammer4.13 Brush/broom5 Electrode quiver6 Status of welding Machine calibration7 Welding arc stability 1 Ensure welding machine validity is within calibration period2 Ensure welding machine in functioning and safe operating condition

161 Lecture2 Group Discussion

1 SMAW welding machine functionality affirmed2 Complete welding accessories installed to welding machine3 Relevant welding PPE worn4 Complete and proper welding tools ensured5 Status of welding machine calibration confirmed6 Machine arc stability assured

6. 1 Affirm SMAW welding machine functionality2 Assure complete welding accessories installed to welding machine3 Ensure complete and proper welding tools for use4 Confirm status of welding machine calibration5 Assure welding arc stability3 241 Demonstration2 Observation3 Case study

7. Perform SMAW process

1 Joint Configuration2 Joint preparation marking and cutting2.1 Mechanical cutting2.2 Oxy-acetylene gas cutting2.3 Plasma cutting3 Check Angle (included angle & bevel angle4 Root face 5 Root gap /opening6 Fit-up / jig & fixture setup7 Tack weld8 Surface cleaning9 Welding position - 5G and 6G10 Operation of SMAW machine11 Arc blow effect12 Parameter setting13 Root pass / penetration14 Root pass cleaning15 Hot pass 16 Hot pass cleaning17 Interpass18 Interpass cleaning19 Capping20 Weldment cleaning21 Gouging technique (carbon steel only)22 Grinding technique23 Surface inspection and testing (PT/MT)24 Back welding/ back filled25 Welding machine shut down procedure26 Good housekeeping1 Ensure PPE in good usage condition2 Ensure PPE are worn accordingly3 Cautious when dispensing hot electrode butt4 Ensure glove free from oil base and any moisture during electrode handling5 Electrode to be handled according to manufacturer recommendation6 Ensure proper welding environment condition (eg. under shade from rain and barricade from heavy wind, etc)7 Ensure grinding work are carried out safely

401 Lecture2 Group Discussion1 Joint configuration identified2 Weld joint marking and cutting prepared3 Angle check carried out 4 Root face identified 5 Root gap /opening identified6 Fit-up / jig & fixture set up 7 SMAW machine operated8 Arc striking test performed9 Tack weld carried out 10 Surface cleaning carried out 11 Welding performed in position - 5G and 6G12 Pre-heating carried out as required13 Welding parameters set14 Root pass / penetration carried out15 Root pass cleaning executed16 Hot pass carried out17 Hot pass cleaning executed 18 Interpass carried out 19 Interpass cleaning executed20 Capping executed21 Weldment cleaning carried out22 Post-heating carried out as required23 Attitude/ Safety/ Environmental requirement carried out during performing SMAW process 24 Welding machine shut down procedure executed25 Housekeeping carried out

i. 1 Identify joint configuration2 Prepare weld joint2.1 Carry out mechanical cutting2.2 Carry out oxy-acetylene gas cutting2.3 Carry out plasma cutting3 Carry out check Angle (included angle & bevel angle4 Identify root face 5 Identify root gap /opening6 Setup fit-up / jig & fixture 7 Operate SMAW machine8 Carry out arc striking test run to obtain arc stability9 Carry out tack weld10 Carry out surface cleaning11 Setup welding position - 5G and 6G12 Carry out pre-heating as required13 Set the parameters14 Carry out root pass / penetration15 Execute root pass cleaning16 Carry out hot pass 17 Execute hot pass cleaning18 Carry out interpass19 Execute interpass cleaning20 Execute capping21 Carry out weldment cleaning22 Carry out post-heating as required23 Carry out welding machine shut down procedure24 Carry out housekeeping3521 Demonstration2 Observation3 Project

8. Perform visual inspection and testing (destructive test)

1 Welding inspection kit2 Root inspection3 Weldment profile4 Type of welding defect and causes such as:4.1 Irregular weld profile4.2 Incomplete penetration4.3 Undercut4.4 Arc strike4.5 Spatter4.6 Crack4.7 Slag inclusion4.8 Porosity4.9 Overlap4.10 Lack of fusion (surface) 4.11 Underfill4.12 Burn-through4.13 Misalignment (linear & angular)5 Welding specimen test5.1 For butt weld - root bend (RB), face bend (FB), side bend test6 Acceptance & rejection criteria according to code1 Meticulous in checking visual inspection2 Inquisitive in seeking advice to confirm acceptance & rejection criteria from superior 3 Open to comments on weld imperfection4 Ensure safety when performing bend test

401 Lecture2 Group Discussion1 Relevant welding inspection tools selected2 Root penetration checked3 Weldment profile for butt weld checked4 Type of surface defect Identified5 Welding specimen visual and testing carried out6 Acceptance & rejection criteria confirmed

i. 1 Select relevant welding inspection tools2 Check root penetration for butt weld only3 Check weldment profile for butt weld4 Identify type of surface defect5 Carry out welding specimen test5.1 For butt weld - root bend (RB), face bend (FB), side bend test6 Seek advice on acceptance & rejection criteria from superior401 Demonstration2 Observation3 Case study

9. Compile work completion checklist1 Welding checklist2 Work completion hand over1 Precise in filling welding checklist2 Integrity in compiling report41 Lecture2 Group Discussion1 Welding checklist fill up complete2 Report compile and submitted to superior for hand over

1 Fill-up welding checklist2 Compile and submit report to superior41 Observation2 Case study

Employability Skills Core AbilitiesSocial Skills

1.01Identify and gather information1.02Document information, procedures or processes1.11Apply thinking skills and creativity2.01Interpret and follow manuals, instructions and SOPs2.03Communicate clearly2.04Prepare brief reports and checklists using standard forms2.05Read/interpret flowcharts and pictorial information2.11Convey information and ideas to people3.01Apply cultural requirements to the workplace3.02Demonstrate integrity and apply ethical practices3.03Accept responsibility for own work and work area3.04Seek and act constructively upon feedback about performance3.05Demonstrate safety skills3.06Respond appropriately to people and situations3.07Resolve interpersonal conflicts3.13Develop and maintain team harmony and resolve conflicts3.15Liase to achieve identified outcomes3.16Identify and assess client/customer needs5.01Implement project/work plans5.02Inspect and monitor work done and/or in progress4.01Organize own work activities4.02Set and revise own objectives and goals4.03Organize and maintain own workplace4.04Apply problem solving strategies4.05Demonstrate initiative and flexibility6.01Understand systems6.02Comply with and follow chain of command6.03Identify and highlight problems6.05Analyse technical systems6.06Monitor and correct performance of systems6.07Develop and maintain networks1. Communication Skills2. Interpersonal Skills3. Learning Skills4. Multitasking and prioritizing5. Self-discipline6. Teamwork

Tools, Equipment and Materials (TEM)ITEMSRATIO (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) form8. Base metal pipe: 6"to 8" NPS schedule 80 (minimum range)9. Safety shoe10. Coverall11. Leather gloves12. Fire extinguisher13. Muffler / ear plug14. First aid kit15. Hazard signage16. Material mill certificate17. Material standard18. Welding electrode (2.5mm - 4.0mm)19. Electrode baking oven20. Electrode holding oven21. SMAW welding machine (electrical driven transformer) and accessories22. Marking tools and hand tools23. Electrode quiver24. Welding inspection kit25. Welding bay c/w accessories (eg. Power supply, lighting, welding curtain, fume extractor, welding table with positioner, etc)26. Jig & fixture fit-up clamp 27. Hydraulic press28. Guided bend test jig29. High speed cutting machine30. Spark lighter31. Oxy-acetylene gas cutting (manual) and accessories with flash back arrester32. Oxy-acetylene gas cutting machine (semi-auto) and accessories with flash back arrester33. Oxy-acetylene pipe cutting machine and accessories with flash back arrester34. Band saw machine35. Power saw machine36. Gouging torch and accessories37. Air compressor and receiver38. Welding checklist1:11:11:11:11:111111:11:11:11:11:51:11:151:151:11:1As required1:151:151:11:11:11:15

1:11:51:151:151:151:1

1:15

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1:151:151:151:51:21:1

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: 978-00772387732 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- 99938973023 Robert L. O'Brien, 1997, Jefferson's Welding Encyclopaedia, 18th Edition, 550 N.W. Lejeune Road, Miami, Florida, 33126 USA, American Welding Society, ISBN: 978-08717150674 Joseph W. Giachino, William, Weeks, 1985, Welding Skills & Practices, 6th edition, Western Michigan University, Kalmazoo, Michigan, Chicago, 60637, USA, American Technical Society, ISBN:978-08269300195 Griffin, Roden, Briggs, 1985, Pipe Welding Techniques, 4th edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-08273224866 Ivan H. Griffin, Edward M. Roden and Charles W. Briggs,1984, Basic Arc Welding4th edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-08273213117 ASM International, 1983, Metal Reference Book, 2nd edition, Material Park, Ohio, 44073 USA, American Society For Metals, ISBN:978-08717015658 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: 978-067297990310 Frank R. Schell, 1977, Welding Procedures: Electric Arc, 1st edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-082731603411 Giachino, Weeks, Johnson, 1974, Welding Technology, 2nd edition, Chicago, 60637 USA, American Technical Society, ISBN: 978-0826930637

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