Training Regulations: Shielded Metal Arc Welding (Smaw) NC Ii
Training Regulations: Shielded Metal Arc Welding (Smaw) NC Ii
Training Regulations: Shielded Metal Arc Welding (Smaw) NC Ii
REGULATIONS
TABLE OF CONTENTS
METALS AND ENGINEERING SECTOR
SHIELDED METAL ARC WELDING (SMAW) NC II
Page No.
SECTION 1
SECTION 2
SECTION 3
SECTION 4
Basic Competencies
Common Competencies
Core Competencies
2-46
2-15
16-43
44-46
TRAINING STANDARDS
47-54
3.1
3.2
3.3
3.4
3.5
3.6
3.7
47-50
51
52
52-53
53
54
54
Curriculum Design
Training Delivery
Trainee Entry Requirements
List of Tools, Equipment and Materials
Training Facilities
Trainers' Qualifications
Institutional Assessment
55
COMPETENCY MAP
56
DEFINITION OF TERMS
57
ACKNOWLEDGEMENTS
58
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BASIC COMPETENCIES
Participate in Workplace Communication
Work in Team Environment
Practice career professionalism
Practice occupational health and safety procedures
COMMON COMPETENCIES
Apply Safety Practices
Interpret Drawings and Sketches
Perform Industry Calculations
Contribute to Quality System
Use Hand Tools
Prepare Weld Materials
Setup Welding Equipment
Fit up Weld Materials
Repair Welds
CORE COMPETENCIES
Weld Carbon Steel Plates and Pipes Using SMAW
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UNIT CODE
500311105
UNIT DESCRIPTOR
ELEMENT
1. Obtain and convey
workplace
information
1.2
1.3
1.4
1.5
1.6
2. Participate in
workplace meetings
and discussions
1.7
2.1
2.2
2.3
2.4
2.5
2.6
3. Complete relevant
work related
documents
3.1
3.2
3.3
3.4
3.5
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RANGE OF VARIABLES
VARIABLE
1. Appropriate sources
RANGE
Team members
Suppliers
Trade personnel
Local government
Industry bodies
2. Medium
Memorandum
Circular
Notice
Information discussion
Follow-up or verbal instructions
Face to face communication
3. Storage
4. Forms
5. Workplace interactions
6. Protocols
Observing meeting
Compliance with meeting decisions
Obeying meeting instructions
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EVIDENCE GUIDE
1. Critical Aspects of
1.1.
Competency
1.2.
1.3.
1.4.
2. Underpinning
Knowledge and
Attitudes
2.1.
2.2.
2.3.
2.4.
2.5.
2.6.
3.1.
3. Underpinning Skills
3.2.
3.3.
3.4.
3.5.
3.6.
3.7.
3.8.
4. Resource
Implications
5. Methods of
Assessment
6. Context of
Assessment
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4.1.
4.2.
4.3.
4.4.
5.1.
5.2.
6.1.
UNIT OF COMPETENCY:
UNIT CODE
:
UNIT DESCRIPTOR
ELEMENT
PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
3. Work as a team
member
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RANGE OF VARIABLES
VARIABLE
RANGE
1. Role
and
objective
of
team
1.1.
1.2.
2. Sources
of
information
2.1.
2.2.
Job procedures
2.3.
Machine/equipment
manufacturers
specifications and instructions
2.4.
2.5.
Client/supplier instructions
2.6.
Quality standards
2.7.
3.1.
3.2.
3.3.
3.4.
3.5.
3. Workplace
context
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EVIDENCE GUIDE
1. Critical
aspects of
competency
1.2.
1.3.
1.4.
1.5.
1.6.
Reported outcomes
2.1.
Communication process
2.2.
Team structure
2.3.
Team roles
2.4.
3. Underpinning
Skills
3.1.
4. Resource
Implications
2. Underpinning
Knowledge
and Attitude
5. Methods of
Assessment
6. Context for
Assessment
UNIT OF COMPETENCY:
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4.1.
4.2.
5.2.
5.3.
6.1.
6.2.
UNIT CODE
500311107
UNIT DESCRIPTOR
ELEMENT
1. Integrate personal
objectives with
organizational goals
3. Maintain professional
growth and development
RANGE OF VARIABLES
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VARIABLE
RANGE
1. Evaluation
2. Resources
2.1 Human
2.2 Financial
2.3 Technology
2.3.1 Hardware
2.3.2 Software
4. Recognitions
4.1
4.2
4.3
4.4
4.5
4.6
Recommendations
Citations
Certificate of Appreciations
Commendations
Awards
Tangible and Intangible Rewards
5. Licenses and/or
certifications
5.1
5.2
5.3
5.4
National Certificates
Certificate of Competency
Support Level Licenses
Professional Licenses
EVIDENCE GUIDE
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1. Critical Aspects of
Competency
2. Underpinning
Knowledge
3. Underpinning Skills
4. Resource
Implications
5. Methods of
Assessment
6. Context of
Assessment
UNIT OF COMPETENCY :
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SAFETY PROCEDURES
UNIT CODE
500311108
UNIT DESCRIPTOR
1.
ELEMENT
Identify hazards and
risks
1.2
1.3
2.
Evaluate hazards and 2.1 Terms of maximum tolerable limits which when
risks
exceeded will result in harm or damage are identified
based on threshold limit values (TLV)
2.2 Effects of the hazards are determined
2.3 OHS issues and/or concerns and identified safety
hazards are reported to designated personnel in
accordance with workplace requirements and
relevant workplace OHS legislation
PERFORMANCE CRITERIA
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ELEMENT
3. Control hazards
and risks
4.
Maintain OHS
awareness
RANGE OF VARIABLES
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VARIABLE
RANGE
1. Safety regulations
2. Hazards/Risks
VARIABLE
3. Contingency
measures
4. PPE
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5. Emergency-related
drills and training
6. OHS personal
records
6.1
6.2
6.3
6.4
EVIDENCE GUIDE
1. Critical Aspects of
Competency
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Medical/Health records
Incident reports
Accident reports
OHS-related training completed
14
2. Underpinning
Knowledge and
Attitude
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3. Underpinning
Skills
4. Resource
Implications
5. Methods of
Assessment
6. Context for
Assessment
COMMON COMPETENCIES
UNIT OF COMPETENCY: APPLY SAFETY PRACTICES
UNIT CODE:
MEE721201
UNIT DESCRIPTOR:
ELEMENTS
PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1.
1.1
1.2
2.
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2.1
3.
3.1
3.2
4.
4.1
5.
5.1
RANGE OF VARIABLES
VARIABLE
1. Hazards
1.1
1.2
1.3
1.4
1.5
RANGE
Cluttered tools and materials
Slippery floors (caused by oil, grease or any liquid)
Exposed electrical wires
Sharp edges
Machine without guards or with exposed moving
parts
3. Injuries
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3.3
3.4
3.5
3.6
3.7
4. Type of fires
EVIDENCE GUIDE
1. Critical aspects Assessment requires evidence that the candidate:
of evidence
1.1 identified hazardous area
1.2 used protective clothing and devices
1.3 handled tools, equipment and materials properly
1.4 performed first aid
1.5 used fire extinguisher
2.
Underpinning
knowledge and
attitude
2.1
2.2
2.3
2.4
2.5
2.6
2.7
3.
Underpinning
skills
3.1
3.2
3.3
3.4
4.
Resource
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implications
5.
Method of
assessment
6.
Context for
assessment
MEE721202
UNIT DESCRIPTOR:
ELEMENTS
PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1.
Identify standard
alphabet of lines
1.1
1.2
2.
Identify orthographic/
isometric views
2.1
2.2
3.
Interpret standard
drawing symbols,
dimensional tolerances
and notations
3.1
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3.2
18
RANGE OF VARIABLES
VARIABLE
1. Drawing
RANGE
Drawing technique include
1.1 Perspective
1.2 Exploded view
1.3 Hidden view technique
Projections
1.4 First angle projections
1.5 Third angle projections
2. Tolerance
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EVIDENCE GUIDE
1. Critical aspects Assessment requires evidence that the candidate interpreted
of evidence
technical drawings and sketches.
2.
Underpinning
knowledge
2.1
2.2
2.3
2.4
2.5
3.
Underpinning
skills
4.
Resource
implications
5.
Method of
assessment
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Alphabet of lines
Projections
Drawing symbols
Dimensioning techniques
Tolerances
20
5.2
5.3
5.4
5.5
6.
Context for
assessment
ELEMENTS
PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1.
Perform four
fundamental operations.
1.1
2.
Perform conversion of
units
2.1
2.2
3.
Perform calculations on
algebraic expressions
3.1
3.2
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3.3
3.4
4.
Compute percentage
and ratio
4.1
4.2
RANGE OF VARIABLES
VARIABLE
1. Four fundamental
operations
2. Units
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RANGE
1.1
1.2
1.3
1.4
Addition
Subtraction
Multiplication
Division
2.1 Fractions
2.2 Mixed numbers
2.3 decimal
22
1.
EVIDENCE GUIDE
Critical aspects Assessment requires evidence that the candidate performed
of evidence
calculations:
1.1 using four fundamental operations
1.2 involving fractions and mixed numbers
1.3 involving fractions and decimals
1.4 on algebraic expressions
1.5 involving ratio and proportion
2.
Underpinning
knowledge and
attitude
2.1
2.2
2.3
2.4
3.
Underpinning
skills
3.1 Performing calculations using pen and paper or with the use
of calculator
4.
Resource
implications
5.
Method of
assessment
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Context for
assessment
MEE721204
PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1.
1.1
1.2
1.3
2.
2.1
2.2
2.3
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Protect company
property and customer
interests
RANGE OF VARIABLES
VARIABLE
1. Quality system and
procedures
2. Company property
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2.4
3.1
3.2
RANGE
Quality system and procedures may be contained in:
1.1 work instructions
1.2 safe work procedures
1.3 product specifications
1.4 equipment maintenance schedules
1.5 technical procedures adopted or specifically
prepared standards
1.6 company/industry rules
Company properties includes :
2.1 production and/or fabrication equipment
2.2 hand and power tools
2.3 OH&S paraphernalia
2.4 facilities
25
1.
EVIDENCE GUIDE
Critical aspects Assessment requires evidence that the candidate:
of evidence
1.1 inspected work done against specification
1.2 applied quality standards to work
1.3 protected company property and customer interests
2.
Underpinning
knowledge and
attitude
3.
Underpinning
skills
4.
Resource
implications
5.
Method of
assessment
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Context for
assessment
MEE721205
UNIT DESCRIPTOR: This unit covers the competencies required to use hand tools.
ELEMENTS
PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1.
1.1
1.2
2.
2.1
2.2
3.
3.1
3.2
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RANGE OF VARIABLES
VARIABLE
1. Hand tools
RANGE
Hand tools includes but not limited to:
1.1 Hacksaws
1.2 Hammers (ball peen, chipping)
1.3 Punches
1.4 Screwdrivers
1.5 Wrenches
1.6 Scrapers
1.7 Chisels
1.8 Gouges
1.9 Files
1.10 Clamps
2. Task
3. Routine maintenance
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EVIDENCE GUIDE
1. Critical aspects Assessment requires evidence that the candidate:
of evidence
1.1 Selected and used hand tools appropriate to the job
1.2 Performed routine maintenance and storage of hand tools
2.
Underpinning
knowledge and
attitude
3.
Underpinning
skills
4.
Resource
implications
5.
Method of
assessment
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6.
Context for
assessment
UNIT TITLE:
UNIT CODE:
MEE721206
DESCRIPTOR:
ELEMENTS
PERFORMANCE CRITERIA
Italicized terms are elaborated in the range of Variables
1. Set up cutting
equipment
4. Prepare welding
consumables
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manufacturers instructions
5. Prepare welding
safety and protective
equipment
RANGE OF VARIABLE
VARIABLE
1. Materials and
consumables
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
RANGE
Mild steel
Carbon steel
Alloy steel
Cutting gases
Gouging electrodes
Grinding/cutting discs
Run on/run off, backing plates/ring
Cutting accessories
2. Cut
3. Specification
Specifications based on
3.1 Welding codes
3.2 Reference Industry standards
3.3 Client specification
4. Cleaned
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EVIDENCE GUIDE
1. Critical Aspects of
Competency
2. Underpinning Knowledge
3. Underpinning Skills
4. Resource Implications
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6. Context of Assessment
UNIT TITLE:
UNIT CODE:
MEE721207
DESCRIPTOR:
ELEMENTS
PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
2. Set up welding
accessories
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3. Set up welding
positioners, jigs and
fixtures
3.1 Braces, stiffeners, rails and other jigs are provided and
in conformity with job requirements.
3.2 Work items/materials are protected from strong winds,
drafts and rainfall
4. Set up pre-heating
tools/equipment as
required
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RANGE OF VARIABLE
VARIABLE
1. Welding machine
RANGE
Types, kind and uses of
1.1 SAW equipment
1.2 SMAW/GTAW equipment
1.3 GMAW/FCAW equipment
1.4 Multi-process welding equipment
2. Polarity
3. Power supply
3.1
3.2
3.3
3.4
4. Accessories
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4.16
4.17
5. Gases
5.1
5.2
5.3
5.4
6. Pre-heating equipment
EVIDENCE GUIDE
1. Critical Aspects of
Competency
2. Underpinning Knowledge
3. Underpinning Skills
4. Resource Implications
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4.2 PPE
5. Method of Assessment
6. Context of Assessment
UNIT TITLE:
UNIT CODE:
MEE721208
DESCRIPTOR:
ELEMENTS
PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
3. Set up welding
positioner
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RANGE OF VARIABLE
VARIABLE
1. Tack welding
RANGE
Kinds of tacking
1.1 Bridge tacking
1.2 Permanent tacking
1.3 Temporary tacking
2. Visually and
dimensionally
acceptable
3. Root gap
4. Backing materials
4.1 Stiffeners
4.2 Backing plate
4.3 Strong back
5. Alignment
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EVIDENCE GUIDE
1. Critical Aspects of
Competency
2. Underpinning Knowledge
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Fit up tolerances
Mensuration
WPS
Welding materials and consumables
Drawing and plan interpretation
Welding codes (symbols)
Identification of weld defects
Fit up
3. Underpinning Skills
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4. Resource Implications
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5. Method of Assessment
6. Context of Assessment
UNIT TITLE:
REPAIR WELDS
UNIT CODE:
MEE721209
DESCRIPTOR:
ELEMENTS
PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1. Mark/locate weld
defects
1.1
3. Remove defects
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4. Perform re-welding
RANGE OF VARIABLE
VARIABLE
1. Weld defects
RANGE
1.1 Porosity
1.2 Root undercut
1.3 Wire and solid material inclusion
1.4 Concavity/convexity
1.5 Degree of reinforcement
1.6 Burn Through
1.7 Crater cracks
1.8 Cracks
1.9 Lack of Fusion (tie-in)
1.10 Pinholes/Blowholes
1.11 Under Fill
1.12 Excess/incomplete penetration
1.13 Slag/tungsten inclusion
1.14 Overlap
1.15 Misalignment
1.16 Distortion
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3. Removed/excavated
Defects removed by
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3.1
3.2
3.3
3.4
EVIDENCE GUIDE
1. Critical Aspects of
Competency
Grinding
Arc/air Gouging
Cutting (mechanical, gas)
Plasma gouging
2. Underpinning Knowledge
3. Underpinning Skills
4. Resource Implications
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6. Context of Assessment
CORE COMPETENCIES
UNIT OF COMPETENCY:
UNIT CODE:
MEE721306
DESCRIPTOR:
ELEMENTS
PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
3. Weld subsequent/
filling passes
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RANGE OF VARIABLE
VARIABLE
1. WPS
2. Defects
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RANGE
WPS Requirements
1.1 Welding positions
1.1.1 4G (plate)
1.1.2 1G, 2G, 5G and 6G (pipe)
1.2 Material thickness
1.2.1 1.6mm unlimited (plate)
1.2.2 1.6mm and above (pipe wall thickness)
1.3 Pipe diameter
1.3.1 25.4mm (1in.) - unlimited
1.4 Type of material
1.4.1 Carbon or mild steel
1.5 Type and size of mild steel electrode
1.6 Travel speed
1.7 Current setting (polarity, amperage, voltage)
1.8 Preheating requirement
1.9 Joint preparation
2.1 Porosity
2.2 Undercut
2.3 Arc Strike
2.4 Spatters
2.5 Slag inclusion
2.6 Concavity/convexity
2.7 Degree of reinforcement
2.8 Burn Through
2.9 Crater cracks
2.10 Cracks
2.11 Lack of Fusion
44
2.12 Pinholes/Blowholes
2.13 Under Fill
2.14 Overlap
2.15 Misalignment
2.16 Distortion
EVIDENCE GUIDE
1. Critical Aspects of
Competency
2. Underpinning Knowledge
2 Underpinning Skills
3.1
3.2
3.3
3.4
3.5
3.6
3 Resource Implications
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Measuring skills
Communication skills
Rectifying weld defects
Applying weld techniques
Handling welding tools and equipment
Handling welding materials and
consumables
45
4 Method of Assessment
5 Context of Assessment
CURRICULUM DESIGN
NC Level: NC II
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1.
Interaction
Demonstration
Observation
Interviews/
questioning
Demonstration
Demonstration
2. Work in a
team
environment
3.
Group
discussion
4. Practice
occupational
health and
safety
Observation
Interviews/
questioning
Observation
Interviews/
questioning
Discussion
Observation
Plant tour
Interview
Symposium
COMMON COMPETENCIES
Unit of
Competency
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Learning Outcomes
Methodology
Assessment
Approach
47
Lecturette
Practical
application
Oral
questioning
Written
Demonstration
Lecturette
Practical
application
Oral
questioning
Written
Demonstration
3. Use hand
tools
Lecturette
Practical
application
4. Interpret
Blueprints
Lecturette
Oral
questioning
Written
Demonstration
Oral
questioning
Written test
1. Perform
work safely
2. Contribute to
quality
system
Practical
application
5.1 Solve mathematical problems
5.2 Convert systems of
measurement
5.3 Measure workpiece
Lecturette
Practical
application
Oral
questioning
6. Prepare
Weld
Materials
Lecturette
Practical
application
Observation
Demonstration
and oral
questioning
Written test
7. Set-up
Welding
Equipment
Lecturette
Observation
and oral
Demonstrati
questioning
on
Demonstration
5. Perform
industry
calculations
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Written test
48
8. Fit up Weld
Materials
9. Repair
Welds
Lecturette
Observation
and oral
Demonstrati
questioning
on
Demonstration
and oral
questioning
Written test
CORE COMPETENCIES
Unit of
Learning Outcomes
Competency
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and oral
questioning
Written test
Methodology
Assessment
Approach
49
1. Weld
Carbon
Steel
Plates
Using
SMAW
2.
Weld
Carbon
Steel
Plates
and
Pipes
Using
SMAW
3.2
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Discussion
Demonstration
Observation
and oral
questioning
Demonstration
and oral
questioning
Written test
Discussion
Demonstration
Observation
and oral
questioning
Demonstration
and oral
questioning
TRAINING DELIVERY
50
3.3
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Trainees or students wishing to gain entry into this course should possess
the following requirements:
completed training in SMAW NC I or a holder of SMAW NC I
can communicate both oral and written
physically and mentally fit
can perform basic mathematical computation
3.4
EQUIPMENT
Qty.
Description
8 units
Arc Welding
machine AC/DC
and accessories
8 pcs.
Welding
table/positioners
MATERIAL
Qty.
Description
6 boxes Electrode
3.2mm E6011
1 unit
Electrode oven
20 pcs.
12 pcs. Plier/tong
1 unit
Automatic gas
cutting machine
20 pcs.
10 pcs. Files-bastard
cut
5 units
Portable disc
grinder
2 pcs.
12 pcs. Head
shield/helmet
12 sets Leather
apron/jacket
12 sets Leather glove,
long
1 unit
Exhaust fan
20 pcs.
Electrode
3.2mm
E7018/6013
Mild steel plate
10mm X 150mm
X 6m
Mild steel plate
3.2mm X
150mm X 6m
Carbon steel
pipe, schedule
40 dia. 150 X
3m
Filter lens
1 unit
Power hacksaw
20 pcs.
2 units
Anvil
20 pcs
2 pcs.
2 units
Work bench w/
bench vice on 4
corners
Oxyacetylene/OxyLPG cylinder
with content
Pedestal /bench
5 pcs.
2 pcs.
Ballpeen
Hammer
Safety goggle,
wide vision,
clear
Oxy-acetylene
goggles
2 sets
1 unit
6 boxes
1 box
Metal chalk
52
1 unit
grinding machine
Industrial fan
TRAINING FACILITIES
SMAW NC II
SIZE IN
METERS
AREA IN
SQ.
METERS
QTY
TOTAL AREA
IN SQ.
METERS
Welding Booth
2 X 1.5
24
Grinding Booth
2 X 1.5
2 X2
1.5 X 2.5
4 X 5
20
20
Learning Resource
Area*
5 X9
45
45
2.5 X 4
10
10
Materials/Preparation
Area*
4
2
Total
117
Circulation Area**
35
152
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4.2
Assessment shall focus on the core unit of competency, weld carbon steel
plates and pipes using SMAW. The basic and common units shall be
integrated or assessed concurrently with the core units.
4.3
4.4
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Competency Map
Metals and Engineering Sector
(WELDING)
C
O
R
E
C
O
M
P
E
T
E
N
CI
E
S
COM
MON
COM
PET
ENCI
ES
BASI
C
COM
PET
ENCI
ES
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Weld carbon
steel plates
using GTAW
Weld carbon
steel pipes
using GTAW
Weld carbon
steel plates
using GMAW
Weld pipes
using SAW
Weld carbon
steel pipes
using GMAW
Weld alloy
steel pipes
using GMAW
Weld alloy
steel pipes
using FCAW
Weld alloy
steel plates
using GMAW
Weld carbon
steel plates
using SMAW
Weld carbon
steel plates
and pipes
using SMAW
Perform gas
welding in
carbon steel
plates and tubes
Perform gas
welding in alloy
steel plates
and tubes
using SAW
Weld plates
Weld carbon
steel plates
using FCAW
Weld carbon
steel pipes
using FCAW
Weld alloy
steel plates
using FCAW
Apply safety
practices
Interpret drawing
and sketches
Perform industry
calculations
Contributes to
quality system
Prepare weld
materials
Set-up welding
equipment
Fit up weld
materials
Repair welds
Receive and
respond to
workplace
communication
Demonstrate
work values
Participate in
workplace
communication
Work in team
environment
Lead in
workplace
communication
Develop and
practice
negotiation skills
Use
mathematical
concepts and
techniques
Work with
others
Practice basic
housekeeping
procedures
Practice career
professionalism
Practice
occupational
health and
safety
procedures
Lead small
teams
Solve problems
related to
work activities
Use relevant
technologies
Utilize specialist
communication
skills
Develop team
and individual
Apply problemsolving
techniques
in the workplace
Collect, analyze
and organize
information
Plan and
organize work
Promote
environmental
protection
Use hand
tools
Legend
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57
DEFINITION OF TERMS
1) base metal
2) weld bead
3) weld defect
4) weld line
the junction of weld metal and the base metal, or the junction of
base metal parts when filler metal is not used
5) weldment
6) welding
joining two metals by applying heat to melt and fuse them, with
or without filler metal
7) welding electrode the current-carrying rod used to strike an arc between rod
and metal
8) welding rod
9) welding torch a gas mixing and burning tool for the welding of metal
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ACKNOWLEDGEMENTS
The Technical Education and Skills Development Authority (TESDA) wishes to extend
thanks and appreciation to the many representatives of business, industry, academe
and government agencies who donated their time and expertise to the development
and validation of this Training Regulation.
THE INDUSTRY EXPERTS
MR. ANTONIO M. REYES
Pilipinas Shell Foundation, Inc.
San Isidro, Batangas City
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