Metal Inert Gas - Metal Active Gas - Gas Metal Arc Welder (MIG - MAG - GMAW) - (CSC - Q0209)

*
QUALIFICATIONS PACK - OCCUPATIONAL STANDARDS FOR

CAPITAL GOODS INDUSTRY
Contents
1. Introduction and Contacts……………………….1
2. Qualifications Pack……….……………………......2
3. Glossary of Key Terms………………………….….4
4. OS Units………………………………………………....6
5. Annexure: Nomenclature for QP & OS…..61
➢ OS describe what 6. Assessment Criteria……………………………….63
individuals need
to do, know and
understand in Introduction
order to carry out Qualifications Pack- Metal Inert Gas/ Metal Active Gas/
a particular job
role or function Gas Metal Arc Welder (MIG/MAG/GMAW)
ces Helpdesk Attendant
SECTOR/S: CAPITAL GOODS
➢ OS are
performance SUB-SECTOR:
standards that 1. Machine Tools 5. Process Plant Machinery
individuals must 2. Dies, Moulds and Press Tools 6. Electrical and Power Machinery
achieve when 3. Plastics Manufacturing Machinery 7. Light Engineering Goods
carrying out 4. Textile Manufacturing Machinery
functions in the
workplace, OCCUPATION: Welding and Cutting
together with REFERENCE ID: CSC/Q0209
specifications of
the underpinning ALIGNED TO: NCO-2004/7212.2
knowledge and Brief Job Description: Perform manual (semi-automatic) MIG/MAG (GMAW)
understanding welding for a range of standard welding job requirements and weld different
materials (carbon steel, aluminum and stainless steel) in various positions. The
welder can prepare various joints including corner, butt, fillet and tee. Set-up and
Capital Goods Skill prepare for operations interpreting the right information from the WPS.
Council, C/O Awfis, 1st
Floor, L-29 Outer Circle Personal Attributes: Basic communication, numerical and computational abilities.
Connaught Place Openness to learning, ability to plan and organize own work and identify and solve
New Delhi – 110001 problems in the course of working. Understanding the need to take initiative and
E-mail:
manage self and work to improve efficiency and effectiveness.
[email protected]
Qualifications Pack For MIG/ MAG/ GMAW Welder
Qualifications Pack Code CSC/Q0209

Metal Inert Gas/ Metal Active Gas/ Gas Metal Arc Welder
Job Role (MIG/ MAG/ GMAW)
Job Details
[Applicable for National Scenarios]

Credits TBD Version number 1.0
Sector Capital Goods Drafted on 10/04/2014
1. Machine Tools
2. Dies, Moulds and Press
Tools
3. Plastics Manufacturing
Machinery
4. Textile Manufacturing
Sub-sector Last reviewed on 24/11/2017
Machinery
5. Process Plant Machinery
6. Electrical and Power
Machinery
7. Light Engineering
Goods
Occupation Welding and Cutting Next review date 24/11/2021
NSQC Clearance on 26/03/2015
2
Job Role MIG/ MAG/ GMAW Welder
Perform manual (semi-automatic) operations for performing

metal inert gas/metal active gas welding (MIG/MAG) also known
Role Description
as gas metal arc welding (GMAW) for welding joints in all
positions as per welding procedure specification (WPS).
NSQF level 4
Minimum Educational Qualifications 10th Standard pass, Preferably
Maximum Educational Qualifications Not Applicable
Prerequisite License or Training Manual/Shielded Metal Arc Welding

Minimum Job Entry Age 18 Years
Experience 3 months Manual/ Shielded Metal Arc Welding
Compulsory:
1. CSC/N0209 Manually (semi-automatic) welding joints
using the MIG/MAG (GMAW) process
2. CSC/N0204 Manually weld carbon and low alloy steels in
1G/1F, 2G/2F and 3G/3F welding positions using Manual
Metal Arc Welding/ Shielded Metal Arc Welding
Applicable National Occupational
3. CSC/N0203 Manually cut metal and metal alloys using
Standards (NOS)
oxyfuel gas
4. CSC/N0207 Manually cut metal materials using plasma arc
5. CSC/N1335 Use basic health and safety practices at the
workplace
6. CSC/N1336 Work effectively with others
Performance Criteria As described in the relevant OS units
3
Keywords /Terms
Description
Definitions
Sector Sector is a conglomeration of different business operations having similar

business and interests. It may also be defined as a distinct subset of the
economy whose components share similar characteristics and interests.
Sub-sector Sub-sector is derived from a further breakdown based on the
characteristics and interests of its components.
Occupation Occupation is a set of job roles, which perform similar/ related set of
functions in an industry.
Jobrole Job role defines a unique set of functions that together form a unique
employment opportunity in an organisation.
Occupational Standards OS specify the standards of performance an individual must achieve when
(OS) carrying out a function in the workplace, together with the knowledge and
understanding they need to meet that standard consistently. Occupational
Standards are applicable both in the Indian and global contexts.
Performance Criteria Performance criteria are statements that together specify the standard of
performance required when carrying out a task.
National Occupational NOS are occupational standards which apply uniquely in the Indian context.
Standards (NOS)
Qualifications Pack(QP) QP comprises the set of OSs, together with the educational, training and
other criteria required to perform a job role. A QP is assigned a unique
qualifications pack code.
Electives Electives are NOS/set of NOS that are identified by the sector as
contributive to specialization in a job role. There may be multiple electives
within a QP for each specialized job role. Trainees must select at least one
elective for the successful completion of a QP with Electives.
Options Options are NOS/set of NOS that are identified by the sector as additional
skills. There may be multiple options within a QP. It is not mandatory to
select any of the options to complete a QP with Options.
Unit Code Unit code is a unique identifier for an Occupational Standard, which is
denoted by an ‘N’
Unit Title Unit title gives a clear overall statement about what the incumbent should
be able to do.
Description Description gives a short summary of the unit content. This would be
helpful to anyone searching on a database to verify that this is the
appropriate OS they are looking for.
Scope Scope is a set of statements specifying the range of variables that an
individual may have to deal with in carrying out the function which have a
critical impact on quality of performance required.
Knowledge and Knowledge and understanding are statements which together specify the
Understanding technical, generic, professional and organisational specific knowledge that
an individual need to perform to the required standard.
Organisational Context Organisational context includes the way the organisation is structured and
how it operates, including the extent of operative knowledge managers
have of their relevant areas of responsibility.
Technical Knowledge Technical knowledge is the specific knowledge needed to accomplish
specific designated responsibilities.
4
Core Skills/ Generic Core skills or generic skills are a group of skills that are the key to learning
Skills and working in today’s world. These skills are typically needed in any work
environment in today’s world. In the context of the OS, these include
communication related skills that are applicable to most job roles.
Keywords/Terms Description
MIG Metal Inert Gas
Acronyms
MAG Metal Active Gas

GMAW Gas Metal Arc Welding
WPS Welding Procedure Speciation
NDT Non-Destructive Testing
DT Destructive Testing
RT Radiographic Testing
UT Ultrasonic Testing
DPT Dye Penetrant Testing
MPT Magnetic Particle Testing
FPT Fluorescent Penetrant Testing
IS Indian Standards
EN European Standards
ASME American Society of Mechanical Engineers
ISO International Organization for Standardization
D.C. Direct Current
STT Surface Tension Transfer
PQR Process Qualification Record
CO2 Carbon dioxide
CPR Cardiac Pulmonary Resuscitation
PPE Personal Protective Equipment
5
CSC/N0209 Manually (semi-automatic) welding joints using the MIG/MAG (GMAW)
process
----------------------------------------------------------------------------------------------------------------------------- ----------
Overview
This unit is about performing manual (semi-automatic) operations for metal inert gas welding
(MIG)/metal active gas welding(MAG) also known as gas metal arc welding (GMAW) for
welding joints in all positions as per welding procedure specification (WPS).
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Unit Code CSC/N0209
Unit Title
National Occupational Standard
Manually (semi-automatic) welding joints using the MIG/MAG (GMAW) process

(Task)
Description This unit is about performing manual (semi-automatic) operations for metal inert gas
welding (MIG)/ metal active gas welding (MAG) also known as gas metal arc welding
(GMAW) for welding joints in all positions as per welding procedure specification (WPS).
Scope This unit/ task covers the following:
• Work Safely
• Prepare for welding operations
• Carry out welding operations
• Test for quality
• Post welding activities
• Deal with contingencies
Performance Criteria(PC) w.r.t. the Scope

Element Performance Criteria
Work safely To be competent, the user/individual on the job must be able to:
PC1. work safely at all times, complying with health and safety legislation,
regulations and other relevant guidelines
PC2. adhere to procedures or systems in place for health and safety, personal
protective equipment (PPE) and other relevant safety regulations for
MIG/MAG welding operations
Safety precautions: e.g. general workshop safety; fire prevention; general
hazards; manual lifting; overhead lifting; shopfloor housekeeping including
surface conditions; waste disposal; stability of surrounding structures,
furniture, etc.
PC3. check the condition of welding leads, gas connection arrangements, earthing
arrangements and electrode holder
PC4. report any faults or potential hazards to appropriate authority
Prepare for welding To be competent, the user/individual on the job must be able to:
operations PC5. interpret weld procedure data sheets specifications, PQR and WPS
Interpreting WPS: e.g. welding process (ISO codes); parent metal;
consumables; pre welding joining preparation (cleaning, edge preparation,
assembly, pre-heat); welding parameters; welding positions (EN ISO 6947 –
PA, PB, PC, PD, PE, PF, PG; ASME IX – I-6 G/1-6 F); number and arrangement
of runs to fully fill/weld joints; electrode sizes for joint thicknesses;
electrode/filler wire; electrical conditions required (direct [D.C..], electrode
polarity (positive, negative), welding current and voltage ranges; methods of
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arc ignition (scratch, high frequency, lift start); shielding gas (type, flow rate,
pre-weld gas flow, post-weld gas flow); welding techniques; sequence of
welding; control of heat input; interpass/run cleaning/back gouging methods;
post welding activities (wiring brushing, removal of excess weld metal where
required); post-weld heat treatment; etc.
PC6. select welding machines such as inverters, rectifiers and generators,
according to the task
PC7. select electrodes according to classification and specifications
PC8. prepare the materials and joint in readiness for welding
Material and joint preparation: made rust free; cleaned – free from scaling,
paint, oil/grease; made dry and free from moisture; edges to be welded
prepared as per job requirement - such as flat, square or bevelled; use various
machines and techniques for the above (eg. chamfering machine, gas and
plasma cutting, grinding and stripping, etc.); correctly positioned-positioning:
devices and techniques- jigs and fixtures; restraining devices such as clamps
and weights/blocks; setting up the joint in the correct position and alignment
PC9. check the condition of, and correctly connect, welding leads/cables, hoses,
shielding gas supply and wire feed mechanisms
Welding concepts and mechanisms: rated output (duty cycle); measurement
of electrical output and continuity; relationship between wire feed speed
control and welding current; power source characteristics (volt/ampere
graph, flat characteristic, constant voltage output); function of induction
(principle, effect, fixed, stepped, variable control, return; earth; wire feed
control (variable speed motor, direct control of wire feed rate); indirect
control of welding current; relay for electrical power
PC10. prepare the welding equipment for a range of given applications
Welding equipment: rectifier (diode, thyristor/transistor), inverter,
generator; wire feed system; measurement equipment for measuring
electrical output and continuity (voltmeter/multi-meter,
ammeter/shunts/coils, tong tester); welding cables - wire feed to torch (air
cooled, harness construction); welding guns/torches (air cooled, construction,
types [push, pull, reel-on-gun] swan neck design, pistol design); nozzles (dip,
spray); return clamps (types, clamping mechanisms) and cables; solenoid
valves (shielding gas); jog-feed control, gas purge control; ancillary equipment
(angle grinders, wire brushes, linishers, hammer, power saw, angle, pedestal
and straight grinders, chisel); other tools and equipment such as wrenches,
wire cutters and MIG pliers
PC11. select the welding shielding gases and equipment for a range of given
applications
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Shielding gases: applications for shielding gases/gas mixtures (argon, mixture,
helium, argon/helium mixtures, helium/argon mixtures, argon/hydrogen
mixtures, nitrogen argon/nitrogen mixtures, CO2 and CO2 mixtures); flow
rates for applications; identify percentage of purity and mixture with respect
to WPS (Welding Procedure Specification)/PQR (Process Qualification Record)
Shielding gas equipment: cylinders; manifold systems; regulators (fixed,
single stage, two-stage); gas flow meters; gas tubes and connectors; use of
solenoid valves
PC12. plan the welding activities before they start them effectively and efficiently
for achieving specifications as per WPS
PC13. clean wire feeder and torch tip
PC14. connect torches and components
PC15. connect and adjust regulators and flow meters to cylinders
PC16. adjust wire feed rate and read and set current as required
PC17. set other welding parameters (eg. voltage, slope of current versus voltage
curve where required)
Parameters: correct set-up of the joint; proper condition of electrical
connections; welding return and earthing arrangements; operating
parameters
PC18. choose appropriate mode of metal transfer
PC19. set pre-purge with shielding gas as required
PC20. set and verify gas flow rates
PC21. prepare and support the joint, using the appropriate methods
PC22. tack weld the joint at appropriate intervals, and check the joint for accuracy
before final welding
Carry out welding To be competent, the user/individual on the job must be able to:
operations PC23. use manual welding and related equipment, to carry out MIG/MAG welding
processes
PC24. perform MIG/MAG welding operations using various welding techniques to
meet welding procedure specification requirements
Welding techniques: e.g. fine adjustment of parameters, correct
manipulation of the torch, blending in stops/starts, tack welds, angle of the
torch, setting of individual parameters like wire feed speed, voltage, gas flow
rate, stick-out, etc.
PC25. adjust wire stick-out as per requirement
PC26. use welding consumables appropriate to the material and application to DC
current types
Welding consumables: wire electrodes, wires and rods for arc welding;
shielding gases; welding spools and drum packs; anti-spatter compound
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PC27. produce joints of the required quality and of specified dimensional accuracy
which achieve a weld quality equivalent to Level C of ISO 5817
Weld quality standards: required parameters for dimensional accuracy; weld
finishes are built up to the full section of the weld; joins at stop/start
positions merge smoothly; weld surface is; free from cracks, substantially free
from porosity, free from any pronounced hump or crater, substantially free
from shrinkage cavities, substantially free from trapped slag, substantially
free from arcing or chipping marks; fillet welds are: equal in leg length,
slightly convex in profile (where applicable, size of the fillet equivalent to the
thickness of the material welded; weld contour is; of linear and of uniform
profile, smooth and free from excessive undulations, regular and has an even
ripple formation; welds are adequately fused, and there is minimal undercut,
overlap and surface inclusions; tack welds are blended in to form part of the
finished weld, without excessive hump; corner joints have minimal burn
through to the underside of the joint or, where appropriate
PC28. produce joints from various materials in different forms
Types of ferrous metals/materials: carbon steel, stainless steel
Types of forms: sheet (less than 1.5 mm), plate, structural section, pipe/tube,
other forms
PC29. weld joints in good access situations, in select positions
Welding positions: flat (PA) IG/1F, horizontal vertical (PB) 2F, horizontal (PC)
2G, vertical upwards (PF) 3F / 3G, vertical downwards (PG) 3F / 3G, plate to
pipe (fixed) 5F
PC30. make sure that the work area is maintained and left in a safe and tidy
condition
Test for quality To be competent, the user/individual on the job must be able to:
PC31. identify various weld defects use appropriate methods and equipment to
check the quality, and that all dimensional and geometrical aspects of the
weld are to the specification
Weld defects: lack of continuity of the weld; uneven and irregular ripple
formation; excessive spatter; incorrect weld size or profile; burn through;
undercutting; overlap; inclusions; distortion; porosity; internal cracks; surface
cracks; lack of fusion or incomplete fusion; lack of penetration; excessive
penetration; gouges; stray arc strikes; sharp edges; excessive convexity
PC32. check that the welded joint conforms to the specification, by checking various
quality parameters by visual inspection
Quality parameters: dimensional accuracy; alignment/squareness; size and
profile of weld; visual defects; NDT/DT tested defects
Visual inspections: use of visual techniques, distance of observation, angel of
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observation, adequate lighting, low powered magnification, fillet weld gauges
PC33. detect surface imperfections and deal with them appropriately
PC34. carry out DPT tests to assess fine defect open to the surface not detected by
visual inspection (VT)
Post welding To be competent, the user/individual on the job must be able to:
activities PC35. assist in preparation for non-destructive testing of the welds, for a range of
tests
Non-destructive tests (NDT): dye penetrant (DPT), fluorescent penetrant
(FPT), magnetic particle (MPT)
PC36. prepare for destructive tests on weld specimens for fillet, butt and corner
Destructive tests (DT): macro examination, nick break test, bend tests (such
as face, root or side, as appropriate), mechanical (peel, tensile and shear,
fatigue, impact tests), chemical
PC37. shut down and make safe the welding equipment on completion of the
welding activities
PC38. follow the established organisational process for dealing with the welded
pieces including handover, storage, safety and security, record keeping, etc.
Deal with To be competent, the user/individual on the job must be able to:
contingencies PC39. detect equipment malfunctions and deal with them safely and as per
organisation procedures
PC40. deal promptly and effectively with problems within own control, and seek
timely and appropriate help and guidance from relevant personnel where
required
Knowledge and Understanding (K)
A. Organizational The user/individual on the job needs to know and understand:
Context KA1. relevant legislation, standards, policies, and procedures followed in the
(Knowledge of the company
company / KA2. key purpose of the organization
organization and KA3. department structure and hierarchy protocols
its processes) KA4. work flow and own role in the workflow
KA5. dependencies and interdependencies in the workflow
KA6. support functions and types of support available for incumbents in this role
B. Technical The user/individual on the job needs to know and understand:
Knowledge KB1. types of fire extinguishers and their suitable uses in case of welding related
fires
KB2. effects of exposure to welding fume and related safety practices
KB3. range of welding equipment available for GMAW welding
Welding equipment: rectifier (diode, thyristor/transistor), inverter,
generator; wire feed system; measurement equipment for measuring
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electrical output and continuity (voltmeter/multi-meter,
ammeter/shunts/coils, tong tester); welding cables - wire feed to torch (air
cooled, harness construction); welding guns/torches (air cooled, construction,
types [push, pull, reel-on-gun] swan neck design, pistol design); nozzles (dip,
spray); return clamps (types, clamping mechanisms) and cables; solenoid
valves (shielding gas); jog-feed control, gas purge control; ancillary equipment
(angle grinders, wire brushes, linishers, hammer, power saw, angle, pedestal
and straight grinders, chisel); other tools and equipment such as wrenches,
wire cutters and MIG pliers
KB4. functions of welding equipment
KB5. principles and techniques of MIG/MAG welding
Welding technique: e.g. fine adjustment of parameters, correct manipulation
of the torch, blending in stops/starts, tack welds, angle of the torch, setting of
individual parameters like wire feed speed, voltage, gas flow rate, stick-out,
etc.
KB6. relationship between wire feed, speed control and welding current
KB7. how to compare welding consumables for suitability for a range of given
applications
Welding consumables: wire electrodes, wires and rods for arc welding;
shielding gases; welding spools and drum packs; anti-spatter compound
KB8. welding consumables classification as applicable to GMAW
KB9. safe working practices and procedures to be followed when preparing and
using MIG/MAG welding equipment
KB10. hazards associated with MIG/MAG welding and safety precautions to
minimize risk
Safety precautions (MIG/MAG Welding): protection from live and other
electrical components, including insulation, proper earthing, etc; proper
handling and placement of hot metal; taking account of spatter and related
safe distance; adequate lighting; appropriate personal protective equipment:
suitable aprons, welding gloves, respirators, safety boots, correctly fitting
overalls, suitable eye shields/goggles (higher grade of glasses DIN 13);
protection of self and others from the effects of the welding arc; fume
extraction/control measures; safety measures for working in enclosed spaces
KB11. personal protective equipment to be worn for the welding activities
KB12. correct handling and storage of gas cylinders for welding purposes
KB13. manual MIG/MAG welding process
KB14. type and thickness of base metals for welding purposes
KB15. types (availability, typical sizes), storage (storage, identification, segregation
(classification, size) of ferrous metals
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KB16. current and polarity required for GMAW
KB17. types, selection and application of filler wires and welding electrodes
KB18. reasons for using shielding gases, and the types and application of the various
gases
Shielding gases: applications for shielding gases/gas mixtures (argon, mixture,
helium, argon/helium mixtures, helium/argon mixtures, argon/hydrogen
mixtures, nitrogen argon/nitrogen mixtures, CO2 and CO2 mixtures); flow
rates for applications; identify percentage of purity and mixture with respect
to WPS/PQR
KB19. use, impact and importance of gas pressures and flow rates (in relationship to
the type of material being welded)
Types of ferrous metals/materials: carbon steel, stainless steel
KB20. methods/modes of metal transfer and their uses
Methods: globular, short circuit transfer, spray arc, pulse, surface tension
transfer (STT)
KB21. types of welded joints to be produced
Types of joints: fillet lap joints, tee fillet joints, corner joints, butt joints:
square, single vee, double vee
KB22. terminology used for the appropriate welding positions
Welding positions: flat (PA) IG/1F, horizontal vertical (PB) 2F, horizontal (PC)
2G, vertical upwards (PF) 3F / 3G, vertical downwards (PG) 3F / 3G, plate to
pipe (fixed) 5F
KB23. type, components and features of a manual gas shielded arc welding torch
Components of torch: handle; neck; trigger; hose package; shielding gas
nozzle; contact tip and tip fixture; insulator; wire guide tube (liner); shielding
gas supply lead; welding current supply lead
KB24. how to prepare the materials in readiness for the welding activity
KB25. purpose and correct use of anti-spatter compound
KB26. importance and procedure to clean torch tip and liner
KB27. how to set up and restrain the joint, and the tools and techniques to be used
KB28. appropriate tack welding size and spacing (in relationship to material
thickness)
KB29. checks to be made prior to welding
KB30. factors that determine weld bead shape
Factors: gun angles and weld bead profiles (push, perpendicular, drag);
electrode extensions stick out (short, normal, long); fillet weld electrode
extension stick out (short, normal, long); gun travel speed (slow, normal,
fast); current and voltage
KB31. types of weld beads and uses (stringer, weave, weave patterns)
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KB32. weld bead quality characteristics
Bead characteristics: spatter deposits, roughness, evenness, fill, crater,
overlap, contour – convex, concave, mitre
KB33. techniques of operating the welding equipment to produce a range of joints
in the various joint positions
KB34. effects of the electrical characteristics of the MIG/MAG welding arc
KB35. how to control distortion (such as welding sequence; deposition technique)
Distortion (causes and control methods): Causes- improper sequence of weld
runs; direction of weld runs; heat input errors; lack of inaccuracy of jigs and
fixture, Control Methods: sequence of welding as materials; proper direction;
tacking and its frequency (where applicable); use clamping and jigs and
fixtures (where applicable)
KB36. problems that can occur with the welding activities and how to address them
KB37. how to close down the welding equipment safely and correctly
KB38. own responsibility to assist in preparation of the welds and weld pieces for
examination
KB39. how to check the welded joints for uniformity, alignment, position, weld size
and profile
KB40. gouging and back gouging, its importance, principles, methods and
procedures in welding
KB41. purpose and importance of pre-heating requirements for base metals in
preparation for welding
KB42. purpose and importance of post-heating in welding
KB43. methods to achieve pre-heat and post heat requirements for welding
purposes
KB44. tools and methods to measure temperature for pre-heat and post-heat
requirements such as thermal chalk, thermocouple, etc.
KB45. significance of diffusible hydrogen for welds and how it is measured
KB46. procedure to conduct dye penetrant test to assess weld quality
KB47. various procedures for visual examination of the welds for cracks
Visual inspections: use of visual techniques, distance of observation, angel of
observation, adequate lighting, low powered magnification, fillet weld gauges
KB48. types of non-destructive and destructive tests for assessing weld quality
Non-destructive tests (NDT): dye penetrant (DPT), fluorescent penetrant
(FPT), magnetic particle (MPT)
Destructive tests (DT): macro examination, nick break test, bend tests (such
as face, root or side, as appropriate), mechanical (peel, tensile and shear,
fatigue, impact tests), chemical
KB49. methods of removing a test piece of weld from a suitable position in the joint
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KB50. safe working practices, handling and procedures to be adopted when
preparing the welds for examination
Handling specimens for tests: handling hot materials; using chemicals for
cleaning and etching; using equipment to fracture welds
KB51. importance of leaving the work area and equipment in a safe condition on
completion of the welding activities
Skills (S)
A. Core Skills/ Reading Skills
Generic Skills
The user/ individual on the job needs to know and understand how to:
SA1. read and interpret information correctly from various job specification
documents, health and safety instructions, memos, etc. applicable to the job
in English and/or local language
Writing Skills
The user/individual on the job needs to know and understand how to:
SA2. fill up appropriate technical forms, process charts, activity logs as per
organizational format in English and/or local language
SA3. undertake numerical operations, geometry and calculations/ formulae
(including addition, subtraction, multiplication, division, fractions and
decimals, percentages and proportions, simple ratios and averages)
SA4. use appropriate measuring techniques
SA5. use and convert imperial and metric systems of measurements
SA6. apply appropriate degree of accuracy to express numbers
Units and number systems representing degree of accuracy: decimals places,
significant figures, fractions as a decimal quantity
SA7. use and understand tolerance in terms of limits of size
SA8. check measurements, angles, orientation and slopes
SA9. types of reference lines such as tangent lines, datam lines, centre lines and
work points
SA10. check square of material using corner-to-corner dimensions and triangulation
(3-4-5) method
SA11. select and use tools and equipment such as measuring tapes, levels, squares,
protractors and dividers
SA12. ability to check dimensions of components
SA13. calculate the value of angles in a triangle
Oral Communication (Listening and Speaking skills)
SA14. convey and share technical information clearly using appropriate language
SA15. check and clarify task-related information
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SA16. liaise with appropriate authorities using correct protocol
SA17. communicate with people in respectful form and manner in line with
organizational protocol
B. Professional Skills Decision Making
NA
Plan and Organize
SB1. plan, prioritize and sequence work operations as per job requirements
SB2. organize and analyze information relevant to work
SB3. basic concepts of shop-floor work productivity including waste reduction,
efficient material usage and optimization of time
Customer Centricity
SB4. exercise restraint while expressing dissent and during conflict situations
SB5. avoid and manage distractions to be disciplined at work
SB6. manage own time for achieving better results
SB7. work in a team in order to achieve better results
SB8. identify and clarify work roles within a team
SB9. communicate and cooperate with others in the team for better results
SB10. seek assistance from fellow team members
Problem Solving
SB11. identify problems with work planning, procedures, output and behavior and
their implications
SB12. prioritize and plan for problem solving
SB13. communicate problems appropriately to others
SB14. identify sources of information and support for problem solving
SB15. seek assistance and support from other sources to solve problems
SB16. identify effective resolution techniques
SB17. select and apply resolution techniques
SB18. seek evidence for problem resolution
Analytical Thinking
SB19. undertake and express new ideas and initiatives to others
SB20. modify work plan to overcome unforeseen difficulties or developments that
occur as work progresses
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SB21. participate in improvement procedures including process, quality and
internal/external customer/supplier relationships
SB22. enhance one’s competencies in new and different situations and contexts to
achieve more
Critical Thinking
SB23. participate in on-the-job and other learning, training and development
interventions and assessments
SB24. clarify task related information with appropriate personnel or technical
adviser
SB25. seek to improve and modify own work practices
SB26. maintain current knowledge of application standards, legislation, codes of
practice and product/process developments
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NOS Version Control
NOS Code CSC/N0209

Industry Capital Goods Drafted on 10/04/2014
1. Machine Tools
2. Dies, Moulds and
Press Tools
3. Plastics
Manufacturing
Machinery
4. Textile
Manufacturing
Industry Sub-sector Last reviewed on 24/11/2017
Machinery
5. Process Plant
Machinery
Machinery
Goods
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CSC/N0204 Manually weld carbon and low alloy steels in 1G/1F, 2G/2F and 3G/3F welding
positions using Manual Metal Arc Welding/ Shielded Metal Arc Welding
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Overview
This unit covers the performing of manual metal arc welding (MMAW) also known as shielded
metal arc welding (SMAW) for producing various types of joints on low carbon and low alloy
steels in a range of welding positions as per specific instructions given.
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Unit Code CSC/N0204
Unit Title Manually weld carbon and low alloy steels in 1G/1F, 2G/2F, 3G/3F welding positions
(Task) using Metal Arc Welding/ Shielded Metal Arc Welding

Description This OS unit is about performing manual metal arc welding (MMAW) welding also
known as Shielded Metal Arc Welding (SMAW) for producing various types of joints on
carbon and low alloy steels in 1G/1F, 2G/2F and 3G/3F welding positions as per specific
instructions given.
Scope This unit/task covers the following:
• Work safely
• Prepare for welding operations
• Carry out welding operations

PC2. adhere to procedures or systems in place for health and safety, personal
protective equipment (PPE) and other relevant safety regulations
Safety precautions (general): general workshop safety; fire prevention;
general hazards; manual lifting; overhead lifting; shopfloor housekeeping
including surface conditions; waste disposal; stability of surrounding
structures, furniture etc.
PC3. check the condition of, welding leads, earthing arrangements and electrode
holder
PC4. report any faults or potential hazards to appropriate authority
PC5. follow fume extraction safety procedures
Prepare for welding To be competent, the user/individual on the job must be able to:
operations PC6. read and interpret routine information on written job instructions and
drawings, welding procedure specifications and standard operating
procedures
Interpreting the WPS: e.g. welding process (ISO codes); parent metal;
consumables; pre welding joint preparation (edge preparation, assembly,
preheat); welding parameters; welding positions (ISO 6947 – PA, PB, PC, PD,
PE, PF, PG; ASME IX–I-6 G/1-6 F); number & arrangement of runs to fully fill
/weld joints; electrode sizes for joint thicknesses; electrode & covering;
electrical conditions required (type of current, alternating [A.C.] direct [D.C.],
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electrode polarity (positive or negative), welding current ranges); welding
techniques (string/weave);welding sequence; heat input control; bead
length/travel speed preheat/ post heat; interpass run cleaning/back gouging
methods; post welding activities (wire brushing and grinding, removal of
excess weld metal where required); post-weld heat treatment (normalising,
stress relief); etc.
PC7. identify welding machines eg. transformers, rectifiers, inverters and
generators, according to the task
PC8. prepare the work area for the welding activities
PC9. perform measurements for joint preparation and routine MMAW
PC10. prepare the materials and joint in readiness for welding
Materials: carbon, low alloy steel,
Form: plate (1.5 - 24mm)/ sheet (1.5mm)
Joint preparation: made rust free; cleaned – free from scaling, paint, oil/
grease; made dry and free from moisture; edges to be welded prepared as
per job requirement - such as flat, square or bevelled; use various machines
and techniques for the above (eg. chamfering machine, grinding and
stripping, gas or plasma cutting, etc.); correctly positioned (positioning:
devices and techniques; jigs and fixtures; setting up joint in correct position &
alignment)
PC11. use manual metal-arc welding and related equipment to include a. alternating
current (AC) equipment b. direct current (DC) equipment
MMAW equipment: transformers; rectifiers; generators; invertors;
consumables – electrodes, dyes; welding accessories - holders, cables and
accessories; ancillary equipment - (power saw, angle, pedestal and straight
grinders, tong tester, etc.)
PC12. connect equipment to power source
PC13. connect cables, electrode holders, return leads and ground clamps to
appropriate terminal
PC14. re-dry electrodes as per electrode classification requirement
PC15. set, read and adjust amperage controls
PC16. verify set up by running test weld specimen (scrap plate)
PC17. tack weld the joint at appropriate intervals, and check the joint for accuracy
before final welding
PC18. report any faults or problem to appropriate authority
Carry out welding To be competent, the user/individual on the job must be able to:
operations PC19. strike and maintain a stable arc
PC20. stop and properly re-start arc to avoid welding defects (scratch start, tapping
techniques)
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PC21. maintain constant puddle by using appropriate travel speed
PC22. maintain proper bead sequence with respect to groove/fillet configurations
and positions
PC23. remove slag in an appropriate manner (eg. wire brush, hammer, etc.)
PC24. produce welded joints to the specified quality, dimensions and profile
applicable to carbon and low alloy steel sheets and plates from 1.5 – 24 mm
Quality standards: required parameters for dimensional accuracy; weld
positions merge smoothly; weld surface is (free from cracks; substantially
free from porosity; free from any pronounced hump or crater; substantially
free from shrinkage cavities; substantially free from trapped slag;
substantially free from arcing or chipping marks); fillet welds are (equal in leg
length, slightly convex in profile (where applicable), size of the fillet
equivalent to the thickness of the material welded); weld contour is (of linear
and of uniform profile; smooth and free from excessive undulations; regular
and has an even ripple formations); welds are adequately fused, there is
minimal undercut, overlap and surface inclusions; tack welds are blended in
to form part of the finished weld, without excessive hump; corner joints have
minimal burn through to the underside of the joint or, where appropriate
Joints: fillet lap joints, tee fillet joints, corner joints, butt joints (square, single,
vee, double vee)
PC25. produce fillet and grove joints in 1F/1G, 2F/2G and 3F/ 3G welding positions
as per the WPS specified using single or multi-run welds
Positions: flat (PA) IG/1F, horizontal vertical (PB)2F, horizontal (PC)2G, vertical
upwards (PF) 3F / 3G, vertical downwards (PG) 3F / 3G, Plate to Pipe (Fixed)
5F
PC26. deal promptly and effectively with problems within their control, and seek
help and guidance from the relevant people if they have problems that they
cannot resolve
PC27. produce joints on carbon and low alloy steel materials using various methods
Methods: drag, weave, whip
PC28. shut down and make safe the welding equipment on completion of the
welding activities
MMAW equipment: e.g. transformers; rectifiers; generators; invertors;
accessories; ancillary equipment - power saw, angle, pedestal and straight
grinders, tong tester; etc.
PC29. measure and check that all dimensional and geometrical aspects of the weld
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are as per instructions
PC30. check that the welded joint conforms to the instructions given, by checking
various quality parameters by visual inspection
Quality parameters: dimensional accuracy; alignment/squareness; size and
profile of weld; visual defects
PC31. identify various weld defects using visual inspection
Visual inspections: e.g. use of visual techniques, distance from workpiece,
angle of observation, adequate lighting, low powered magnification, fillet
weld gauges, etc.
PC32. detect and report surface imperfections to appropriate authority
PC33. deal with defects in welding as per instructions given
Context KA1. relevant legislation, standards, policies, and procedures followed in the
company / KA2. department structure and hierarchy protocols
organization and KA3. work flow and own role in the workflow
its processes) KA4. dependencies and interdependencies in the workflow
Knowledge KB1. health and safety hazards associated with MMAW/SMAW welding
Safety precautions (MMAW/SMAW Welding): protection from live and other
electrical components, including insulation, proper earthing, etc.; proper
handling and placement of hot metal; taking account of spatter and related
safe distance; adequate lighting; appropriate personal protective equipment);
protection of self and others from the effects of the welding arc; fume
extraction/control measures; safety measures for elevated and trench
workings (eg. harness, etc.)
KB2. effects of exposure to the electric arc
KB3. types of fire extinguishers and their suitable uses
KB4. effects of exposure to welding fume
KB5. methods of managing welding fume hazards
KB6. personal protective equipment (PPE) and clothing to be worn during
MMAW/SMAW welding
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Personal protective equipment (PPE): (suitable aprons, welding gloves,
respirators, safety boots, correctly fitting overalls, suitable eye
shields/goggles, hard hat/helmet
KB7. welding specific equipment requirements for MMAW/SMAW welding
MMAW equipment: e.g. transformers; rectifiers; generators; invertors;
accessories; ancillary equipment - power saw, angle, pedestal and straight
grinders, tong tester; etc.
KB8. main components and controls of welding equipment
KB9. how to connect electrical components correctly
KB10. type of current used and implication
KB11. welding symbols used and their correct interpretation
KB12. types of consumables used for MMAW/SMAW welding
KB13. various defects associated with the MMAW/SMAW welding process
KB14. types of joint configurations for welding
Types: groove and fillet
KB15. factors that determine weld bead shape
Factors: electrode angles and welding technique (push, perpendicular, drag);
arc length; thickness of base metal; travel speed (slow, normal, fast)
KB16. types of beads, characteristics and uses (stringer, weave, weave patterns)
Bead characteristics: spatter deposits, roughness, evenness, fill, crater,
overlap
KB17. factors that affect weld quality standards
Quality standards: required parameters for dimensional accuracy; weld
positions merge smoothly; weld surface is (free from cracks; substantially free
from porosity; free from any pronounced hump or crater; substantially free
from shrinkage cavities; substantially free from trapped slag; substantially
free from arcing or chipping marks); fillet welds are (equal in leg length,
slightly convex in profile (where applicable), size of the fillet equivalent to the
thickness of the material welded); weld contour is (of linear and of uniform
profile; smooth and free from excessive undulations; regular and has an even
ripple formations); welds are adequately fused, and there is minimal
undercut, overlap and surface inclusions; tack welds are blended in to form
24 | P a g e
part of the finished weld, without excessive hump; corner joints have minimal
burn through to the underside of the joint or, where appropriate
KB18. weld positions such as flat, horizontal, vertical and overhead
Positions: flat (PA) IG/1F, horizontal vertical (PB) 2F, horizontal (PC) 2G and
3G/3F vertical downwards and upwards
KB19. types of equipment components such as electrode holders, work leads cables
and ground clamps
KB20. awareness and importance of cable size and length
KB21. types of polarity such as DC electrode negative and DC electrode positive for
welding purposes
KB22. various types of base metals used in welding and their implications
KB23. distortion and how to control distortion
Distortion (causes and control methods): Causes (improper sequence of weld
runs; direction of weld runs; heat input errors; lack of inaccuracy of jigs and
fixture); Control Methods (sequence of welding as materials; proper
direction; tacking and its frequency (where applicable); use clamping and jigs
and fixtures (where applicable)
KB24. magnetic arc blow or arc deflection, causes and methods to avoid or
compensate
KB25. significance of diffusible hydrogen for welds
KB26. storage requirements for consumable electrodes
KB27. welding process specification sheet, process qualification record (PQR) and
related essential variables
KB28. travel speed and heat inputs
KB29. amperage requirements for different classification of electrodes and positions
KB30. importance and implications of various diameters of electrodes
KB31. gouging and back gouging principles, methods and procedures
KB32. purpose and importance of pre-heating requirements for base metals
KB33. tools and methods to measure temperature for pre-heat and post-heat
requirements such as thermal chalk, thermocouple, etc.
KB34. purpose and importance of post-heating in welding
KB35. types of visual inspection indicators and methods
Visual inspections: e.g. use of visual techniques, distance from workpiece,
angle of observation, adequate lighting, low powered magnification, fillet
weld gauges, etc.
KB36. awareness of common welder testing codes and their purpose
Welder testing codes: ASME section IX, EN 287, ISO 9606, IS 7310
Skills (S)
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Generic Skills
Writing Skills
SA6. calculate tolerance in terms of limits of size
SA8. types of reference lines such as tangent lines, datum lines, centre lines and
work points
NA
Plan and Organize
26 | P a g e
Customer Centricity
Problem Solving
their implications
Analytical Thinking
achieve more
Critical Thinking
adviser
27 | P a g e
NOS Version Control
NOS Code CSC/N0204

1. Machine Tools
2. Dies, Moulds and
Press Tools
3. Plastics
Manufacturing
Machinery
4. Textile
Manufacturing
Machinery
5. Process Plant
Machinery
Machinery
Goods
28 | P a g e
CSC/N0203 Manually cut metal and metal alloys using oxyfuel gas
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Overview
This unit is about competencies required for manual cutting operations using oxy-fuel gas. The
person would be able to independently carry out oxy-fuel gas cutting operations as per welding
procedure specification (WPS).
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Unit Code CSC/N0203

Unit Title
Manually cut metal and metal alloys using oxyfuel gas

(Task)
Description This unit is about competencies required for manual cutting operations using oxy-fuel
gas such as oxy-acetylene. The person would be able to independently carry out oxyfuel
cutting operations for as per welding procedure specification (WPS).
• Work safely
• Prepare for cutting operations
• Carry out cutting operations
• Test for accuracy

Safety precautions: general workshop safety, fire prevention, general
hazards, manual lifting, overhead lifting, surface conditions, stability of
surrounding structures, furniture, etc.
PC2. take necessary safety precautions for gas cutting operations including
equipment, processes and checks
Prepare for cutting To be competent, the user/individual on the job must be able to:
operations PC3. interpret cutting procedure data sheets specifications
PC4. check regulators, hoses and check that valves are securely connected and free
from leaks and damage
PC5. check equipment is calibrated and approved for use
PC6. check/fit the correct size gas nozzle to the torch
PC7. ensure preheat and oxygen holes on the tips are clean
PC8. check that a flashback arrestor is fitted
PC9. set appropriate gas pressures
PC10. use the correct procedure for lighting, adjusting and extinguishing the flame
Lighting and cutting procedures: lighting the cutting torch; adjusting gas
controls to produce a neutral flame; methods of starting the cut and
controlling the cutting speed; direction and angle of cut; procedure for
extinguishing the flame
PC11. adjust torch valve for type of flame such as neutral, carburizing and oxidizing
30 | P a g e
PC12. follow sequence of operations such as pre-heating material and initiating cut
PC13. mark out the locations for cutting accurately and as per requirement
PC14. use appropriate and safe procedures for handling and storing of gas cylinders
PC15. prepare the work area for the cutting activities
PC16. obtain the appropriate tools and equipment for the oxy-fuel gas cutting
operations, and check that they are in a safe and usable condition
Equipment: hand-held oxy-fuel gas cutting equipment, simple, portable,
track-driven cutting equipment (electrical or mechanical), fixed bench gas
cutting equipment
PC17. check that the oxy-fuel gas cutting equipment is set up for the operations to
be performed
PC18. adjust cylinder valves and adjust regulator for operating pressure to achieve
specifications for required operations
PC19. where appropriate, mark out the components for the required operations,
using appropriate tools and techniques
PC20. perform trial cut to check for cut defects
Carry out cutting To be competent, the user/individual on the job must be able to:
operations PC21. operate the oxy-fuel gas cutting equipment to produce items/cut shapes to
the dimensions and profiles specified
PC22. use various types of oxy-fuel gas cutting methods
PC23. perform various cutting operations correctly
Cutting operations: down-hand straight cuts (freehand), making straight cuts
(track guided), cutting regular shapes, cutting irregular shapes, making angled
cuts, cutting chamfers, making radial cuts, gouging/flushing, beveled edge –
weld preparations, cutting out holes
PC24. produce thermal cuts in various forms of material (metal of 3mm and above)
PC25. produce cut profiles for various type of materials and forms
Materials: mild carbon steel, high tensile and special steels, other materials
Forms: plate, rolled section, pipe/tube, solid bars
PC26. produce thermally-cut components which meet specified quality criteria
Quality criteria: dimensional accuracy is within the tolerances specified on
the drawing/specification, or within +/- 2mm; angled/radial cuts are within
specification requirements; cuts are clean and smooth and free from flutes;
no drags
PC27. recognize and correct burnback and flashback
PC28. detect and correct defects in cut
PC29. ensure the work area is left in a safe and tidy condition on completion of the
cutting activities
Test for accuracy To be competent, the user/individual on the job must be able to:
PC30. check that the finished components meet the standard required
31 | P a g e
PC31. use appropriate methods and equipment to check the quality, and that all
dimensional and geometrical aspects of the cut material are to the
specification
PC32. identify various cutting defects and follow organisation recommended
procedures to address them
Defects: distortion; grooved, fluted or ragged cuts; poor draglines; rounded
edges; tightly adhering slag
contingencies PC33. report any difficulties or problems that may arise with the cutting activities,
and carry out any agreed actions
PC34. detect equipment malfunctions and deal with them appropriately
cannot resolve
PC36. shut down and make safe the cutting equipment on completion of the
cutting activities
PC37. follow standard emergency procedures in case of emergencies
Emergencies (safety procedures): sustained backfire in a blowpipe; close the
oxygen valve of the blowpipe; followed by the fuel valve and then close both
cylinder valves; investigate the cause and rectify the fault; re-light the
blowpipe only after it is completely cooled down; flashback into the hose and
equipment, or a hose fire or explosion, or a fire at the gas regulator
connections; isolate the fuel gas and oxygen supplies by closing the cylinder
valves only when this can be done safely; may attempt to control the fire by
fire-fighting equipment only when there is no undue risk of personal injury;
activate the fire alarm and call for the Fire Services Department as per
organizational procedures; fires involving acetylene cylinders; always best
dealt with by firemen from the Fire Services Department. However, the
following initial response may be appropriate: cool the cylinder by spraying
with water only if it is safe to do so; close the cylinder valve to control the fire
only if it is safe to do so; evacuate the building by activating the fire alarm or
by any other means; to avoid explosion never move an acetylene cylinder
involved in a fire or which has been affected by heat from a nearby fire even if
it seems cooled down
Context KA1. job relevant legislation, standards, policies, and procedures followed in the
32 | P a g e
Knowledge KB1. types of fire extinguishers and their suitable uses in case of gas cutting related
fires
KB2. specific safety precautions to be taken when working with oxy-fuel gas cutting
equipment in a fabrication environment
Safety precautions: safety from trailing hoses; safety from naked flames;
appropriate fume and gases extraction/control measures; safety from
explosive gas mixtures and oxygen enrichment; safety from spatter and hot
metal (distance, PPE, proper handling and placement); protection from live
and other electrical components, including insulation, proper earthing, proper
loading, etc.; adequate lighting; appropriate personal protective equipment;
protection of self and others from the effects of the flame; safety measures
for elevated and trench working; gas cylinder safety: right color code;
correctly labelled; no leakage; away from heat or ignition source; never use
hose other than that designed for the specified gas; use ferrules or clamps
designed for the hose (not ordinary wire or other substitute) to connect hoses
to fittings; upright position (fuel gas); physical care to avoid damage and falls,
throws and bumps; move on trolleys, cap closed and without regulators;
valves closed on empty cylinders
KB3. personal protective clothing and equipment (PPE) to be worn when working
with gas cutting equipment
Personal protective equipment: suitable aprons, gloves, safety boots,
correctly fitting overalls, suitable eye shields/goggles, respirators
KB4. hazards associated with carrying out gas cutting activities and how they can
be minimized
KB5. safe working practices and procedures for using thermal equipment
KB6. principles of oxy-fuel gas cutting
Principles: oxygen cutting for materials which readily get oxidized; oxides
have lower melting points than the metals; widely used for ferrous materials;
oxygen cutting is not used for materials like aluminum, bronze, mild steels
which resist oxidation; cutting of high carbon steels and cast irons require
special attention due to formation of heat affected zone (HAZ) where
structural transformation occurs; substitute hydrocarbon gases (propane,
butane and natural gas) not suitable for cutting ferrous materials due to their
oxidizing characteristics
KB7. procedure for obtaining the required drawings, job instructions and other
related specifications
33 | P a g e
KB8. how to use and extract information from engineering drawings and related
specifications, workpiece reference points and system of tolerances
KB9. various types of gas cutting equipment available
Equipment: hand-held oxy-fuel gas cutting equipment, simple, portable,
track-driven cutting equipment (electrical or mechanical), fixed bench gas
cutting equipment
KB10. various components of the gas cutting equipment
Components: color coded cylinder oxygen; color coded cylinder acetylene;
cylinder valve; flashback arrestor; set of nozzles; gas lighter nozzle; cutting
tips; pressure regulator; pressure gauge; non-return valves; color coded
flexible hose; trolleys; torches (rose-bud heating, cutting, others)
KB11. construction of the heating and cutting torch
KB12. types of oxy-fuel gases such as acetylene, natural gas and propane
KB13. accessories that can be used with handheld gas cutting equipment to aid
cutting operations (such as cutting guides, trammels, templates)
KB14. importance of correct marking procedure before a cut (eg. allowances for
post-cut operations, punch marks, etc.)
KB15. types of regulators such as low- and high-pressure, and single- and two-stage
KB16. how to identify the gases used in the cutting process, and the color coding of
gas cylinders
KB17. type and thickness of base metals related to nozzle type
KB18. preparations prior to cutting (including checking connections for leaks, setting
gas pressures, setting up the material/workpiece, and checking the
cleanliness of materials used)
KB19. holding methods that are used to aid thermal cutting, and the equipment that
can be used
KB20. correct procedure for lighting, cutting and extinguishing the flame
Lighting and cutting procedures: lighting the cutting torch; adjusting gas
controls to produce a neutral flame; methods of starting the cut and
controlling the cutting speed; direction and angle of cut; procedure for
KB21. types of flames and their implication for cutting
KB22. importance of following the correct procedure for lighting, cutting and
extinguishing a flame
KB23. problems that can occur with thermal cutting, and how they can be avoided
(including causes of distortion during thermal cutting and methods of
controlling distortion)
KB24. effects of oil, grease, scale or dirt on the cutting process
KB25. gas mixture ratio required to get various flames
KB26. quality parameters for gas cut materials
34 | P a g e
Quality parameters: shape and length of the draglines; smoothness of the
sides; sharpness of the top edges; amount of slag adhering to the metal
KB27. special grade materials used in industry and their behavior with oxy fuel gas
KB28. causes of cutting defects, how to recognize them, and methods of correction
and prevention
Defects: distortion; grooved, fluted or ragged cuts; poor draglines; rounded
edges; tightly adhering slag
KB29. importance of leaving the work area in a safe and clean condition on
completion of activities
KB30. correct handling and storage of gas cylinders
KB31. emergency procedures for backfires, flashback and other fires
Emergencies (safety procedures): sustained backfire in a blowpipe; close
the oxygen valve of the blowpipe; followed by the fuel valve and then
close both cylinder valves; investigate the cause and rectify the fault;
re-light the blowpipe only after it is completely cooled down; flashback
into the hose and equipment, or a hose fire or explosion, or a fire at
the gas regulator connections; isolate the fuel gas and oxygen supplies
by closing the cylinder valves only when this can be done safely; may
attempt to control the fire by fire-fighting equipment only when there
is no undue risk of personal injury; activate the fire alarm and call for
the Fire Services Department as per organizational procedures; fires
involving acetylene cylinders; always best dealt with by firemen from
the Fire Services Department. However, the following initial response
may be appropriate: cool the cylinder by spraying with water only if it is
safe to do so; close the cylinder valve to control the fire only if it is safe to do
so; evacuate the building by activating the fire alarm or by any
other means; to avoid explosion never move an acetylene cylinder
involved in a fire or which has been affected by heat from a nearby fire
even if it seems cooled down
KB32. how to close down the cutting equipment safely and correctly
KB33. purging tools and their function
Skills (S)
Generic Skills
Writing Skills
35 | P a g e
decimals)
Units and number systems representing degree of accuracy: decimals places,
significant figures, fractions as a decimal quantity
Angles in a triangle: right-angled, isosceles, equilateral
NA
Plan and Organize
Customer Centricity
Problem Solving
36 | P a g e
their implications
Analytical Thinking
achieve more
Critical Thinking
adviser
37 | P a g e
NOS Version Control
NOS Code CSC/N0203

1. Machine Tools
2. Dies, Moulds and
Press Tools
3. Plastics
Manufacturing
Machinery
4. Textile
Manufacturing
Machinery
5. Process Plant
Machinery
Machinery
Goods
38 | P a g e
CSC/N0207 Manually cut metal materials using plasma arc
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Overview
This unit covers manual cutting operations using plasma arc cutting process. The person would
be able to independently carry out plasma arc cutting operations for as per welding procedure
specification (WPS).
39 | P a g e
Unit Code CSC/N0207

Unit Title
Manually cut metal materials using plasma arc

(Task)
Description This unit is about competencies required for manual cutting operations using plasma
arc. The candidate will be able to cut different materials (mild carbon steel, stainless
steel, aluminum, high tensile and special steels, and other materials) in various profiles
pertaining to the gas cutting process.
• Work safely
• Prepare for cutting operations
• Carry out cutting operations

Safety precautions (general): general workshop safety; fire prevention;
general hazards; manual lifting; overhead lifting; surface conditions; stability
of surrounding structures, furniture, etc.
PC2. take necessary safety precautions for plasma cutting operations including
equipment, processes and checks
Prepare for cutting To be competent, the user/individual on the job must be able to:
operations PC3. interpret cutting procedure data sheets specifications
PC4. check regulators, hoses and check that valves are securely connected and
free from leaks and damage
PC5. check equipment is calibrated and approved for use
PC6. check/fit the correct nozzle to the torch
PC7. match correct tips and cups to the torch as per requirement and
manufacturer’s equipment instructions
PC8. set the amperage and gas pressure as per metal thickness, metal type, and
type of gas
Materials type: mild steel; high alloy steel; stainless steel; aluminium and its
alloys; other appropriate metal
Types of gases: Primary Plasma Gas – used to create the plasma arc
(Nitrogen, Argon, Hydrogen, Compressed air); Secondary Shielding Gas – used
40 | P a g e
to protect the cut metals from oxidation (CO2, Compressed Air)
PC9. use the correct procedure for lighting, adjusting and extinguishing the arc
PC10. use appropriate and safe procedures for handling and storing of gas cylinders
PC11. prepare the work area for the cutting activities
PC12. obtain the appropriate tools and equipment for the plasma arc cutting
operations, and check that they are in a safe and usable condition
Equipment: plasma power source; pilot arc ignition system; torch; portable
straight line cutters; profile cutting machines; air filter with regulator; burner
electrode; compressor; nozzle; electrode holder; contact tube; front cap; gas
supply system with gauges; cooling system; earthing clamp; connecting leads
and cables
PC13. check that the plasma arc cutting equipment is correctly set up for the
operations to be performed
PC14. carry out correct measurements required using appropriate equipment and
methods for planning the cut
PC15. where appropriate, mark out the components for the required operations,
using appropriate tools and techniques
PC16. perform trial cut to check for cut defect
Carry out cutting To be competent, the user/individual on the job must be able to:
operations PC17. operate the plasma cutting equipment to produce items/cut shapes to the
dimensions and profiles as specified
PC18. use the correct angles to cut and the right speed
PC19. use various types of plasma arc cutting methods/techniques
Cutting techniques: stand-off, circle cutting, profile cutting, edge, stenting
hole, piercing technique
PC20. perform various cutting operations correctly
Cutting operations: down-hand straight cuts (freehand), making straight cuts
(track guided), cutting regular shapes, cutting irregular shapes, making angled
cuts, cutting chamfers, making radial cuts, gouging/flushing, bevelled edge –
weld preparations, cutting out holes
PC21. produce thermal cuts in various forms of material
Forms: plate, rolled section, pipe/tube, solid bars
PC22. produce cut profiles for various type of materials
Materials type: mild steel; high alloy steel; stainless steel; aluminium and its
alloys; other appropriate metal
PC23. produce thermally-cut components which meet specified quality criteria
Quality criteria: dimensional accuracy is within the tolerances specified on
the drawing/specification, or within +/- 1mm; angled/radial cuts are within
specification requirements; cuts are clean and smooth and free from flutes;
no drags
41 | P a g e
PC24. detect and correct defects in cut
PC25. leave the work area in a safe and tidy condition on completion of the cutting
activities
PC26. check that the finished components meet the required standard
PC27. use appropriate methods and equipment to check the quality, and that all
dimensional and geometrical aspects of the cut material are to the
specification
PC28. identify various cutting defects
Defects: grooved, fluted or ragged cuts, poor draglines, rounded edges,
tightly adhering slag, dross, burr, distortion
contingencies PC29. report any difficulties or problems that may arise with the cutting activities,
and carry out any agreed actions
PC30. detect equipment malfunctions and deal with them appropriately
cannot resolve
PC32. shut down and make safe the cutting equipment on completion of the
cutting activities or during an emergency
PC33. follow standard emergency procedures in case of emergencies
Context KA1. job relevant legislation, standards, policies, and procedures followed in the
Knowledge KB1. types of fire extinguishers and their suitable uses in case of gas cutting related
fires
KB2. specific safety precautions to be taken when working with plasma arc cutting
equipment in a fabrication environment
Safety precautions: safety from trailing hoses; safety from arc; appropriate
fume and gases extraction/control measures; safety from spatter and hot
metal (distance, PPE, proper handling and placement); protection from live
and other electrical components, including insulation, proper earthing,
proper loading, etc.; adequate lighting; appropriate personal protective
42 | P a g e
equipment; protection of self and others from the effects of the arc; cylinder
safety; safety measures including nozzles. valves, flowmeter, flashback
arrestors, etc.; safety measures for elevated and trench working
KB3. personal protective clothing and equipment (PPE) to be worn when working
with plasma cutting equipment
Personal protective equipment: suitable aprons, gloves, safety boots,
correctly fitting overalls, suitable eye shields/goggles, ear plugs or covering
KB4. hazards associated with carrying out plasma arc cutting activities and how
they can be minimized
KB5. safe working practices and procedures for using plasma equipment
KB6. principles of plasma arc cutting
Principles: plasma an ionized gas that conducts electricity; plasma is created
by adding energy to an electrically neutral gas; gas is compressed air, energy
is electricity; more electrical energy added, the hotter the plasma; plasma
cutting machines constrict the arc and force it through a concentrated area
(the nozzle); pilot arc, cutting arc; increasing air pressure and intensifying the
arc with higher amperage, the arc becomes hotter and more capable of
blasting through thicker metals and blowing away the cuttings and it does not
require a pre-heat cycle; using an inert gas for pressure prevents the cut
areas from oxidizing; for most ferrous metals, compressed air is used; for
nonferrous metals the inert gas is essential to prevent oxidation; different
plasma tip diameters are used for different cutting thickness; has smaller heat
affected zone (HAZ) preventing the area around the cut from warping and
minimizes paint damage; provides gouging and piercing capabilities; minimal
cleanup required, small and more precise kerf (width of the cut); cuts any
type of electrically conductive metals including aluminum, copper, brass and
stainless steel
KB7. common terminology used in plasma cutting
KB8. procedure for obtaining the required drawings, job instructions and other
related specifications
KB9. how to use and extract information from engineering drawings and related
specifications, workpiece reference points and system of tolerances
KB10. various types of plasma arc cutting equipment
Types: transferred, non-transferred (welding)
KB11. various components of the cutting equipment and types of consumables
used
Consumables: electrode, gases, tips, cups
KB12. construction of the cutting torch
KB13. types of plasma arc gases used
Types of gases: Primary Plasma Gas – used to create the plasma arc
43 | P a g e
(Nitrogen, Argon, Hydrogen, Compressed air); Secondary Shielding Gas – used
to protect the cut metals from oxidation (CO2, Compressed Air)
KB14. accessories that can be used with handheld gas cutting equipment to aid
cutting operations (such as cutting guides, templates)
KB15. types of regulators such as low- and high-pressure, and single- and two-stage
KB16. nozzle type as per type and thickness of base materials
KB17. preparations prior to cutting (including checking connections for leaks, setting
gas pressures, setting up the material/workpiece, and checking the
cleanliness of materials used)
KB18. holding methods that are used to aid plasma cutting, and the equipment that
can be used
KB19. correct procedure for lighting, cutting and extinguishing the arc
KB20. importance of following the correct procedure for lighting, cutting and
extinguishing an arc
KB21. importance of torch to arc distance in relation to thickness of materials, types
of torches and gases
Torches: air plasma, oxygen injected, duel gas
KB22. factors that impact nozzle life
KB23. double arcing and its impact
KB24. problems that can occur with plasma cutting, and how they can be avoided
(including causes of distortion during plasma cutting and methods of
controlling distortion)
KB25. effects of oil, grease, scale or dirt on the cutting process
KB26. quality parameters for plasma cut materials
Quality parameters: shape and length of the draglines; squareness; angle
deviation; smoothness of the sides; sharpness of the top edges; amount of
slag adhering to the metal
KB27. causes of cutting defects, how to recognize them, and methods of correction
and prevention
KB28. gouging and back gouging principles, methods and procedures
KB29. importance of leaving the work area in a safe and clean condition on
completion of activities
KB30. emergency procedures for electrical and other fires
KB31. how to close down the cutting equipment safely and correctly
KB32. purging tools and their function
Skills (S)
Generic Skills
44 | P a g e
Writing Skills
SA7. use tolerance in terms of limits of size
SA9. types of reference lines such as tangent lines, datum lines, center lines and
work points
SA10. check square of material using corner-to-corner dimensions and triangulation
(3-4-5) method
NA
Plan and Organize
Customer Centricity
45 | P a g e
Problem Solving
their implications
Analytical Thinking
achieve more
Critical Thinking
adviser
46 | P a g e
NOS Version Control
NOS Code CSC/N0207

1. Machine Tools
2. Dies, Moulds and
Press Tools
3. Plastics
Manufacturing
Machinery
4. Textile
Manufacturing
Machinery
5. Process Plant
Machinery
Machinery
Goods
47 | P a g e
CSC/N1335 Use basic health and safety practices at the workplace
----------------------------------------------------------------------------------------------------------------------------- ----------
Overview
This unit covers health, safety and security at the workplace. This includes procedures and
practices that candidates need to follow to help maintain a healthy, safe and secure work
environment.
48 | P a g e
Unit Code CSC/N1335

Unit Title
Use basic health and safety practices at the workplace

(Task)
Description This OS unit is about knowledge and practices relating to health, safety and security
that candidates need to use in the workplace. It covers responsibilities towards self,
others, assets and the environment.
• Health and safety

• Fire safety
• Emergencies, rescue and first-aid procedure

Health and safety To be competent, the user/individual on the job must be able to:
PC1. use protective clothing/equipment for specific tasks and work conditions
Protective clothing: leather or asbestos gloves, flame proof aprons, flame
proof overalls buttoned to neck, cuffless (without folds), trousers, reinforced
footwear, helmets/hard hats, cap and shoulder covers, ear defenders/plugs,
safety boots, knee pads, particle masks, glasses/goggles/visors
Equipment: hand shields, machine guards, residual current devices, shields,
dust sheets, respirator
PC2. state the name and location of people responsible for health and safety in the
workplace
PC3. state the names and location of documents that refer to health and safety in
the workplace
PC4. identify job-site hazardous work and state possible causes of risk or accident
in the workplace
Hazards: sharp edged and heavy tools; heated metals; oxy fuel and gas
cylinders; welding radiation; hazardous surfaces (sharp, slippery, uneven,
chipped, broken, etc.); hazardous substances (chemicals, gas, oxy-fuel, fumes,
dust, etc.); physical hazards (working at heights, large and heavy objects and
machines, sharp and piercing objects, tolls and machines, intense light, load
noise, obstructions in corridors, by doors, blind turns, noise, over stacked
shelves and packages, etc.) electrical hazards (power supply and points, loose
and naked cables and wires, electrical machines and appliances, etc.)
Possible causes of risk and accident: physical actions; reading; listening to and
giving instructions; inattention; sickness and incapacity (such as
drunkenness); health hazards (such as untreated injuries and contagious
49 | P a g e
illness)
PC5. carry out safe working practices while dealing with hazards to ensure the
safety of self and others
Safe working practices: using protective clothing and equipment; putting up
and reading safety signs; handle tools in the correct manner and store and
maintain them properly; keep work area clear of clutter, spillage and unsafe
object lying casually; while working with electricity take all electrical
precautions like insulated clothing, adequate equipment insulation, use of
control equipment, dry work area, switch off the power supply when not
required, etc.; safe lifting and carrying practices; use equipment that is
working properly and is well maintained; take due measures for safety while
working in confined places, trenches or at heights, etc. including safety
harness, fall arrestors, etc.
PC6. state methods of accident prevention in the work environment of the job role
Methods of accident prevention: training in health and safety procedures;
using health and safety procedures; use of equipment and working practices
(such as safe carrying procedures); safety notices, advice; instruction from
colleagues and supervisors
PC7. state location of general health and safety equipment in the workplace
General health and safety equipment: fire extinguishers; first aid equipment;
safety instruments and clothing; safety installations (eg fire exits, exhaust
fans)
PC8. inspect for faults, set up and safely use steps and ladders in general use
Ladder faults: corrosion of metal components, deterioration, splits and cracks
timber components, imbalance, loose rungs, missing/ unfixed nuts or bolts,
etc.
Ladders set up: firm/level base, clip/lash down, leaning at the correct angle,
etc.
PC9. work safely in and around trenches, elevated places and confined areas
PC10. lift heavy objects safely using correct procedures
PC11. apply good housekeeping practices at all times
Good housekeeping practices: clean/tidy work areas, removal/disposal of
waste products, protect surfaces
PC12. identify common hazard signs displayed in various areas
Various areas: on chemical containers; equipment; packages; inside buildings;
in open areas and public spaces, etc.
PC13. retrieve and/or point out documents that refer to health and safety in the
workplace
Documents: fire notices, accident reports, safety instructions for equipment
and procedures, company notices and documents, legal documents (eg
50 | P a g e
government notices)
Fire safety To be competent, the user/individual on the job must be able to:
PC14. use the various appropriate fire extinguishers on different types of fires
correctly
Types of fires: Class A: eg. ordinary solid combustibles, such as wood, paper,
cloth, plastic, charcoal, etc.; Class B: flammable liquids and gases, such as
gasoline, propane, diesel fuel, tar, cooking oil, and similar substances; Class C:
eg. electrical equipment such as appliances, wiring, breaker panels, etc.
(These categories of fires become Class A, B, and D fires when the electrical
equipment that initiated the fire is no longer receiving electricity); Class D:
combustible metals such as magnesium, titanium, and sodium (These fires
burn at extremely high temperatures and require special suppression agents)
PC15. demonstrate rescue techniques applied during fire hazard
PC16. demonstrate good housekeeping in order to prevent fire hazards
PC17. demonstrate the correct use of a fire extinguisher
Emergencies, rescue To be competent, the user/individual on the job must be able to:
and first-aid PC18. demonstrate how to free a person from electrocution
procedures PC19. administer appropriate first aid to victims where required eg. in case of
bleeding, burns, choking, electric shock, poisoning etc.
PC20. demonstrate basic techniques of bandaging
PC21. respond promptly and appropriately to an accident situation or medical
emergency in real or simulated environments
PC22. perform and organize loss minimization or rescue activity during an accident
in real or simulated environments
PC23. administer first aid to victims in case of a heart attack or cardiac arrest due to
electric shock, before the arrival of emergency services in real or simulated
cases
PC24. demonstrate the artificial respiration and the CPR Process
PC25. participate in emergency procedures
Emergency procedures: raising alarm, safe/efficient, evacuation, correct
means of escape, correct assembly point, roll call, correct return to work
PC26. complete a written accident/incident report or dictate a report to another
person, and send report to person responsible
Incident Report includes details of: name, date/time of incident, date/time of
report, location, environment conditions, persons involved, sequence of
events, injuries sustained, damage sustained, actions taken, witnesses,
supervisor/manager notified
PC27. demonstrate correct method to move injured people and others during an
emergency
51 | P a g e
Context KA1. names (and job titles if applicable), and where to find, all the people
(Knowledge of the responsible for health and safety in a workplace
company / KA2. names and location of documents that refer to health and safety in the
organization and workplace
its processes)
Knowledge KB1. meaning of “hazards” and “risks”
KB2. health and safety hazards commonly present in the work environment and
related precautions
KB3. possible causes of risk, hazard or accident in the workplace and why risk
and/or accidents are possible
KB4. possible causes of risk and accident
Possible causes of risk and accident: physical actions; reading; listening to and
giving instructions; inattention; sickness and incapacity (such as
drunkenness); health hazards (such as untreated injuries and contagious
illness)
KB5. methods of accident prevention
Methods of accident prevention: training in health and safety procedures;
using health and safety procedures; use of equipment and working practices
(such as safe carrying procedures); safety notices, advice; instruction from
colleagues and supervisors
KB6. safe working practices when working with tools and machines
KB7. safe working practices while working at various hazardous sites
KB8. where to find all the general health and safety equipment in the workplace
KB9. various dangers associated with the use of electrical equipment
KB10. preventative and remedial actions to be taken in the case of exposure to toxic
materials
Exposure: ingested, contact with skin, inhaled
Preventative action: ventilation, masks, protective clothing/ equipment);
Remedial action: immediate first aid, report to supervisor
Toxic materials: solvents, flux, lead
KB11. importance of using protective clothing/equipment while working
KB12. precautionary activities to prevent the fire accident
KB13. various causes of fire
Causes of fires: heating of metal; spontaneous ignition; sparking; electrical
heating; loose fires (smoking, welding, etc.); chemical fires; etc.
KB14. techniques of using the different fire extinguishers
KB15. different methods of extinguishing fire
KB16. different materials used for extinguishing fire
52 | P a g e
Materials: sand, water, foam, CO2, dry powder
KB17. rescue techniques applied during a fire hazard
KB18. various types of safety signs and what they mean
KB19. appropriate basic first aid treatment relevant to the condition eg. shock,
electrical shock, bleeding, breaks to bones, minor burns, resuscitation,
poisoning, eye injuries
KB20. content of written accident report
KB21. potential injuries and ill health associated with incorrect manual handing
KB22. safe lifting and carrying practices
KB23. personal safety, health and dignity issues relating to the movement of a
person by others
KB24. potential impact to a person who is moved incorrectly
Skills (S)
Generic Skills
SA1. read and comprehend basic content to read labels, charts, signages
SA2. read and comprehend basic English to read manuals of operations
SA3. read an accident/incident report in local language or English
Writing Skills
SA4. write an accident/incident report in local language or English
SA5. question coworkers appropriately in order to clarify instructions and other
issues
SA6. give clear instructions to coworkers, subordinates others
SB1. make appropriate decisions pertaining to the concerned area of work with
respect to intended work objective, span of authority, responsibility, laid
down procedure and guidelines
Plan and Organize
SB2. plan and organize their own work schedule, work area, tools, equipment and
materials to maintain decorum and for improved productivity
Customer Centricity
SB3. remain congenial while discussing and debating issues with co-workers
53 | P a g e
SB4. follow appropriate protocols for communication based on situation, hierarchy,
organizational culture and practice
SB5. ask for, provide and receive required assistance where possible to ensure
achievement of work related objectives
SB6. thank coworkers for any assistance received
SB7. offer appropriate respect based on mutuality and respect for fellow
workmanship and authority
Problem Solving
SB8. think through the problem, evaluate the possible solution(s) and suggest an
optimum /best possible solution(s)
SB9. identify immediate or temporary solutions to resolve delays
SB10. identify sources of support that can be availed of for problem solving for
various kind of problems
SB11. seek appropriate assistance from other sources to resolve problems
SB12. report problems that you cannot resolve to appropriate authority
Analytical Thinking
SB13. identify cause and effect relations in their area of work
SB14. use cause and effect relations to anticipate potential problems and their
solution
Critical Thinking
NA
54 | P a g e
NOS Version Control
NOS Code CSC/N1335

1. Machine Tools
2. Dies, Moulds and
Press Tools
3. Plastics
Manufacturing
Machinery
4. Textile
Manufacturing
Machinery
5. Process Plant
Machinery
Machinery
Goods
55 | P a g e
CSC/N1336 Work effectively with others
----------------------------------------------------------------------------------------------------------------------------- ----------
Overview
This unit covers basic practices that improve effectiveness of working with others in an
organizational set-up.
56 | P a g e
Unit Code CSC/N1336

Unit Title
Work effectively with others

(Task)
Description This unit covers basic etiquette and competencies that a candidate is required to
possess and demonstrate in their behavior and interactions with others at the
workplace. These cover areas such as communication etiquette, discipline, listening etc.
• Work effectively with others
Performance Criteria (PC) w.r.t. the Scope

Work effectively with To be competent, the user/individual on the job must be able to:
others PC1. accurately receive information and instructions from the supervisor and
fellow workers, getting clarification where required
PC2. accurately pass on information to authorized persons who require it and
within agreed timescale and confirm its receipt
PC3. give information to others clearly, at a pace and in a manner that helps them
to understand
PC4. display helpful behavior by assisting others in performing tasks in a positive
manner, where required and possible
PC5. consult with and assist others to maximize effectiveness and efficiency in
carrying out tasks
PC6. display appropriate communication etiquette while working
Communication etiquette: do not use abusive language; use appropriate titles
and terms of respect; do not eat or chew while talking (vice versa) etc.
PC7. display active listening skills while interacting with others at work
PC8. use appropriate tone, pitch and language to convey politeness, assertiveness,
care and professionalism
PC9. demonstrate responsible and disciplined behaviors at the workplace
Disciplined behaviors: e.g. punctuality; completing tasks as per given time and
standards; not gossiping and idling time; eliminating waste, honesty, etc.
PC10. escalate grievances and problems to appropriate authority as per procedure
to resolve them and avoid conflict
Context KA1. legislation, standards, policies, and procedures followed in the company
(Knowledge of the relevant to own employment and performance conditions
company / KA2. reporting structure, inter-dependent functions, lines and procedures in the
organization and work area
57 | P a g e
its processes) KA3. relevant people and their responsibilities within the work area
KA4. escalation matrix and procedures for reporting work and employment related
issues
Knowledge KB1. various categories of people that one is required to communicate and co-
ordinate with in the organization
KB2. importance of effective communication in the workplace
KB3. importance of teamwork in organizational and individual success
KB4. various components of effective communication
KB5. key elements of active listening
KB6. value and importance of active listening and assertive communication
KB7. barriers to effective communication
KB8. importance of tone and pitch in effective communication
KB9. importance of avoiding casual expletives and unpleasant terms while
communicating professional circles
KB10. how poor communication practices can disturb people, environment and
cause problems for the employee, the employer and the customer
KB11. importance of ethics for professional success
KB12. importance of discipline for professional success
KB13. what constitutes disciplined behavior for a working professional
KB14. common reasons for interpersonal conflict
KB15. importance of developing effective working relationships for professional
success
KB16. expressing and addressing grievances appropriately and effectively
KB17. importance and ways of managing interpersonal conflict effectively
Skills (S)
Generic Skills
SA1. read basic terms and terminologies to accurately interpret work related
documents, labels, supervisor instructions in the local language
SA2. read and interpret accurate information from various relevant work
instructions and records
Writing Skills
SA3. write clear and legible notes to self, colleagues and seniors to pass messages,
keep records, prepare to-do lists, take down instructions
SA4. write basic numbers, quantities and work related terminology for operational
requirements in the local language
58 | P a g e
SA5. interact with the supervisor appropriately (correct protocol and manner of
speaking) in order to understand the basic requirements of the product,
production plans and other associated requirements
SA6. give clear instructions to co-workers about the type of output required and
answer queries
SA7. display active listening skills while interacting with co-workers and other in
the workplace
NA
Plan and organize
SB1. use appropriate planning to maintain a smooth relationship with fellow team
members
SB2. take steps within one’s limits of authority to initiate modification in plan if the
circumstances require it
Customer centricity
SB3. check that work meets customer requirements
SB4. deliver consistent and reliable service to internal and external customers
Problem Solving
SB5. work with co-workers and supervisor to resolve any issues that threaten
disruption, increase risk, cause delays or under-achievement of quality and
targets as per the planned schedule
Analytical Thinking
NA
Critical Thinking
NA
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NOS Version Control
NOS Code CSC/N1336

1. Machine Tools
2. Dies, Moulds and
Press Tools
3. Plastics
Manufacturing
Machinery
4. Textile
Industry Sub-sector Manufacturing Last reviewed on 24/11/2017
Machinery
5. Process Plant
Machinery
Machinery
Goods
60 | P a g e
Qualifications Pack for MIG/ MAG/ GMAW Welder
Annexure
Nomenclature for QP and NOS
Qualifications Pack
9 characters
[ABC]/ Q 0101
[Insert 3 letter codes for SSC] QP number (2 numbers)
Q denoting Qualifications Pack Occupation (2 numbers)
Occupational Standard
An example of NOS with ‘N’

9 characters
[ABC] / N 0101
[Insert 3 letter codes for SSC] OS number (2 numbers)
N denoting National Occupational Standard Occupation (2 numbers)
Back to top…
61
The following acronyms/ codes have been used in the nomenclature above:
Sub-sector Range of Occupation numbers
Machine Tools 01-13

Dies, Moulds and Press Tools 01-13
Plastic Manufacturing Machinery 01-13
Textile Manufacturing Machinery 01-13
Process Plant Machinery 01-13
Electrical and Power Machinery 01-13
Light Engineering Goods 01-13
Sequence Description Example
Three letters Capital Goods CSC

Slash / /
Next letter Whether QP or NOS N
Next two numbers Occupation code 01
Next two numbers OS number 01
62
Criteria For Assessment Of Trainees

Job Role: Metal Inert Gas/ Metal Active Gas/ Gas Metal Arc Welder (MIG/MAG/GMAW)
Qualification Pack: CSC/Q0209
Sector Skill Council: Capital Goods Skill Council
Guidelines for Assessment
1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance
Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for
Theory and Skills Practical for each PC.
2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC.
3. Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set
of NOS.
4. Individual assessment agencies will create unique question papers for theory part for each candidate at each
examination/training center (as per assessment criteria below).
5. Individual assessment agencies will create unique evaluations for skill practical for every student at each
examination/training center based on this criterion.
6. To pass the Qualification Pack , every trainee should score a minimum of 70% of aggregate marks to successfully clear
the assessment.
7. In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.
Compulsory NOS Marks Allocation

Total Marks: 600
Assessment Assessment Criteria for outcomes Total Out Theory Skills
outcomes Marks of Practical
CSC/N0209
Manually (semi- PC1.work safely at all times, complying with health and
automatic) welding safety legislation, regulations and other relevant
joints using the 3 1 2
guidelines protective equipment (PPE) and other relevant
MIG/MAG (GMAW) safety regulations for MIG/MAG welding operations
process
PC3. check the condition of welding leads, gas connection
arrangements, earthing arrangements and electrode 2 0 2
holder
100
PC4.report any faults or potential hazards to appropriate
2 0 2
authority
PC5.interpret weld procedure data sheets specifications,
3 1 2
PQR and WPS
PC6.select welding machines such as inverters, rectifiers

2 0 2
and generators,according to the task
PC7.select electrodes according to classification and

3 1 2
specifications
63
PC8.prepare the materials and joint in readiness for

2 1 1
welding
PC9.check the condition of, and correctly connect, welding

leads/cables, hoses, shielding gas supply and wire feed 2 0 2
mechanisms
PC10.prepare the welding equipment for a range of given

2 0 2
applications
PC11.select the welding shielding gases and equipment
2 1 1
for a range of givenapplications
PC12.plan the welding activities before they start them
effectively and efficiently for achieving specifications as 2 0 2
per WPS
PC13.clean wire feeder and torch tip 2 0 2
PC14.connect torches and components 2 0 2
PC15.connect and adjust regulators and flow meters to
3 1 2
cylinders
PC16.adjust wire feed rate and read and set current as
2 1 1
required
PC17.set other welding parameters (eg. voltage, slope of

3 1 2
current versus voltage curve where required)
PC18.choose appropriate mode of metal transfer 3 1 2
PC19.set pre-purge with shielding gas as required 2 0 2

PC20.set and verify gas flow rates 3 1 2
PC21.prepare and support the joint, using the appropriate
2 0 2
methods
PC22.tack weld the joint at appropriate intervals, and

4 1 3
check the joint for accuracy before final welding
PC23.use manual welding and related equipment, to carry

2 0 2
out MIG/MAG weldingprocesses
PC24.perform MIG/MAG welding operations using various

welding techniques to meet welding procedure 3 1 2
specification requirements
PC25.adjust wire stick-out as per requirement 2 0 2
PC26.use welding consumables appropriate to the

3 0 3
material and application to DC current types
PC27.produce joints of the required quality and of

specified dimensional accuracy which achieve a weld 3 1 2
quality equivalent to Level C of ISO 5817
64
PC28.produce joints from various materials in different

2 0 2
forms
PC29.weld joints in good access situations, in select
2 0 2
positions
PC30.make sure that the work area is maintained and left

3 1 2
in a safe and tidy condition
PC31.identify various weld defects use appropriate

methods and equipment to check the quality, and that all
3 1 2
dimensional and geometrical aspects of the weld are to
the specification
PC32.check that the welded joint conforms to the

specification, by checking various quality parameters by 3 1 2
visual inspection
PC33.detect surface imperfections and deal with them
3 1 2
appropriately
PC34.carry out DPT tests to assess fine defect open to the

3 1 2
surface not detected by visual inspection (VT)
PC35.assist in preparation for non-destructive testing of

2 0 2
the welds, for a range of tests
PC36.prepare for destructive tests on weld specimens for

3 1 2
fillet, butt and corner
PC37.shut down and make safe the welding equipment on

2 1 1
completion of thewelding activities
PC38.follow the established organisational process for

dealing with the weldedpieces including handover, 2 1 1
storage, safety and security, record keeping, etc.
PC39.detect equipment malfunctions and deal with them

3 1 2
safely and as peorganisation procedures
PC40.deal promptly and effectively with problems where

3 1 2
required
Total 100 23 77
CSC/N0204 PC1.work safely at all times, complying with health and
Manually weld safety legislation, regulations and other relevant 3 1 2
carbon and low guidelines
alloy steels in
1G/1F, 2G/2F and PC2.adhere to procedures or systems in place for health
100
3G/3F welding and safety, personal protective equipment (PPE) and 3 1 2
positions using other relevant safety regulations
Manual Metal Arc
PC3.check the condition of, welding leads, earthing
2 0 2
arrangements and electrode holder
65
Welding/ Shielded PC4.report any faults or potential hazards to appropriate

3 1 2
Metal Arc Welding authority
PC5.follow fume extraction safety procedures 3 1 2
PC6.read and interpret routine information on written job

instructions and drawings, welding procedure 5 2 3
specifications and standard operating procedures
PC7.identify welding machines eg. transformers, rectifiers,

2 0 2
inverters and generators, according to the task
PC8.prepare the work area for the welding activities 2 0 2

PC9.perform measurements for joint preparation and
4 1 3
routine MMAW
PC10.prepare the materials and joint in readiness for
4 1 3
welding
PC11.use manual metal-arc welding and related

equipment to include a. alternating current (AC) 2 0 2
equipment b. direct current (DC) equipment
PC12.connect equipment to power source 2 0 2

PC13.connect cables, electrode holders, return leads and
3 1 2
ground clamps to appropriate terminal
PC14.re-dry electrodes as per electrode classification

3 1 2
requirement
PC15.set, read and adjust amperage controls 4 2 2
PC16.verify set up by running test weld specimen (scrap

2 1 1
plate)
PC17.tack weld the joint at appropriate intervals, and

3 1 2
check the joint for accuracy before final welding
PC18.report any faults or problem to appropriate

3 1 2
authority
PC19.strike and maintain a stable arc 2 0 2
PC20.stop and properly re-start arc to avoid welding
2 0 2
defects (scratch start, tapping techniques)
PC21.maintain constant puddle by using appropriate

3 1 2
travel speed
PC22.maintain proper bead sequence with respect to

3 1 2
groove/fillet configurations and positions
PC23.remove slag in an appropriate manner (eg. wire

3 1 2
brush, hammer, etc.)
66
PC24.produce welded joints to the specified quality,

dimensions and profile applicable to carbon and low alloy 4 1 3
steel sheets and plates from 1.5 – 24 mm
PC25.produce fillet and grove joints in 1F/1G, 2F/2G and

3F/ 3G welding position as per the WPS specified using 4 1 3
single or multi-run welds
PC26.deal promptly and effectively with problems within

their control, and seek help and guidance from the
4 1 3
relevant people if they have problems that they cannot
resolve
PC27.produce joints on carbon and low alloy steel
materials using various methods Methods: drag, weave, 4 1 3
whip
PC28.shut down and make safe the welding equipment on

3 1 2
completion of the welding activities
PC29.measure and check that all dimensional and

4 2 2
geometrical aspects of the weld are as per instructions
PC30.check that the welded joint conforms to the

instructions given, by checking various quality parameters 3 1 2
by visual inspection
PC31.identify various weld defects using visual inspection 2 0 2

PC32.detect and report surface imperfections to
3 1 2
appropriate authority
PC33.deal with defects in welding as per instructions given 3 1 2

Total 100 28 72
CSC/N0203 PC1.work safely at all times, complying with health and
Manually cut metal safety legislation, regulations and other relevant 3 1 2
and metal alloys guidelines
using oxyfuel gas
PC2.take necessary safety precautions for gas cutting
3 1 2
operations including equipment, processes and checks
PC3.interpret cutting procedure data sheets specifications 3 1 2

100
PC4.check regulators, hoses and check that valves are
2 0 2
securely connected and free from leaks and damage
PC5.check equipment is calibrated and approved for use 2 0 2
PC6.check/ fit the correct size gas nozzle to the torch 2 0 2
67
PC7.ensure preheat and oxygen holes on the tips are clean 2 0 2

PC8.check that a flashback arrestor is fitted 2 0 2
PC9.set appropriate gas pressures 2 0 2
PC10.use the correct procedure for lighting, adjusting and
3 1 2
PC11.adjust torch valve for type of flame such asneutral,
3 1 2
carburizing and oxidizing
PC12.follow sequence of operations such as preheating
3 1 2
material and initiating cut
PC13.mark out the locations for cutting accurately and as
3 1 2
per requirement
PC14.use appropriate and safe procedures for handling
3 1 2
and storing of gas cylinders
PC15.prepare the work area for the cutting activities 2 0 2
PC16.obtain the appropriate tools and equipment for the

oxy-fuel gas cutting operations, and check that they are in 2 0 2
a safe and usable condition
PC17.check that the oxy-fuel gas cuttingequipment is set

2 0 2
up for the operations to be performed
PC18.adjust cylinder valves and adjust regulator for

operating pressure to achieve specificationsfor required 3 1 2
operations
PC19.where appropriate, mark out the components for
the required operations, using appropriate tools and 2 0 2
techniques
PC20.perform trial cut to check for cut defects 2 0 2
PC21.operate the oxy-fuel gas cutting equipment to

produce items/cut shapes to the dimensions and profiles 5 1 4
specified
PC22.use various types of oxy-fuel gas cutting methods 4 1 3
PC23.perform various cutting operations correctly 4 1 3
PC25.produce cut profiles for various type of materials 4 1 3

PC26.produce thermally-cut components which meet
4 1 3
specified quality criteria leave
PC27.recognize and correct burnback and flashback 3 1 2
PC28.detect and correct defects in cut 3 1 2
PC29.ensure the work area is left in a safe and tidy
2 0 2
condition on completion of the cutting activities
68
PC30.check that the finished components meet the

3 1 2
standard required
PC31.use appropriate methods and equipment to check

the quality, and that all dimensional and geometrical 3 1 2
aspects of the cut material are to the specification
PC32.identify various cutting defects and follow

3 1 2
organisation recommended procedures to address them
PC33.report any difficulties or problems that may arise

3 1 2
with the cutting activities, and carry outany agreed actions

3 1 2
appropriately
2 0 2
resolve
PC36.shut down and make safe the cutting equipment on

3 1 2
completion of the cutting activities
PC37.follow standard emergency procedures incase of

2 0 2
emergencies
Total 100 22 78
CSC/N0207
PC1.work safely at all times, complying with health 3 1 2
Manually cut metal
materials using
plasma arc PC2.take necessary safety precautions for plasma cutting
3 1 2
operations including equipment, processes and checks
PC3.interpret cutting procedure data sheets specifications 3 1 2
PC4.check regulators, hoses and check that valves are

3 1 2
securely connected and free from leaks and damage
PC5.check equipment is calibrated and approved for use 2 0 2

100
PC6.check/fit the correct nozzle to the torch 3 1 2
PC7.match correct tips and cups to the torch as per
2 0 2
requirement and manufacturer’s equipment instructions
PC8.set the amperage and gas pressure as per metal

2 0 2
thickness, metal type, and type of gas
PC9.use the correct procedure for lighting, adjusting and

3 1 2
extinguishing the arc
PC10.use appropriate and safe procedures for handling
3 1 2
and storing of gas cylinders
69
PC11.prepare the work area for the cutting activities 3 1 2
PC12.obtain the appropriate tools and equipment for the

plasma arc cutting operations, and check that they are in a 3 1 2
safe and usable condition
PC13.check that the plasma arc cutting equipment is

2 0 2
correctly set up for the operations to be performed
PC14.carry out correct measurements required using

3 1 2
appropriate equipment and methods for planning the cut
PC15.where appropriate, mark out the components for

the required operations, using appropriate tools and 3 1 2
techniques
PC17.operate the plasma cutting equipment to produce

items/cut shapes to the dimensions and profiles as 4 1 3
specified
PC18.use the correct angles to cut and the right speed 4 1 3
PC19.use various types of plasma arc cutting

4 1 3
methods/techniques
PC20.perform various cutting operations correctly 4 1 3
PC21.produce thermal cuts in various forms of material 4 1 3
PC22.produce cut profiles for various type of materials 4 1 3

PC23.produce thermally-cut components which meet
4 1 3
specified quality criteria
PC25.leave the work area in a safe and tidy condition on
2 0 2
completion of the cutting activities
PC26.check that the finished components meet the

3 1 2
required standard
PC27.use appropriate methods and equipment to check

the quality, and that all dimensional and geometrical 4 2 2
aspects of the cut material are to the specification
PC28.identify various cutting defects 3 1 2

PC29.report any difficulties or problems that may arise
with the cutting activities, and carry out any agreed 3 1 2
actions
2 0 2
appropriately
70

4 1 3
resolve
PC32.shut down and make safe the cutting equipment on
completion of the cutting activities or during an 2 0 2
emergency
PC33.follow standard emergency procedures incase of
2 0 2
emergencies
Total 100 26 74
CSC/N1335 Use PC1.use protective clothing/equipment for specific tasks
5 2 3
basic health and and work conditions
safety practices at PC2.state the name and location of people responsible for
the workplace health and safety in the workplace 3 1 2
PC3.state the names and location of documents that refer

to health and safety in the workplace 3 1 2
PC4.identify job-site hazardous work and state possible

causes of risk or accident in the workplace 5 2 3
PC5.carry out safe working practices while dealing with

hazards to ensure the safety of self and others 4 2 2
PC6.state methods of accident prevention in the work

3 2 1
environment of the job role
PC7.state location of general health and safety equipment
5 2 3
in the workplace
PC8.inspect for faults, set up and safely use steps and
100 5 2 3
ladders in general use
PC9.work safely in and around trenches, elevated places
5 2 3
and confined areas
PC10.lift heavy objects safely using correct procedures
4 2 2
PC11.apply good housekeeping practices at all times
5 2 3
PC12.identify common hazard signs displayed in various
3 1 2
areas
PC13.retrieve and/or point out documents that refer to
health and safety in the workplace 4 1 3
PC14.use the various appropriate fire extinguishers on

different types of fires correctly 4 1 3
PC15.demonstrate rescue techniques applied during fire

3 1 2
hazard
PC16.demonstrate good housekeeping in order to prevent
4 1 3
fire hazards
71
PC17.demonstrate the correct use of a fire extinguisher

4 1 3
PC18.demonstrate how to free a person from
4 1 3
electrocution
PC19.administer appropriate first aid to victims where
required eg. in case of bleeding, burns, choking, electric
3 1 2
shock, poisoning etc.
PC20.demonstrate basic techniques of bandaging

4 1 3
PC21.respond promptly and appropriately to an accident
situation or medical emergency in real or simulated 3 1 2
environments
PC22.perform and organize loss minimization or rescue
activity during an accident in real or simulated 3 1 2
environments
PC23.administer first aid to victims in case of a heart
attack or cardiac arrest due to electric shock, before the
arrival of emergency services in real or simulated cases 3 1 2
PC24.demonstrate the artificial respiration and the CPR

3 2 1
Process
PC25.participate in emergency procedures 2 1 1
PC26.complete a written accident/incident report or
dictate a report to another person, and send report to 3 1 2
person responsible
PC27.demonstrate correct method to move injured
3 1 2
people and others during an emergency
Total 100 37 63
CSC/N1336 Work PC1.accurately receive information and instructions from
effectively with the supervisor and fellow workers, getting clarification 10 3 7
others where required
PC2.accurately pass on information to authorized persons
who require it and within agreed timescale and confirm its 10 3 7
receipt
PC3.give information to others clearly, at a pace and in a 10 3 7

manner that helps them to understand 100
PC4.display helpful behavior by assisting others in
performing tasks in a positive manner, where required 10 3 7
and possible
PC5.consult with and assist others to maximize 10 3 7

effectiveness and efficiency in carrying out tasks
PC6.display appropriate communication etiquette while
10 3 7
working
72
PC7.display active listening skills while interacting with

10 3 7
others at work
PC8.use appropriate tone, pitch and language to convey 10 3 7

politeness, assertiveness, care and professionalism
PC9.demonstrate responsible and disciplined behaviors at
10 3 7
the workplace
PC10.escalate grievances and problems to appropriate
authority as per procedure to resolve them and avoid 10 3 7
conflict
Total 100 30 70
73
Model Curriculum
Oxy Fuel Gas Cutter
SECTOR: CAPITAL GOODS
SUB-SECTOR: 1.Machine Tools
2.Dies, Moulds And Press Tools
3.Plastic Manufacturing Machinery
4.Textile Manufacturing Machinery
5.Process Plant Machinery
6.Electrical and Power Machinery
7.Light Engineering Goods
OCCUPATION: Welding and Cutting
REF ID: CSC/Q0203, V1.0
NSQF LEVEL: 3
TABLE OF CONTENTS
1. Curriculum 01
2. Trainer Prerequisites 07
3. Annexure: Assessment Criteria 08
Oxy Fuel Gas Cutter
CURRICULUM / SYLLABUS
This program is aimed at training candidates for the job of a “Oxy Fuel Gas Cutter”, in the “Capital
Goods” Sector/Industry and aims at building the following key competencies amongst the learner
Program Name Oxy Fuel Gas Cutter
Qualification Pack Name

CSC/Q0203, v1.0
& Reference ID. ID
Version No. 1.0 Version Update Date
Pre-requisites to
8th Standard passed, preferably
Training
Training Outcomes After completing this programme, participants will be able to:
 Work safely: state the importance of safe working practices at
the workplace, and comply with health and safety legislation,
regulations and other guidelines.
 Prepare for cutting operation: identify oxy fuel gas cutting
accessories and their functions, arrange the oxy fuel gas cutting
setup and test the equipment for any malfunction or leakages
and prepare surface for cutting operation.
 Carry out the cutting operation, and test for accuracy: cut
the metal piece to the required shape as per the specification by
using oxy fuel gas setup and range of hand tools to ensure that
the final product meets tolerance requirement.
 Deal with contingency: adherence to standard operating
procedure in case of equipment failure or hazards arising out of
gas cutting equipment during the operation.
 Basic health and safety practices at the workplace: identify
risks and hazards at workplace, use of PPE, and apply good
housekeeping practices, etc.,
 Work effectively with others: effectively communicate with
others and demonstrate good ethical practices and discipline
Oxy Fuel Gas Cutter 1

This course encompasses 3 out of 3 National Occupational Standards (NOS) of “Oxy Fuel Gas
Cutter” Qualification Pack issued by “Capital Goods Skill Council”.
Sr. Equipment
Module Key Learning Outcomes
No. Required
1 Introduction  State the various opportunities Training Kit
available in fabrication industry (PowerPoint,
Theory Duration  Describe the role and responsibilities of Trainer Guide)
(hh:mm) an oxyfuel cutter
03:00  Explain various types of cutting process
Practical Duration used in the fabrication industry
(hh:mm)  Classify materials and state their
00:00 properties and composition
 List advantages and disadvantages of
Corresponding NOS various metal cutting methods
Code  Explain the principle and application of
Bridge Module oxy fuel gas cutting
 Compare oxy-fuel gas welding and
cutting
2 Work safely  Explain importance of safe working Training kit
practices at the work place (Trainer guide,
Theory Duration  Apply electrical safety practices at the PowerPoint)
(hh:mm) work place
10:00  Explain and comply with health and Leather apron;
Practical Duration safety legislation, regulations and other leather gloves;
(hh:mm) guidelines welding screen –
02:00  Follow general safety practices at the helmet type; hand
workplace screen welding;
Corresponding NOS  Identify hazards at the workplace and safety shoes; fire
Code take corrective actions to avoid such extinguisher- dry
CSC/N0203 hazards powder type; fire
 Follow the stated procedure for material bucket with sand
handling and first aid kit
 State the causes of fire and
demonstrate methods to control fire
accidents
 List the personal protective equipment
(PPE) required for gas cutting operation
 Wear suggested personal protective
equipment correctly
 Follow the safety recommendations
while handling oxy-fuel gas set up
3 Prepare for cutting  Read drawings to interpret specification Training kit
operations and cutting procedure (Trainer guide,
 Identify oxy fuel gas set up, PowerPoint)
Theory Duration accessories and their functions
(hh:mm)  Identify oxygen and acetylene cylinders Oxygen cylinder -
5:00 by colour coding 7m3,
 Connect accessories to oxygen and acetylene cylinder-
Practical Duration acetylene cylinders – regulators, hoses, 6 m3,
(hh:mm) clamps etc., oxygen pressure
25:00  Select right sized nozzle and connect to regulator;
the torch acetylene pressure
Corresponding NOS  Check for any leakages in the system. regulator;
Code Use of soap solution to detect flashback
CSC/N0203 acetylene leakage and fresh water for arrestors;

Sr. Equipment
No. Required
oxygen leakage cutting torch;
 Operate pressure regulators and set rubber hoses;
correct pressure for oxygen and cutting nozzles;
acetylene trolley to secure
 State the purpose of cutting aids like, oxygen and
spade guide, small circle cutting acetylene
attachment, radius guide, circle cutting cylinders;
attachment, bevel guide chain to secure
 Explain various types of flames and oxygen and
their application acetylene
 Generate neutral flame i.e. balanced cylinders;
flame, oxidizing flame (excess oxygen) lighter/ flint;
and carburizing flame (excess spanner set;
acetylene) by varying oxygen supply spindle key;
 Carry out gas cutting using a neutral non return valves;
flame on a test piece spade guides;
 Use other tools required for gas cutting radius guide;
operation bevel guide;
 Prepare work area by cleaning the gas welding/
table and organize all the tools and cutting table 822
equipment required cm x 92 cm x 60
cm; surface plate;
 Carryout marking operations for cutting
scriber - 15 cm;
accurately as per the requirement
dividers 20 cm;
 Check for the readiness of the
calliper outside 15
equipment
cm; prick punch;
 Take trial cut and check for any chisel cold flat - 19
defects mm; centre punch
– 9 mm x 127 mm;
rule 60 cm; two
fold; brass toped to
read inches and
mm; hammer
scaling 0.25 kg
with handle; steel
rule - 30 cm to
read inch and
millimetre; Vernier
calliper - digital - 0-
150 mm; ball peen
hammer with
handle - 0.25 kg;
cross peen
hammer with
handle - 0.25 kg;
holding tongs - 30
cm; wire brush –
15 cm x 3.7 cm
and double ended
spanner

Sr. Equipment
No. Required
4 Carryout cutting  Read drawing to interpret procedure Training kit
operation and test for and cutting tolerance (Trainer guide,
accuracy  Explain various gas cutting methods PowerPoint)
 Select the right sized tip based on the Tools and
Theory Duration plate thickness to be cut equipment as
(hh:mm)  Check connection of the accessories, mentioned above
10:00 and ensure that there is no gas leakage
in the system
 Perform various cutting operations
Practical Duration o Down –hand straight cuts
(hh:mm) o Track- guided cuts
55:00 o Cut regular shapes
o Cut irregular shapes
Corresponding NOS o Angled cuts
Code o Chamfer cuts
CSC/N0203 o Radius cuts
o Gouging/flushing
o Bevelled edge operations
o Cutting out holes
o Materials
 Mild carbon steel
 High tensile and
special steels
 Other suitable
materials
o Forms
 Plate
 Rolled section
 Pipe/tube
 Solid bars
 Produce thermally cut components to
meet the specified quality criteria
o Within +/- 2mm
o Angled/radial cuts are within
the specification
o Clean and smooth cuts
o Cuts are free from flutes and
drags
5 Test for accuracy  Measure dimensional accuracies using Training kit
suitable equipment (Trainer guide,
Theory Duration  Identify various cutting defects PowerPoint),
(hh:mm) o Distortion defective parts
05:00 o Grooved
o Fluted or dragged cuts
o Poor draglines
Practical Duration o Rounded edges
(hh:mm) o Tightly adhering slag
10:00
Corresponding NOS
Code
CSC/N0203
6 Deal with  Able to communicate with superiors Training kit
contingencies regarding malfunctioning of any (Trainer guide,

Sr. Equipment
No. Required
Theory Duration component in the setup PowerPoint)
(hh:mm)  Seek assistance from superiors in case
05:00 of any difficulty Oxy-acetylene gas
 Take necessary actions in case of cutting setup
Practical Duration following emergencies:
(hh:mm)  contact with heat, sparks, molten
10:00 metal or direct contact
Corresponding NOS  fire/ explosion caused by gas leaks
Code  sustained back fire in blow pipe
CSC/N0203  State relevant legislation, standards,
policies and procedures followed in the
organization
 Explain the workflow and own role in
the workflow
 State hierarchy and protocols
 Read and interpret information correctly
 Fill appropriate forms
 Perform numerical calculations
 Participate in on-the-job learning,
training and development, interventions
and assessments
 Use problem solving skills
 Explain the importance of planning and
organizing day-to-day activities
 Develop analytical thinking capabilities
 Critically evaluate the work done
 State the importance of team work
7 Health and safety  Explain the importance of personal Training kit

protective equipment (PPE) required for (Trainer guide,
Theory Duration gas cutting operation PowerPoint)
(hh:mm)  State the causes for accidents
10:00  Identify job site hazardous work and Leather gloves,
state possible causes of risk or leather apron,
Practical Duration accident at the workplace welding screen –
(hh:mm)  Explain the importance of ‘5S’ at the helmet types, hand
08:00 workplace screen welding and
safety shoes
Corresponding NOS
Code
CSC/N1335
8 Fire Safety  Explain types of fires - Class A, B, C Training kit
and D (Trainer guide,
PowerPoint)
Theory Duration
(hh:mm)  Select appropriate fire extinguisher to Class A, B, C, D
05:00 control fire and K fire
 Use PASS method to operate a fire extinguishers
extinguisher
Practical Duration  Follow fire safety signs and safe
(hh:mm) evacuation method in case of a fire
30:00  Identify the location of assembly point,
fire exit, fire alarm
Corresponding NOS  Follow reporting procedure in case of a

Sr. Equipment
No. Required
Code fire
CSC/N1335
9 Emergencies, rescue  Follow electrical safety procedures Training kit

and first aid procedure  Use approved method to rescue a (Trainer guide,
person from electrocution PowerPoint)
Theory Duration  State the importance of first aid
(hh:mm)  Identify the contents of a first aid kit and First aid kit with all
09:00 their application contents
 Administer first aid in case of bleeding,
Practical Duration burns, choking, electrical shock,
(hh:mm) poisoning, etc.
18:00  Use of CPR process
 Bandage wounds
Corresponding NOS
 Explain stages of crisis and crisis
Code
management
CSC/N1335
 Prepare an incident report
10 Work effectively with  Explain the importance of team work Training kit
others and team dynamics (Trainer guide,
 State 4Cs of working in a team PowerPoint)
Theory Duration  Explain types of communication
(hh:mm)  Apply effective communication
20:00 technique
 Overcome barriers to effective
Practical Duration communication
(hh:mm)  Demonstrate active listening skills
60:00  Demonstrate good customer service
skills
Corresponding NOS
 Explain the importance of ethical
Code
behaviour in your day-to-day work
CSC/N1336
 State the importance of discipline in life
and apply the same at workplace
Total Duration Unique Equipment Required:

Leather gloves; leather apron; welding screen - helmet type; hand
Theory Duration screen welding; safety shoes; fire extinguishers - dry powder fire
82:00 extinguisher; fire bucket with sand, first aid kit; gas cutting
equipment with all accessories; surface plate - standard size;
Practical Duration scriber - 15 cm; dividers 20 cm; calliper outside 15 cm; prick
218:00 punch; chisel cold flat - 19 mm; centre punch – 9 mm x 127 mm;
rule 60 cm; two fold; brass toped to read inches and mm; hammer
scaling 0.25 kg with handle; steel rule - 30 cm to read inch and
millimetre; Vernier calliper (digital) - 0-150 mm; ball peen hammer
with handle - 0.25 kg; cross peen hammer with handle - 0.25 kg;
holding tongs - 30 cm; wire brush – 15 cm x 3.7 cm and double
ended spanner
Grand Total Course Duration: 300 Hours, 0 Minutes
(This syllabus/ curriculum has been approved by Capital Goods Skill Council)

Trainer Prerequisites for Job role: “ Oxy Fuel Gas Cutter” mapped to
Qualification Pack: “CSC/Q0203 v1.0”
Sr.
Area Details
No.
1 Description Perform manual oxy-fuel cutting for a range of standard cutting job
requirements using oxy-fuel gas. This is for a skilled cutter who can cut
carbon steels in the basic positions.
2 Personal Basic communication, numerical and computational abilities. Openness to
Attributes learning, ability to plan and organize own work and identify and solve
problems in the course of working. Understanding the need to take initiative
and manage self and work to improve efficiency and effectiveness.
3 Minimum
Educational Diploma /Degree in Mechanical Engineering
Qualifications
4a Domain Certified for Job Role: “Oxy Fuel Gas Cutter” mapped to QP: “CSC/Q0203,
Certification v1.0”. Minimum accepted score is 80%
4b Platform Recommended that the Trainer is certified for the Job Role: “Trainer”,
Certification mapped to the Qualification Pack: “MEP/Q0102”. Minimum accepted as
per respective SSC guidelines is 80%.
5 Experience  3-4 years of industry experience in the relevant field
 3-4 years of teaching experience

Annexure: Assessment Criteria
Assessment Criteria
Job Role Oxy Fuel Gas Cutter
Qualification Pack CSC/Q0203, v1.0
Sector Skill Council Capital Goods Skill Council
Sr.
Guidelines for Assessment
No.
1 Criteria for assessment for each Qualification Pack will be created by the Sector Skill
Council. Each Performance Criteria (PC) will be assigned marks proportional to its
importance in NOS. SSC will also lay down proportion of marks for Theory and Skills
Practical for each PC.
2 The assessment for the theory part will be based on knowledge bank of questions created
by the SSC.
3 Individual assessment agencies will create unique question papers for theory part for each
candidate at each examination/training centre(as per assessment criteria below)
4 Individual assessment agencies will create unique evaluations for skill practical for every
student at each examination/training canter based on this criteria
5 To pass the Qualification Pack, every trainee should score a minimum of 70% in every NOS
6 In case of successfully passing only certain number of NOS's, the trainee is eligible to take
subsequent assessment on the balance NOS's to pass the Qualification Pack.

Marks
Allocation
Total
Assessable Out Skill
Assessment Criteria Mark Th
Outcome Of s
(300) eor
Pract
y
ical
PC1.work safely at all times, complying with
health and safety legislation, regulations and 3 1 2
other relevant guidelines
PC2.take necessary safety precautions for gas
cutting operations including equipment, 2 0 2
processes and checks
PC3.interpret cutting procedure data sheets
3 1 2
specifications
PC4.check regulators, hoses and check that
valves are securely connected and free from 2 0 2
leaks and damage
PC5.check equipment is calibrated and approved
2 0 2
for use
PC6.check/fit the correct size gas nozzle to the
2 0 2
torch
PC7.ensure preheat and oxygen holes on the
2 0 2
tips are clean
PC8.check that a flashback arrestor is fitted 2 0 2
PC9.set appropriate gas pressures 2 0 2
PC10.use the correct procedure for lighting,
3 1 2
adjusting and extinguishing
PC11.adjust torch valve for type of flame such as
2 0 2
1.CSC/N0203 neutral, carburizing and oxidizing
Manually cut PC12.follow sequence of operations such as pre-
3 1 2
metal and heating material and initiating cut 100
metal alloys PC13.mark out the locations for cutting
using oxy-fuel 3 1 2
accurately and as per requirement
gas PC14.use appropriate and safe procedures for
3 1 2
handling and storing of gas cylinders
PC15.prepare the work area for the cutting
2 0 2
activities
PC16.obtain the appropriate tools and equipment
for the oxy-fuel gas cutting operations, and check 2 0 2
that they are in a safe and usable condition
PC17.check that the oxy-fuel gas cutting
equipment is set up for the operations to be 2 0 2
performed
PC18.adjust cylinder valves and adjust regulator
for operating pressure to achieve specifications 3 1 2
for required operations
PC19.where appropriate, mark out the
components for the required operations, using 2 0 2
appropriate tools and techniques
PC21.operate the oxy-fuel gas cutting equipment
to produce items/cut shapes to the dimensions 5 1 4
and profiles specified
PC22.use various types of oxy-fuel gas cutting
4 0 4
methods
PC23.perform various cutting operations 4 0 4

Marks
Allocation
Total
Outcome Of s
(300) eor
Pract
y
ical
correctly
PC24.produce thermal cuts in various forms of
4 0 4
material (metal of 3mm and above)
PC25.produce cut profiles for various type of
3 0 3
materials
PC26.produce thermally-cut components which
4 1 3
meet specified quality criteria
PC27.recognize and correct burn back and
3 1 2
flashback
PC29.ensure the work area is left in a safe and
tidy condition on completion of the cutting 2 0 2
activities
PC30.check that the finished components meet
3 1 2
the standard required
PC31.use appropriate methods and equipment to
check the quality, and that all dimensional and
4 1 3
geometrical aspects of the cut material are to the
specification
PC32.identify various cutting defects and follow
organization recommended procedures to 3 1 2
address them
PC33.report any difficulties or problems that may
arise with the cutting activities, and carry out any 2 0 2
agreed actions
PC34.detect equipment malfunctions and deal
2 0 2
with them appropriately
PC35.deal promptly and effectively with problems
within their control, and seek help and guidance
2 0 2
from the relevant people if they have problems
that they cannot resolve
PC36.shut down and make safe the cutting
2 0 2
equipment on completion of the cutting activities
PC37.in case of emergencies follow standard
3 1 2
emergency procedures
Total 100 14 86
PC1.use protective clothing/equipment for
5 2 3
specific tasks and work conditions
PC2.state the name and location of people
responsible for health and safety in the 3 1 2
2.CSC/ 1335 workplace
Use basic PC3.state the names and location of documents
3 1 2
health and that refer to health and safety in the workplace
100
safety PC4.identify job-site hazardous work and state
practices at possible causes of risk or accident in the 5 2 3
the workplace workplace
PC5.carry out safe working practices while
dealing with hazards to ensure the safety of self
4 2 2
and others state methods of accident prevention
in the work environment of the job role

Marks
Allocation
Total
Outcome Of s
(300) eor
Pract
y
ical
PC6.state location of general health and safety
3 2 1
equipment in the workplace
PC7.inspect for faults, set up and safely use
5 2 3
steps and ladders in general use
PC8.work safely in and around trenches,
5 2 3
elevated places and confined areas
PC9.lift heavy objects safely using correct
5 2 3
procedures
PC10.apply good housekeeping practices at all
4 2 2
times
PC11.identify common hazard signs displayed in
5 2 3
various areas
PC12.retrieve and/or point out documents that
3 1 2
refer to health and safety in the workplace
PC13.use the various appropriate fire
4 1 3
extinguishers on different types of fires correctly
PC14.demonstrate rescue techniques applied
4 1 3
during fire hazard
PC15.demonstrate good housekeeping in order
3 1 2
to prevent fire hazards
PC16.demonstrate the correct use of a fire
4 1 3
extinguisher
PC17.demonstrate how to free a person from
4 1 3
electrocution
PC18.administer appropriate first aid to victims
where required eg. in case of bleeding, burns, 4 1 3
choking, electric shock, poisoning etc.
PC19.demonstrate basic techniques of
3 1 2
bandaging
PC20.respond promptly and appropriately to an
accident situation or medical emergency in real 4 1 3
or simulated environments
PC21.perform and organize loss minimization or
rescue activity during an accident in real or 3 1 2
simulated environments
PC22.administer first aid to victims in case of a
heart attack or cardiac arrest due to electric
3 1 2
shock, before the arrival of emergency services
in real or simulated cases
PC23.demonstrate the artificial respiration and
3 1 2
the CPR Process
PC24.participate in emergency procedures 3 2 1
PC25.complete a written accident/incident report
or dictate a report to another person, and send 4 1 3
report to person responsible
PC26.demonstrate correct method to move
4 1 3
injured people and others during an emergency
Total 100 36 64
PC1.accurately receive information and
3.CSC/N1336 100 10 3 7
instructions from the supervisor and fellow

Marks
Allocation
Total
Outcome Of s
(300) eor
Pract
y
ical
Work workers, getting clarification where required
effectively PC2.accurately pass on information to authorized
with others persons who require it and within agreed 10 3 7
timescale and confirm its receipt
PC3.give information to others clearly, at a pace
10 3 7
and in a manner that helps them to understand
PC4.display helpful behavior by assisting others
in performing tasks in a positive manner, where 10 3 7
required and possible
PC5.consult with and assist others to maximize
10 3 7
effectiveness and efficiency in carrying out tasks
PC6.display appropriate communication etiquette
10 3 7
while working
PC7.display active listening skills while
10 3 7
interacting with others at work
PC8.use appropriate tone, pitch and language to
convey politeness, assertiveness, care and 10 3 7
professionalism
PC9.demonstrate responsible and disciplined
10 3 7
behaviors at the workplace
PC10.escalate grievances and problems to
appropriate authority as per procedure to resolve 10 3 7
them and avoid conflict
Total 100 30 70
Grand Total 300 300 80 220
Percentage Weightage: 27 73
Minimum Pass% to qualify (aggregate): 70

Metal Inert Gas - Metal Active Gas - Gas Metal Arc Welder (MIG - MAG - GMAW) - (CSC - Q0209)

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QUALIFICATIONS PACK - OCCUPATIONAL STANDARDS FOR

Qualifications Pack Code CSC/Q0209

[Applicable for National Scenarios]

Job Role MIG/ MAG/ GMAW Welder

Perform manual (semi-automatic) operations for performing

Prerequisite License or Training Manual/Shielded Metal Arc Welding

Performance Criteria As described in the relevant OS units

Sector Sector is a conglomeration of different business operations having similar

MAG Metal Active Gas

Manually (semi-automatic) welding joints using the MIG/MAG (GMAW) process

Performance Criteria(PC) w.r.t. the Scope

NOS Version Control

NOS Code CSC/N0209

Credits TBD Version number 1.0

Occupation Welding and Cutting Next review date 24/11/2021

(Task) using Metal Arc Welding/ Shielded Metal Arc Welding

Performance Criteria(PC) w.r.t. the Scope

NOS Version Control

NOS Code CSC/N0204

Credits TBD Version number 1.0

Occupation Welding and Cutting Next review date 24/11/2021

Unit Code CSC/N0203

Manually cut metal and metal alloys using oxyfuel gas

Performance Criteria(PC) w.r.t. the Scope

NOS Version Control

NOS Code CSC/N0203

Credits TBD Version number 1.0

Occupation Welding and Cutting Next review date 24/11/2021

Unit Code CSC/N0207

Manually cut metal materials using plasma arc

Performance Criteria(PC) w.r.t. the Scope

NOS Version Control

NOS Code CSC/N0207

Credits TBD Version number 1.0

Occupation Welding and Cutting Next review date 24/11/2021

Unit Code CSC/N1335

Use basic health and safety practices at the workplace

• Health and safety

Performance Criteria(PC) w.r.t. the Scope

NOS Version Control

NOS Code CSC/N1335

Credits TBD Version number 1.0

Occupation Welding and Cutting Next review date 24/11/2021

Unit Code CSC/N1336

Work effectively with others

Performance Criteria (PC) w.r.t. the Scope

NOS Version Control

NOS Code CSC/N1336

Credits TBD Version number 1.0

Occupation Welding and Cutting Next review date 24/11/2021

Nomenclature for QP and NOS

[Insert 3 letter codes for SSC] QP number (2 numbers)

Q denoting Qualifications Pack Occupation (2 numbers)

An example of NOS with ‘N’

[Insert 3 letter codes for SSC] OS number (2 numbers)

N denoting National Occupational Standard Occupation (2 numbers)

Sub-sector Range of Occupation numbers

Machine Tools 01-13