FLUX-CORED ARC WELDING (FCAW) NC III – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR FLUX-CORED ARC WELDING (FCAW) NC III COURSE

The TEDA Course in Flux-Cored Arc Welding (FCAW) NC III consists of competencies that a person must achieve to weld alloy steel plate and pipe components as specified by layout, blueprints, diagrams, work order, welding procedure or oral instructions using FCAW welding equipment.

A student who has achieved this TESDA Course in FLUX-CORED ARC WELDING (FCAW) NC III is competent to be:

• Plate Welder (FCAW)
• Pipe Welder (FCAW)
• FCAW Plate Welder (Alloy Steel )
• FCAW Pipe Welder (Alloy Steel)

TRAINEE ENTRY REQUIREMENTS

Trainees or students wishing to gain entry into this course should possess the following requirements:

• completed training in FCAW NC II or a holder of FCAW NC II
• can communicate either oral and written
• physically and mentally fit
• can perform basic mathematical computation

FLUX-CORED ARC WELDING (FCAW) NC III COURSE MODULE

Course Title: FLUX-CORED ARC WELDING (FCAW)
Level: NC III
Nominal Training Duration :

(Basic Competency) 20 hours
(Common Competency) 56 hours
(Core Competency) 72 hours

TOTAL DURATION: 148 Hours

This course is designed to enhance the knowledge, skills and attitudes of FCAW Welder in accordance with industry standards. It covers core competencies such as Setting-up Welding Equipment, Preparing Weld Materials, Fitting up Weld Materials, Welding Alloy Plates and Pipes Using FCAW and Repairing Welds.

COMPETENCIES REQUIRED IN FLUX-CORED ARC WELDING (FCAW) NC III

This units of competency comprising this qualification include Basic, Common and Core Competencies.

To obtain this TESDA Course in FLUX-CORED ARC WELDING (FCAW) NC III, all units prescribed below for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (72 hours)
MEE721305	Weld Alloy Steel Plates Using FCAW
MEE721319	Weld Alloy Steel Pipes Using FCAW
UNIT CODE	COMMON COMPETENCIES (56 hours)
MEE721201	Apply safety practices
MEE721202	Interpret working drawings and sketches
MEE721203	Perform Industry Calculations
MEE721204	Contribute to Quality System
MEE721205	Use Hand Tools
MEE721206	Prepare Weld Materials
MEE721207	Setup Welding Equipment
MEE721208	Fit up Weld Materials
MEE721209	Repair Welds
UNIT CODE	BASIC COMPETENCIES (20 hours)
500311109	Lead Workplace Communication
500311110	Lead Small Teams
500311111	Develop and Practice Negotiation skills
500311112	Solve Problems Related to Work Activities
500311113	Use Mathematical Concepts and Techniques
500311114	Use Relevant Technologies

These guidelines are set to provide the Technical Vocational Education and Training (TVET) providers with information and other important requirements to consider when designing training programs for FLUX-CORED ARC WELDING (FCAW) NC III.

CORE COMPETENCIES

UNIT OF COMPETENCY : Weld alloy steel plates using FCAW
UNIT CODE : MEE721115

This unit covers the skills, knowledge and attitudes required in welding alloy steel plates in 1F-4F and 1G-3G positions using FCAW process.

1. Perform root pass (backing material)
   • Root pass performed in accordance with WPS and/or client specifications.
   • Weld visually checked for defects and repaired, as required
   • Weld visually acceptable in accordance with applicable codes and standards
2. Clean root pass
   • Root pass cleaned is free from defects and discontinuities
   • Task performed in accordance with approved WPS
3. Weld subsequent/filling passes
   • Subsequent/ filling passes performed in accordance with approved WPS
   • Weld visually checked for defects and repaired, as required
   • Weld visually acceptable in accordance with applicable codes and standards
4. Perform capping
   • Capping performed in accordance with WPS and/or client specifications
   • Weld visually checked for defects and repaired, as required
   •  Weld visually acceptable in accordance with applicable codes and standards

UNIT OF COMPETENCY : Weld alloy-steel pipes using FCAW
UNIT CODE : MEE7721119

This unit covers the skills, knowledge and attitudes in welding alloy-steel pipes using FCAW process.

1. Perform root pass (backing material)
   • Root pass performed in accordance with WPS and/or client specifications.
   • Weld visually checked for defects and repaired, as required
   • Weld visually acceptable in accordance with applicable codes and standards
2. Clean root pass
   • Root pass cleaned is free from defects and discontinuities
   • Task performed in accordance with approved WPS
3. Weld subsequent/filling passes
   • Subsequent/ filling passes performed in accordance with approved WPS
   • Weld visually checked for defects and repaired, as required
   • Weld visually acceptable in accordance with applicable codes and standards
4. Perform capping
   • Capping performed in accordance with WPS and/or client specifications
   • Weld visually checked for defects and repaired, as required
   • Weld visually acceptable in accordance with applicable codes and standards

COMMON COMPETENCIES

UNIT OF COMPETENCY : APPLY SAFETY PRACTICES
UNIT CODE : MEE722201

This unit covers the competencies required to apply safety practices in the workplace.

1. Identify hazards
   • Hazards are identified correctly in accordance with OHS principles.
   • Safety signs and symbols are identified and adhered to.
2. Use protective clothing and devices
   • Appropriate protective clothing and devices correctly selected and used in accordance with OHS requirements or industry/ company policy.
3. Perform safe handling of tools, equipment and materials
   • Safety procedures for pre-use check and operation of tools and equipment followed in accordance with industry/ company policies.
   • Tools, equipment and materials handled safely in accordance with OHS requirements and industry/ company policies.
4. Perform first aid
   • First aid treatment of injuries are carried out according to recommended procedures.
5. Use fire extinguisher
   • Fire extinguisher selected and operated correctly according to the type of fire.

UNIT OF COMPETENCY : INTERPRET WORKING DRAWINGS And SKETCHES
UNIT CODE : MEE721202

This unit covers the competencies required to read and interpret drawings and sketches.

1. Interpret technical drawing
   • Components, assemblies or objects recognized as required.
   • Dimensions identified as appropriate.
   • Instructions identified and followed as required.
   • Material requirements identified as required.
   • Symbols recognized as appropriate in the drawing.
   • Tolerance, limits and fits identified in the drawing.
2. Prepare freehand sketch of parts
   • Sketch drawn correctly and appropriately.
   • Sketch depicted objects or part appropriately.
   • Dimensions indicated in sketch are clear and correct.
   • Instructions included in sketch are clear and correct.
   • Base line or datum points indicated as required.
3. Interpret details from freehand sketch
   • Components, assemblies or objects recognized as required.
   • Dimensions identified as appropriate.
   • Instructions identified and followed as required.
   • Material requirements identified as required.
   • Symbols recognized as appropriate in the drawing.

UNIT OF COMPETENCY : PERFORM INDUSTRY CALCULATIONS
UNIT CODE : MEE721203

This unit covers the competencies required to perform basic calculations using the four fundamental operation.

1. Perform four fundamental operations
   • Simple calculations involving whole numbers, mixed numbers, fraction and decimal are performed using four fundamental operations.
2. Perform conversion of units
   • Units are converted to the required figure using the given formulae
   • English measurements are converted to metric measurements according to procedure.
3. Perform calculations on algebraic expressions
   • Simple calculations are performed on algebraic expressions using four fundamental operations.
   • Simple transposition of formulae are carried out to isolate the variable required, involving the four fundamental operations.
   • Where appropriate, formulae are constructed to enable problems to be solved.
   • Equations involving on unknown solved correctly.
4. Compute percentage and ratio
   • Percentages are computed using appropriate formula.
   • Ratio and proportion are computed using appropriate formula.

UNIT OF COMPETENCY : CONTRIBUTE TO QUALITY SYSTEM
UNIT CODE : MEE721204

This unit involves competence required to inspect work against specification and standards and apply quality standards to work.

1. Inspect work done
   • Appropriate inspections are conducted to ensure company quality systems and procedures are maintained/ followed.
   • Job specifications/work order and quality standards are identified.
   • Faults/Defects are identified and rectified according to company procedures.
2. Apply quality standards to work
   • Inspections are conducted throughout the manufacturing processes to ensure quality standards are maintained.
   • Appropriate quality standards are applied throughout the production/fabrication process.
   • All activities are coordinated throughout the workplace to ensure efficient quality work outcomes.
   • Records of work quality are maintained according to the company requirements.
3. Protect company property and customer interests
   • Possible damage to company property is avoided by adherence to company quality procedures.
   • Quality of work is reviewed to ensure customer requirements and company standards are met.

UNIT OF COMPETENCY : USE HAND TOOLS
UNIT CODE : MEE721205

This unit covers the competencies required to use hand tools.

1. Select hand tools
   • Hand tools selected are appropriate to the requirements of the task.
   • Unsafe or defective tools are identified and marked for repair according to procedure.
2. Use hand tools
   • Hand tools are used to produce the desired outcomes to job specifications.
   • Task performed in accordance with company or industry safety procedure.
3. Maintain hand tools
   • Routine maintenance of hand tools is undertaken according to standard operating procedures, principles and techniques.
   • Hand tools are stored in designated location in accordance with manufacturer’s instruction/standard operating procedure.

UNIT TITLE : PREPARE WELD MATERIALS
UNIT CODE : MEE721206

This unit covers the skills, knowledge and attitudes in preparing welding materials.

1. Set up cutting equipment
   • Cutting equipment should be operational and should conform to acceptable OH&S standards
   • Appropriate for operation intended
2. Cut and prepare edge of materials
   • Materials are cut to specified dimension/specifications.
   • Task performed in accordance with company or industry requirements and safety procedure.
3. Clean surfaces and edges
   • Surfaces are cleaned to required specifications.
   • Task performed in accordance with company or industry requirements and safety procedure
4. Prepare welding consumables
   • Consumables are prepared in accordance with required specifications
   • Recommended manufacturer’s instructions are observed
5. Prepare welding safety and protective equipment
   • PPE should conform to acceptable OH&S requirement and standards

UNIT TITLE : SET UP WELDING EQUIPMENT
UNIT CODE : MEE721207

This unit covers the skills, knowledge and attitudes in preparing equipment for welding.

1. Set up welding machine
   • Requirements for welding is determined from job requirements, welding procedures and specifications and/or technical drawings.
   • Welding machine is set up in accordance with job requirements, welding procedures and specifications, technical drawings and manufacturer’s instructions.
   • Welding machine should be connected to an independent power supply and wired up or set to the polarity indicated in the welding procedures/specifications or as recommended by the manufacturer.
   • Current and voltage fine-tuned or adjusted consistent with job requirements to produce acceptable weld.
   • Task is completed without causing damage to the tools, equipment and materials and injury to self and others.
2. Set up welding accessories
   • Welding machine accessories and consumables are identified from job requirements, welding procedures and specifications.
   • Welding machine accessories and consumables are set up in accordance with job requirements, welding procedures and specifications and/or manufacturer’s instructions.
3. Set up welding positioners, jigs and fixtures
   • Braces, stiffeners, rails and other jigs are provided and in conformity with job requirements.
   • Work items/materials are protected from strong winds, drafts and rainfall
4. Set up pre-heating tools/equipment as required
   • Pre-heating equipment appropriate to the job requirement and specifications
   • Equipment operated in conformance with the manufacturer’s instructions.

UNIT TITLE : FIT UP WELD MATERIALS
UNIT CODE : MEE721208

This unit covers the skills, knowledge and attitudes in fitting up welding materials.

1. Perform tack welding
   • Tack welding performed in accordance with the requirements of WPS and client’s specifications.
   • Tack weld visually and dimensionally acceptable.
   • Tack on root for pipe or as required.
   • Backing plate, stiffener, running plate installed as required.
   • Joints are free from rust, paints, grease and other foreign materials prior to fit up or tacking.
2. Check gap and alignment
   • Root gap is performed in accordance with the requirements of WPS.
   • Alignment within the range of acceptability of code and standard.
   • Fitted materials visually free from stresses
3. Set up welding positioner
   • Weld specimen positioned and secured according to the requirements.

UNIT TITLE : REPAIR WELDS
UNIT CODE : MEE721209

This unit covers the skills, knowledge and attitudes in repairing welds.

1. Mark/locate weld defects
   • Identified weld defects marked/located according to recommended practice
2. Prepare tools and equipment
   • Tools and equipment prepared are appropriate to the job requirements including the provision of wind barriers.
   • Task performed in accordance with company or industry requirements and safety procedure
3. Remove defects
   • Weld defects removed/excavated in accordance with approved industry procedures or client requirements.
   • Removal of non-defective welds is minimized and cleaned.
   • Visual and dye-penetrant test performed to verify the extent of removal of defects, where applicable
   • Welding inspector informed to verify the extent of defect removal.
   • Task performed in accordance with company or industry requirement and safety procedure
4. Perform re-welding
   • Re-welding performed in accordance with approved repair procedure.
   • Task performed in accordance with company or industry requirement and safety procedure
   • No new weld defects or damages occurred during re-welding.
   • Weld visually checked after re-welding for acceptability

BASIC COMPETENCIES

The BASIC COMPETENCIES refer to non-technical skills (knowledge, skills and attitudes) that everybody will need in order to perform satisfactorily at work and in society and are considered portable and transferable irrespective of jobs and industrial settings.

UNIT OF COMPETENCY : LEAD WORKPLACE COMMUNICATION
UNIT CODE : 500311109

This unit covers the knowledge, skills and attitudes required to lead in the dissemination and discussion of ideas, information and issues in the workplace.

1. Communicate information about workplace processes
   • Appropriate communication method is selected
   • Multiple operations involving several topics areas are communicated accordingly
   • Questions are used to gain extra information
   • Correct sources of information are identified
   • Information is selected and organized correctly
   • Verbal and written reporting is undertaken when required
   • Communication skills are maintained in all situations
2. Lead workplace discussions
   • Response to workplace issues are sought
   • Response to workplace issues are provided immediately
   • Constructive contributions are made to workplace discussions on such issues as production, quality and safety
   • Goals/objectives and action plan undertaken in the workplace are communicated
3. Identify and communicate issues arising in the workplace
   • Issues and problems are identified as they arise
   • Information regarding problems and issues are organized coherently to ensure clear and effective communication
   • Dialogue is initiated with appropriate personnel
   • Communication problems and issues are raised as they arise

UNIT OF COMPETENCY : LEAD SMALL TEAMS
UNIT CODE : 500311110

This unit covers the knowledge, skills and attitudes to lead small teams including setting and maintaining team and individual performance standards.

1. Provide team leadership
   • Work requirements are identified and presented to team members
   • Reasons for instructions and requirements are communicated to team members
   • Team members’ queries and concerns are recognized, discussed and dealt with
2. Assign responsibilities
   • Duties, and responsibilities are allocated having regard to the skills, knowledge and aptitude required to properly undertake the assigned task and according to company policy
   • Duties are allocated having regard to individual preference, domestic and personal considerations, whenever possible
3. Set performance expectations for team members
   • Performance expectations are established based on client needs and according to assignment requirements
   • Performance expectations are based on individual team members duties and area of responsibility
   • Performance expectations are discussed and disseminated to individual team members
4. Supervised team performance
   • Monitoring of performance takes place against defined performance criteria and/or assignment instructions and corrective action taken if required
   • Team members are provided with feedback, positive support and advice on strategies to overcome any deficiencies
   • Performance issues which cannot be rectified or addressed within the team are referenced to appropriate personnel according to employer policy
   • Team members are kept informed of any changes in the priority allocated to assignments or tasks which might impact on client/customer needs and satisfaction
   • Team operations are monitored to ensure that employer/client needs and requirements are met
   • Follow-up communication is provided on all issues affecting the team
   • All relevant documentation is completed in accordance with company procedures

UNIT OF COMPETENCY : DEVELOP AND PRACTICE NEGOTIATION SKILLS
UNIT CODE : 500311111

This unit covers the skills, knowledge and attitudes required to collect information in order to negotiate to a desired outcome and participate in the negotiation.

1. Plan negotiations
   • Information on preparing for negotiation is identified and included in the plan
   • Information on creating non verbal environments for positive negotiating is identified and included in the plan
   • Information on active listening is identified and included in the plan
   • Information on different questioning techniques is identified and included in the plan
   • Information is checked to ensure it is correct and up-to- date
2. Participate in negotiations
   • Criteria for successful outcome are agreed upon by all parties
   • Desired outcome of all parties are considered
   • Appropriate language is used throughout the negotiation
   • A variety of questioning techniques are used
   • The issues and processes are documented and agreed upon by all parties
   • Possible solutions are discussed and their viability assessed
   • Areas for agreement are confirmed and recorded
   • Follow-up action is agreed upon by all parties

UNIT OF COMPETENCY : SOLVE PROBLEMS RELATED TO WORK ACTIVITIES
UNIT CODE : 500311112

This unit of covers the knowledge, skills and attitudes required to solve problems in the workplace including the application of problem solving techniques and to determine and resolve the root cause of problems.

1. Identify the problem
   • Variances are identified from normal operating parameters; and product quality
   • Extent, cause and nature are of the problem are defined through observation, investigation and analytical techniques
   • Problems are clearly stated and specified
2. Determine fundamental causes of the problem
   • Possible causes are identified based on experience and the use of problem solving tools / analytical techniques.
   • Possible cause statements are developed based on findings
   • Fundamental causes are identified per results of investigation conducted
3. Determine corrective action
   • All possible options are considered for resolution of the problem
   • Strengths and weaknesses of possible options are considered
   • Corrective actions are determined to resolve the problem and possible future causes
   • Action plans are developed identifying measurable objectives, resource needs and timelines in accordance with safety and operating procedures
4. Provide recommendation/s to manager
   • Report on recommendations are prepared
   • Recommendations are presented to appropriate personnel.
   • Recommendations are followed-up, if required

UNIT OF COMPETENCY : USE MATHEMATICAL CONCEPTS AND TECHNIQUES
UNIT CODE : 500311113

This unit covers the knowledge, skills and attitudes required in the application of mathematical concepts and techniques.

1. Identify mathematical tools and techniques to solve problem
   • Problem areas are identified based on given condition
   • Mathematical techniques are selected based on the given problem
2. Apply mathematical procedure/solution
   • Mathematical techniques are applied based on the problem identified
   • Mathematical computations are performed to the level of accuracy required for the problem
   • Results of mathematical computation is determined and verified based on job requirements
3. Analyze results
   • Result of application is reviewed based on expected and required specifications and outcome
   • Appropriate action is applied in case of error

UNIT OF COMPETENCY : USE RELEVANT TECHNOLOGIES
UNIT CODE : 500311114

This unit of competency covers the knowledge, skills, and attitude required in selecting, sourcing and applying appropriate and affordable technologies in the workplace.

1. Study/select appropriate technology
   • Usage of different technologies is determined based on job requirements
   • Appropriate technology is selected as per work specification
2. Apply relevant technology
   • Relevant technology is effectively used in carrying out function
   • Applicable software and hardware are used as per task requirement
   • Management concepts are observed and practiced as per established industry practices
3. Maintain/enhance relevant technology
   • Maintenance of technology is applied in accordance with the industry standard operating procedure, manufacturer’s operating guidelines and occupational health and safety procedure to ensure its operative ability
   • Updating of technology is maintained through continuing education or training in accordance with job requirement
   • Technology failure/ defect is immediately reported to the concern/responsible person or section for appropriate action

DEFINITION OF TERMS

• base metal – the metal that is to be worked or welded
• weld bead – a deposit of filler metal from a single welding pass
• weld defect– an irregularity that spoils the weld appearance or impairs the effectiveness of the weld or weldment by causing weakness or failure
• weld line – the junction of weld metal and the base metal, or the junction of base metal parts when filler metal is not used
• weldment – an assembly or structure whose component parts are joined by welding
• welding – joining two metals by applying heat to melt and fuse them, with or without filler metal
• welding electrode – the current-carrying rod used to strike an arc between rod and metal
• welding rod – filler metal in the form of a rod or heavy wire
• welding torch – a gas mixing and burning tool for the welding of metal