GAS METAL ARC WELDING (GMAW) NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR GAS METAL ARC WELDING (GMAW) NC II COURSE

The TESDA Course in Gas Metal Arc Welding (GMAW) NC II consists of competencies that a person must achieve to weld carbon steel pipes components as specified by layout, blueprints, diagrams, work order, welding procedure or oral instructions using GMAW welding equipment.

This Qualification conforms with American Welding Society (AWS) D 1.1 Structural Welding Code; American Society of Mechanical Engineers (ASME) IX Boiler and Pressure Vessel Code; American Petroleum Institute (API) 1104 Code for Gas and Oil Pipeline Facilities; and International Standards Organization (ISO) 9606-1 Qualification of Welders for Steel.

A student who has achieved this Course in GAS METAL ARC WELDING (GMAW) NC II is competent to be:

• Plate Welder (GMAW)
• Pipe Welder (GMAW)

TRAINEE ENTRY REQUIREMENTS

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

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

GAS METAL ARC WELDING (GMAW) NC II – TRAINING AND REGULATION MODULE

Course Title: GAS METAL ARC WELDING (GMAW)
Level: NC II
Nominal Training Duration :

(Basic Competency) 18 Hours
(Common Competency) 56 Hours
(Core Competency) 194 Hours

Total Training Duration 268 Hours

This course is designed to enhance the knowledge, skills and attitudes of trainees in Gas Metal Arc Welding in accordance with industry standards. It covers core competencies such as Welding Carbon Steel Plates Using GMAW, Welding Carbon Steel Plates and Pipes Using GMAW.

COMPETENCIES REQUIRED IN GAS METAL ARC WELDING (GMAW) NC II

This units of competency comprising this qualification include Basic, Common and Core Competencies. To obtain this course, all units prescribed for this qualification must be achieved.

UNIT CODE	CORE COMPETENCIES (194 Hours)
MEE721309	Weld Carbon Steel Pipes Using GMAW
UNIT CODE	COMMON COMPETENCIES (56 Hours)
MEE721201	Apply Safety Practices
MEE721202	Interpret 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 (18 Hours)
500311105	Participate in Workplace Communication
500311106	Work in Team Environment
500311107	Practice career professionalism
500311108	Practice occupational health and safety procedures

This section gives the details of the contents of the core units of competency required in GAS METAL ARC WELDING (GMAW) NC II. These units of competency are categorized into basic, common and core competencies.

CORE COMPETENCIES

UNIT OF COMPETENCY: Weld carbon steel pipes using GMAW
UNIT CODE: MEE721109

This unit covers the skills, knowledge and attitudes required in welding carbon steel pipes using GMAW 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 : MEE721201

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

1. Identify hazardous area
   • 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 DRAWINGS AND SKETCHES
UNIT CODE : MEE721202

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

1. Identify standard alphabet of lines
   • Alphabet of lines are identified Uses of the alphabet of lines are explained
2. Identify orthographic/isometric views
   • Orthographic and isometric drawing are identified
   • Orthographic and isometric views are explained
3. Interpret standard drawing symbols, dimensional tolerances and notations
   • Drawing symbols are interpreted according to drawing standards
   • Dimensional tolerances, notations are interpreted according to specifications

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

UNIT OF COMPETENCY : PARTICIPATE IN WORKPLACE COMMUNICATION
UNIT CODE : 500311105

This unit covers the knowledge, skills and attitudes required to gather, interpret and convey information in response to workplace requirements.

1. Obtain and convey workplace information
   • Specific and relevant information is accessed from appropriate sources
   • Effective questioning, active listening and speaking skills are used together and convey information
   • Appropriate medium is used to transfer information and ideas
   • Appropriate non- verbal communication is used
   • Appropriate lines of communication with supervisors and colleagues are identified and followed
   • Defined workplace procedures for the location and storage of information are used
   • Personal interaction is carried out clearly and concisely
2. Participate in workplace meetings and discussions
   • Team meetings are at ended on time
   • Own opinions are clear expressed and those of others are listened to without interruption
   • Meeting inputs are consistent with the meeting purpose and established protocols
   • Workplace interactions are conducted in a courteous manner
   • Questions about simple routine workplace procedures and matters concerning working conditions of employment are asked and responded to.
   • Meetings outcomes are interpreted and implemented
3. Complete relevant work related documents
   • Range of forms relating to conditions of employment are completed accurately and legibly
   • Workplace data is recorded on standard workplace forms and documents
   • Basic mathematical processes are used for routine calculations
   • Errors in recording information on forms/documents are identified and properly acted upon
   • Reporting requirements to supervisor are completed according to organizational guidelines

UNIT OF COMPETENCY : WORK IN TEAM ENVIRONMENT
UNIT CODE : 500311106

This unit covers the skills, knowledge and attitudes to identify role and responsibility as a member of a team.

1. Describe team role and scope
   • The role and objective of the team is identified from available sources of information
   • Team parameters, reporting relationships and responsibilities are identified from team discussions and appropriate external sources.
2. Identify own role and responsibility within team
   • Individual role and responsibilities within the team environment are identified.
   • Roles and responsibility of other team members are identified and recognized.
   • Reporting relationships within team and external to team are identified.
3. Work as a team member
   • Effective and appropriate forms of communications used and interactions undertaken with team members who contribute to known team activities and objectives.
   • Effective and appropriate contributions made to complement team activities and objectives, based on individual skills and competencies and workplace context.
   • Observed protocols in reporting using standard operating procedures.
   • Contribute to the development of team work plans based on an understanding of team’s role and objectives and individual competencies of the members.

UNIT OF COMPETENCY : PRACTICE CAREER PROFESSIONALISM
UNIT CODE : 500311107

This unit covers the knowledge, skills and attitudes in promoting career growth and advancement.

1. Integrate personal objectives with organizational goals
   • Personal growth and work plans are pursued towards improving the qualifications set for the profession
   • Intra- and interpersonal relationships is are maintained in the course of managing oneself based on performance evaluation
   • Commitment to the organization and its goal is demonstrated in the performance of duties
2. Set and meet work priorities
   • Competing demands are prioritized to achieve personal, team and organizational goals and objectives.
   • Resources are utilized efficiently and effectively to manage work priorities and commitments
   • Practices along economic use and maintenance of equipment and facilities are followed as per established procedures
3. Maintain professional growth and development
   • Trainings and career opportunities are identified and availed of based on job requirements
   • Recognitions are sought/received and demonstrated as proof of career advancement
   • Licenses and/or certifications relevant to job and career are obtained and renewed

UNIT OF COMPETENCY : PRACTICE  OCCUPATIONAL HEALTH AND SAFETY PROCEDURES
UNIT CODE : 500311108

This unit covers the outcomes required to comply with regulatory and organizational requirements for occupational health and safety.

1. Identify hazards and risks
   • Safety regulations and workplace safety and hazard control practices and procedures are clarified and explained based on organization procedures
   • Hazards/risks in the workplace and their corresponding indicators are identified to minimize or eliminate risk to co-workers, workplace and environment in accordance with organization procedures
   • Contingency measures during workplace accidents, fire and other emergencies are recognized and established in accordance with organization procedures
2. Evaluate hazards and risks
   • Terms of maximum tolerable limits which when exceeded will result in harm or damage are identified based on threshold limit values (TLV)
   • Effects of the hazards are determined
   • OHS issues and/or concerns and identified safety hazards are reported to designated personnel in accordance with workplace requirements and relevant workplace OHS legislation
3. Control hazards and risks
   • Occupational Health and Safety (OHS) procedures for controlling hazards/risks in workplace are consistently
     followed
   • Procedures for dealing with workplace accidents, fire and emergencies are followed in accordance with organization OHS policies
   • Personal protective equipment (PPE) is correctly used in accordance with organization OHS procedures and practices
   • Appropriate assistance is provided in the event of a workplace emergency in accordance with established organization protocol
4. Maintain OHS awareness
   • Emergency-related drills and trainings are participated in as per established organization guidelines and procedures
   • OHS personal records are completed and updated in accordance with workplace requirements

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