SHIELDED METAL ARC WELDING (SMAW) IV – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR SHIELDED METAL ARC WELDING (SMAW) IV

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

This Qualification conforms with AWS D 1.1 Structural Welding Code; ASME IX Boiler and Pressure Vessel Code; API 1104 Code for Gas and Oil Pipeline Facilities; and ISO 9606-1 Qualification of Welders for Steel.

A student who has achieved this Course in SHIELDED METAL ARC WELDING (SMAW) IV is competent to be:

  • Plate Welder (SMAW)
  • Pipe Welder (SMAW)
  • Plate Welder (SMAW-Alloy Steel)
  • Pipe Welder (SMAW-Alloy Steel)

SHIELDED METAL ARC WELDING (SMAW) IV – TRAINING AND REGULATION MODULE

Course Title: SHIELDED METAL ARC WELDING (SMAW)
Level: NC IV
Nominal Training Duration :

56 hrs. ( Basic Competencies)
56 hrs. ( Common Competencies)
56 hrs. ( Core Competencies)

This course is designed to enhance the knowledge, skills and attitudes in Shielded Metal Arc Welding in accordance with industry standards. It covers core competencies such as Setting-up Welding Equipment, Preparing Weld Materials, Fitting up Weld Materials, Weld alloy steel pipes using SMAW and Repairing Welds.

TRAINEE ENTRY REQUIREMENTS

Trainees or students who would like to enroll in this program must possess the following requirements:

  • Must have completed training in SMAW NC III or a holder of SMAW NC III
  • can communicate either oral and written
  • physically and mentally fit
  • with good moral character
  • can perform basic mathematical computation

COMPETENCIES REQUIRED IN SHIELDED METAL ARC WELDING (SMAW) IV

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

To obtain this TESDA course in SHIELDED METAL ARC WELDING (SMAW) IV, all units prescribed for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE CORE COMPETENCIES (56 hours)
MEE721317 Weld Alloy Steel Pipes Using SMAW
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
UNIT CODE BASIC COMPETENCIES (20 hours)
500311115 Utilize specialized communication skills
500311116 Develop teams and individuals
500311117 Apply problem solving techniques in the workplace
500311118 Collect, analyze and organize information
500311119 Plan and organize work
500311120 Promote environmental protection

CORE COMPETENCIES

This section gives the details of the contents of the core units of competency required in SHIELDED METAL ARC WELDING (SMAW) IV.

UNIT OF COMPETENCY : Weld alloy steel pipes using SMAW
UNIT CODE : MEE721317

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

  1. Perform root pass
    • Root pass performed in accordance with WPS and/or client specifications.
    • Task performed in accordance with company or industry requirement and safety procedure.
    • 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 industry/company 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

This section gives the details of the contents of the basic units of competency required in AUTOMOTIVE SERVICING NC IV

UNIT OF COMPETENCY : UTILIZE SPECIALIZED COMMUNICATION SKILLS
UNIT CODE : 500311115

This unit covers the knowledge, skills and attitudes required to use specialized communication skills to meet specific needs of internal and internal clients, conduct interviews, facilitate group of discussions, and contribute to the development of communication strategies.

  1. Meet common and specific communication needs of clients and colleagues
    • Specific communication needs of clients and colleagues are identified and met
    • Different approaches are used to meet communication needs of clients and colleagues
    • Conflict is addressed promptly and in a timely way and in a manner which does not compromise the standing of the organization
  2. Contribute to the development of communication strategies
    • Strategies for internal and external dissemination of information are developed, promoted, implemented and reviewed as required
    • Channels of communication are established and reviewed regularly
    • Coaching in effective communication is provided
    • Work related network and relationship are maintained as necessary
    • Negotiation and conflict resolution strategies are used where required
    • Communication with clients and colleagues is appropriate to individual needs and organizational objectives
  3. Represent the organization
    • When participating in internal or external forums, presentation is relevant, appropriately researched and presented  in a manner to promote the organization
    • Presentation is clear and sequential and delivered within a predetermined time
    • Utilize appropriate media to enhance presentation
    • Differences in views are respected
    • Written communication is consistent with organizational standards
    • Inquiries are responded in a manner consistent with organizational standard
  4. Facilitate group discussion
    • Mechanisms which enhance effective group interaction is defined and implemented
    • Strategies which encourage all group members to participate are used routinely
    • Objectives and agenda for meetings and discussions are routinely set and followed
    • Relevant information is provided to group to facilitate outcomes
    • Evaluation of group communication strategies is undertaken to promote participation of all parties
    • Specific communication needs of individuals are identified and addressed
  5. Conduct interview
    • A range of appropriate communication strategies are employed in interview situations
    • Records of interviews are made and maintained in accordance with organizational procedures
    • Effective questioning, listening and nonverbal communication techniques are used to ensure that required message is communicated

UNIT OF COMPETENCY : DEVELOP TEAMS AND INDIVIDUALS
UNIT CODE : 500311116

This unit covers the skills, knowledge and attitudes required to determine individual and team development needs and facilitate the development of the workgroup.

  1. Provide team leadership
    • Learning and development needs are systematically identified and implemented in line with organizational requirements
    • Learning plan to meet individual and group training and developmental needs is collaboratively developed and implemented
    • Individuals are encouraged to self evaluate performance and identify areas for improvement
    • Feedback on performance of team members is collected from relevant sources and compared with established team learning process
  2. Foster individual and organizational growth
    • Learning and development program goals and objectives are identified to match the specific knowledge and skills requirements of competency standards
    • Learning delivery methods are appropriate to the learning goals, the learning style of participants and availability of equipment and resources
    • Workplace learning opportunities and coaching/mentoring assistance are provided to facilitate individual and team achievement of competencies
    • Resources and timelines required for learning activities are identified and approved in accordance with organizational requirements
  3. Monitor and evaluate workplace learning
    • Feedback from individuals or teams is used to identify and implement improvements in future learning arrangements
    • Outcomes and performance of individuals/teams are assessed and recorded to determine the effectiveness of development programs and the extent of additional support
    • Modifications to learning plans are negotiated to improve the efficiency and effectiveness of learning
    • Records and reports of competency are maintained within organizational requirement
  4. Develop team commitment and cooperation
    • Open communication processes to obtain and share information is used by team
    • Decisions are reached by the team in accordance with its agreed roles and responsibilities
    • Mutual concern and camaraderie are developed in the team
  5. Facilitate accomplishment of organizational goals
    • Team members actively participated in team activities and communication processes
    • Teams members developed individual and joint responsibility for their actions
    • Collaborative efforts are sustained to attain organizational goals

UNIT OF COMPETENCY : APPLY PROBLEM SOLVING TECHNIQUES IN THE WORKPLACE
UNIT CODE : 500311117

This competency covers the knowledge, skills and attitudes required to apply the process of problem solving and other problems beyond those associated directly with the process unit. It includes the application of structured processes and improvement tools. This competency is typically performed by an experienced technician, team leader or supervisor.

  1. Analyze the problem
    • Issues/concerns are evaluated based on data gathered
    • Possible causes of problem are identified within the area of responsibility as based on experience and the use of problem solving tools/analytical techniques
    • Possible cause statements are developed based on findings
  2. Identify possible solutions
    • All possible options are considered for resolution of the problem in accordance with safety and operating procedures
    • Strengths and weaknesses of possible options are considered
    • Corrective action is determined to resolve the problem and its possible future causes
  3. Recommend solution to higher management
    • Report/communication or documentation are prepared
    • Recommendations are presented to appropriate personnel
    • Recommendations are followed-up, if required
  4. Implement solution
    • Measurable objectives are identified
    • Resource needs are identified
    • Timelines are identified in accordance with plan
  5. Evaluate/Monitor results and outcome
    • Processes and improvements are identified based on evaluative assessment of problem
    • Recommendations are prepared and submitted to superiors.

UNIT OF COMPETENCY : COLLECT, ANALYZE AND ORGANIZE INFORMATION
UNIT CODE : 500311118

This unit covers the outcomes required to process, analyze, interpret and organize workplace information and other relevant data.

  1. Study information requirements
    • Needs are identified using established research procedures
    • Relevant forms and recording systems are used to gather the information.
    • Respondents are selected to implement survey / research based on established procedures.
  2. Process data
    • Data are collected and collated based on the prescribed method.
    • Relevant data are used as references in accordance with the objectives of the program.
    • Information is compiled according to the required form.
  3. Analyze, interpret and organize information gathered
    • Data are analyzed using relevant methodologies
    • Where applicable, statistical analysis/methods are employed according to the objectives of the program
    • Graphs and other visual presentations are prepared to facilitate analysis / interpretation of information
  4. Present findings/recommendations
    • Findings/recommendations summarized and presented/packaged in user-friendly manner
    • Relevant inputs gathered to finalize report
    • Draft report prepared based on standard format.
    • Technical reports are submitted and disseminated to concerned offices.

UNIT OF COMPETENCY : PLAN AND ORGANIZE WORK
UNIT CODE : 500311119

This unit covers the outcomes required in planning and organizing work. It may be applied to a small independent operation or to a section of a large organization.

  1. Set objectives
    • Objectives are consistent with and linked to work activities in accordance with organizational aims
    • Objectives are stated as measurable targets with clear time frames
    • Support and commitment of team members are reflected in the objectives
    • Realistic and attainable objectives are identified
  2. Plan and schedule work activities
    • Tasks/work activities to be completed are identified and prioritized as directed
    • Tasks/work activities are broken down into steps in accordance with set time frames achievable components in accordance with set time frames
    • Resources are allocated as per requirements of the activity
    • Schedule of work activities is coordinated with personnel concerned
  3. Implement work plans
    • Work methods and practices are identified in consultation with personnel concerned
    • Work plans are implemented in accordance with set time frames, resources and standards
  4. Monitor work activities
    • Work activities are monitored and compared with set objectives
    • Work performance is monitored
    • Deviations from work activities are reported and recommendations are coordinated with appropriate personnel and  in accordance with set standards
    • Reporting requirements are complied with in accordance with recommended format
    • Observe timeliness of report
    • Files are established and maintained in accordance with standard operating procedures
  5. Review and evaluate work plans and activities
    • Work plans, strategies and implementation are reviewed based on accurate, relevant and current information
    • Review is based on comprehensive consultation with appropriate personnel on outcomes of work plans and reliable feedback
    • Results of review are provided to concerned parties and formed as the basis for adjustments/simplifications to be made to policies, processes and activities
    • Performance appraisal is conducted in accordance with organization rules and regulations
    • Performance appraisal report is prepared and documented regularly as per organization requirements.
    • Recommendations are prepared and presented to appropriate personnel/authorities
    • Feedback mechanisms are implemented in line with organization policies

UNIT OF COMPETENCY : PROMOTE ENVIRONMENTAL PROTECTION
UNIT CODE : 500311120

This unit covers the knowledge, skills and attitudes required in adhering to environmental protection principles, strategies and guidelines

  1. Study guidelines for environmental concerns.
    • Environmental legislations/conventions and local ordinances are identified according to the different environmental aspects/impact.
    • Industrial standard/environmental practices are described according to the different environmental concerns.
  2. Implement specific environmental programs.
    • Programs/Activities are identified according to organizations policies and guidelines.
    • Individual roles/responsibilities are determined and performed based on the activities identified.
    • Problems/ constraints encountered are resolved in accordance with organizations’ policies and guidelines
    • Stakeholders are consulted based on company guidelines.
  3. Monitor activities on environmental protection/programs
    • Activities are periodically monitored and evaluated according to the objectives of the environmental program
    • Feedback from stakeholders are gathered and considered in proposing enhancements to the program based on consultations
    • Data gathered are analyzed based on evaluation requirements
    • Recommendations are submitted based on the findings.
    • Management support systems are set/established to sustain and enhance the program
    • Environmental incidents are monitored and reported to concerned/proper authorities.

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

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