Transnational Skill Standards MIG/MAG/GMAW Welder level 4 · 2018-01-10 · TRANSNATIONAL SKILL...

TRANSNATIONAL SKILL STANDARDS FOR CAPITAL GOODS INDUSTRY

Transnational Skill Standards

MIG/MAG/GMAW Welder level 4

REFERENCE ID: TOS/ CSC / Q 0209


Mapping for MIG/MAG/GMAW Welder (CSC / Q 0209) with UK Welding materials by the Semi-Automatic MIG/MAG and Flux Cored Arc processes (UK NOS SEMFWE3-5 /UK NOS SEMFWE3-04 / UK NOS SEMFWE233/ UK NOSSEMMAN123-01 /UK NOS SEMMAN3-03)

Link to Indian Qualification Pack: http://www.nsdcindia.org/sites/default/files/files/CGSC%20Metal%20Inert%20Gas_Metal%20Active%20Gas%20Welder%20MIG_MAG%20or%20GMAW%20Welder%20final.pdf

Links to UK Qualification: http://nos.ukces.org.uk/PublishedNos/SEMFWE35.pdfhttp://nos.ukces.org.uk/PublishedNos/SEMFWE34.pdfhttp://nos.ukces.org.uk/PublishedNos/SEMFWE233.pdfhttp://nos.ukces.org.uk/PublishedNos/MAN123%2001%20New%20version.pdfhttp://nos.ukces.org.uk/PublishedNos/MAN3%2003%20New%20version.pdf

How to Read this Document This document has two sections - Section I and Section II.

Section I: Compares the NOS listing in the Indian QP – Metal Inert Gas / Metal Active Gas / Gas Metal Arc Welder (MIG/MAG/GMAW) within UK Qualification Welding materials by the Semi-Automatic MIG/MAG and Flux Cored Arc processes 3.

Section II: Compares the competencies described in each of the Indian NOS with those of UK.

The language of the compared competencies of the two countries differs. However, the competency pointers of the described competency can be mapped. Wherever the competency pointer maps it is reported as ‘None’ under the column ‘Gap in Indian NOS’. Wherever the competency pointers do not map, it is identified as a gap and the corresponding UK competency is noted under the column ‘Gap in Indian NOS’.

Usage of Benchmarked Transnational Standards

There will be two types of users of these benchmarked standards. One type will be of those individuals who are already trained and are certified on the corresponding Indian QP. This set of individuals will have to undergo a bridge course comprising of the identified gaps only. Thereafter, they will be assessed under the aegis of a UK Awarding

1


body through the Indian SSC on the competency portions acquired via the bridge course. All qualifying individuals will be awarded a co-branded certificate comprising of logo of Skill India, Indian SSC and UK Awarding Body.

Those individuals who wish to be certified afresh will have to undergo training on both the Indian QP and the gaps in the Indian NOS with regard to UK competencies. Thereafter, they will be assessed under the aegis of a UK Awarding body through the Indian SSC and they will obtain a co-branded certificate comprising of logo of Skill India, Indian SSC and UK Awarding Body.

2


Section I: NOS Mapping of MIG/MAG/GMAW Welder level 4 QP (CSC /Q 0209) with the Welding materials by the Semi-Automatic MIG/MAG and Flux Cored Arc processes in UK NOS SEMFWE3-05; SEMFWE3-04;SEMFWE233; SEMMAN123-01; SEMMAN3-03

NOS Mapping: A Summary Indian NOS

Code Indian NOS UK NOS Code UK NOS Remarks, if

any CSC/N 0209 Manually (semi-

automatically)welding joints using the MIG /MAG (GMAW) process

SEMFWE3-05

Welding materials by the Semi-Automatic MIG/MAG and Flux Cored Arc processes

CSC/N 0204 Manually weld metal and metal alloys using metal arc

SEMFWE3-04

Welding materials by the manual metal arc process

CSC/N 0203 Manually cut metal and metal alloys using oxy-fuel gas

SEMFWE233

Cutting materials using hand operated thermal cutting equipment

CSC/N 0207 Manually cut metal materials using plasma arc

SEMFWE233 Cutting materials using hand operated thermal cutting equipment

CSC /N1335 Use basic health and safety practices at the workplace

SEMMAN123-01

Complying with statutory regulations and organisational safety requirements

CSC/ N 1336 Working effectively with others

SEMMAN3-03 Working efficiently and effectively in engineering

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Section II: Compares the competencies in Indian NOS with those of UK NOS.

NOS Mapping Descriptions

Indian QP Title MIG/MAG/GMAW Welder

UK Qualification

Indian QP Code CSC/ Q0209 UK Qualification Code

Indian NOS Code

CSC/N 0209 UK NOS Code SEMFWE3-05

Indian NOS Manually (semi-automatically)welding joints using the MIG /MAG (GMAW) process

UK NOS Welding materials by the Semi-Automatic MIG/MAG and Flux Cored Arc processes

Scope

This unit/task covers the following: 1.Working Safely

2.Prepare for welding operations

3.Carry out welding operations

4.Test for quality

5.Post welding activities

6.Dealing with contingencies

Overview

This standard identifies the competencies you need to prepare and operate semi-automatic MIG, MAG and flux cored wire arc welding equipment in accordance with approved welding procedures. You will be required to set up and check the welding equipment and associated work holding and manipulating devices required. In setting up the equipment you will need to connect all the required leads/cables, hoses, shielding gas supply and wire feed mechanisms ready for

4


Scope

Overview

use, and set and adjust the welding conditions in line with the welding procedure specification. You must operate the equipment safely and correctly and make any necessary adjustments to settings in order to produce the welded joints to the required specification.

Your responsibilities will require you to comply with organisational policy and procedures for the welding activities undertaken and to report any problems with the welding equipment or welding activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying welding

5


Scope

Overview

procedures and instructions. You will understand the MIG, MAG or flux cored wire welding process used, and its application, and will know about the equipment, materials and consumables in adequate depth to provide a sound basis for setting up and operating the equipment, recognising and correcting faults and ensuring the work output is produced to the required specification. Visual inspection and non-destructive testing of your completed work is implied. You will understand the safety precautions required when working with the welding equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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Competency Mapping

Performance Criteria - Indian NOS

Performance Criteria - UK NOS Gaps in Indian NOS

PC1. work safely at all times, complying with health and safety legislation, regulations and other relevant guidelines

P1 work safely at all times, complying with health and safety and other relevant regulations and guidelines

None

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; shop floor housekeeping including surface conditions; waste disposal; stability of surrounding structures, furniture, etc.

P8 deal promptly with excess and waste materials and temporary attachments, in line with approved and agreed procedures

None

PC3. check the condition of welding leads, gas connection arrangements, earthing arrangements and electrode holder

P4 check that joining and related equipment and consumables are as specified and fit for purpose

None

PC4. report any faults or potential hazards to appropriate authority

None

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,

P2 follow the relevant joining procedure and job instructions P3 check that the joint preparation complies with the specification 1. set up, check, adjust and use welding and related equipment for one of the following welding processes:

Range Statement 1. set up, check, adjust and use welding and related equipment for one of the following welding processes: 1.1 MIG 1.2 MAG 1.3 Flux cored wire

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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 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.

1.1 MIG 1.2 MAG 1.3 Flux cored wire 2. use consumables appropriate to the material and application to include both of the following: 2.1 two wire types and sizes from different material groups 2.2 two different shielding gases (where applicable)

2. use consumables appropriate to the material and application to include both of the following: 2.1 two wire types and sizes from different material groups 2.2 two different shielding gases (where applicable)

PC6. select welding machines such as inverters, rectifiers and generators, according to the task

None

PC7. select electrodes according to classification and specifications

None

PC8. prepare the materials and joint in readiness for welding

P3 check that the joint preparation complies with the specification

None

8




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 (e.g.. 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

None

PC9. check the condition of, and correctly connect, welding leads/cables, hoses, shielding gas supply and wire feed mechanisms


None

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

None

9




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

None

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

None

PC11. select the welding shielding gases and equipment for a range of given applications

None

10




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

None

PC12. plan the welding activities before they start them effectively and efficiently for achieving specifications as per WPS

None

PC13. clean wire feeder and torch tip

None

PC14. connect torches and components

PC15. connect and adjust regulators and flow meters to cylinders

None

PC16. adjust wire feed rate and read and set current as required

None

PC17. set other welding parameters (e.g.. voltage, slope of current versus voltage curve where required) Parameters: correct set-up of

None

11




the joint; proper condition of electrical connections; welding return and earthing arrangements; operating parameters PC18. choose appropriate mode of metal transfer

None

PC19. set pre-purge with shielding gas as required

None

PC20. set and verify gas flow rates

None

PC21. prepare and support the joint, using the appropriate methods

None

PC22. tack weld the joint at appropriate intervals, and check the joint for accuracy before final welding

None

PC23. use manual welding and related equipment, to carry out MIG/MAG welding processes

P5 make the joints as specified using the appropriate thermal joining technique P6 produce joints of the required quality and of specified dimensional accuracy

None

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.

None

PC25. adjust wire stick-out as per requirement PC26. use welding

None

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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 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

P5 make the joints as specified using the appropriate thermal joining technique P6 produce joints of the required quality and of specified dimensional accuracy 6. produce welded components which: 6.1 achieve a weld quality equivalent to Suite B of BS EN ISO 5817 except for excess weld metal, excessive convexity, excess throat thickness and excessive penetration for which Suite C shall apply (for aluminium EN 30042/ISO 10042 applies) 6.2 meet the required dimensional accuracy within specified tolerances

None

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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

4. produce joints in two forms of specified materials from different material groups to include the following: 4.1 plate 4.2 section 4.3 sheet (<3mm) 4.4 pipe/tube 4.5 other forms

Range Statement 4. produce joints in two forms of specified materials from different material groups to include the following: 4.1 plate 4.2 section 4.3 sheet (<3mm) 4.4 pipe/tube 4.5 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

3. produce welded joints which incorporate both of the following: 3.1 butt welds 3.2 fillet welds 5. weld joints according to approved welding procedures in good access situations in the following BS EN ISO 6947 positions: 5.1 vertical upwards (PF) butt weld and four other positions chosen from: 5.2 flat (PA) 5.3 horizontal (PC) 5.4 overhead (PE) 5.5 horizontal vertical (PB) 5.6 vertical downwards (PG) 5.7 inclined pipe/tube (H-LO 45

Range Statement 3. produce welded joints which incorporate both of the following: 3.1 butt welds 3.2 fillet welds 5. weld joints according to approved welding procedures in good access situations in the following BS EN ISO 6947 positions: 5.1 vertical upwards (PF) butt weld and four other positions chosen from: 5.2 flat (PA) 5.3 horizontal (PC) 5.4 overhead (PE) 5.5 horizontal vertical (PB) 5.6 vertical downwards (PG) 5.7 inclined pipe/tube (H-LO 45 or J-LO45)

14




or J-LO45)

PC30. make sure that the work area is maintained and left in a safe and tidy condition


None

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

None

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

None

15




observation, angel of observation, adequate lighting, low powered magnification, fillet weld gauges PC34. carry out DPT tests to assess fine defect open to the surface not detected by visual inspection (VT)

None

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)

None

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

None

PC37. shut down and make safe the welding equipment on completion of the welding activities

P7 shut down the equipment to a safe condition on completion of joining activities

None

PC38. follow the established organisational process for dealing with the welded pieces including handover, storage, safety and security, record keeping, etc.

None

PC39. detect equipment malfunctions and deal with them safely and as per organisation procedures

None

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PC40. deal promptly and effectively with problems within own control, and seek timely and appropriate help and guidance from relevant personnel where required

P9 deal promptly and effectively with problems within your control and report those that cannot be solved

None

KA1. relevant legislation, standards, policies, and procedures followed in the company

K1 the safe working practices and procedures to be observed when working with MIG, MAG or flux cored wire welding equipment (general workshop and site safety; appropriate personal protective equipment (PPE); fire prevention; protecting other workers from the effects of the electric arc; safety in enclosed/confined spaces; fume control; accident procedure; statutory requirements; risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

Relevant UK safety regulations.

KA2. key purpose of the organization

None

KA3. department structure and hierarchy protocols

K15 the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

None

KA4. work flow and own role in the workflow

None

KA5. dependencies and interdependencies in the workflow

None

KA6. support functions and types of support available for incumbents in this role

None

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KB1. types of fire extinguishers and their suitable uses in case of welding related fires

None

KB2. effects of exposure to welding fume and related safety practices

None

KB3. range of welding equipment available for GMAW welding 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

None

KB4. functions of welding equipment

None

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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.

K4 principles of MIG, MAG, or flux cored wire arc welding, the equipment and its operation (fusion welding principles, characteristics of the metal arc, power sources, typical equipment and power ranges, care of equipment, control systems, filler wires, gas supply and control, terminology used in welding)

None

KB6. relationship between wire feed, speed control and welding current

None

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

K6 types and classification of consumables (wires, shielding gases -inert and active; control and storage of consumables)

None

KB8. welding consumables classification as applicable to GMAW

None

KB9. safe working practices and procedures to be followed when preparing and using MIG/MAG welding equipment

K1 Too None

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

K2 the hazards associated with arc welding and how they can be minimised (live electrical components, poor earthing, the electric arc, fumes and gases, gas supply leaks, spatter, hot slag and metal, grinding and mechanical metal/slag removal; elevated working, enclosed

None

19




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

spaces)

KB11. personal protective equipment to be worn for the welding activities

K1 Too None

KB12. correct handling and storage of gas cylinders for welding purposes

K3 the correct handling and storage of gas cylinders, (manual handling and use of cylinder trolley, leak detection procedures, relevant BCGA codes of practice, cylinder identification, gas pressures, cylinder and equipment safety features, emergency shutdown procedures)

None

KB13. manual MIG/MAG welding process

None

KB14. type and thickness of base metals for welding purposes

None

KB15. types (availability, typical sizes), storage (storage, identification, segregation (classification,

None

20




size) of ferrous metals

KB16. current and polarity required for GMAW

None

KB17. types, selection and application of filler wires and welding electrodes

None

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

None

KB19. use, impact and importance of gas pressures and flow rates (in relationship to the type of material being welded)

None

KB20. methods/modes of metal transfer and their uses Methods: globular, short circuit transfer, spray arc, pulse, surface tension transfer (STT)

None

KB21. types of welded joints to be produced Types of joints: fillet lap joints, tee fillet joints, corner joints, butt

K7 types and features of welded joints in plate, sheet and tube (fillet and butt welds, single and multi-run welds, welding

None

21




joints: square, single vee, double vee

positions, weld quality)

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

None

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

K11 the techniques of operating the welding equipment to produce a range of joints in the various joint positions (fine tuning parameters; correct manipulation of the welding gun; safe closing down of the welding equipment)

None

KB24. how to prepare the materials in readiness for the welding activity

None

KB25. purpose and correct use of anti-spatter compound

None

KB26. importance and procedure to clean torch tip and liner

None

KB27. how to set up and restrain the joint, and the tools and techniques to be used

K5 extracting information required from drawings and welding procedure specifications (interpretation of welding symbols; scope, content and application of the welding procedure specification such as preheat) to include symbols and conventions to appropriate

None

22




British, European or relevant International standards in relation to work undertaken K9 methods of setting up the joint to achieve correct location of components and control of distortion (edge preparation; correct joint set-up; cleanliness of materials used; use of jigs/fixtures, manipulators and positioners; tack welding, size and spacing in relationship to material thickness and component size; use of temporary attachments; pre-setting)

KB28. appropriate tack welding size and spacing (in relationship to material thickness)

None

KB29. checks to be made prior to welding

K10 setting up the welding equipment and checks that need to be made to ensure that it is safe and ready to use (electrical connections, power return and earthing arrangements; wire feed mechanisms; gas supply; equipment calibration; setting welding parameters; care and maintenance of equipment)

None

KB30. factors that determine weld bead shape Factors: gun angles and weld bead profiles (push, perpendicular, drag); electrode extensions stickout (short, normal, long); fillet weld electrode extension stickout (short, normal, long); gun travel speed (slow, normal, fast); current and voltage

None

23




KB31. types of weld beads and uses (stringer, weave, weave patterns)

None

KB32. weld bead quality characteristics Bead characteristics: spatter deposits, roughness, evenness, fill, crater, overlap, contour – convex, concave, mitre

None

KB33. techniques of operating the welding equipment to produce a range of joints in the various joint positions

None

KB34. effects of the electrical characteristics of the MIG/MAG welding arc

None

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)

None

KB36. problems that can occur with the welding activities and how to address them

K8 problems that can occur with the welding activities and how these can be overcome (causes of distortion and methods of control, effects of welding on materials and sources of weld defects; methods of prevention)

None

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KB37. how to close down the welding equipment safely and correctly

None

KB38. own responsibility to assist in preparation of the welds and weld pieces for examination

K12 the organisational quality systems used and weld standards to be achieved K14 personal approval tests and their applicability to your work

None

KB39. how to check the welded joints for uniformity, alignment, position, weld size and profile

K13 weld inspection and test procedures used including destructive and non-destructive methods

None

KB40. gouging and back gouging, its importance, principles, methods and procedures in welding

None

KB41. purpose and importance of pre-heating requirements for base metals in preparation for welding

None

KB42. purpose and importance of post-heating in welding

None

KB43. methods to achieve pre-heat and post heat requirements for welding Purposes

None

KB44. tools and methods to measure temperature for pre-heat and post-heat requirements such as thermal chalk, thermocouple, etc.

None

KB45. significance of diffusible hydrogen for welds and how it is measured

None

KB46. procedure to conduct dye penetrant test to assess weld quality

None

KB47. various procedures for visual examination of the welds for cracks Visual

K13 weld inspection and test procedures used including destructive and non-destructive

None

25




inspections: use of visual techniques, distance of observation, angel of observation, adequate lighting, low powered magnification, fillet weld gauges

methods

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

None

KB49. methods of removing a test piece of weld from a suitable position in the joint

None

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

None

KB51. importance of leaving the work area and equipment in a safe condition on completion of the welding activities

None

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SA1. read and interpret information correctly from various job specification documents, manuals, health and safety instructions, memos, etc. applicable to the job in English and/or local language

None

SA2. fill up appropriate technical forms, process charts, activity logs as per organizational format in English and/or local language

None

SA3. convey and share technical information clearly using appropriate language

None

SA4. check and clarify task-related information

None

SA5. liaise with appropriate authorities using correct protocol

None

SA6. communicate with people in respectful form and manner in line with organizational protocol

None

SA7. undertake numerical operations, geometry and calculations/ formulae (including addition, subtraction, multiplication, division, fractions and decimals, percentages and proportions, simple ratios and averages)

None

SA8. use appropriate measuring techniques

None

SA9. use and convert imperial and metric systems of measurements

None

27




SA10. apply appropriate degree of accuracy to express numbers

None

SA11. use and understand tolerance in terms of limits of size

None

SA12. check measurements, angles, orientation and slopes

None

SA13. types of reference lines such as tangent lines, datum lines, centre lines and work points

None

SA14. check square of material using corner-to-corner dimensions and triangulation (3-4-5) method

None

SA15. select and use tools and equipment such as measuring tapes, levels, squares, protractors and dividers

None

SA16. ability to check dimensions of components

None

SA17. calculate the value of angles in a triangle

None

SA18. participate in on-the-job and other learning, training and development interventions and assessments

None

SA19. clarify task related information with appropriate personnel or technical adviser

None

SA20. seek to improve and modify own work practices

None

SA21. maintain current knowledge of application standards, legislation, codes of practice and

None

28




product/process developments

SB1. identify problems with work planning, procedures, output and behaviour and their implications SB2. prioritize and plan for problem solving SB3. communicate problems appropriately to others SB4. identify sources of information and support for problem solving SB5. seek assistance and support from other sources to solve problems SB6. identify effective resolution techniques SB7. select and apply resolution techniques SB8. seek evidence for problem resolution

None

SB9. plan, prioritize and sequence work operations as per job requirements SB10. organize and analyse information relevant to work SB11. basic concepts of shop-floor work productivity including waste reduction, efficient material usage and optimization of time

None

SB12. undertake and express new ideas and initiatives to others SB13. modify work plan to overcome unforeseen difficulties or developments that occur as work progresses SB14. participate in improvement procedures

None

29




including process, quality and internal/external customer/supplier relationships SB15. one’s competencies in new and different situations and contexts to achieve more SB16. exercise restraint while expressing dissent and during conflict situations SB17. avoid and manage distractions to be disciplined at work SB18. Manage own time for achieving better results SB19. work in a team in order to achieve better results SB20. identify and clarify work roles within a team SB21. communicate and cooperate with others in the team for better results SB22. seek assistance from fellow team members

None

30


Section II continued: Compares the competencies in Indian NOS Manually weld metal and metal alloys using metal arc CSC /N 0204 with the UK NOS Welding materials by the manual metal arc process SEMFWE3-04.



UK Qualification


Indian NOS Code

CSC/N 0204 UK NOS Code SEMFWE3-04

Indian NOS Manually weld metal and metal alloys using metal arc

UK NOS Welding materials by the manual metal arc process

Scope


2.Preparing for welding operations

3.Carrying out welding operations

4.Testing for quality

Overview

This standard identifies the competencies you need to prepare and operate manual metal arc (MMA) welding equipment in accordance with approved welding procedures. You will be required to set up and check the welding equipment and associated work holding and manipulating devices required. In setting up the equipment you will need to connect all the required leads/cables, electrode holder and workpiece earthing arrangements ready for use, and set and adjust the welding conditions

31


Scope

Overview

in line with the welding procedure specification. You must operate the equipment safely and correctly and make any necessary adjustments to settings in order to produce the welded joints to the required specification.

Your responsibilities will require you to comply with organisational policy and procedures for the welding activities undertaken and to report any problems with the welding equipment or welding activities that you cannot resolve, or are outside your permitted authority, to the relevant person. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying welding procedures and instructions. You will

32


Scope

Overview

understand the manual metal-arc welding process, and its application, and will know about the equipment, materials and consumables in adequate depth to provide a sound basis for setting up and operating the equipment, recognising and correcting faults and ensuring the work output is produced to the required specification. Non-destructive testing of your completed work is implied. You will understand the safety precautions required when working with the welding equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

33


Competency Mapping



PC1. work safely at all times, complying with health and safety legislation, regulations and other relevant guidelines


None

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; shop floor housekeeping including surface conditions; waste disposal; stability of surrounding structures, furniture, etc.


None

PC3. check the condition of, welding leads, earthing arrangements and electrode holder


None

PC4. report any faults or potential hazards to appropriate authority

None

PC5. follow fume extraction safety procedures

None

PC6. read and interpret routine information on written job instructions, welding procedure specifications and standard operating procedures WPS: welding process (ISO codes); parent metal; consumables; pre welding

P2 follow the relevant joining procedure and job instructions 1. set up, check, adjust and use manual metal-arc welding and related equipment to include either: 1.1. alternating current equipment (AC) 1.2. direct current equipment

Range Statement P2 follow the relevant joining procedure and job instructions 1. set up, check, adjust and use manual metal-arc welding and related equipment to include either: 1.1. alternating current

34




joint preparation (edge preparation, assembly, pre-heat); welding parameters; welding positions (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 and covering; electrical conditions required (type of current, alternating [A.C.] direct [D.C.], electrode polarity (positive or negative), welding current ranges); welding techniques; sequence of welding; control of heat input; 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)

(DC) 2. use two types and two sizes of electrode from the following: 2.1. rutile 2.2. basic 2.3. nickel alloy 2.4. cellulosic 2.5. stainless steel 2.6. other electrodes

equipment (AC) 1.2. direct current equipment (DC) 2. use two types and two sizes of electrode from the following: 2.1. rutile 2.2. basic 2.3. nickel alloy 2.4. cellulosic 2.5. stainless steel 2.6. other electrodes

PC7. identify welding machines e.g.. transformers, rectifiers, inverters and generators, according to the task

None

PC8. prepare the work area for the welding activities

None

PC9. performing measurements for joint preparation and routine MMAW

None

35




PC10. 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 (e.g.. chamfering machine, grinding and stripping, gas or plasma cutting, etc.); correctly positioned- positioning: devices and techniques; jigs and fixtures; setting up the joint in the correct position and alignment Materials: carbon steels, low alloy steel, plate, sheet (1.5mm), other forms (hollow tubes, etc.)

P3 check that the joint preparation complies with the specification

None

PC11. use manual metal-arc welding and related equipment to include a. alternating current (AC) equipment b. direct current (DC) equipment MMAW equipment: e.g. transformers; rectifiers; generator; invertors; consumables – electrodes, dyes; welding accessories - holders, cables and accessories; ancillary equipment - (power saw, angle, pedestal and straight grinders, tong tester, etc.)

None

36




PC12. connect equipment to power source safely and securely to carry out various welding methods Methods: drag, weave, whip

None

PC13. connect cables, electrode holders, return leads and ground clamps to appropriate terminal

None

PC14. re-dry electrodes as per electrode classification requirement

None

PC15. set, read and adjust amperage controls as required

None

PC16. tack weld the joint at appropriate intervals, and check the joint for accuracy before final welding

None

PC17. verify set up by running test weld specimen (scrap plate)

None

PC18. report any faults or problem to appropriate authority

None

PC19. strike and maintain a stable arc

None

PC20. stop and properly re-start arc to avoid welding defects (scratch start, tapping techniques)

None

PC21. maintain constant puddle by using appropriate travel speed

None

PC22. remove slag in an appropriate manner (e.g.. wire brush, hammer, etc.)

None

PC23. produce tee fillet and corner joints in simple welding positions as per specific instructions given

3. produce welded joints which incorporate both of the following: 3.1 butt welds

Range Statement 3. produce welded joints which incorporate both of the following:

37




using single or multi-run welds Positions: flat (PA) IG/1F, horizontal vertical (PB) 2F, horizontal (PC) 2G

3.2 fillet welds 5. weld joints according to approved welding procedures in good access situations in the following BS EN ISO 6947 positions: 5.1 vertical upwards (PF) butt weld and four other positions chosen from: 5.2 flat (PA) 5.3 horizontal (PC) 5.4 overhead (PE) 5.5 horizontal vertical (PB) 5.6 vertical downwards (PG) 5.7 inclined pipe/tube (H-LO 45 or J-LO45)

3.1 butt welds 3.2 fillet welds 5. weld joints according to approved welding procedures in good access situations in the following BS EN ISO 6947 positions: 5.1 vertical upwards (PF) butt weld and four other positions chosen from: 5.2 flat (PA) 5.3 horizontal (PC) 5.4 overhead (PE) 5.5 horizontal vertical (PB) 5.6 vertical downwards (PG) 5.7 inclined pipe/tube (H-LO 45 or J-LO45)

PC24. produce joints on carbon steel and low carbon alloy steel sheets and plates Joints: fillet lap joints, tee fillet joints, corner joints, butt joints- square, single vee, double vee

None

PC25. weld the joint to the specified quality, dimensions and profile applicable to low carbon alloy steel sheets and plates from 1.5 mm – 24 mm Weld quality specification: 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;

P5 make the joints as specified using the appropriate thermal joining technique P6 produce joints of the required quality and of specified dimensional accuracy 4. produce joints in two forms of specified materials from different material groups to include the following: 4.1. plate 4.2. section 4.3. pipe/tube 4.4. other forms

Range Statement 4. produce joints in two forms of specified materials from different material groups to include the following: 4.1. plate 4.2. section 4.3. pipe/tube 4.4. other forms

38




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

6. produce welded components which: 6.2 achieve a weld quality equivalent to Suite B of BS EN ISO 5817 except for excess weld metal, excessive convexity, excess throat thickness and excessive penetration for which Suite C shall apply (for aluminium, EN30042/ISO10042 applies) 6.2 meet the required dimensional accuracy within specified tolerances

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


None

PC27. shut down and make safe the welding equipment on completion of the welding activities

P7 shut down the equipment to a safe condition on completion of joining activities

None

PC28. measure and check that all dimensional and geometrical aspects of the weld are as per instructions

None

39




PC29. 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 Visual inspections: e.g. use of visual techniques, distance from workpiece, angle of observation, adequate lighting, low powered magnification, fillet weld gauges

None

PC30. identify various weld defects using visual inspection 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

None

PC31. detect and report surface imperfections to appropriate authority

None

40




PC32. deal with defects in welding as per instructions given and organisational procedure

None

PC33. follow the established organisational process for dealing with the pieces that have cleared the testing process Organisational Process: e.g. handover, storage, safety and security, record keeping, etc.

None

KA1. relevant legislation, standards, policies, and procedures followed in the company

K1 the safe working practices and procedures to be observed when working with MMA welding equipment (general workshop and site safety; appropriate personal protective equipment (PPE); fire prevention; protecting other workers from effects of the arc; safety in enclosed/confined spaces; fume control; accident procedure; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

Relevant UK safety regulations..


K11 the organisational quality systems used and weld standards to be achieved K14 the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

None


None

41





None


None

KB1. health and safety, precautions and 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 (suitable aprons, welding gloves, respirators, safety boots, correctly fitting overall, suitable eye shields/goggles, hard hat/helmet); protection of self and others from the effects of the welding arc; fume extraction/control measures; safety measures for elevated and trench workings (e.g.. harness, etc.)

K1 Too K2 the hazards associated with MMA welding and how they can be minimised (live electrical components; poor earthing; the electric arc; fumes and gases; spatter; hot slag and metal; grinding and mechanical metal/slag removal; elevated working; enclosed spaces)

None

KB2. effects of exposure to the electric arc

None

KB3. types of fire extinguishers and their suitable uses

None

42




KB4. effects of exposure to welding fume

None

KB5. methods of managing welding fume hazards

None

KB6. personal protective equipment (PPE) and clothing to be worn during MMAW/SMAW welding

None

KB7. various welding methods and specific equipment requirements for MMAW/SMAW welding MMAW equipment: e.g. transformers; rectifiers; generator; invertors; consumables – electrodes, dyes; welding accessories - holders, cables and accessories; ancillary equipment - (power saw, angle, pedestal and straight grinders, tong tester, etc.) Methods: drag, weave, whip

K4 extracting information required from drawings and welding procedure specifications (interpretation of welding symbols; scope, content and application of the welding procedure specification) to include symbols and conventions to appropriate British, European or relevant International standards in relation to work undertaken K3 principles of MMA welding, the equipment and its operation (fusion welding principles, characteristics of the metal arc, AC and DC power sources, typical equipment and power ranges, care of equipment, terminology used in welding) K8 methods of setting up the joint to achieve correct location of components and control of distortion (edge preparation, use of jigs/fixtures; manipulators and positioners, tack welding, size and spacing in relationship to material thickness and component size, use of temporary attachments, pre-setting)

None

43




KB8. main components and controls of welding equipment

None

KB9. how to connect electrical components of welding equipment correctly

K9 setting up the welding equipment and checks that need to be made to ensure that it is safe and ready to use (electrical connections, power return and earthing arrangements; equipment calibration, setting welding parameters, care and maintenance of equipment)

None

KB10. type of current used and implication for welding

None

KB11. types of consumables used for MMAW/SMAW welding

K5 types and classification of electrodes (flux coverings, correct control, storage and drying of electrodes)

None

KB12. various defects associated with the MMAW/SMAW welding process

None

KB13. types of joint configurations for which welding is used

K6 types and features of welded joints in plate, tube and sections (fillet and butt welds, single and multi-run welds, welding positions, weld quality)

None

KB14. 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)

None

KB15. types of beads, their characteristics and uses (stringer, weave, weave patterns) Bead characteristics: spatter

K10 the techniques of operating the welding equipment to produce a range of joints in the various joint positions (fine tuning

None

44




deposits, roughness, evenness, fill, crater, Overlap

parameters, correct manipulation of electrode, safe closing down of the welding equipment)

KB16. factors that affect weld quality

K7 problems that can occur with the welding activities and how these can be overcome (causes of distortion and methods of control, effects of welding on materials and sources of weld defects; methods of prevention)

None

KB17. weld positions such as flat, horizontal, vertical and overhead Positions: flat (PA) IG/1F, horizontal vertical (PB) 2F, horizontal (PC) 2G

None

KB18. types of equipment components such as electrode holders, work leads cables and ground clamps

None

KB19. awareness and importance of cable size and length KB20. types of polarity such as DC electrode negative and DC electrode positive for welding purposes 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;

None

45




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) KB25. storage requirements for consumable electrodes

K5 Too

KB26. purpose of re-drying and procedure for different classification of electrode

KB27. welding process specification sheet, process qualification record (PQR) and related essential variables

K4 Too None

KB28. travel speed and heat inputs and its impact on the weld

None

KB29. amperage requirements for different classification of electrodes and positions

None

KB30. importance and implications of various diameters of electrodes

None

KB31. gouging and back gouging principles, methods and procedures

None

KB32. purpose and importance of pre-heating requirements for base metals

None

KB33. purpose and importance of post-heating in welding

None

KB34. types of visual inspection indicators and

None

46




methods Visual inspections: e.g. use of visual techniques, distance from workpiece, angle of observation, adequate lighting, low powered magnification, fillet weld gauges KB35. awareness of common welder testing codes and their purpose Testing codes: ASME section IX, EN 287, ISO 9606, IS 7310

K12 weld inspection and test procedures used including destructive and non-destructive methods K13 personal approval tests and their applicability to your work

None

SA1. read and interpret information correctly from various job specification documents, manuals, health and safety instructions, memos, etc. applicable to the job in English or local language

None


None


None


None


None

SA6. undertake numerical operations, geometry and calculations/ formulae (including addition, subtraction, multiplication, division, fractions and decimals, percentages and

None

47




proportions, simple ratios and averages)

SA7. use appropriate measuring techniques SA8. apply appropriate degree of accuracy to express numbers SA9. calculate tolerance in terms of limits of size SA10. check measurements, angles, orientation and slopes SA11. types of reference lines such as tangent lines, datum lines, centre lines and work points SA12. select and use tools and equipment such as measuring tapes, levels, squares, protractors and dividers SA13. ability to check dimensions of components SA14. calculate the value of angles in a triangle

None

SA15. participate in on-the-job and other learning, training and development interventions and assessments SA16. clarify task related information with appropriate personnel or technical adviser SA17. seek to improve and modify own work practices SA18. maintain current knowledge of application standards, legislation, codes of practice and product/process developments

None

48




SB1. identify problems with work planning, procedures, output and behaviour and their implications SB2. prioritize and plan for problem solving SB3. communicate problems appropriately to others SB4. identify sources of information and support for problem solving SB5. seek assistance and support from other sources to solve problems SB6. seek evidence for problem resolution

None

SB7. plan, prioritize and sequence work operations as per job requirements SB8. organize and analyse information relevant to work SB9. use basic concepts of shop-floor work productivity including waste reduction, efficient material usage and optimization of time for better results

None

SB10. undertake and express new ideas and initiatives to others

None

SB11. modify work plan to overcome unforeseen difficulties or developments that occur as work progresses SB12. participate in improvement procedures including process, quality and internal/external customer/supplier relationships SB13. apply one’s

None

49




competencies in new and different situations and contexts to achieve more SB14. exercise restraint while expressing dissent and during conflict situations

None

SB15. avoid and manage distractions to be disciplined at work

None

SB16. manage own time for achieving better results

None

SB17. work in a team in order to achieve better results

None

SB18. identify and clarify work roles within a team

None

SB19. communicate and cooperate with others in the team for better results

None

SB20. seek assistance from fellow team members

None

50


Section II continued: Compares the competencies in Indian NOS Manually cut metal and metal alloys using oxy-fuel gas (CSC/N 0203) with the UK NOS Cutting materials using hand operated thermal cutting equipment (SEMFWE233).



UK Qualification


Indian NOS Code

CSC/N 0203 UK NOS Code SEMFWE233

Indian NOS Manually cut metal and metal alloys using oxy-fuel gas

UK NOS Cutting materials using hand operated thermal cutting equipment

Scope


2.Prepare for cutting operations

3.Carry out cutting operations

4.Test for accuracy

5. Dealing with contingencies

Overview

This standard identifies the competencies you need for cutting and shaping plate (3mm thickness and above), rolled sections, pipe and tube for fabrications, using portable thermal cutting equipment, in accordance with approved procedures. The equipment to be used will include hand held oxy/fuel gas cutting equipment, plasma cutting equipment and simple portable machines running on tracks.

You will be required to assist in assembling and setting up the appropriate equipment

51


Scope

Overview

to be used, for the material and thickness to be cut, the type of operation to be carried out and the accuracy to be achieved. Materials to be cut and shaped may include mild steel, stainless steel, special steels and other appropriate materials, and will include guided cuts, external curved contours, round and square holes and demolition work, as appropriate. This will call for care in the use of the equipment and tools, so as to avoid damage to the material and tools, and danger to oneself.

Your responsibilities will require you to comply with organisational policy and procedures for the cutting operations undertaken, and to report any problems with the equipment, materials, consumables or cutting activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with a

52


Scope

Overview

minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will provide an informed approach to applying thermal cutting procedures. You will have an understanding of the processes, and will know about the equipment and its application, the materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with the thermal cutting equipment, especially those with regard to fire and potential explosion, and the safeguards necessary for

53


Scope

Overview undertaking the activities safely and correctly. You will be expected to demonstrate safe working practices throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

Competency Mapping



PC1. work safely at all times, complying with health and safety legislation, regulations and other relevant guidelines Safety precautions: general workshop safety, fire prevention, general hazards, manual lifting, overhead lifting, surface conditions, stability of surrounding structures, furniture, etc.


None

PC2. take necessary safety precautions for gas cutting operations including equipment, processes and checks

None

PC3. interpret cutting procedure data sheets specifications PC4. check regulators, hoses and check that valves are

1. confirm that the equipment is safe and fit for purpose by carrying out all of the following checks: 1.1 regulators, hoses and valves

None

54




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

are securely connected and free from leaks and damage 1.2 the correct gas nozzle is fitted to the cutting torch 1.3 that a flashback arrestor is fitted to gas equipment 1.4 gas pressures are set and maintained as instructed 1.5 the correct procedure is used for lighting, adjusting and extinguishing the cutting flame 1.6 hoses are safely routed and protected at all times 1.7 gas cylinders are handled and stored safely and correctly

PC11. adjust torch valve for type of flame such as neutral, carburizing and oxidizing

None

PC12. follow sequence of operations such as pre-heating material and initiating cut

None

PC13. mark out the locations for cutting accurately and as per requirement

None

PC14. use appropriate and safe procedures for handling and storing of gas cylinders

None

55




PC15. prepare the work area for the cutting activities

None

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

2. use one of the following thermal cutting methods: 2.1 hand held oxy/fuel gas cutting equipment 2.2 hand held plasma gas cutting equipment 2.3 simple portable track driven cutting equipment (electrical or mechanical)

Range Statement 2. use one of the following thermal cutting methods: 2.1 hand held oxy/fuel gas cutting equipment 2.2 hand held plasma gas cutting equipment 2.3 simple portable track driven cutting equipment (electrical or mechanical)

PC17. check that the oxy-fuel gas cutting equipment is set up for the operations to be performed

P2 confirm that the machine is set up and ready for the machining activities to be carried out

None

PC18. adjust cylinder valves and adjust regulator for operating pressure to achieve specifications for required operations

None

PC19. where appropriate, mark out the components for the required operations, using appropriate tools and techniques

None

PC20. perform trial cut to check for cut defects

None

PC21. operate the oxy-fuel gas cutting equipment to produce items/cut shapes to the dimensions and profiles specified

P3 manipulate the machine tool controls safely and correctly in line with operational procedures

None

PC22. use various types of oxy-fuel gas cutting methods

None

56




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, bevelled edge – weld preparations, cutting out holes

3. perform thermal cutting operations to produce four of the following features: 3.1 down-hand straight cuts (freehand) 3.2 irregular shapes 3.3 square holes 3.4 down-hand straight cuts (track guided) 3.5 angled cuts 3.6 rough cutting (demolition) 3.7 external curved contours 3.8 weld preparations 3.9 vertical cuts 3.10 round holes 3.11 square/rectangular shapes

Range Statement 3. perform thermal cutting operations to produce four of the following features: 3.1 down-hand straight cuts (freehand) 3.2 irregular shapes 3.3 square holes 3.4 down-hand straight cuts (track guided) 3.5 angled cuts 3.6 rough cutting (demolition) 3.7 external curved contours 3.8 weld preparations 3.9 vertical cuts 3.10 round holes 3.11 square/rectangular shapes

PC24. produce thermal cuts in various forms of material (metal of 3mm and above)

4. produce thermal cuts in two of the following forms of material (metal of 3mm and above, and two different thickness): 4.1 plate 4.2 rolled sections 4.3 structures 4.4 bar 4.5 pipe/tube

Range Statement 4. produce thermal cuts in two of the following forms of material (metal of 3mm and above, and two different thickness): 4.1 plate 4.2 rolled sections 4.3 structures 4.4 bar 4.5 pipe/tube

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

5. produce cut profiles for one type of material from the following: 5.1 mild steel 5.2 special steels 5.3 stainless steel 5.4 other appropriate metal

Range Statement 5. produce cut profiles for one type of material from the following: 5.1 mild steel 5.2 special steels 5.3 stainless steel 5.4 other appropriate metal

PC26. produce thermally-cut components which meet specified quality criteria Quality criteria: dimensional

P4 produce components to the required quality and within the specified dimensional accuracy 6. produce thermally cut

None

57




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

components which meet all of the following quality and accuracy standards: 6.1 dimensional accuracy is within the tolerances specified on the drawing/specification or within +/- 3 mm 6.2 angled cuts are within specification requirements (perpendicular/angularity) 6.3 cuts are clean and smooth and free from flutes

PC27. recognize and correct burn back and flashback

None

PC28. detect and correct defects in cut

None

PC29. ensure the work area is left in a safe and tidy condition on completion of the cutting activities

None

PC30. check that the finished components meet the standard required

P5 carry out quality sampling checks at suitable intervals

None

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

None

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

None

58




PC33. report any difficulties or problems that may arise with the cutting activities, and carry out any agreed actions


None

PC34. detect equipment malfunctions and deal with them appropriately

None


None

PC36. shut down and make safe the cutting equipment on completion of the cutting activities

P7 shut down the equipment to a safe condition on conclusion of the machining activities

None

PC37. in case of emergencies follow standard emergency procedures 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

None

59




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 KA1. job relevant legislation, standards, policies, and procedures followed in the company

K1 the specific safety precautions to be taken when working with thermal cutting equipment in a fabrication environment (general workshop and site safety, appropriate personal protective equipment (PPE), fire and explosion prevention, protecting other workers, safety in enclosed/confined spaces; fume control; accident procedure; statutory requirements, risk assessment procedures and

Relevant safety regulations as applicable to country of work.

60




relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)


None


K25 reporting lines and procedures, line supervision and technical experts

None


None


None


K24 the extent of your own authority and whom you should report to if you have problems that you cannot Resolve

None

KB1. types of fire extinguishers and their suitable uses in case of gas cutting related fires

None

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

K1 Too None

61




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 colour 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

K2 the personal protective clothing and equipment that needs to be worn when working with fabrications and thermal cutting equipment (such as leather aprons and gloves, eye/ear protection, safety helmets)

None

KB4. hazards associated with carrying out gas cutting activities and how they can be minimized

K3 the correct methods of moving or lifting plate materials and components K4 the hazards associated with

None

62




thermal cutting (naked flames, fumes and gases, explosive gas mixtures, oxygen enrichment, spatter, hot metal, elevated working, enclosed spaces), and how they can be minimised

KB5. safe working practices and procedures for using thermal equipment

K5 safe working practices and procedures for using thermal equipment in line with British Compressed Gas Association (BCGA) codes of practice, to include setting up procedures, permit-to-work procedures and emergency shutdown procedures

None

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 aluminium, 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

K8 the thermal cutting process (basic principles of thermal cutting and related equipment; the various techniques and their limitation; care of the equipment to ensure that it is safe and ready to use)

None

KB7. procedure for obtaining the required drawings, job instructions and other related specifications

K6 how to obtain the necessary drawings and thermal cutting specifications

None

63




KB8. how to use and extract information from engineering drawings and related specifications, workpiece reference points and system of tolerances

K7 how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate British, European or relevant International standards in relation to work undertaken)

None

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

K9 the various types of thermal cutting equipment available, and typical applications of each type

None

KB10. various components of the gas cutting equipment Components: colour coded cylinder oxygen; colour coded cylinder acetylene; cylinder valve; flashback arrestor; set of nozzles; gas lighter nozzle; cutting tips; pressure regulator; pressure gauge; non-return valves; colour coded flexible hose; trolleys; torches (rose-bud heating, cutting, others)

K18 material thermal cutting characteristics and material preparation requirements K19 the terminology used in thermal cutting in relation to the operations being performed

None

KB11. construction of the heating and cutting torch

None

KB12. types of oxy-fuel gases such as acetylene, natural gas and propane

K11 Too None

KB13. accessories that can be used with handheld gas cutting equipment to aid cutting operations (such as cutting guides, trammels,

K10 the accessories that can be used with hand held thermal cutting equipment to aid cutting operations (such as guides, trammels,

None

64




templates) templates); arrangements for attaching cutting aids to the equipment

KB14. importance of correct marking procedure before a cut (e.g.. allowances for post-cut operations, punch marks, etc.)

None

KB15. types of regulators such as low- and high-pressure, and single- and two-stage

None

KB16. how to identify the gases used in the cutting process, and the colour coding of gas cylinders

K11 the gases used in thermal cutting; gas identification and colour codes; their particular characteristics and safety procedures

None

KB17. type and thickness of base metals related to nozzle type

None

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)

K12 how to set up the thermal cutting equipment (connection of hoses, regulators and flashback arrestors, selection of cutting torch and nozzle size in relationship to material thickness and operations performed) K13 preparations prior to cutting (checking connections for leaks, setting gas pressures, setting up the material/workpiece, checking cleanliness of materials used)

None

KB19. holding methods that are used to aid thermal cutting, and the equipment that can be used

K14 the holding methods that are used to aid thermal cutting, and the equipment that can be used

None

KB20. correct procedure for lighting, cutting and extinguishing the flame Lighting and cutting

K17 procedures to be followed for cutting specific materials, and why these procedures must always be

None

65




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

adhered to

KB21. types of flames and their implication for cutting

None

KB22. importance of following the correct procedure for lighting, cutting and extinguishing a flame

K15 setting of operating conditions (flame control and the effects of mixtures and pressures associated with thermal cutting) K16 the correct procedure for lighting and extinguishing the flame, and the importance of following the procedure

None

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)

K20 the problems that can occur with thermal cutting, and how they can be avoided; causes of distortion during thermal cutting and methods of controlling distortion

None

KB24. effects of oil, grease, scale or dirt on the cutting process

K21 the effects of oil, grease, scale or dirt on the cutting process

None

KB25. gas mixture ratio required to get various flames

None

KB26. quality parameters for gas cut materials Quality parameters: shape and length of the draglines; smoothness of the sides; sharpness of the top edges; amount of slag adhering to the metal

K23 quality requirements of the type of work being undertaken

None

66




KB27. special grade materials used in industry and their behaviour with oxy fuel gas

None

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

K22 the causes of cutting defects, how to recognise them, and methods of correction and prevention

None

KB29. importance of leaving the work area in a safe and clean condition on completion of activities

None

KB30. correct handling and storage of gas cylinders

None

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-

None

67




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

None

KB33. purging tools and their function

None


None

68





None


None


None

SA5. liaise with appropriate authorities using correct protocol communicate with people in respectful form and manner in line with organizational protocol

None

SA6. undertake numerical operations, geometry and calculations/ formulae (including addition, subtraction, multiplication, division, fractions and decimals)

None


None


None

SA9. 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 SA10. calculate the value of angles in a triangle Angles in a triangle: right-

None

69




angled, isosceles, equilateral

SA11. participate in on-the-job and other learning, training and development interventions and assessments

None


None


None

SA14. maintain current knowledge of application standards, legislation, codes of practice and product/process developments

None

SB1. identify problems with work planning, procedures, output and behaviour and their implications

None

SB2. prioritize and plan for problem solving

None

SB3. communicate problems appropriately to others

None

SB4. identify sources of information and support for problem solving

None

SB5. seek assistance and support from other sources to solve problems

None

SB6. identify effective resolution techniques

None

SB7. select and apply resolution techniques

None

70




SB8. seek evidence for problem resolution

None

SB9. plan, prioritize and sequence work operations as per job requirements

None

SB10. organize and analyse information relevant to work

None

SB11. basic concepts of shop-floor work productivity including waste reduction, efficient material usage and optimization of time

None


None

SB13. modify work plan to overcome unforeseen difficulties or developments that occur as work progresses

None

SB14. participate in improvement procedures including process, quality and internal/external customer/supplier relationships

None

SB15. apply one’s competencies in new and different situations and contexts to achieve more

None

SB16. exercise restraint while expressing dissent and during conflict situations

None


None

SB18. importance of time management for achieving better results

None

71





None


None

SB21. communicate and cooperate with others in the team for better results

None


None

72


Section II continued: Compares the competencies in Indian NOS Manually cut metal and metal alloys using plasma arc (CSC/N 0207) with the UK NOS Cutting materials using hand operated thermal cutting equipment (SEMFWE233).



UK Qualification


Indian NOS Code

CSC/N 0207 UK NOS Code SEMFWE233

Indian NOS Manually cut metal materials using plasma arc

UK NOS Cutting materials using hand operated thermal cutting equipment

Scope


2.Prepare for cutting operations

3.Carry out cutting operations

4.Test for quality

5. Dealing with contingencies

Overview

This standard identifies the competencies you need for cutting and shaping plate (3mm thickness and above), rolled sections, pipe and tube for fabrications, using portable thermal cutting equipment, in accordance with approved procedures. The equipment to be used will include hand held oxy/fuel gas cutting equipment, plasma cutting equipment and simple portable machines running on tracks.

You will be required to assist in assembling and setting up the

73


Scope

Overview

appropriate equipment to be used, for the material and thickness to be cut, the type of operation to be carried out and the accuracy to be achieved. Materials to be cut and shaped may include mild steel, stainless steel, special steels and other appropriate materials, and will include guided cuts, external curved contours, round and square holes and demolition work, as appropriate. This will call for care in the use of the equipment and tools, so as to avoid damage to the material and tools, and danger to oneself.

Your responsibilities will require you to comply with organisational policy and procedures for the cutting operations undertaken, and to report any problems with the equipment, materials, consumables or cutting activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will

74


Scope

Overview

be expected to work to instructions, with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will provide an informed approach to applying thermal cutting procedures. You will have an understanding of the processes, and will know about the equipment and its application, the materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with the thermal cutting equipment, especially those with regard to fire and potential explosion,

75


Scope

Overview

and the safeguards necessary for undertaking the activities safely and correctly. You will be expected to demonstrate safe working practices throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

Competency Mapping



PC1. work safely at all times, complying with health and safety legislation, regulations and other relevant guidelines Safety precautions: general workshop safety, fire prevention, general hazards, manual lifting, overhead lifting, surface conditions, stability of surrounding structures, furniture, etc.


None

PC2. take necessary safety precautions for plasma cutting operations including equipment, processes and checks

P1 Too None

PC3. interpret cutting procedure data sheets specifications

1. confirm that the equipment is safe and fit for purpose by carrying out all of the following

76




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 to protect the cut metals from oxidation (CO2, Compressed Air)

checks: 1.1 regulators, hoses and valves are securely connected and free from leaks and damage 1.2 the correct gas nozzle is fitted to the cutting torch 1.3 that a flashback arrestor is fitted to gas equipment 1.4 gas pressures are set and maintained as instructed 1.5 the correct procedure is used for lighting, adjusting and extinguishing the cutting flame 1.6 hoses are safely routed and protected at all times 1.7 gas cylinders are handled and stored safely and correctly

PC9. use the correct procedure for lighting, adjusting and extinguishing the arc

None

PC10. use appropriate and safe procedures for handling and storing of gas cylinders

None

PC11. prepare the work area for the cutting activities

None

77




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

2. use one of the following thermal cutting methods: 2.1 hand held oxy/fuel gas cutting equipment 2.2 hand held plasma gas cutting equipment 2.3 simple portable track driven cutting equipment (electrical or mechanical)

Range Statement 2. use one of the following thermal cutting methods: 2.1 hand held oxy/fuel gas cutting equipment 2.2 hand held plasma gas cutting equipment 2.3 simple portable track driven cutting equipment (electrical or mechanical)

PC13. check that the plasma arc cutting equipment is correctly set up for the operations to be performed

P2 confirm that the machine is set up and ready for the machining activities to be carried out

None

PC14. carry out correct measurements required using appropriate equipment and methods for planning the cut

None

PC15. where appropriate, mark out the components for the required operations, using appropriate tools and techniques

None

PC16. perform trial cut to check for cut defect

None

PC17. operate the plasma cutting equipment to produce items/cut shapes to the dimensions and profiles as specified

P3 manipulate the machine tool controls safely and correctly in line with operational procedures

None

78




PC18. use the correct angles to cut and the right speed

None

PC19. use various types of plasma arc cutting methods/techniques Cutting techniques: stand-off, circle cutting, profile cutting, edge, stenting hole, piercing technique

None

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

P3 Too 3. perform thermal cutting operations to produce four of the following features: 3.1 down-hand straight cuts (freehand) 3.2 irregular shapes 3.3 square holes 3.4 down-hand straight cuts (track guided) 3.5 angled cuts 3.6 rough cutting (demolition) 3.7 external curved contours 3.8 weld preparations 3.9 vertical cuts 3.10 round holes 3.11 square/rectangular shapes

Range Statement 3. perform thermal cutting operations to produce four of the following features: 3.1 down-hand straight cuts (freehand) 3.2 irregular shapes 3.3 square holes 3.4 down-hand straight cuts (track guided) 3.5 angled cuts 3.6 rough cutting (demolition) 3.7 external curved contours 3.8 weld preparations 3.9 vertical cuts 3.10 round holes 3.11 square/rectangular shapes

PC21. produce thermal cuts in various forms of material Forms: plate, rolled section, pipe/tube, solid bars

4. produce thermal cuts in two of the following forms of material (metal of 3mm and above, and two different thickness): 4.1 plate 4.2 rolled sections 4.3 structures 4.4 bar 4.5 pipe/tube

Range Statement 4. produce thermal cuts in two of the following forms of material (metal of 3mm and above, and two different thickness): 4.1 plate 4.2 rolled sections 4.3 structures 4.4 bar 4.5 pipe/tube

79




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

5. produce cut profiles for onetype of material from thefollowing:5.1 mild steel5.2 special steels5.3 stainless steel5.4 other appropriate metal

Range Statement 5. produce cut profiles forone type of material fromthe following:5.1 mild steel5.2 special steels5.3 stainless steel5.4 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

P4 produce components to the required quality and within the specified dimensional accuracy

None

PC24. detect and correct defects in cut

None

PC25. leave the work area in a safe and tidy condition on completion of the cutting activities

None

PC26. check that the finished components meet the required standard

P5 carry out quality sampling checks at suitable intervals

None

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

6. produce thermally cutcomponents which meet all ofthe following quality andaccuracy standards:6.1 dimensional accuracy iswithin the tolerances specifiedon the drawing/specification orwithin +/- 3 mm6.2 angled cuts are withinspecification requirements(perpendicular/angularity)

None

80




6.3 cuts are clean and smooth and free from flutes

PC28. identify various cutting defects Defects: grooved, fluted or ragged cuts, poor draglines, rounded edges, tightly adhering slag, dross, burr, distortion

None

PC29. report any difficulties or problems that may arise with the cutting activities, and carry out any agreed actions


None

PC30. detect equipment malfunctions and deal with them appropriately

None



None

PC32. shut down and make safe the cutting equipment on completion of the cutting activities or during an emergency

P7 shut down the equipment to a safe condition on conclusion of the machining activities

None

PC33. in case of emergencies follow standard emergency procedures

None

KA1. job relevant legislation, standards, policies, and procedures followed in the company

K1 the specific safety precautions to be taken when working with thermal cutting equipment in a fabrication environment (general workshop and site safety, appropriate personal protective equipment (PPE), fire and explosion prevention, protecting other workers, safety in

Relevant safety regulations as applicable to country of work.

81




enclosed/confined spaces; fume control; accident procedure; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)


None


K25 reporting lines and procedures, line supervision and technical experts

None


None


None


K24 the extent of your own authority and whom you should report to if you have problems that you cannot Resolve

None

KB1. types of fire extinguishers and their suitable uses in case of gas cutting related fires

None

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);

None

82




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 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

K2 the personal protective clothing and equipment that needs to be worn when working with fabrications and thermal cutting equipment (such as leather aprons and gloves, eye/ear protection, safety helmets)

None

KB4. hazards associated with carrying out plasma arc cutting activities and how they can be minimized

K3 the correct methods of moving or lifting plate materials and components K4 the hazards associated with thermal cutting (naked flames, fumes and gases, explosive gas mixtures, oxygen enrichment, spatter, hot metal, elevated working, enclosed spaces), and how they can be minimised

None

KB5. safe working practices and procedures for using plasma equipment

K5 safe working practices and procedures for using thermal equipment in line with British Compressed Gas Association (BCGA) codes of

None

83




practice, to include setting up procedures, permit-to-work procedures and emergency shutdown procedures

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;

K8 the thermal cutting process (basic principles of thermal cutting and related equipment; the various techniques and their limitation; care of the equipment to ensure that it is safe and ready to use)

None

84




provides gouging and piercing capabilities; minimal clean up required, small and more precise kerf (width of the cut); cuts any type of electrically conductive metals including aluminium, copper, brass and stainless steel KB7. common terminology used in plasma cutting

K19 the terminology used in thermal cutting in relation to the operations being performed

None

KB8. procedure for obtaining the required drawings, job instructions and other related specifications

K6 how to obtain the necessary drawings and thermal cutting specifications

None

KB9. how to use and extract information from engineering drawings and related specifications, workpiece reference points and system of tolerances

K7 how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate British, European or relevant International standards in relation to work undertaken)

None

KB10. various types of plasma arc cutting equipment available Types: transferred, non-transferred (welding)

K9 the various types of thermal cutting equipment available, and typical applications of each type

None

KB11. various components of the cutting equipment and types of consumables used Consumables: electrode, gases, tips, cups

None

KB12. construction of the cutting torch

None

KB13. types of plasma arc gases used Types of gases: Primary Plasma Gas – used to create the plasma arc (Nitrogen, Argon, Hydrogen,

K11 the gases used in thermal cutting; gas identification and colour codes; their particular characteristics and safety procedures

None

85




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)

K10 the accessories that can be used with hand held thermal cutting equipment to aid cutting operations (such as guides, trammels, templates); arrangements for attaching cutting aids to the equipment

None

KB15. types of regulators such as low- and high-pressure, and single- and two-stage

None

KB16. nozzle type as per type and thickness of base materials

None

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)

K12 how to set up the thermal cutting equipment (connection of hoses, regulators and flashback arrestors, selection of cutting torch and nozzle size in relationship to material thickness and operations performed) K13 preparations prior to cutting (checking connections for leaks, setting gas pressures, setting up the material/workpiece, checking cleanliness of materials used) K18 material thermal cutting characteristics and material preparation requirements

None

KB18. holding methods that are used to aid plasma cutting, and the equipment that can be used

K14 the holding methods that are used to aid thermal cutting, and the equipment that can be used

None

86




KB19. correct procedure for lighting, cutting and extinguishing the arc

K15 setting of operating conditions (flame control and the effects of mixtures and pressures associated with thermal cutting)

None

KB20. importance of following the correct procedure for lighting, cutting and extinguishing an arc

K16 the correct procedure for lighting and extinguishing the flame, and the importance of following the procedure K17 procedures to be followed for cutting specific materials, and why these procedures must always be adhered to

None

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

None

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)

K20 the problems that can occur with thermal cutting, and how they can be avoided; causes of distortion during thermal cutting and methods of controlling distortion

None

KB25. effects of oil, grease, scale or dirt on the cutting process

K21 the effects of oil, grease, scale or dirt on the cutting process

None

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

K23 quality requirements of the type of work being undertaken

None

87




edges; amount of slag adhering to the metal

KB27. causes of cutting defects, how to recognize them, and methods of correction and prevention

K22 the causes of cutting defects, how to recognise them, and methods of correction and prevention

None

KB28. gouging and back gouging principles, methods and procedures

None

KB29. importance of leaving the work area in a safe and clean condition on completion of activities

None

KB30. emergency procedures for electrical and other fires

None

KB31. how to close down the cutting equipment safely and correctly

None

KB32. purging tools and their function

None


None


None


None


None

88





None


None

SA7. undertake numerical operations, geometry and calculations/ formulae (including addition, subtraction, multiplication, division, fractions and decimals, percentages and proportions, simple ratios and averages)

None


None


None

SA10. 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

None

SA12. select and use tools and equipment such as measuring tapes, levels, squares, protractors and dividers

None

SA13. calculate the value of angles in a triangle Angles in a triangle: right-angled, isosceles, equilateral

None

SA14. participate in on-the-job and other learning, training and development interventions and

None

89




assessments


None


None

SA17. maintain current knowledge of application standards, legislation, codes of practice and product/process developments

None

SB1. identify problems with work planning, procedures, output and behaviour and their implications

None

SB2. prioritize and plan for problem solving

None

SB3. communicate problems appropriately to others

None

SB4. identify sources of information and support for problem solving

None

SB5. seek assistance and support from other sources to solve problems

None

SB6. identify effective resolution techniques

None

SB7. select and apply resolution techniques

None

SB8. seek evidence for problem resolution

None

SB9. plan, prioritize and sequence work operations as per job requirements

None

90




SB10. organize and analyse information relevant t

None

SB11. basic concepts of shop-floor work productivity including waste reduction, efficient material usage and optimization of time

None


None

SB13. modify work plan to overcome unforeseen difficulties or developments that occur as work progresses

None

SB14. participate in improvement procedures including process, quality and internal/external customer/supplier relationships

None

SB15. apply one’s competencies in new and different situations and contexts to achieve more

None

SB16. exercise restraint while expressing dissent and during conflict situations

None


None

SB18. Manage own time for achieving better results

None


None


None

SB21. communicate and cooperate with others in the

None

91




team for better results


None

*General Note: In the CGSC NOS, Range statement is not separated out. It is integrated holistically into the PCs and Technical knowledge within the QPs.

92


Section II continued: Compares the competencies in Indian NOS Use basic health and safety practices at the workplace CSC /N1335 with the UK NOS Complying with statutory regulations and organisational safety requirements SEMMAN123-01.



UK Qualification


Indian NOS Use basic health and safety practices at the workplace

UK Unit Title Complying with statutory regulations and organisational safety requirements

Indian NOS Code

CSC /N1335 UK NOS Code SEMMAN123-01

Scope

1.Health and safety

2.Fire safety

3.Emergencies, rescue and first-aid procedures

Overview

This standard identifies the competencies you need to deal with statutory regulations and organisational safety requirements, in accordance with approved procedures. You will be required to comply with all relevant regulations that apply to your area of work as well as your general responsibilities as defined in the Health and Safety at Work Act. You will also need to be able to identify the relevant qualified first aiders or appointed person, and must know the location of the first aid facilities. You will

93


Scope Overview have an understanding of the procedures to be adopted in the case of accidents involving injury, and in situations where there are dangerous occurrences or hazardous malfunctions of equipment, processes or machinery. You will also need to be fully conversant with the organisation's procedures for fire alerts and the evacuation of premises.

You will be required to identify the hazards and risks that are associated with your job. Typically these will focus on your working environment, the tools and equipment that you use, materials and substances that you use, working practices that do not follow laid-down procedures, and manual lifting and carrying techniques.

Your responsibilities will require you to comply with organisational policy and procedures for the statutory regulations and

94


Scope

Overview

organisational safety activities undertaken, and to report any problems with the safety activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the way in which you carry out the required engineering activities.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying statutory regulations and organisational safety requirements and procedures. You will understand the safety requirements and their application, in adequate depth to provide a sound basis for carrying out the activities safely and correctly.

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Competency Mapping:



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; oxyfuel 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

P1 comply with your duties and obligations as defined in the Health and Safety at Work Act P2 present yourself in the workplace suitably prepared for the activities to be undertaken P3 follow organisational accident and emergency procedures P4 recognise and control hazards in the workplace P5 use correct manual lifting and carrying techniques P6 apply safe working practices and procedures

1. demonstrate yourunderstanding of your duties andobligations to health and safetyby carrying out all of thefollowing:1.1 applying, in principle, yourduties and responsibilities as anindividual under the Health andSafety at Work Act and otherrelevant current legislation1.2 identifying, within yourworking environment,appropriate sources ofinformation and guidance onhealth and safety issues, toinclude eye protection andpersonal protective equipment(PPE), COSHH regulations and riskassessments1.3 identifying the warning signsand labels of the main groups ofhazardous or dangeroussubstances1.4 complying with theappropriate statutory regulations

None

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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 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

at all times and specified regulations to your work 2. comply with all emergency requirements, to include: 2.1 identifying the appropriate qualified first aiders or appointed person and the location of first aid facilities 2.2 identifying the procedures to be followed in the event of injury to yourself or others 2.3 following organisational procedures in the event of fire/fire drills and the evacuation of premises/work area 2.4 identifying the procedures to be followed in the event of dangerous occurrences or hazardous malfunctions of equipment, processes or machinery 3. identify the hazards and risks that are associated with all of the following: 3.1 your working environment (such as working at heights, confined spaces, environmental conditions) 3.2 the tools and equipment that you use (such as machine tools, power tools, cutting tools) 3.3 the materials and substances that you use (such as fluids, oils, fluxes) 3.4 using working practices that do not follow laid-down procedures

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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(e.g. 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:

4. demonstrate the following method of manual lifting and carrying techniques: 4.1 lifting alone Plus one from: 4.2 with assistance of others 4.3 with mechanical assistance 5. apply safe working practices in an industrial environment, to include all of the following: 5.1 maintaining a tidy workplace with exits and gangways free from obstructions 5.2 using tools and equipment safely and only for the purpose intended 5.3 observing organisational safety rules, signs and hazard warnings 5.4 taking measures to protect others from harm resulting from any work you are carrying out 5.5 observe personal protection and hygiene procedures at all times

None

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clean/tidy work areas, removal/disposal of waste products, protect surfaces PC12. identify common hazard signs displayed in various areas 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 (e.g. government notices) PC14. use the various appropriate fire extinguishers on different types of fires correctly Types of fires: Class A: e.g.. 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: e.g.. 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

None

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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 PC18. demonstrate how to free a person from electrocution PC19. administer appropriate first aid to victims where required e.g.. 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

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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 KA1. names (and job titles if applicable), and where to find, all the people responsible for health and safety in a workplace. KA2. names and location of documents that refer to health and safety in the workplace.

None

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

K1 the roles and responsibilities of yourself and others under the Health and Safety at Work Act 1974 and other current legislation (e.g., The Management of Health and Safety at Work Regulations; Workplace Health and Safety and Welfare Regulations; Personal Protection at Work Regulations; Manual Handling Operations Regulations; Provision and Use of Work Equipment Regulations; Display Screen at Work Regulations) K2 the specific regulations and safe working practices and procedures that apply to your

None

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(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, leadKB11. 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;

work activities K3 the warning signs for the main groups of hazardous substances defined by Classification, Labelling and packaging of Dangerous Substances and mixtures Regulations K4 how to locate relevant health and safety information for your tasks, and the sources of expert assistance when help is needed K5 what constitutes a hazard in the workplace (such as moving parts of machinery, electricity, slippery and uneven surfaces, dust and fumes, handling and transporting, contaminants and irritants, material ejection, fire, working at height, environment, pressure/stored energy systems, volatile or toxic materials, unshielded processes) K6 your responsibilities for dealing with hazards and reducing risks in the workplace (such as hazard spotting and safety inspections; the use of hazard check lists, carrying out risk assessments, COSHH assessments and safe systems of working) K7 the risks associated with your working environment (the tools, materials and equipment that you use, spillages of oil and chemicals, not reporting accidental breakages of tools or equipment and not following laid-down working practices and procedures) K8 the processes and procedures that are used to identify and rate

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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 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

the level of risk (such as safety inspections, the use of hazard check lists, carrying out risk and COSHH assessments) K9 control measures that can be used to eliminate/reduce the hazard (such as lock-off and permit top work procedures, provision of safe access and egress, use of guards and fume extraction equipment, use of personal protective equipment) K10 the first aid facilities that exist within your work area and within the organisation in general, and the procedures to be followed in the case of accidents involving injury K11 what constitutes dangerous occurrences and hazardous malfunctions, and why these must be reported even when no one was injured K12 the procedures for sounding the emergency alarms, evacuation procedures and escape routes to be used, and the need to report your presence at the appropriate assembly point K13 the organisational policy with regard to fire fighting procedures; the common causes of fire and what you can do to help prevent them

KB19. appropriate basic first aid treatment relevant to the condition e.g.. shock, electrical shock, bleeding, breaks to bones, minor burns, resuscitation, poisoning, eye injuries KB20. content of written accident report

K14 the protective clothing and equipment that is available for your areas of activity K15 the need to observe personal protection and hygiene procedures at all times (such as skin care (barrier creams, gloves), eye protection (safety glasses,

None

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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

goggles, full face helmets), hearing protection (ear plugs, ear defenders), respiratory protection (fume extraction, face masks, breathing apparatus), head protection (caps with hair restraints, protective helmets), foot protection (safety footwear), dangers of ingestion and the importance of washing hands) K16 how to act responsibly within the working environment (such as observing restricted area notices, complying with warning signs, walking not running, using equipment only for its intended purpose, not interfering with equipment or processes that are not within your job role, following approved safety procedures at all times) K17 how to lift and carry loads safely, and the manual and mechanical aids available K18 how to prepare and maintain safe working areas; standards and procedures to ensure good housekeeping K19 the importance of safe storage of tools, equipment, materials and products K20 the extent of your own authority and whom you should report to in the event of problems that you cannot resolve

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SA1. read and comprehend basic content to read labels, charts, signages SA2. read and comprehend basic English to read manuals of operations SA3. read and write an accident/incident report in local language or English

None

SA4. question co-workers appropriately in order to clarify instructions andother issues SA5. give clear instructions to co-workers, subordinates others

None

SA6. make appropriate decisions pertaining to the concerned area of workwith respect to intended work objective, span of authority, responsibility, laid down procedure and guidelines

None

SB1. plan and organize their own work schedule, work area, tools, equipment and materials to maintain decorum and for improved productivity

None

SB2. remain congenial while discussing and debating issues with co-workers SB3. follow appropriate protocols for communication based on situation, hierarchy, organizational culture and practice SB4. ask for, provide and receive required assistance where possible to ensure achievement of work related objectives SB5. thank co-workers for any assistance received SB6. offer appropriate respect based on mutuality and respect for fellow workmanship and

P35. ensure the client's records are completed and signed by you and the client

None

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authority

SB7. think through the problem, evaluate the possible solution(s) and suggest an optimum /best possible solution(s) SB8. identify immediate or temporary solutions to resolve delays SB9. identify sources of support that can be availed of for problem solving for various kind of problems SB10. seek appropriate assistance from other sources to resolve problems SB11. report problems that you cannot resolve to appropriate authority SB12. identify cause and effect relations in their area of work SB13. use cause and effect relations to anticipate potential problems and their solution

None

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Section II continued: Compares the competencies in Indian NOS Working effectively with others CSC /N1336 with the UK NOS Working efficiently and effectively in engineering SEMMAN3-03



UK Qualification


Indian NOS Working effectively with others

UK Unit Title Working efficiently and effectively in engineering

Indian NOS Code

CSC /N1336 UK NOS Code SEMMAN3-03

Scope

This unit/task covers the following:

Working with others

Overview

This standard identifies the competencies you need to work efficiently and effectively in the work place, in accordance with approved procedures and practices. Prior to undertaking the engineering activity, you will be required to carry out all necessary preparations within the scope of your responsibility. This may include preparing the work area and ensuring that it is in a safe condition to carry out the intended activities, ensuring you have the appropriate job specifications and instructions, and

107


Scope

Overview

ensuring that any tools, equipment, materials and other resources required are available and in a safe and usable condition.

On completion of the engineering activity, you will be required to return your immediate work area to an acceptable condition before recommencing further work requirements. This may involve placing completed work in the correct location, returning and/or storing any tools and equipment in the correct area, identifying any waste and/or scrapped materials and arranging for their disposal, and reporting any defects or damage to tools and equipment used.

In order to be efficient and effective in the workplace, you will also be required to demonstrate that you can create and maintain effective working relationships with colleagues and line management. You will be expected to review objectives and targets

108


Scope

Overview

for your personal development and make recommendations and communicate any opportunities for improvements that could be made to working practises and procedures.

Your responsibilities will require you to comply with health and safety requirements, organisational policy and procedures for the engineering activities undertaken, and to report any problems with the activities, tools or equipment that you cannot personally resolve, or are outside your permitted, authority to the relevant people. Working with minimal supervision you will be expected to take personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to working efficiently and effectively in an

109


Scope

Overview

engineering environment. You will understand the need to work efficiently and effectively, and will know about the areas you need to consider when preparing and tidying up the work place, how to recommend improvements, deal with problems, maintain effective working relationships and agree your development objectives and targets, in adequate depth to provide a sound basis for carrying out the activities safely and correctly.

Competency Mapping



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


P2 prepare the work area to carry out the engineering activity

P3 check there are sufficient supplies of materials and/or consumables and that they meet work requirements



P3 check there are sufficient supplies of materials and/or consumables and that they meet work requirements

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manner that helps them to understand

PC4. display helpful behaviour 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 behaviours at the workplace

Disciplined behaviours: e.g. punctuality; completing tasks as per given time and standards; not gossiping and idling time; eliminating waste, honesty, etc.

P4 ensure completed products or resources are stored in the appropriate location on completion of the activities

P5 tidy up the work area on completion of the engineering activity

P6 deal promptly and effectively with problems within your control and report those that cannot be resolved

P7 contribute to and communicate opportunities for improvements to working practises and procedures

P8 maintain effective working relationships with colleagues

P9 review personal training and development as appropriate to the job role

1. prepare to carry out theengineering activity, ensuring allof the following, as applicableto the work to be undertaken:

1.1 the work area is free from hazards and suitably prepared for the activities to be undertaken

1.2 any required safety procedures are implemented

1.3 any necessary personal protection equipment (PPE) is

P4 ensure completed products or resources are stored in the appropriate location on completion of the activities

P5 tidy up the work area on completion of the engineering activity

1. prepare to carry out theengineering activity,ensuring all of thefollowing, as applicable tothe work to be undertaken:

1.1 the work area is free from hazards and suitably prepared for the activities to be undertaken

1.2 any required safety procedures are implemented

1.3 any necessary personal protection equipment (PPE) is obtained and is in a usable condition

1.4 tools and equipment required are obtained and checked that they are in a safe and useable condition

1.5 all necessary drawings, specifications and associated documentation is obtained

1.6 job instructions are obtained and understood

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PC10. escalate grievances and problems to appropriate authority as per procedure to resolve them and avoid conflict

obtained and is in a usable condition

1.4 tools and equipment required are obtained and checked that they are in a safe and useable condition

1.5 all necessary drawings, specifications and associated documentation is obtained

1.6 job instructions are obtained and understood

1.7 the correct materials, components or resources are obtained

1.8 storage arrangements for work are appropriate

1.9 appropriate authorisation to carry out the work is obtained

2. complete work activities, to include all of the following as applicable to the work undertaken:

2.1 returning tools and equipment

2.2 returning drawings and work instructions

2.3 arranging for the safe disposal of waste materials

2.4 completing all necessary documentation accurately and

1.7 the correct materials, components or resources are obtained

1.8 storage arrangements for work are appropriate

1.9 appropriate authorisation to carry out the work is obtained

2. complete work activities, to include all of the following as applicable to the work undertaken:

2.1 returning tools and equipment

2.2 returning drawings and work instructions

2.3 arranging for the safe disposal of waste materials

2.4 completing all necessary documentation accurately and legibly

2.5 identifying, where appropriate, any unusable tools, equipment, components or other resources

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legibly

2.5 identifying, where appropriate, any unusable tools, equipment, components or other resources

3. make recommendations forimproving two of the following:

3.1 working practises

3.2 working methods

3.3 quality

3.4 safety

3.5 tools and equipment

3.6 supplier relationships

3.7 internal communication

3.8 customer service

3.9 training and development

3.10 teamwork

3.11 other specific opportunity

4. deal with problems affectingthe engineering process, toinclude two of the following:

4.1 materials

4.2 job specification

4.3 timescales

4.4 tools and equipment

4.5 quality

3. make recommendationsfor improving two of thefollowing:3.1 working practises3.2 working methods3.3 quality3.4 safety3.5 tools and equipment3.6 supplier relationships3.7 internal communication3.8 customer service3.9 training anddevelopment3.10 teamwork3.11 other specificopportunity4. deal with problemsaffecting the engineeringprocess, to include two ofthe following:4.1 materials4.2 job specification4.3 timescales4.4 tools and equipment4.5 quality4.6 safety4.7 drawings4.8 people4.9 activities or procedures5. maintain effectiveworking relationships, toinclude two of thefollowing:5.1 colleagues within own

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4.6 safety

4.7 drawings

4.8 people

4.9 activities or procedures

5. maintain effective working relationships, to include two of the following:

5.1 colleagues within own working group

5.2 line management

5.3 people outside your normal working group

5.4 external contacts

6. review personal development objectives and targets, to include one of the following:

6.1 dual or multi-skilling

6.2 understanding of company working practices, procedures, plans and policies

6.3 training on new equipment/technology

6.4 increased responsibility

6.5 other specific requirements

working group 5.2 line management 5.3 people outside your normal working group 5.4 external contacts 6. review personal development objectives and targets, to include one of the following: 6.1 dual or multi-skilling 6.2 understanding of company working practices, procedures, plans and policies 6.3 training on new equipment/technology 6.4 increased responsibility 6.5 other specific requirements

KA1. legislation, standards, policies, and procedures followed in the company relevant to own employment and performance conditions

KA2. reporting structure, inter-

K1 the safe working practices and procedures to be followed whilst preparing and tidying up your work environment

K2 the correct use of any equipment to protect the health

None

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dependent functions, lines and procedures in the work area

KA3. relevant people and their responsibilities within the work area

KA4. escalation matrix and procedures for reporting work and employment related issues

and safety of you and your colleagues

K3 the procedure for ensuring that all documentation relating to the work being carried out is available and current, prior to starting the activity

K4 the action that should be taken if documentation received is incomplete and/or incorrect

K5 the procedure for ensuring all tools and equipment are available prior to undertaking the activity

K6 the checks to be carried out to ensure tools and equipment are in full working order, prior to undertaking the activity

K7 the action that should be taken if tools and equipment are not in full working order

K8 the checks to be carried out to ensure all materials and resources required are correct and complete, prior to undertaking the activity

K9 the action that should be taken if materials/resources do not meet the requirements of the activity

K10 whom to inform when the work activity has been completed

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K11 the information and/or documentation require to confirm with others that the activity has been completed

K12 what materials, resources, equipment and tools can be re-used

K13 how any waste materials and/or products are transferred, stored and disposed of

K14 where tools and equipment should be stored and located

K15 the importance of making recommendations to improving working practises

K16 the procedures and format for making suggestions for improvements

K17 what the benefits are to you and the organisation if improvements can be identified and implemented

K18 the importance of maintaining effective working relationships within the workplace

K19 the procedures to deal with and reporting any problems that can affect working relationships

K20 the difficulties that can occur in working relationships

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and how to resolve them

K21 the regulations that affect how you should be treated at work (such as Equal Opportunities Act, Race, Disability and Sex Discrimination, Working Time Directive)

K22 the benefits of continuous personal development

K23 the training opportunities that are available in the workplace

K24 the importance of reviewing your training and development

K25 with whom to discuss training and development issues

K26 the extent of your own responsibility and whom you should report to if you have any problems that you cannot resolve

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