Smaw L3

Copyright DSD 2012
Department of Skills Development (DSD)

Federal Government Administrative Centre
62530 PUTRAJAYA, MALAYSIA
STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN

(NATIONAL OCCUPATIONAL SKILL STANDARD)
STANDARD PRACTICE, STANDARD CONTENT
&
CURICULUM of COMPETENCY UNIT
FOR
SHIELDED METAL ARC WELDING (SMAW) PROCESS
(PROSES KIMPALAN ARKA KEPINGAN LOGAM)
LEVEL 3
(TAHAP 3)
First Publish 2012
All rights reserved

No part of this publication may be produced, stored in data base, retrieval system, or in any form by any
means, electronic, mechanical, photocopying, recording or otherwise without prior written permission from
Department of Skills Development (DSD)
STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN

(NATIONAL OCCUPATIONAL SKILL STANDARD)
STANDARD PRACTICE, STANDARD CONTENT
&
CURICULUM of COMPETENCY UNIT
FOR
LEVEL 3
(TAHAP 3)
Jabatan Pembangunan Kemahiran

Kementerian Sumber Manusia, Malaysia
Contents
STANDARD PRACTICE ............................................................................................................................................................ 3

1.
INTRODUCTION ......................................................................................................................................................... 3
Pre-requisite ......................................................................................................................................................................... 4
2.
OCCUPATIONAL STRUCTURE ................................................................................................................................. 5
Fig. 1.0 Occupational Profile Chart for Shielded Metal Arc Welding (SMAW) Process (Level 3) personnel ........................ 5
Fig. 1.1 Occupational Area Analysis for Shielded Metal Arc Welding (SMAW) Process (Level 3) personnel ...................... 5
3.
DEFINITION OF COMPETENCY LEVEL.................................................................................................................... 6
4.
MALAYSIAN SKILL CERTIFICATION......................................................................................................................... 7
Training delivery ................................................................................................................................................................... 7

5.
JOB COMPETENCIES ................................................................................................................................................ 7
6.
WORKING CONDITIONS ........................................................................................................................................... 7
7.
EMPLOYMENT PROSPECTS .................................................................................................................................... 7
Malaysian Market ................................................................................................................................................................. 7

International Market .............................................................................................................................................................. 8
8.
TRAINING, INDUSTRIAL/PROFESSIONAL RECOGNITION, OTHER QUALIFICATIONS AND ADVANCEMENT .. 8
9.
SOURCES OF ADDITIONAL INFORMATION ............................................................................................................ 9
Local ..................................................................................................................................................................................... 9
International .......................................................................................................................................................................... 9
10.
VALIDATION ........................................................................................................................................................ 11
11.
ENDORSEMENT .................................................................................................................................................. 11
12.
ACKNOWLEDGEMENT ....................................................................................................................................... 11
13.
COMMITTEE MEMBERS FOR DEVELOPMENT OF STANDARD PRACTICE (SP), JOB PROFILE CHART
(JPC), COMPETENCY PROFILE (CP) AND CURRICULUM OF COMPETENCY UNIT (CoCu) ...................................... 12
STANDARD CONTENT...........................................................................................................................................................13
COMPETENCY PROFILE CHART (CPC)...............................................................................................................................14
COMPETENCY PROFILE (CP)...............................................................................................................................................15
CURRICULUM of COMPETENCY UNIT (CoCU)....................................................................................................................32
SHIELDED METAL ARC WELDING (SMAW) FOR FILLET WELD 1F, 2F, 3F, 4F, BUTT WELD 1G AND 2G......................33
SHIELDED METAL ARC WELDING (SMAW) FOR 3G AND 4G.............................................................................................57
SHIELDED METAL ARC WELDING (SMAW) FOR 5G AND 6G (UP-HILL AND DOWN-HILL).............................................79
SHIELDED METAL ARC WELDING (SMAW) 6GR ..............................................................................................................100
SUBMERGED ARC WELDING (SAW) 1G ...........................................................................................................................120
TRAINING HOUR SUMMARY ..............................................................................................................................................141
STANDARD PRACTICE
NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR;
LEVEL 3
1. INTRODUCTION
Welding is a fabrication or sculptural process that joins materials, usually metals (such as steel,
aluminium, brass, stainless steel etc.) or thermoplastics (plastic or polymer), by causing coalescence to
form a permanent bond. The fabrication or sculptural process refers to building metal structures by
cutting, bending, and assembling. They apply heat to metal pieces, melting and fusing them. They may
work in a manual mode or in a semiautomatic mode, using machinery such as a wire feeder to help
them perform tasks. In the domain of welding, arc welding is part of the welding types.
Arc welding is a type of welding that uses a welding power supply to create an electric arc between an
electrode and the base material to melt the metals at the welding point. They can use either direct or
alternating current and consumable or non- consumable electrode. The welding region is usually
protected by some type of shielding gas, vapour, and/ or slag. Shielded Metal Arc Welding (SMAW), are
one of the many processes in arc welding.
Shielded Metal Arc Welding (SMAW), also known as Manual Metal Arc (MMA) welding, flux shielded arc
welding or informally as stick welding, is a manual arc welding process that uses a consumable
electrode coated in flux to lay the weld. An electric current, in the form of either alternating current or
direct current from a welding power supply, is used to form an electric arc between the electrode and
the metals to be joined. As the weld is laid, the flux coating of the electrode disintegrates, giving off
vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area
from atmospheric contamination.
A person who is competent in Shielded Metal Arc Welding (SMAW) Process (Level 3) is an individual
who is trained and qualified in compliance to codes, standards and requirements.
This NOSS document shows the structured career path of Shielded Metal Arc Welding (SMAW)
Process (Level 3) personnel. It provides structured set of activities that enables a person who aspires to
achieve competency in this particular occupation, ultimately enhancing him or her on a career in the
welding industry.
Standard Practice and Standard Content are part of NOSS document. The job areas being develop are
based on the Occupational Area Analysis (OAA). This document covers the competency standard of
Shielded Metal Arc Welding (SMAW) Process (Level 3) that is currently gaining priority in the welding
industry. The panel of experts had concluded that this job area starts from tier 3 due to requirement of
significant range of varied work activities and performed in a variety of context, most of which are
complex and non-routine. There is considerable responsibility and autonomy and control or guidance of
others is often required. Where by some of the activities are non-routine and required individual
responsibility and autonomy. To produce skilled workers in this industry, the needs for structured
training are essential.
Pre-requisite
Based on the workshop findings, it was decided that the minimum requirement for those interested to
enrol this course are as follows:
16 years of age or above
Good eyesight.
Medically and physically fit.
Able to read, write and perform simple calculation.
These pre-requisite is in line with minimum requirements set by Construction Industry development
Board (CIDB) and Department of Occupational Safety and Health (DOSH). With respect to the
regulating bodies, the role is as follows:
Construction Industry development Board (CIDB)
As welding is an essential aspect of within the construction industry, the Board has taken the functions
related to welding practices performed within the construction industry. Thus, functions of the Board as
laid down under subsection 4 (1) of Act 520 are as follows:
To promote and stimulate the development, improvement and expansion of construction industry;
To advise and make recommendations to the Federal Government and the State Governments on
matters affecting or connected with the construction industry;
To promote, stimulate and undertake research into any matter related to the construction industry;
To promote, stimulate and assist in the export of service related to the construction industry;
To provide consultancy and advisory services with respect to the construction industry;
To promote quality assurance in the construction industry;
To initiate and maintain the construction industry information systems;
To encourage the standardisation and improvement of construction techniques and materials;
To provide, promote, review and coordinate training programmed organized by the public and
private construction training centres for skilled construction workers and construction site
supervisors;
To accredit and register contractors and to cancel, suspend or reinstate the registration of any
registered contractor; and
To accredit and certify skilled construction workers and construction site supervisors.
Department of Occupational Safety and Health (DOSH)
As a regulatory body which enforces the occupational safety and health aspects in Malaysia, the role of
DOSH is to study and review the policies and legislations of occupational safety and health. This in
particular is enforced in risky occupations such as in the welding industry. The following acts are been
enforced by DOSH:
a) Occupational Safety and Health Act 1994 and its regulations.
b) Factories and Machinery Act 1967 and its regulations.
c) Part of Petroleum Act 1984 (Safety Measures) and its regulations.
d) Guidelines, codes of practice, circulars.
With regard to the respective acts, DOSH comes forward to apply the functions as to:
Conduct research and technical analysis on issues related to occupational safety and health at the
workplace.
Carry out promotional and publicity programs to employers, workers and the general public to foster
and increase the awareness of occupational safety and health.
Carry out promotional and publicity programs to employers, workers and the general public to foster
and increase the awareness of occupational safety and health.
Become a secretariat for the National Council regarding occupational safety and health
4
2. OCCUPATIONAL STRUCTURE
Shielded Metal Arc Welding (SMAW) Process (Level 3) weldercomes under the sub-sector Welding
Process and Fabrication. Fig. 1.0 and 1.1 show the structured career path and area of Shielded Metal
Arc Welding (SMAW) Process (Level 3) personnel.
SECTOR
MACHINERYANDEQUIPMENT
SUBSECTOR
WELDINGTECHNOLOGYANDFABRICATION
JOBAREA
ARCWELDING
JOBSUB
AREA
SHIELDEDMETAL
ARCWELDING
(SMAW)
JOBLEVEL
GASTUNGSTEN
ARCWELDING
(GTAW)
FLUXCOREDARC
WELDING(FCAW)
WELDINGENGINEER
L5
L4
L3
GASMETALARC
WELDING
(GMAW)
SMAWWELDER
WELDINGCOORDINATOR
GMAWWELDER GTAWWELDER
L2
N/A
L1
N/A
FCAWWELDER
Fig. 1.0 Occupational Profile Chart for Shielded Metal Arc Welding (SMAW) Process (Level 3)
personnel
SECTOR
SUB
SECTOR
JOB
AREA
JOB
SUB
AREA
JOB
LEVEL
ARCWELDING
SHIELDEDMETAL
ARCWELDING
(SMAW)
GASMETALARC
WELDING(GMAW)
GASTUNGSTENARC
WELDING(GTAW)
FLUXCOREDARC
WELDING(FCAW)
WELDINGENGINEERING
L5
L4
L3
WELDINGCOORDINATION
SMAW
PROCESS
GMAW
PROCESS
GTAW
PROCESS
L2
N/A
L1
N/A
FCAW
PROCESS
Fig. 1.1 Occupational Area Analysis for Shielded Metal Arc Welding (SMAW) Process (Level 3)
personnel
3. DEFINITION OF COMPETENCY LEVEL

The NOSS is developed for various occupational areas. Candidates for certification must be assessed and
trained at certain levels to substantiate competencies. Below is a guideline of each NOSS Level as defined
by the Department of Skills Development, Ministry of Human Resources, Malaysia.
Malaysia Skills Certificate Level 1:
(Operation and Production Level)
Competent in performing a range of varied

work activities, most of which are routine and predictable.

(Operation and Production Level)
Competent in performing a significant range

of varied work activities, performed in a variety of contexts.
Some of the activities are non-routine and required
individual responsibility and autonomy.

(Supervisory Level)
Competent in performing a broad range of

varied work activities, performed in a variety of contexts,
most of which are complex and non-routine. There is
considerable responsibility and autonomy and control or
guidance of others is often required.
Malaysia Skills Diploma Level 4:

(Executive Level)
Competent in performing a broad range of

complex technical or professional work activities performed
in a wide variety of contexts and with a substantial degree
of personal responsibility and autonomy. Responsibility for
the work of others and allocation of resources is often
present.
Malaysia Skills Advanced Diploma

Level 5: (Managerial Level)
Competent in applying a significant range of

fundamental principles and complex techniques across a
wide and often unpredictable variety of contexts. Very
substantial personal autonomy and often significant
responsibility for the work of others and for the allocation of
substantial resources features strongly, as do personal
accountabilities for analysis, diagnosis, planning, execution
and evaluation.
4.
MALAYSIAN SKILL CERTIFICATION

Candidates after being assessed and verified and fulfilled Malaysian Skill Certification requirements
shall be awarded with Sijil Kemahiran Malaysia (SKM) for Level 3.
Training delivery
- Delivery in Bahasa Malaysia and/or English (especially for welding terminology)
5. JOB COMPETENCIES
Shielded Metal Arc Welding (SMAW) Process (Level 3) welders are competent in performing welding in
accordance to Welding Qualification Test (WQT) as follows:
Shielded Metal Arc Welding (SMAW) For Fillet All Position, 1G And 2G
Shielded Metal Arc Welding (SMAW) For 3G And 4G
Shielded Metal Arc Welding (SMAW) For 5G And 6G
Optionally, the Shielded Metal Arc Welding (SMAW) Process (Level 3) personnel are competent in
performing the following elective competencies:
Shielded Metal Arc Welding (SMAW) 6GR

Submerged Arc Welding (SAW) 1G
6. WORKING CONDITIONS
The Shielded Metal Arc Welding (SMAW) Process welder should be able to concentrate on detailed
work for long periods and be able to bend, stoop, and weld in awkward positions. They may work
outdoors, and must wear special clothingsafety shoes, gloves, and goggles, face shields or hoods,
dust maskto protect from the intense ultra violet (UV) rays created by arcs, hazardous fumes, and
spark burns (spatters).
Where ever applicable, the individual must obtain Permit To Work (PTW) from employers to ensure safe
working condition. In order to be employed at work, the individual need to be qualified by the employer
via Welder Qualification Test (WQT).
Good eyesight is needed for visual inspection to check welding condition.
7. EMPLOYMENT PROSPECTS
Malaysian Market
Ahead of 2011, the drive for Malaysian welding industries will be mainly driven by foreign investors and
Government Link Companys (GLCs). This will eventually creates competition among service providers
and contractors in providing competent welders, inspectors and all other related personnel.
Thus, the welding industries in Malaysia are poised to grow in the near future. With the Government
encouraging foreign investment, the country is set to become a manufacturing and construction hub in
the region.
Nevertheless current practice shows appointments of competent welders within construction domain are
dominantly appointed on project basis. This resulted in most competent welders personnel within the
construction domain to practice freelancing.
With the growth of the welding industry in Malaysia the number of competent coded welders is greatly in
demand, however the current volume of the welders is shortage to support the industry. Hence, this
National Occupational Skill Standard (NOSS) was developed as reference to train and qualify welders
to meet the growing industrial needs.
The sectors in the industry which required welding expertise with respect to employment opportunities
are:
Oil and Gas

Boilers and Pressure vessels
Shipbuilding
Construction / Infrastructure
Power industry
Heavy equipment
Industrial machinery
Aerospace
Automotive
Vocational training
International Market
This NOSS was developed taking into consideration of international standards and requirements. As
such welders who have been trained and qualified would have better opportunities entering into the
international market. For example, there is a high demand of competent coded welder in the Middle
Eastern and African countries as well as Asian countries like Turkmenistan, Azerbaijan, etc due to its
rapid industrial development.
The most widely used international standards for welders certification are as follows:
American Society of Mechanical Engineers (ASME)

American Welding Society (AWS)
American Petroleum Institute (API)
British Standard European Norm (BSEN)
International Standards Organisation (ISO).
8. TRAINING, INDUSTRIAL/PROFESSIONAL RECOGNITION, OTHER QUALIFICATIONS AND

ADVANCEMENT
As for career advancement, most competent welders learn their craft on the job. They usually begin as
qualified welders and gradually learn their new skills as they gain experience. Further certification may
increase their chances of career advancement. Thus with additional formal training/education and
certification, this experience competent welders can advance to become a certified welding inspector
and welding engineer.
9. SOURCES OF ADDITIONAL INFORMATION

Local
Construction Industry development Board (CIDB)
Tingkat 7, Grand Seasons Avenue, 72, Jalan Pahang,
53000 Kuala Lumpur
Tel: 603-2617 0200
Fax: 603-2617 0220
Email: cidb@cidb.gov.my
Web: http://www.cidb.gov.my

Ministry of Human Resource,
Level 2, 3 & 4, Block D3, Complex D
Federal Government Administrative Centre
62530 W. P. Putrajaya
Tel: 603 - 8886 5000
Fax: 603 - 8889 2443
Email: jkkp@mohr.gov.my
Web: http://www.dosh.gov.my
Department of Standards Malaysia (Standards Malaysia)

Century Square, Level 1 & 2, Block 2300, Jalan Usahawan,
63000 Cyberjaya, Selangor Darul Ehsan, Malaysia
Tel: 603-8318 0002
Fax: 603-8319 3131
Email: central@standardsmalaysia.gov.my
Web: http://www.standardsmalaysia.gov.my
SIRIM Berhad
No. 1, Persiaran Dato' Menteri, Seksyen 2,
Peti Surat 7035, 40700 Shah Alam
Selangor Darul Ehsan
Tel: 603-55446000
Fax: 603-55108095
Email: web@sirim.my
Web: http://www.sirim.my
International
American Society of Mechanical Engineers (ASME)
Three Park Avenue
New York, NY 10016-5990
United States of America
Tel: 973-882-1170
Fax: 973-882-1717
Email: infocentral@asme.org
Web: http://www.asme.org
American Petroleum Institute (API)
1220 L Street, NW
Washington, DC 20005-4070
Tel: 202-682-8000
Fax: Email: Web: http://www.api.org
9
American Welding Society (AWS)

550 N.W. LeJeune Road,
Miami, Florida 33126
Tel: 800-443-9353
Fax: Email: Web:http://awsnow.org
American National Standard Institute (ANSI)

1899 L Street, NW, 11th Floor
Washington, DC, 20036
Tel: 202-293-8020
Fax: 202-293-9287
Email: Web:http://www.ansi.org/
American Society for Testing and Materials (ASTM)

100 Barr Harbor Drive,
West Conshohocken, Pennsylvania,
Tel: 610-832-9500
Fax: 610-832-9555
Email: Web: http://www.astm.org
British Standards International (BSI) Group

389 Chiswick High Road,
London, W4 4AL,
United Kingdom
Tel: 44-20-8996-9001
Fax: 44-20-8996-7001
Email: cservices@bsigroup.com
Web: http://www.bsigroup.com
International Organization for Standardization

ISO Central Secretariat,
1, ch. de la Voie-Creuse, CP 56,
CH-1211, Geneva 20,
Switzerland
Tel: 41-22-749 01 11
Fax: 41-22-733 34 30
E-mail: central@iso.org
Web: http://www.iso.org
International Labour Organisation (ILO)

4 route des, Morillons,
CH-1211,Geneva 22,
Switzerland
Tel: 41-22-799-6111
Fax: 41-22-798-8685
Website: www.ilo.org
E-mail: ilo@ilo.org
10
10. VALIDATION
This Standard has been circulated to the respective industry for two weeks for validation and feedback.
The list of companies that have received the draft are as follow;
i)
ii)
iii)
This Standard has been checked by the Standard Technical Evaluation Committee (STEC), DSD and
validated by the members of Skills Development Advisory Committee (SDAC) on
5th of September 2012 The SDAC members as listed below have agreed in consensus to this
..
standard;
i. En. Abd. Halim Bin Hasan
JPK Cawangan Cyberjaya,
Suite 0-10, 4803, Bangunan CDB Perdana
Persiaran Flora, 63000 Cyberjaya.
Selangor Darul Ehsan
ii. En. Mohd Darus Bin Taib
TWI Training & Certification (S.E. Asia) Sdn. Bhd,
No 8, Jalan TSB 10, Sungai Buloh Industrial Park,
47000 Sungai Buloh, Selangor Darul Ehsan.
iii. En. Dawot Bin Hussin
Malaysian Welding & Joining Society (MWJS),
Lot 10-20, Jalan Beremban 15/12, Seksyen 15,
40300 Shah Alam, Selangor
11. ENDORSEMENT
The National Skills Development Board (MPKK), Ministry of Human Resources has agreed and
endorsed this Standard on .
12. ACKNOWLEDGEMENT
The Director General of DSD would like to express sincere appreciation to the team of experts invited
and their respective organisations involved during development of this standard for their contribution,
perseverance and support until completion. Their experience and technical assistance has enhanced
the capabilities of the document in hopes of alleviating the methodology and process of the NOSS
development.
The Director General of DSD also wishes to applaud the support and participation of all the
organizations involved, especially TWI Training & Certification (S.E. Asia) Sdn. Bhd, Malaysian Welding
& Joining Society (MWJS) whose major contributions and dedicated efforts were essential to the
successful completion of this standard.
Not forget, great appreciation go to the rest of the development committee members staffs and their
beloved families that help, shared their experience and concern from time to time during the standard
development. Their kindness and understanding kept the standard development team spirited and
aspired
Above all, very much thankful to the Great God Almighty for carrying the team through all the difficulties
in the completion and preparation of this standard.
11
13. COMMITTEE MEMBERS FOR DEVELOPMENT OF STANDARD PRACTICE (SP), JOB PROFILE
CHART (JPC), COMPETENCY PROFILE (CP) AND CURRICULUM OF COMPETENCY UNIT (CoCU)
SHIELDED METAL ARC WELDING (SMAW) PROCESS LEVEL 3

PANEL EXPERTS
1
En. Mohd Herman Bin Rosli
En. Mansor Bin Ibrahim
En. Awaldin Bin Mohd Arif
En. Azaddin Bin A. Aziz
En. Lokman Bin Zakaria
En. Hamzah Bin Mohamed Kasa
En. Mohd Salleh Bin Mohd Noh
En. Zahidi Bin Zainuddin
En. Wan Yusof Bin Wan Hasan
10
En. Mohd Ali Bin Moh Salleh
12
En. Mohd Sufie Bin Mohamed
13
En. Mohd Ali Man Shah Bin Abu

Samah
Johor State Occupational Safety and Health officer

Technical Instructor
Malaysia Marine And Heavy Engineering Sdn Bhd (MMHE)
Managing Director
Industrial Testing & engineering Inspection Sdn Bhd
QA/QC and HSE Senior Manager 1
Sime Darby Engineering Sdn Bhd
QA and Risk Manager
MISC Sdn Bhd,
Training Manager Welding Inspection
TWI Training & Certification (S.E. Asia) Sdn. Bhd,
Branch Manager
TWI-ABM Training & Certification (Johor) Sdn. Bhd,
Welding Operations Officer
Akademi Binaan Malaysia, CIDB
Welding Operations Officer
Akademi Binaan Malaysia, CIDB
Welding Specialist
Time Temasek Sdn Bhd
Welding Specialist
Welding Specialist
FACILITATORS
En. Syed Mahathir Bin Syed Azman

Shah
En. Ahmad Azran Bin Ranaai
Tn. Hj. Razalee Bin Che Ros
En. Mohd Lutfi Bin Mohd Darjak
Assistant Director
JPK, Cyberjaya, Selangor
Assistant Director
Senior Skills Development Officer
Senior Skills Development Officer
12
STANDARD CONTENT
LEVEL 3
(TAHAP 3)
13
COMPETENCYPROFILECHART(CPC)
SECTOR
SUBSECTOR
JOBAREA
SHIELDEDMETALARCWELDING(SMAW)
JOBLEVEL
LEVEL3
JOBAREACODE
COMPETENCY
COMPETENCYUNIT
CORE
ELECTIVE
SHIELDED METAL
ARC WELDING
(SMAW) FOR FILLET
WELD 1F, 2F, 3F, 4F,
BUTT WELD 1G AND
2G
SHIELDED METAL ARC

WELDING (SMAW) FOR
3G AND 4G
SHIELDED METAL ARC

WELDING (SMAW) FOR
5G AND 6G (UP-HILL
AND DOWN-HILL)
MC0243:2012C01
MC0243:2012C02
MC0243:2012C03
SHIELDED METAL
ARC WELDING
(SMAW) 6GR
SUBMERGED ARC
WELDING (SAW) 1G
MC0243:2012E01
MC0243:2012E02
14
COMPETENCY PROFILE (CP)

Sub Sector
Job Area
SHIELDEDMETALARCWELDING(SMAW)
Level
THREE (3)
CU Title
CU Code
CU Descriptor
Work Activity
SHIELDED METAL
ARC WELDING
(SMAW) FOR
FILLET WELD 1F,
2F, 3F, 4F, BUTT
WELD 1G AND 2G
MC024
3:2012C01
Shielded
Metal
Arc
Welding
(SMAW) For Fillet Weld 1F, 2F, 3F,
4F, Butt Weld 1G and 2G describes
the competency of a welder to
perform SMAW process in specified
positions on carbon steel, stainless
steel according to established
welding procedure specification
(WPS) and work instruction. The
person who is competent in
performing Shielded Metal Arc
Welding (SMAW) For Fillet weld 1F,
2F, 3F, 4F, Butt Weld 1G and 2G
will be able to Carry out safety
assessment at work area; Comply
to work instruction and relevant
welding
procedure specification
(WPS); Verify based metal used;
Verify consumable as specified;
Check SMAW equipment and
accessories functionality; Perform
SMAW process; Perform visual
inspection and specimen test
(destructive test); Carry out back
gouging and grinding as required in
accordance with test specimen
1. Carry out safety

assessment at work
area
1.1
1.3
2.1
2.2
3. Verify base metal
Performance Criteria
1.2
2. Comply to work
instruction and relevant
Welding Procedure
Specification (WPS)
3.1
Safety hazard
checked against
safety checklist and
legislative
requirement
Relevant personal
protective
equipment (PPE)
acquired as per
Standard Operating
Procedure (SOP)
Hotwork permit
secured as per SOP
Work instruction and
WPS obtained from
supervisor/ clients
representative
WPS content
checked and
confirmed against
applicable code,
standard and
specification
Type of base metal
15
CU Title
CU Code
CU Descriptor
(plate and pipe); and Compile work

completion checklist.
Work Activity
material confirmed
against WPS and
mill certificate
material used
4. Verify consumable as
specified
4.1
Classification of
electrode checked
against WPS and
mill certificate
5. Check SMAW
equipment and
accessories
functionality
5.1
Welding machine
calibration status
confirmed valid as
per certification
Cable connections
secured as per SOP
Welding
accessories
condition confirmed
functional
5.2
5.3
6. Perform SMAW
process
6.1
6.2
6.3
6.4
Joint configuration
checked against
WPS
Jig and fixtures setup checked and
work piece secured
in 1F, 2F, 3F, 4F,
1G and 2G positions
Cleanliness and
preheating
conducted as per
WPS
Welding in
16
CU Title
CU Code
CU Descriptor
Work Activity
6.5
6.6
7. Perform visual
inspection and
specimen test
(destructive test)
7.1
7.2
7.3
7.4
7.5
accordance to WPS
requirement
Interpass cleaning
carried out as per
WPS
Carry out capping
as per WPS
Weldment
cleanliness carried
out as per work
instruction
Weldment profile
checked against
acceptance and
rejection criteria of
applicable code in
WPS
Weldment test
specimen cut to the
applicable code
standard and
specification
requirements
Weld test coupon
bend test or fracture
test carried out in
accordance to the
applicable code,
standard and
specification
requirements
Bend test result
17
CU Title
CU Code
CU Descriptor
Work Activity
7.6
SHIELDED METAL
ARC WELDING
(SMAW) FOR 3G
AND 4G
MC024
3:2012C02
Shielded
Metal
Arc
Welding
(SMAW) For 3G And 4G describes
8. Carry out back

gouging, grinding and
back welding as
required in accordance
with test specimen
8.1
9. Compile work
completion checklist
9.1
1. Carry out safety

assessment at work
area
1.1
8.2
1.2
checked against
acceptance and
the applicable code
in WPS for 1G and
2G
Fracture test result
checked against
acceptance and
the applicable code
in WPS for 1F, 2F,
3Fand 4F
Air arc gouging
carried out when
required
Grinding carried out
as required
Work completion
checklist recorded
as per work
instruction
Safety hazard
checked safety
checklist and
legislative
requirement
Relevant personal
protective
equipment (PPE)
acquired as per
18
CU Title
CU Code
CU Descriptor

Welding (SMAW) For 3G And 4G
(destructive test); Carry out back
gouging and grinding as required in
accordance with test specimen
(plate); and Compile
work
Work Activity
1.3
2. Comply to work
Welding Procedure
Specification (WPS)
2.1
2.2
SOP
Hotwork permit
secured as per SOP
WPS obtained
from supervisor/
clients
representative
WPS content
checked and
confirmed as per
SOP

material used
3.1
Type of base metal

material confirmed
against WPS and
mill certificate
specified
4.1
Classification of
electrode checked
against WPS and
mill certificate
5. Check SMAW
equipment and
accessories
functionality
5.1
Welding machine
calibration status
confirmed valid as
per certification
Cable connections
secured as per SOP
Welding
accessories
condition confirmed
19
5.2
5.3
CU Title
CU Code
CU Descriptor
Work Activity
functional
6. Perform SMAW
process
6.1
6.2
6.3
6.4
6.5
6.6
7. Perform visual
inspection and
specimen test
(destructive test)
7.1
7.2
Joint configuration
checked against
WPS
work piece secured
in 3G and 4G
positions
Cleanliness and
preheating
conducted as
required per WPS
Welding in
accordance to WPS
requirements
Interpass cleaning
carried out as per
WPS
Carry out capping
as per WPS
Weldment
cleanliness carried
out as per work
instruction
Weldment profile
checked against
acceptance and
applicable code in
WPS
20
CU Title
CU Code
CU Descriptor
Work Activity
7.3
7.4
7.5
8. Carry out back

back welding as
with test specimen
8.1
9. Compile work
9.1
8.2
Weldment test
specimen cut to the
applicable code
standard and
specification
requirements
Weld test coupon
test carried out in
accordance to the
applicable code,
standard and
specification
requirements
Bend test result
checked against
acceptance and
the applicable code
in WPS for 3G and
4G
Air arc gouging
carried out when
required
as required
Work completion
checklist recorded
as per work
instruction
21
CU Title
CU Code
CU Descriptor
Work Activity
SHIELDED METAL
ARC WELDING
(SMAW) FOR 5G
AND 6G (UP-HILL
AND DOWN-HILL)
MC024
3:2012C03
Shielded
Metal
Arc
Welding
(SMAW) For 5G And 6G describes
Welding (SMAW) For 5G And 6G
welding
(destructive test); and Compile work
1. Carry out safety

assessment at work
area
1.1
1.2
1.3
2. Comply to work
Welding Procedure
Specification (WPS)
2.1
2.2
Safety hazard
checked safety
checklist and
legislative
requirement
Relevant personal
protective
equipment (PPE)
acquired as per
SOP
Hotwork permit
secured as per SOP
WPS obtained
from supervisor/
clients
representative
WPS content
checked and
confirmed as per
SOP

material used
3.1
Type of base metal

material confirmed
against WPS and
mill certificate
specified
4.1
Classification of
electrode checked
against WPS and
mill certificate
22
CU Title
CU Code
CU Descriptor
Work Activity
5. Check SMAW
equipment and
accessories
functionality
5.1
5.2
5.3
6. Perform SMAW
process
6.1
6.2
6.3
6.4
6.5
6.6
Welding machine
calibration status
confirmed valid as
per certification
Cable connections
secured as per SOP
Welding
accessories
condition confirmed
functional
Joint configuration
checked against
WPS
work piece secured
in 5G and 6G
positions
Cleanliness and
preheating
conducted as
required per WPS
Welding in
accordance to WPS
requirements
Interpass cleaning
carried out as per
WPS
Carry out capping
as per WPS
23
CU Title
CU Code
CU Descriptor
Work Activity
7. Perform visual
inspection and
specimen test
(destructive test)
7.1
7.2
7.3
7.4
7.5
8. Compile work
8.1
Weldment
cleanliness carried
out as per work
instruction
Weldment profile
checked against
acceptance and
applicable code in
WPS
Weldment test
specimen cut to the
applicable code
standard and
specification
requirements
Weld test coupon
test carried out in
accordance to the
applicable code,
standard and
specification
requirements
Bend test result
checked against
acceptance and
the applicable code
in WPS for 5G and
6G
Work completion
24
CU Title
CU Code
CU Descriptor
Work Activity
SHIELDED METAL
ARC WELDING
(SMAW) 6GR
MC024
3:2012E01
Shielded
Metal
Arc
Welding
(SMAW) For 6GR describes the
competency of a welder to perform
SMAW
process
in
specified
positions on carbon steel, according
to established welding procedure
specification (WPS) and work
instruction. The person who is
competent in performing Shielded
Metal Arc Welding (SMAW) For
6GR will be able to Carry out safety
welding
(destructive test); and Compile work
CU Pre-requisite:
1. Valid certification or minimum
six (6) months experience in
pipe welding using Shielded
Metal Arc Welding (SMAW)
process with evidence of
competency in 5G or 6G
position.
1. Carry out safety

assessment at work
area
1.1
1.2
1.3
2. Comply to work
Welding Procedure
Specification (WPS)
2.1
2.2
checklist recorded
as per work
instruction
Safety hazard
checked safety
checklist and
legislative
requirement
Relevant personal
protective
equipment (PPE)
acquired as per
SOP
Hotwork permit
secured as per SOP
WPS obtained
from supervisor/
clients
representative
WPS content
checked and
confirmed as per
SOP

material used
3.1
Type of base metal

material confirmed
against WPS and
mill certificate
specified
4.1
Classification of
electrode checked
25
CU Title
CU Code
CU Descriptor
Work Activity
against WPS and

mill certificate
5. Check SMAW
equipment and
accessories
functionality
5.1
5.2
5.3
6. Perform SMAW
process
6.1
6.2
6.3
6.4
6.5
7. Perform visual
7.1
Welding machine
calibration status
confirmed valid as
per certification
Cable connections
secured as per SOP
Welding
accessories
condition confirmed
functional
Joint configuration
checked against
WPS
work piece secured
in 6GR position
Cleanliness and
preheating
conducted as
required per WPS
Welding in
accordance to WPS
requirements
Interpass cleaning
carried out as per
WPS
Weldment
26
CU Title
CU Code
CU Descriptor
Work Activity
inspection and
specimen test
(destructive test)
7.2
7.3
7.4
7.5
8. Compile work
8.1
cleanliness carried
out as per work
instruction
Weldment profile
checked against
acceptance and
applicable code in
WPS
Weldment test
specimen cut to the
applicable code
standard and
specification
requirements
Weld test coupon
test carried out in
accordance to the
applicable code,
standard and
specification
requirements
Bend test result
checked against
acceptance and
the applicable code
in WPS for 6GR
Work completion
checklist recorded
as per work
27
CU Title
CU Code
SUBMERGED ARC
MC024
WELDING (SAW) 1G 3:2012E02
CU Descriptor
Work Activity
Submerged Arc Welding (SAW) 1G

describes the competency of a
machine operator to perform SAW
process in 1G position on carbon
Operate Submerged Arc Welding
(SAW) 1G will be able to Carry out
safety assessment at work area;
Comply to work instruction and
relevant
welding
procedure
specification (WPS); Carry out
safety assessment at work area;
Verify based metal used; Verify
consumable as specified; Check
SAW equipment and accessories
functionality; Operate SAW process
Machine; Perform visual inspection
and specimen test (destructive
test); and Compile work completion
checklist.
CU Pre-requisite:
1. Valid certification or minimum
1. Carry out safety

assessment at work
area
three (3) months experience in

Shielded Metal Arc Welding
(SMAW) process with evidence
of competency in minimum 1F
or 1G position.
1.1
1.2
1.3
2. Comply to work
welding procedure
specification (WPS)
2.1
2.2
3. Check SAW equipment

and accessories
functionality
3.1
3.2
3.3
instruction
Safety hazard
checked safety
checklist and
legislative
requirement
Relevant personal
protective
equipment (PPE)
acquired as per
SOP
Hotwork permit
secured as per SOP
WPS obtained
from supervisor/
clients
representative
WPS content
checked and
confirmed as per
SOP
Welding machine
calibration status
confirmed valid as
per certification
Cable connections
secured as per SOP
Welding
accessories
condition confirmed
28
CU Title
CU Code
CU Descriptor
Work Activity
3.4
functional
Wire feeder
functionality
condition confirmed
as per
manufacturers
operating manual
4. Verify based metal

material used
4.1
Type of based metal

verified against
WPS and mill
certificate
specified
5.1
Type of flux
confirmed as per
WPS
Classification of filler
wires checked
against WPS and
manufacturers data
sheet
5.2
6. Operate SAW process
6.1
6.2
6.3
Joint configuration
checked as per
WPS
Jig and fixtures
(roller and track)
set-up checked and
work piece secured
in 1G position
Cleanliness and
preheating
conducted as
29
CU Title
CU Code
CU Descriptor
Work Activity
6.4
6.5
6.6
6.7
6.8
6.9
7. Perform visual
inspection and
specimen test
(destructive test)
7.1
7.2
required as per
WPS
Welding in
accordance to WPS
requirements
Interpass cleaning
carried out as per
WPS
Air arc back gouging
carried out as per
WPS
Back Grinding
carried out as per
WPS
Back welding
carried out as per
WPS
Defective profile
rectified and
accepted as per test
specimen
requirements and
WPS
Weldment
cleanliness carried
out as per work
instruction
Weldment profile
checked against
acceptance and
applicable code in
30
CU Title
CU Code
CU Descriptor
Work Activity
7.3
7.4
7.5
8. Carry out back

back welding as
with test specimen
8.1
9. Compile work
9.1
8.2
WPS
Weldment test
specimen cut to the
applicable code
standard and
specification
requirements
Weld test coupon
test carried out in
accordance to the
applicable code,
standard and
specification
requirements
Bend test result
checked against
acceptance and
the applicable code
in WPS for 1G
Air arc gouging
carried out when
required
as required
Work completion
checklist record as
per work instruction
31
CURRICULUM of COMPETENCY UNIT (CoCU)

FOR;
LEVEL 3
(TAHAP 3)
32

Sub Sector
WELDING TECHNOLOGY AND FABRICATION
Job Area
SHIELDED METAL ARC WELDING (SMAW)
Competency Unit Title
SHIELDED METAL ARC WELDING (SMAW) FOR FILLET WELD 1F, 2F, 3F, 4F, BUTT WELD 1G AND 2G
The person who is competent in this CU shall be able to perform shielded metal arc welding (SMAW) for fillet weld 1F, 2F, 3F, 4F, butt weld
1G and 2G positions on carbon steel or stainless steel material. Upon completion of this competency unit, trainees will be able to:-
1.
2.
3.
4.
5.
6.
7.
8.
9.
Learning Outcomes
Carry out safety assessment at work area

Comply to work instruction and relevant Welding Procedure Specification (WPS)
Verify base metal material used
Verify consumable as specified
Check SMAW equipment and accessories functionality
Perform SMAW process
Perform visual inspection and testing(destructive test)
Carry out back gouging, grinding and back welding as required in accordance with test specimen
Compile work completion checklist
MC-024-3:2012-C01
Competency Unit ID
Work Activities
Related Knowledge
1. Carry out
safety
assessment
at work area
Safety induction in
accordance to
Occupational Safety
and Health Act (OSHA),
Factory and Machinery
Act, Regulation,
Guideline and Code of
Practice which covers:
1
Hazard
identification,
Level
Attitude / Safety /
Environmental
Related Skills
2
3
Demonstrate safe
working habit and
consciousness in
workshop
Adhere to worksite
safety requirement,
regulations
Alert in ensuring
safe working
environment
Training
Duration
Training
Hours
24
580 Hours
Credit Values
Delivery
Mode
1
2
Lecture
Group Discussion
58
Assessment Criteria
Welding hazards
identified which
includes:
1.1 Safety hazard
1.2 Health hazard
1.3 Environmental
hazard
2 Welding risk
assessment
conducted
33
Work Activities
Related Knowledge
risk assessment
and risk control
(HIRARC)
1.1
Safety hazard
and protection
1.1.1 Slipping or
tripping, floor
protection
1.1.2 Fire and
explosion
hazard
1.1.2.1
Fire/ spark/
heat
protection
1.1.2.2
Fire
extinguishe
r type
1.1.2.3
Elements of
fire
1.1.2.4
Flammable
hazard (ex:
painting, oil,
gas, etc)
1.1.2.5
Fire
watcher
1.1.3 Working at
height
1.1.4 Pressure
system
1.1.5 Eye injuries
1.2
Health hazard
and protection
1.2.1 Ergonomic in
Attitude / Safety /
Environmental
Related Skills
5
6
7
Responsible and
accountable in
performing welding
task
Transparent in
reporting to relevant
authority
Ensure
housekeeping
Ensure proper PPE
worn at work site
Training
Hours
Delivery
Mode
Assessment Criteria
Proper protection
addressed
according to risk
assessment
result which
covers:
3.1 Safety hazard
protection
3.2 Health hazard
protection
3.3 Environmental
hazard protection
4 Welding risk
control carried
out which covers:
4.1 Procedure to
obtain Permit To
Work (PTW)
4.2 Lock out, tack
out (LOTO)
4.3 Welding area
emergency
response plan
(ERP)
4.4 First aid
treatment
procedure
conducted such
as:
4.4.1 Cardio
Pulmonary
Resuscitatio
n (CPR)
34
Work Activities
Related Knowledge
1.2.2
1.2.3
1.2.4
1.2.5
1.3
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.3.6
welding
activities - body
posture
Welding fumes,
gases and
protection
Welder health
condition
Personnel
Protective
Equipment
(PPE)
Arc burn
(Intense
ultraviolet
radiation)
Environmental
hazard
Adequate
access and
emergency
escape route
Confined space
Extreme
temperature
(Hotwork/
coldwork)
Adequate
lighting
Falling objects
Radiation /
ultraviolet
protection
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
4.4.2
4.4.3
Minor cut
injuries
Bone
fracture first
aid
treatment
35
Work Activities
Related Knowledge
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
1.3.7 Noise hazard

1.3.7.1
Noise
exposure
1.3.7.2
Noise
protection
1.3.8 Electrical
hazard
1.3.8.1
Electrical
protection
1.3.8.2
Electrical
shock
2
Safety operating
procedure
2.1
Procedure to
obtain Permit To
Work (PTW)
2.2
Lock out, tack
out (LOTO)
2.3
First aid
treatment
procedure
2.3.1 Cardio
Pulmonary
Resuscitation
(CPR)
2.3.2 Minor cut
injuries
2.3.3 Bone fracture
first aid
treatment
2.3.4 Emergency
response plan
(ERP)
36
Work Activities
Related Knowledge
Related Skills
1
1.1
1.2
1.3
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
Identify welding
hazards which
covers:
Safety hazard
Health hazard
Environmental
hazard
Conduct welding
risk assessment
to address proper
protection within
work area which
covers:
Safety hazard
protection
Health hazard
protection
Environmental
hazard protection
Carry out welding
risk control by:
Execute
procedure to
obtain Permit To
Work (PTW)
Execute lock out,
tack out (LOTO)
procedure
Identify welding
area emergency
response plan
(ERP)
Able to conduct
Attitude / Safety /
Environmental
Training
Hours
24
Delivery
Mode
1
2
Assessment Criteria
Case study
Observation
37
Work Activities
Related Knowledge
3.4.1
3.4.2
3.4.3
2. Comply to
work
instruction
and relevant
Welding
Procedure
Specification
(WPS)
1
2
3
4
5
6
7
8
8.1
8.2
9
10
Welding
terminology
Welding drawing
and symbol
WPS content
Procedure
Qualification
Record (PQR)
Welding codes
and standards
Joint design
Material type
and grade (eg.
material mill
certificate)
Welding position
For fillet weld 1F, 2F, 3F, 4F
For butt weld 1G, 2G
Preheat
requirement
Post-weld heat
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
first aid treatment

procedure such
as:
Cardio Pulmonary
Resuscitation
(CPR)
Minor cut injuries
Bone fracture first
aid treatment
1
2
3
Meticulous in
interpreting WPS
content
Refer to superior
for any
uncertainties
Conform to WPS
requirements
30
1
2
Lecture
Group Discussion
1
2
3
4
5
6
7
8
9
Welding
terminology
described
Welding drawing
and symbol
interpreted
WPS content
interpreted
Procedure
Qualification
Record (PQR)
familiarised
Code and
standard
complied
Joint design
interpreted
Type of material
identified
Welding position
interpreted
Reheat
requirement
38
Work Activities
Related Knowledge
11
12
13
14
15
16
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
identified
10 PWHT
requirement
identified
11 SMAW process
determined
12 Consumable
specification,
classification and
type identified
13 Electrical
characteristics
identified
14 Welding
parameter table
interpreted
treatment
(PWHT)
requirement
SMAW process
Consumable
specification,
classification
and type
Electrical
characteristics ampere, volt,
polarity, travel
speed
Welding
parameters table
Role of
Destructive
Testing (DT)
assessment
Role of NonDestructive
Testing (NDT)
1
2
3
4
Describe welding
terminology
Interpret welding
drawing and
symbol
Interpret WPS
content
Familiarise
Procedure
Qualification
10
1
2
Case study
Observation
39
Work Activities
Related Knowledge
Related Skills
5
6
7
8
9
10
11
12
13
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
Record (PQR)
Comply to
welding codes
and standards
Able to interpret
joint design
Able to identify
type of material
Able to interpret
welding position
8.1. For fillet weld 1F, 2F, 3F, 4F
8.2. For butt weld 1G, 2G
Able to identify
preheat
requirement
Able to identify
PWHT
requirement
Able to determine
SMAW process
Able to identify
consumable
specification,
classification and
type
Able to identify
electrical
polarity, travel
speed
40
Work Activities
Related Knowledge
14
3. Verify base
metal
material used
1
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
2
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
Interpret welding
parameter table
1
Carbon Steel
and Stainless
Steel material
Material mill
certificate
Material
standard
Heat number
Chemical
composition
Mechanical
properties
Material form plate and pipe
Material size
Material physical
condition (eg.
Dent, rust,
ovality, etc)
Meticulous in
verifying based
metal material in
accordance to
material mill
certificate
1
2
Lecture
Group Discussion
1.1
1.1.1
1.1.2
Confirm carbon
steel / stainless
steel material to
relevant WPS
Affirm content of
material mill
certificate such
as:
Material standard
Heat number
1
2
Carbon steel /
stainless steel
material
confirmed to
relevant WPS
Content of
material mill
certificate
affirmed
Material
condition
confirmed
Case study
Observation
41
Work Activities
Related Knowledge
1.1.3
1.1.4
1.1.5
1.1.6
2
4. Verify
consumable
as specified
1
1.1
1.2
1.3
2
3
4
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
Chemical
composition
Mechanical
properties
Material form plate and pipe
Material size
Confirm material
physical condition
(eg. Dent, rust,
ovality, etc)
Electrode
specification/
classification
Core wire
Electrode size
Flux coating
(basic, rutile and
cellulose)
Electrode
handling / baking
procedure
Electrode baking
oven
Electrode
holding oven
Cautious practice
when handling hot
electrode from
baking oven
Lecture
4
1
4.1
4.2
Confirm electrode
specification/
classification such
as:
Core wire
Electrode size
1
2
3
Demonstration
Observation
Case study
Electrode
specification/
classification
confirmed
Electrode
handling/baking
procedure
carried out if
required
Oven
temperature for
electrode baking
setup if required
Temperature for
holding oven
setup if required
42
Work Activities
Related Knowledge
4.3
2
3
4
5. Check
SMAW
equipment
and
accessories
functionality
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
SMAW welding
machine
(electrical driven
transformer)
Power supply
switch
Power source
cable
Earth cable
Electrical driven
transformer
SMAW welding
machine (engine
driven)
Diesel engine
Electric
generator set
Earth cable
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
Flux coating
(basic, rutile and
cellulose)
Carry out
electrode
handling/baking
procedure if
required
Setting up oven
temperature for
baking
Setting up
temperature for
holding oven
1
Ensure welding
machine validity is
within calibration
period
Ensure welding
machine in
functioning and
safe operating
condition
16
1
2
Lecture
Group Discussion
3
4
5
SMAW welding
machine
functionality
affirmed
Complete
welding
accessories
installed to
welding machine
Relevant welding
PPE worn
Complete and
proper welding
tools ensured
Status of welding
machine
calibration
confirmed
43
Work Activities
Related Knowledge
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
Accessories:
Welding cable
Electrode holder
Work cable
Work Clamp
Heating torch
with propane
gas / heating
element
Clampmeter/
tongmeter
Contactless
pyrometer
Temperature
indicating
crayon/ chalk
Cutting lens
goggle
Welding shield
Welding gauntlet
Visor / face
shield
Marking tools
and hand tools:
Marking chalk
Steel ruler
Center punch
L square
Chisel
Chalk line
Chipping
hammer
Portable grinding
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
Machine arc
stability assured
44
Work Activities
Related Knowledge
4.9
4.10
4.11
4.12
4.13
5
6
7
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
machine
Grinding disc as
per specification
Wire brush/
power brush
Type of files
Ball peen
hammer
Brush/broom
Electrode quiver
Status of
welding Machine
calibration
Welding arc
stability
1
2
3
5
6
Use relevant PPE

Affirm SMAW
welding machine
functionality
Assure complete
welding
accessories
installed to
welding machine
Ensure complete
and proper
welding tools for
use
Confirm status of
welding machine
calibration
Acquire welding
1
2
3
Demonstration
Observation
Case study
45
Work Activities
Related Knowledge
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
arc stability
6. Perform
SMAW
process
1 Joint Configuration
2 Joint preparation
marking and cutting
2.1
Mechanical
cutting
2.2
Oxy-acetylene
gas cutting
2.3
Plasma cutting
3 Check Angle (included
angle & bevel angle
4 Root face
5 Root gap /opening
6 Fit-up / jig & fixture
setup
7 Tack weld
8 Surface cleaning
9 Welding position - 1F,
2F, 3F, 4F, 1G and
2G
10 Operation of SMAW
machine
11 Arc blow effect
12 Welding parameter
setting
13 Root pass /
penetration
14 Root pass cleaning
15 Hot pass
16 Hot pass cleaning
17 Interpass
18 Interpass cleaning
1
2
3
4
Ensure PPE in
good usage
condition
Ensure PPE are
worn accordingly
Cautious when
dispensing hot
electrode butt
Ensure glove free
from oil base and
any moisture
during electrode
handling
Electrode to be
handled according
to manufacturer
recommendation
Ensure proper
welding
environment
condition (eg.
under shade from
rain and barricade
from heavy wind,
etc)
Ensure grinding
work are carried
out safely
24
1
2
Lecture
Group Discussion
1
2
3
4
5
6
7
8
9
10
11
Joint
configuration
identified
Weld joint
marking and
cutting
prepared
Angle check
carried out
Root face
identified
Root gap
/opening
identified
Fit-up / jig &
fixture set up
SMAW
machine
operated
Arc striking test
performed
Tack weld
carried out
Surface
cleaning
carried out
Welding
performed in
position - 1F,
2F, 3F, 4F, 1G
and 2G
46
Work Activities
Related Knowledge
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
19 Capping
20 Weldment cleaning
21 Welding machine shut
down procedure
22 Good housekeeping
Assessment Criteria
12
13
1
2
2.1
2.2
2.3
3
4
5
6
7
8
9
Identify joint
configuration
Prepare weld joint
Carry out
mechanical
cutting
Carry out oxyacetylene gas
cutting
Carry out plasma
cutting
Carry out check
Angle (included
angle & bevel
angle)
Identify root face
Identify root gap
/opening
Setup fit-up / jig &
fixture
Operate SMAW
machine
Carry out arc
striking test run to
obtain arc stability
Carry out tack
weld
256
1
2
3
Demonstration
Observation
Project
14
15
16
17
18
19
20
21
22
23
Pre-heating
carried out as
required
Welding
parameters set
Root pass /
penetration
carried out
Root pass
cleaning
executed
Hot pass
carried out
Hot pass
cleaning
executed
Interpass
carried out
Interpass
cleaning
executed
Capping
executed
Weldment
cleaning
carried out
Post-heating
carried out as
required
Attitude/
Safety/
Environmental
requirement
47
Work Activities
Related Knowledge
Related Skills
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Carry out surface

cleaning
Setup welding
position - 1F, 2F,
3F, 4F, 1G and
2G
Carry out preheating as
required
Set welding
parameters
Carry out root
pass / penetration
Execute root pass
cleaning
Carry out hot pass
Execute hot pass
cleaning
Carry out
interpass
Execute interpass
cleaning
Execute capping
Carry out
weldment
cleaning
Carry out postheating as
required
Carry out welding
machine shut
down procedure
Carry out
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
24
25
carried out
during
performing
SMAW process
Welding
machine shut
down
procedure
executed
Housekeeping
carried out
48
Work Activities
Related Knowledge
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
housekeeping
7. Perform
visual
inspection
and testing
(destructive
test)
1
2
3
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
Welding
inspection kit
Root inspection
Weldment profile
Type of welding
defects and
causes such as:
Irregular weld
profile
Incomplete
penetration
Undercut
Arc strike
Spatter
Crack
Slag inclusion
Porosity
Overlap
Lack of fusion
(surface)
Under fill
Burn-through
Misalignment
(linear &
angular)
Throat thickness
(fillet)
Unequal leg
length (fillet)
Concavity (fillet)
Convexity (fillet)
1
2
3
4
Meticulous in
checking visual
inspection
Inquisitive in
seeking advice to
confirm
acceptance &
rejection criteria
from superior
Open to
comments on
weld imperfection
Ensure safety
when performing
nick break test
and bend test
40
1
2
Lecture
Group Discussion
2
3
4
5
6
7
Relevant
welding
inspection
tools selected
Root
penetration
checked
Weldment
profile for butt
weld and fillet
weld checked
Type of
surface defect
Identified
Welding
specimen
visual and
testing carried
out
Penetrant test
for fillet weld
conducted
Acceptance &
rejection
criteria
confirmed
49
Work Activities
Related Knowledge
5
5.1
5.2
6
7
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
Welding
specimen test
For fillet weld : nick break test,
fracture test,
macro
examination
For butt weld root bend (RB),
face bend (FB),
side bend test
(SB)
Penetrant test
(PT)
Acceptance &
rejection criteria
according to
code
1
2
3
4
5
Select relevant
welding
inspection tools
Check root
penetration for
butt weld only
Check weldment
profile for butt
weld and fillet
weld
Identify type of
surface defect
Carry out welding
specimen test
40
1
2
3
Demonstration
Observation
Case study
50
Work Activities
Related Knowledge
5.1
5.2
6
7
8. Carry out
back
gouging,
grinding and
back welding
as required in
accordance
with test
specimen
1
2
3
4
5
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
For fillet weld : nick break test,

facture test,
macro
examination
face bend (FB),
side bend test
(SB)
Conduct
penetrant test for
fillet weld
Seek advice on
acceptance &
rejection criteria
from superior
Gouging
technique
Grinding
technique
Surface
inspection and
testing (PT/MT)
Back welding
Weldment
cleaning
1
2
3
Conform to WPS
repair procedure
Perform gouging,
grinding and back
welding with care
Practice
housekeeping
Lecture
3
1
Apply gouging
technique where
applicable
(exclude stainless
steel)
8
1
2
3
Demonstration
Observation
Case study
Gouging
technique
applied to test
specimen
Grinding
technique
applied to test
specimen
Back welding
technique
applied to test
specimen
Weldment
cleaning
applied to test
51
Work Activities
Related Knowledge
2
3
4
9. Compile work
completion
checklist
1
2
Attitude / Safety /
Environmental
Related Skills
Assessment Criteria
specimen
1
2
Delivery
Mode
Apply grinding
technique
Apply back
welding
Apply weldment
cleaning
Welding
checklist
Work
completion
hand over
1
Training
Hours
Fill-up welding
checklist
Compile and
submit report to
superior
Precise in filling
welding checklist
Integrity in
compiling report
1
2
Lecture
Group Discussion
1
2
1
2
Observation
Case study
Welding
checklist fill up
complete
Report
compile and
submitted to
superior for
hand over
52
Employability Skills
Core Abilities
1.01
1.02
1.11
2.01
2.03
2.04
2.05
2.11
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.13
3.15
3.16
5.01
5.02
4.01
4.02
4.03
4.04
4.05
6.01
6.02
6.03
6.05
6.06
6.07
Identify and gather information

Document information, procedures or processes
Apply thinking skills and creativity
Interpret and follow manuals, instructions and SOPs
Communicate clearly
Prepare brief reports and checklists using standard forms
Read/interpret flowcharts and pictorial information
Convey information and ideas to people
Apply cultural requirements to the workplace
Demonstrate integrity and apply ethical practices
Accept responsibility for own work and work area
Seek and act constructively upon feedback about performance
Demonstrate safety skills
Respond appropriately to people and situations
Resolve interpersonal conflicts
Develop and maintain team harmony and resolve conflicts
Liase to achieve identified outcomes
Identify and assess client/customer needs
Implement project/work plans
Inspect and monitor work done and/or in progress
Organize own work activities
Set and revise own objectives and goals
Organize and maintain own workplace
Apply problem solving strategies
Demonstrate initiative and flexibility
Understand systems
Comply with and follow chain of command
Identify and highlight problems
Analyse technical systems
Monitor and correct performance of systems
Develop and maintain networks
Social Skills
1
2
3
4
5
6
Communication Skills
Interpersonal Skills
Learning Skills
Multitasking and prioritizing
Self-discipline
Teamwork
53
Tools, Equipment and Materials (TEM)

ITEMS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
RATIO (TEM : Trainees)
Welding procedure specification (WPS)

Procedure Qualification Record (PQR)
Code and standard (AWS D1.1)
Code and standard (ASME IX)
Permit To Work (PTW) form
Base metal plate: plate 6mm to 12mm (minimum range)
Base metal pipe: 4"to 6" NPS schedule 40 (minimum range)
Safety shoe
Coverall
Leather gloves
Fire extinguisher
Muffler / ear plug
First aid kit
Hazard signage
Material mill certificate
Material standard
Welding electrode (2.5mm - 4.0mm)
Electrode baking oven
Electrode holding oven
SMAW welding machine and accessories
Marking tools and hand tools
Electrode quiver
Welding inspection kit
Welding bay c/w accessories (eg. Power supply, lighting, welding curtain,
fume extractor, welding table with positioner, etc)
Jig & fixture fit-up clamp
Hydraulic press
1 :
1 :
1 :
1 :
1 :
1 :
1 :
1 :
1 :
1 :
1 :
1 :
1 :
1 :
1 :
1 :
As required
1 :
1 :
1 :
1 :
1 :
1 :
1
1
1
1
1
1
1
1
1
1
5
1
15
15
1
1
1
1
1
1
5
15
:
:
:
15
15
1
1
1
15
54
ITEMS
27
28
29
30
31
32
33
34
35
36
37
38
39
Guided bend test jig

High speed cutting machine
Spark lighter
Plasma cutting (for stainless steel)
Oxy-acetylene gas cutting (manual) and accessories with flash back
arrester
Oxy-acetylene gas cutting machine (semi-auto) and accessories with flash
back arrester
Oxy-acetylene pipe cutting machine and accessories with flash back
arrester
Band saw machine
Power saw machine
Gouging torch and accessories
Air compressor and receiver
Welding checklist
Macro test equipment (cutter, polisher and etching acid) and accessories
1
1
1
1
1
:
:
:
:
:
15
15
1
15
15
15
15
1
1
1
1
1
1
:
:
:
:
:
:
15
15
5
2
1
15
55
References
REFERENCES
1
2
3
4
5
6
7
8
9
10
11
Sacks & Bohnart,2007,Welding Principles & Practices,3rd edition, 1221, Avenue of the Americas, New York, NY 10020 USA, Mc Graw Hill, ISBN: 9780077238773
James F. Lincoln, Arc Welding Foundation, 2002, The Procedure Handbook of Arc Welding, 14th Edition, 22801 St. Clair Avenue, Cleveland, Ohio, 44117 USA,
Lincoln Electric Company, ISBN: 978- 9993897302
Robert L. O'Brien, 1997, Jefferson's Welding Encyclopaedia, 18th Edition, 550 N.W. Lejeune Road, Miami, Florida, 33126 USA, American Welding Society, ISBN:
978-0871715067
Joseph W. Giachino, William, Weeks, 1985, Welding Skills & Practices, 6th edition, Western Michigan University, Kalmazoo, Michigan, Chicago, 60637, USA,
American Technical Society, ISBN:978-0826930019
Griffin, Roden, Briggs, 1985, Pipe Welding Techniques, 4th edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-0827322486
Ivan H. Griffin, Edward M. Roden and Charles W. Briggs, 1984, Basic Arc Welding 4th edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 9780827321311
ASM International, 1983, Metal Reference Book, 2nd edition, Material Park, Ohio, 44073 USA, American Society For Metals, ISBN:978-0871701565
Gower A. Kennedy, 1982, Welding Technology - Student's Manual, 2nd edition, Indianapolis, USA, A Howard W. Sams Book, Bobbs- Merill Educational
Publishing, ISBN:978-0672971099
Gower A. Kennedy, 1982, Welding Technology, 2nd edition, Lethbridge Community College, Alberta, New York, USA, Howard W. Sams & Son Inc., ISBN: 9780672979903
Frank R. Schell, 1977, Welding Procedures: Electric Arc, 1st edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-0827316034
Giachino, Weeks, Johnson, 1974, Welding Technology, 2nd edition, Chicago, 60637 USA, American Technical Society, ISBN: 978-0826930637
56

Sub Sector
Job Area
SHIELDED METAL ARC WELDING (SMAW) FOR 3G AND 4G

The person who is competent in this CU shall be able to perform shielded metal arc welding (SMAW) for 3G and 4G positions on carbon
steel or stainless steel material. Upon completion of this competency unit, trainees will be able to:1.
2.
3.
4.
5.
6.
7.
8.
9.
Learning Outcomes

Perform visual inspection and testing (destructive test)
MC-024-3:2012-C02
Competency Unit ID
Work Activities
Related Knowledge
1. Carry out
safety
assessment
at work area
Safety induction in
accordance to
Occupational Safety and
Health Act (OSHA), Factory
and Machinery Act,
Regulation, Guideline and
Code of Practice which
covers:
1
Hazard
identification, risk
assessment and
Level
Attitude / Safety /
Environmental
Related Skills
Demonstrate
safe working
habit and
consciousness
in workshop
Adhere to
worksite safety
requirement,
regulations
Alert in ensuring
safe working
Training
Duration
Training
Hours
24
652 Hours
Credit Values
Delivery
Mode
1
2
Lecture
Group Discussion
65
Assessment Criteria
Welding hazards
identified which
includes:
1.1 Safety hazard
1.2 Health hazard
1.3 Environmental
hazard
2
Welding risk
assessment
conducted
57
Work Activities
Related Knowledge
risk control
(HIRARC)
1.1
Safety hazard and
protection
1.1.1 Slipping or tripping,
floor protection
1.1.2 Fire and explosion
hazard
1.1.2.1
Fire/ spark/
heat protection
1.1.2.2
Fire
extinguisher
type
1.1.2.3
Elements of
fire
1.1.2.4
Flammable
hazard (ex:
painting, oil,
gas, etc)
1.1.2.5
Fire watcher
1.1.3 Working at height
1.1.4 Pressure system
1.1.5 Eye injuries
1.2
Health hazard and
protection
1.2.1 Ergonomic in
welding activities body posture
1.2.2 Welding fumes,
gases and
protection
1.2.3 Welder health
condition
Attitude / Safety /
Environmental
Related Skills
6
7
environment
Responsible
and accountable
in performing
welding task
Transparent in
reporting to
relevant
authority
Ensure
housekeeping
Ensure proper
PPE worn at
work site
Training
Hours
Delivery
Mode
Assessment Criteria
Proper protection
addressed
according to risk
assessment result
which covers:
3.1 Safety hazard
protection
3.2 Health hazard
protection
3.3 Environmental
hazard protection
4
Welding risk control

carried out which
covers:
4.1 Procedure to obtain
Permit To Work
(PTW)
4.2 Lock out, tack out
(LOTO)
4.3 Welding area
emergency
response plan
(ERP)
4.4 First aid treatment
procedure
conducted such as:
4.4.1 Cardio
Pulmonary
Resuscitation
(CPR)
4.4.2 Minor cut
58
Work Activities
Related Knowledge
Personnel
Protective
Equipment (PPE)
1.2.5 Arc burn (Intense
ultraviolet
radiation)
1.3
Environmental
hazard
1.3.1 Adequate access
and emergency
escape route
1.3.2 Confined space
1.3.3 Extreme
temperature
(Hotwork/
coldwork)
1.3.4 Adequate lighting
1.3.5 Falling objects
1.3.6 Radiation /
ultraviolet
protection
1.3.7 Noise hazard
1.3.7.1
Noise
exposure
1.3.7.2
Noise
protection
1.3.8 Electrical hazard
1.3.8.1
Electrical
protection
1.3.8.2
Electrical
shock
2
Safety operating
procedure
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
1.2.4
4.4.3
injuries
Bone fracture
first aid
treatment
59
Work Activities
Related Knowledge
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
Procedure to obtain
Permit To Work
(PTW)
Lock out, tack out
(LOTO)
First aid treatment
procedure
Cardio Pulmonary
Resuscitation
(CPR)
Minor cut injuries
Bone fracture first
aid treatment
Emergency
response plan
(ERP)
1
1.1
1.2
1.3
2
2.1
Identify welding
hazards which
covers:
Safety hazard
Health hazard
Environmental
hazard
24
1
2
Demonstration
Observation
Conduct welding
risk assessment to
address proper
protection within
work area which
covers:
Safety hazard
protection
60
Work Activities
Related Knowledge
Related Skills
2.2
2.3
3
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.4.3
2. Comply to
work
instruction
and relevant
1
2
3
Welding terminology
Welding drawing
and symbol
WPS content
Attitude / Safety /
Environmental
Training
Hours
Meticulous in
interpreting
WPS content
Refer to
30
Delivery
Mode
Assessment Criteria
Health hazard
protection
Environmental
hazard protection
Carry out welding
risk control by:
Execute
procedure to
obtain Permit To
Work (PTW)
Execute lock out,
tack out (LOTO)
procedure
Identify welding
area emergency
response plan
(ERP)
Able to conduct
first aid treatment
procedure such
as:
Cardio Pulmonary
Resuscitation
(CPR)
Minor cut injuries
Bone fracture first
aid treatment
1
2
1
2
Lecture
Group Discussion
1
2
Welding
terminology
described
Welding drawing
61
Work Activities
Welding
Procedure
Specification
(WPS)
Related Knowledge
4
5
6
7
8
8.1
9
10
11
12
13
14
15
16
Procedure
Qualification Record
(PQR)
Welding codes and
standards
Joint design
Material type and
grade (eg. material
mill certificate)
Welding position
For butt weld - 3G,
4G
Preheat
requirement
Post-weld heat
treatment (PWHT)
requirement
SMAW process
Consumable
specification,
classification and
type
Electrical
polarity, travel
speed
Welding parameters
table
Role of Destructive
Testing (DT)
assessment
Role of Non-
Attitude / Safety /
Environmental
Related Skills
superior for any

uncertainties
Conform to
WPS
requirements
Training
Hours
Delivery
Mode
Assessment Criteria
3
4
5
6
7
8
9
10
11
12
13
14
and symbol
interpreted
WPS content
interpreted
Procedure
(PQR) familiarised
Code and standard
complied
Joint design
interpreted
Type of material
identified
Welding position
interpreted
Reheat requirement
identified
PWHT requirement
identified
SMAW process
determined
Consumable
specification,
classification and
type identified
Electrical
characteristics
identified
Welding parameter
table interpreted
62
Work Activities
Related Knowledge
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
Destructive Testing
(NDT)
1
2
3
4
5
6
7
8
8.1
9
10
11
Describe welding
terminology
Interpret welding
drawing and
symbol
Interpret WPS
content
Familiarise
Procedure
Qualification
Record (PQR)
Comply to welding
codes and
standards
Able to interpret
joint design
Able to identify
type of material
Able to interpret
welding position
For butt weld - 3G,
4G
Able to identify
preheat
requirement
Able to identify
PWHT
requirement
Able to determine
SMAW process
10
1
2
Case study
Observation
63
Work Activities
Related Knowledge
12
13
14
3. Verify base
metal
material
used
1
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
2
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
Able to identify
consumable
specification,
classification and
type
Able to identify
electrical
polarity, travel
speed
Interpret welding
parameter table
Carbon Steel and

Stainless Steel
material
Material mill
certificate
Material standard
Heat number
Chemical
composition
Mechanical
Properties
Material form plate
Material size
Material physical
condition (eg. Dent,
rust, ovality, etc)
Meticulous in
verifying based
metal material in
accordance to
material mill
certificate
1
2
Lecture
Group Discussion
2
3
Confirm carbon
steel / stainless
1
2
Carbon steel /
stainless steel
material confirmed
to relevant WPS
Content of material
mill certificate
affirmed
Material condition
confirmed
Demonstration
Observation
64
Work Activities
Related Knowledge
Related Skills
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
2
4. Verify
consumable
as specified
1
1.2
1.3
1.4
2
3
4
Electrode
specification/
classification
Core wire
Electrode size
Flux coating (basic,
rutile and cellulose)
Electrode handling /
baking procedure
Electrode baking
oven
Electrode holding
oven
Attitude / Safety /
Environmental
Training
Hours
Cautious
practice when
handling hot
electrode from
baking oven
Delivery
Mode
Assessment Criteria
steel material to
relevant WPS
Affirm content of
material mill
certificate such as:
Material standard
Heat number
Chemical
composition
Mechanical
Properties
Material form plate
Material size
Confirm material
physical condition
(eg. Dent, rust,
ovality, etc)
1
Lecture
3
4
Electrode
specification/
classification
confirmed
Electrode
handling/baking
procedure carried
out if required
Oven temperature
for electrode baking
setup if required
Temperature for
holding oven setup
65
Work Activities
Related Knowledge
1.2
1.3
1.4
2
3
4
5. Check
SMAW
equipment
and
accessories
functionality
SMAW welding machine

(electrical driven
transformer)
1.1
Power supply
switch
1.2
Power source cable
1.3
Earth cable
1.4
Electrical driven
transformer
2 SMAW welding machine
(engine driven)
2.1 Diesel engine
Attitude / Safety /
Environmental
Related Skills
Confirm electrode
specification/
classification such
as:
Core wire
Electrode size
Flux coating
(basic, rutile and
cellulose)
Carry out
electrode
handling/baking
procedure if
required
Setting up oven
temperature for
baking
Setting up
temperature for
holding oven
1
Ensure welding
machine validity
is within
calibration
period
Ensure welding
machine in
functioning and
safe operating
condition
Training
Hours
Delivery
Mode
1
2
3
Demonstration
Observation
Case study
16
1
2
Lecture
Group Discussion
Assessment Criteria
if required
3
4
SMAW welding
machine
functionality
affirmed
Complete welding
accessories
installed to welding
machine
Relevant welding
PPE worn
Complete and
proper welding tools
66
Work Activities
Related Knowledge
2.2 Generator set

2.3 Earth cable
3 Accessories:
3.1 Welding cable
3.2 Electrode holder
3.3 Work cable
3.4 Work Clamp
3.5 Heating torch with
propane gas /
heating element
3.6 Clampmeter/
tongmeter
3.7 Contactless
pyrometer
3.8 Temperature
indicating crayon/
chalk
3.9 Cutting lense
goggle
3.10 Welding shield
3.11 Welding gauntlet
4 Marking tools and hand
tools:
4.1 Marking chalk
4.2 Steel ruler
4.3 Center punch
4.4 L square
4.5 Chisel
4.6 Chalk line
4.7 Chipping hammer
4.8 Portable grinding
machine
4.9 Grinding disc as
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
5
6
ensured
Status of welding
machine calibration
confirmed
Machine arc
stability assured
67
Work Activities
Related Knowledge
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
per type of material

Wire brush/ power
brush
4.11 Type of files
4.12 Ball peen hammer
4.13 Brush/broom
5 Electrode quiver
6 Status of welding
Machine calibration
7 Machine arc stability
4.10
3
4
5
6
6. Perform
Joint Configuration
24
Affirm SMAW
welding machine
(electrical driven
transformer)
functionality
Assure complete
welding
accessories
installed to
welding machine
Use relevant PPE
for welding
Ensure complete
and proper
welding tools for
use
Confirm status of
welding machine
calibration
Assure machine
arc stability
1
Ensure PPE in
40
Lecture
Joint configuration
68
Work Activities
SMAW
process
Related Knowledge
Attitude / Safety /
Environmental
Related Skills
Joint preparation
marking and cutting
2.1
Mechanical cutting
2.2
Oxy-acetylene gas
cutting
2.3
Plasma cutting
angle & bevel angle
4 Root face
5 Root gap /opening
6 Fit-up / jig & fixture setup
7 Tack weld
8 Surface cleaning
9 Welding position - 3G
and 4G
machine
11 Arc blow effect
12 Parameter setting
13 Root pass / penetration
15 Hot pass
17 Interpass
19 Capping
down procedure
2
3
4
7
1
Identify joint
configuration
good usage
condition
Ensure PPE are
worn
accordingly
Cautious when
dispensing hot
electrode butt
Ensure glove
free from oil
base and any
moisture during
electrode
handling
Electrode to be
handled
according to
manufacturer
recommendatio
n
Ensure proper
welding
environment
condition (eg.
under shade
from rain and
barricade from
heavy wind, etc)
Ensure grinding
work are carried
out safely
Ensure usage of
gauntlet for 4G
Training
Hours
Delivery
Mode
Assessment Criteria
Group Discussion
2
3
4
5
6
7
8
9
10
11
12
13
14
15
352
1
2
Demonstration
Observation
16
17
identified
Weld joint marking
and cutting
prepared
Angle check carried
out
Root face identified
Root gap /opening
identified
Fit-up / jig & fixture
set up
SMAW machine
operated
Arc striking test
performed
Tack weld carried
out
Surface cleaning
carried out
Welding performed
in position - 3G and
4G
Pre-heating carried
out as required
Welding parameters
set
Root pass /
penetration carried
out
Root pass cleaning
executed
Hot pass carried out
Hot pass cleaning
69
Work Activities
Related Knowledge
Related Skills
Prepare weld joint

Carry out
mechanical
cutting
2.2
cutting
2.3
Carry out
plasma cutting
3
Carry out check
Angle (included
angle & bevel
angle
4
Identify root face
5
Identify root gap
/opening
6
fixture
7
Operate SMAW
machine
8
Carry out arc
9
Carry out tack
weld
10
Carry out surface
cleaning
11
Setup welding
position - 3G and
4G
12
required
2.1
Attitude / Safety /
Environmental
position
Training
Hours
Delivery
Mode
Project
Assessment Criteria
execute
18 Interpass carried
out
executed
20 Capping executed
carried out
22 Post-heating carried
out as required
23 Attitude/ Safety/
Environmental
requirement carried
out during
performing SMAW
process
24 Welding machine
shut down
procedure executed
25 Housekeeping
carried out
70
Work Activities
Related Knowledge
13
14
15
16
17
18
19
20
21
22
23
24
7. Perform
visual
inspection
and testing
(destructive
test)
1
2
3
4

Root inspection
Weldment profile
Type of welding defect
and causes such as:
4.1
Irregular weld profile
4.2
Incomplete
penetration
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
Set the
parameters
Carry out root
pass / penetration
Execute root pass
cleaning
Carry out hot pass
Execute hot pass
cleaning
Carry out
interpass
Execute interpass
cleaning
Execute capping
Carry out
weldment cleaning
required
Carry out welding
machine shut
down procedure
Carry out
housekeeping
1
2
Meticulous in
checking visual
inspection
Inquisitive in
seeking advice
to confirm
acceptance &
rejection criteria
40
1
2
Lecture
Group Discussion
1
2
3
Relevant welding
inspection tools
selected
Root penetration
checked
Weldment profile
for butt weld
checked
71
Work Activities
Related Knowledge
Attitude / Safety /
Environmental
Related Skills
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
Undercut
Arc strike
Spatter
Crack
Slag inclusion
Porosity
Overlap
Lack of fusion
(surface)
4.11 Underfill
4.12 Burn-through
4.13 Misalignment (linear
& angular)
5 Welding specimen test
5.1
For butt weld - root
bend (RB), face
bend (FB), side
bend test
6 Acceptance & rejection
criteria according to
code
1
2
3
4
Select relevant
welding inspection
tools
Check root
penetration for
butt weld only
Check weldment
profile for butt
weld
Identify type of
surface defect
Training
Hours
Delivery
Mode
from superior
Open to
comments on
weld
imperfection
Ensure safety
when
performing
bend test
Assessment Criteria
4
5
40
1
2
3
Type of surface
defect Identified
Welding
specimen visual
and testing
carried out
Acceptance &
rejection criteria
confirmed
Demonstration
Observation
Case study
72
Work Activities
Related Knowledge
Related Skills
5
5.1
8. Carry out
back
gouging,
grinding and
back
welding as
required in
accordance
with test
specimen
1
2
3
4
5
1
2
2
3
4
9. Compile
work
completion
1
2
Welding checklist
Work completion hand
over
Training
Hours
Conform to
WPS repair
procedure
Perform
gouging and
grinding with
care
Practice
housekeeping
Delivery
Mode
Assessment Criteria
Carry out welding

specimen test
face bend (FB),
side bend test
Seek advice on
acceptance &
rejection criteria
from superior
Gouging technique
Grinding technique
Surface inspection and
testing (PT/MT)
Back welding
Weldment cleaning
1
Attitude / Safety /
Environmental
Apply gouging
technique where
applicable (exclude
stainless steel)
Apply grinding
technique
Apply back welding
Apply weldment
cleaning
Precise in filling
welding
checklist
Lecture
1
2
1
2
3
Demonstration
Observation
Case study
1
2
Lecture
Group Discussion
Gouging technique
applied to test
specimen
Grinding technique
applied to test
specimen
Back welding
technique applied to
test specimen
Weldment cleaning
applied to test
specimen
Welding checklist fill

up complete
Report compile and
73
Work Activities
checklist
Related Knowledge
Attitude / Safety /
Environmental
Related Skills
1
2
Fill-up welding
checklist
Compile and submit
report to superior
Integrity in
compiling report
Training
Hours
Delivery
Mode
1
2
Observation
Case study
Assessment Criteria
submitted to
superior for hand
over
Core Abilities
Social Skills
1.01
1.02
1.11
2.01
2.03
2.04
2.05
2.11
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.13
3.15
3.16
5.01
5.02
4.01
4.02
4.03
4.04
1
2
3
4
5
6

Communicate clearly
Learning Skills
Self-discipline
Teamwork
74
Core Abilities
4.05
6.01
6.02
6.03
6.05
6.06
6.07
Social Skills

Understand systems
75

ITEMS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

Base metal plate: plate 6mm to 12mm (minimum range)
Safety shoe
Coverall
Leather gloves
Fire extinguisher
Muffler / ear plug
First aid kit
Hazard signage
Material standard
SMAW welding machine (electrical driven transformer) and accessories
Electrode quiver
Hydraulic press
1: 1
1: 1
1: 1
1: 1
1: 1
1: 1
1: 1
1: 1
1: 5
1: 1
1 : 15
1 : 15
1: 1
1: 1
As required
1 : 15
1 : 15
1: 1
1: 1
1: 1
1 : 15
1: 1
1:
1:
1:
1:
5
15
15
15
76
ITEMS
27.
28.
29.
30.
31.
32.
33.
34.
35.
Spark lighter
arrester
back arrester
arrester
Band saw machine
Power saw machine
Welding checklist
1:
1:
15
1:
15
1:
1:
1:
1:
1:
1:
15
15
15
5
2
1
77
References
REFERENCES
1
2
3
4
5
6
7
8
9
10
11
978-0871715067
78

Sub Sector
Job Area
SHIELDED METAL ARC WELDING (SMAW) FOR 5G AND 6G (UP-HILL AND DOWN-HILL)
The person who is competent in this CU shall be able to perform shielded metal arc welding (SMAW) for 5G and 6G (up-hill and downhill) positions on carbon steel or stainless steel material. Upon completion of this competency unit, trainees will be able to:1.
2.
3.
4.
5.
6.
7.
8.
Learning Outcomes

MC-024-3:2012-C03
Competency Unit ID
Work Activities
Related Knowledge
1. Carry out
safety
assessment
at work area
Safety induction in
accordance to
Occupational Safety and
Health Act (OSHA),
Factory and Machinery Act,
Regulation, Guideline and
Code of Practice which
covers:
1
Hazard
assessment and
Level
Attitude / Safety /
Environmental
Related Skills
Demonstrate
safe working
habit and
consciousness
in workshop
Adhere to
worksite safety
requirement,
regulations
Alert in
ensuring safe
Training
Duration
Training
Hours
24
636 Hours
Credit Values
Delivery
Mode
1
2
Lecture
Group Discussion
64
Assessment Criteria
Welding hazards
identified which
includes:
1.1 Safety hazard
1.2 Health hazard
1.3 Environmental
hazard
2 Welding risk
assessment
conducted
3 Proper protection
79
Work Activities
Related Knowledge
risk control
(HIRARC)
1.1
Safety hazard and
protection
floor protection
hazard
1.1.2.1
Fire/ spark/
heat protection
1.1.2.2
Fire
extinguisher
type
1.1.2.3
Elements of
fire
1.1.2.4
Flammable
hazard (ex:
painting, oil,
gas, etc)
1.1.2.5
Fire watcher
1.1.5 Eye injuries
1.2
Health hazard and
protection
1.2.1 Ergonomic in
gases and
protection
1.2.3 Welder health
condition
Attitude / Safety /
Environmental
Related Skills
6
7
working
environment
Responsible
and
accountable in
performing
welding task
Transparent in
reporting to
relevant
authority
Ensure
housekeeping
Ensure proper
PPE worn at
work site
Training
Hours
Delivery
Mode
Assessment Criteria
addressed
according to risk
assessment result
which covers:
3.1 Safety hazard
protection
3.2 Health hazard
protection
3.3 Environmental
hazard protection
4 Welding risk control
carried out which
covers:
Permit To Work
(PTW)
(LOTO)
4.3 Welding area
emergency
response plan
(ERP)
procedure
conducted such as:
4.4.1 Cardio
Pulmonary
Resuscitation
(CPR)
4.4.2 Minor cut
injuries
4.4.3 Bone fracture
first aid
80
Work Activities
Related Knowledge
1.2.4
Personnel
Protective
Equipment (PPE)
ultraviolet
radiation)
1.3
Environmental
hazard
and emergency
escape route
1.3.3 Extreme
temperature
(Hotwork/
coldwork)
1.3.6 Radiation /
ultraviolet
protection
1.3.7 Noise hazard
1.3.7.1
Noise
exposure
1.3.7.2
Noise
protection
1.3.8.1
Electrical
protection
1.3.8.2
Electrical
shock
2
Safety operating
procedure
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
treatment
81
Work Activities
Related Knowledge
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
Procedure to obtain
Permit To Work
(PTW)
Lock out, tack out
(LOTO)
First aid treatment
procedure
Cardio Pulmonary
Resuscitation
(CPR)
Minor cut injuries
Bone fracture first
aid treatment
Emergency
response plan
(ERP)
1
1.1
1.2
1.3
2
2.1
2.2
Identify welding
hazards which
covers:
Safety hazard
Health hazard
Environmental
hazard
Conduct welding
risk assessment
to address proper
protection within
work area which
covers:
Safety hazard
protection
Health hazard
24
1 Case study
2 Observation
82
Work Activities
Related Knowledge
2.3
3
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.4.3
2. Comply to
work
instruction
and relevant
Welding
1
2
3
Welding
terminology
Welding drawing
and symbol
WPS content
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
protection
Environmental
hazard protection
Carry out welding
risk control by:
Execute
procedure to
obtain Permit To
Work (PTW)
Execute lock out,
tack out (LOTO)
procedure
Identify welding
area emergency
response plan
(ERP)
Able to conduct
first aid treatment
procedure such
as:
Cardio Pulmonary
Resuscitation
(CPR)
Minor cut injuries
Bone fracture first
aid treatment
1
2
Meticulous in
interpreting
WPS content
Refer to
superior for any
30
1
2
Lecture
Group Discussion
1
2
3
Welding terminology
described
Welding drawing and
symbol interpreted
WPS content interpreted
83
Work Activities
Procedure
Specificatio
n (WPS)
Related Knowledge
4
5
6
7
8
8.1
9
10
11
12
13
14
15
16
Procedure
Qualification
Record (PQR)
Welding codes and
standards
Joint design
Material type and
grade (eg. material
mill certificate)
Welding position
For butt weld - 5G,
6G
Preheat
requirement
Post-weld heat
treatment (PWHT)
requirement
SMAW process
Consumable
specification,
classification and
type
Electrical
polarity, travel
speed
Welding parameters
table
Role of Destructive
Testing (DT)
assessment
Role of Non-
Attitude / Safety /
Environmental
Related Skills
uncertainties
Conform to
WPS
requirements
Training
Hours
Delivery
Mode
Assessment Criteria
4
5
6
7
8
9
10
11
12
13
14
Procedure Qualification
Record (PQR)
familiarised
Code and standard
complied
Joint design interpreted
Type of material
identified
Welding position
interpreted
Reheat requirement
identified
PWHT requirement
identified
SMAW process
determined
Consumable
specification,
classification and type
identified
Electrical characteristics
identified
Welding parameter table
interpreted
84
Work Activities
Related Knowledge
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
Destructive Testing
(NDT)
1
2
3
4
5
6
7
8
1.1
9
10
11
Describe welding
terminology
Interpret welding
drawing and
symbol
Interpret WPS
content
Familiarise
Procedure
Qualification
Record (PQR)
Comply to
welding codes
and standards
Able to interpret
joint design
Able to identify
type of material
Able to interpret
welding position
For butt weld 5G, 6G
Able to identify
preheat
requirement
Able to identify
PWHT
requirement
Able to determine
SMAW process
10
1
2
Case study
Observation
85
Work Activities
Related Knowledge
12
13
14
3. Verify base
metal
material
used
1
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
2
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
Able to identify
consumable
specification,
classification and
type
Able to identify
electrical
polarity, travel
speed
Interpret welding
parameter table
Carbon Steel and

Stainless Steel
material
Material mill
certificate
Material standard
Heat number
Chemical
composition
Mechanical
properties
Material form pipe
Material size
Material physical
rust, ovality, etc)
Meticulous in
verifying based
metal material
in accordance
to material mill
certificate
1
2
Lecture
Group Discussion
2
3
Confirm carbon
steel / stainless
1
2
Carbon steel /
stainless steel
material confirmed
to relevant WPS
Content of material
mill certificate
affirmed
Material condition
confirmed
Demonstration
Observation
86
Work Activities
Related Knowledge
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
2
4. Verify
consumable
as specified
1
1.1
1.2
1.3
2
3
4
Electrode
specification/
classification
Core wire
Electrode size
baking procedure
Electrode baking
oven
Electrode holding
oven
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
steel material to
relevant WPS
Affirm content of
material mill
certificate such
as:
Material standard
Heat number
Chemical
composition
Mechanical
Properties
Material form pipe
Material size
Confirm material
physical condition
(eg. Dent, rust,
ovality, etc)
1
Cautious
practice when
handling hot
electrode from
baking oven
Lecture
3
4
Electrode
specification/
classification
confirmed
Electrode
handling/baking
procedure carried
out if required
Oven temperature
for electrode baking
setup if required
Temperature for
holding oven setup
87
Work Activities
Related Knowledge
1.1
1.2
1.3
2
3
4
5. Check
SMAW
equipment
and
accessories
functionality
1
1.1
1.2
1.3
1.4
2
SMAW welding
machine (electrical
driven transformer)
Power supply
switch
Power source cable
Earth cable
Electrical driven
transformer
SMAW welding
machine (engine
driven)
Attitude / Safety /
Environmental
Related Skills
Confirm electrode
specification/
classification such
as:
Core wire
Electrode size
Flux coating
(basic, rutile and
cellulose)
Carry out
electrode
handling/baking
procedure if
required
Setting up oven
temperature for
baking
Setting up
temperature for
holding oven
1
Ensure welding
machine validity
is within
calibration
period
Ensure welding
machine in
functioning and
safe operating
condition
Training
Hours
Delivery
Mode
1
2
3
Demonstration
Observation
Case study
16
1
2
Lecture
Group Discussion
Assessment Criteria
if required
3
4
SMAW welding
machine
functionality
affirmed
Complete welding
accessories
machine
Relevant welding
PPE worn
Complete and
proper welding tools
88
Work Activities
Related Knowledge
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
Diesel engine
Electric generator
set
Earth cable
Accessories:
Welding cable
Electrode holder
Work cable
Work Clamp
Heating torch with
propane gas /
heating element
Clampmeter/
tongmeter
Contactless
pyrometer
Temperature
indicating crayon/
chalk
Cutting lens goggle
Welding shield
Welding gauntlet
Marking tools and
hand tools:
Marking chalk
Steel ruler
Center punch
L square
Chisel
Chalk line
Chipping hammer
Portable grinding
machine
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
5
6
ensured
Status of welding
machine calibration
confirmed
Machine arc stability
assured
89
Work Activities
Related Knowledge
4.9
4.10
4.11
4.12
4.13
5
6
7
4
5
1
2
Training
Hours
Delivery
Mode
Assessment Criteria
Grinding disc as per

specification
Wire brush/ power
brush
Type of files
Ball peen hammer
Brush/broom
Electrode quiver
Status of welding
Machine calibration
Welding arc stability
1
6. Perform
SMAW
process
Attitude / Safety /
Environmental
Related Skills
Joint Configuration
Joint preparation
marking and cutting
2.1
Mechanical cutting
Affirm SMAW
welding machine
functionality
Assure complete
welding
accessories
installed to
welding machine
Ensure complete
and proper
welding tools for
use
Confirm status of
welding machine
calibration
Assure welding
arc stability
24
1
2
Ensure PPE in
good usage
condition
Ensure PPE are
40
1
2
3
1
2
Demonstration
Observation
Case study
Lecture
Group Discussion
1
2
Joint configuration
identified
Weld joint marking
and cutting
90
Work Activities
Related Knowledge
Oxy-acetylene gas
cutting
2.3
Plasma cutting
angle & bevel angle
4 Root face
5 Root gap /opening
6 Fit-up / jig & fixture
setup
7 Tack weld
8 Surface cleaning
9 Welding position - 5G
and 6G
machine
11 Arc blow effect
15 Hot pass
17 Interpass
19 Capping
21 Gouging technique
(carbon steel only)
22 Grinding technique
23 Surface inspection and
testing (PT/MT)
24 Back welding/ back filled
down procedure
Attitude / Safety /
Environmental
Related Skills
2.2
3
4
worn
accordingly
Cautious when
dispensing hot
electrode butt
Ensure glove
free from oil
base and any
moisture during
electrode
handling
Electrode to be
handled
according to
manufacturer
recommendatio
n
Ensure proper
welding
environment
condition (eg.
under shade
from rain and
barricade from
heavy wind,
etc)
Ensure grinding
work are carried
out safely
Training
Hours
Delivery
Mode
Assessment Criteria
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
prepared
Angle check carried
out
Root face identified
Root gap /opening
identified
set up
SMAW machine
operated
Arc striking test
performed
Tack weld carried
out
Surface cleaning
carried out
Welding performed
in position - 5G and
6G
Pre-heating carried
out as required
Welding parameters
set
Root pass /
penetration carried
out
Root pass cleaning
executed
Hot pass carried out
Hot pass cleaning
executed
Interpass carried
out
91
Work Activities
Related Knowledge
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
1
2
2.1
2.2
2.3
3
4
5
6
7
8
9
10
11
Identify joint
configuration
Prepare weld joint
Carry out
mechanical
cutting
cutting
Carry out plasma
cutting
Carry out check
Angle (included
angle & bevel
angle
Identify root face
Identify root gap
/opening
fixture
Operate SMAW
machine
Carry out arc
Carry out tack
weld
Carry out surface
cleaning
Setup welding
position - 5G and
352
1
2
3
Demonstration
Observation
Project
Assessment Criteria
executed
20 Capping executed
carried out
22 Post-heating carried
out as required
Environmental
requirement carried
out during
performing SMAW
process
24 Welding machine
shut down
procedure executed
25 Housekeeping
carried out
92
Work Activities
Related Knowledge
12
13
14
15
16
17
18
19
20
21
22
23
24
7. Perform
visual
1
2

Root inspection
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
6G
required
Set the
parameters
Carry out root
pass / penetration
Execute root pass
cleaning
Carry out hot
pass
Execute hot pass
cleaning
Carry out
interpass
Execute interpass
cleaning
Execute capping
Carry out
weldment
cleaning
required
Carry out welding
machine shut
down procedure
Carry out
housekeeping
1
Meticulous in
checking visual
40
1
2
Lecture
Group Discussion
Relevant welding
inspection tools
93
Work Activities
inspection
and testing
(destructive
test)
Related Knowledge
Attitude / Safety /
Environmental
Related Skills
3
4
Weldment profile
and causes such as:
4.1
Irregular weld
profile
4.2
Incomplete
penetration
4.3
Undercut
4.4
Arc strike
4.5
Spatter
4.6
Crack
4.7
Slag inclusion
4.8
Porosity
4.9
Overlap
4.10 Lack of fusion
(surface)
4.11 Underfill
4.12 Burn-through
& angular)
5.1
bend (RB), face
bend (FB), side
bend test
criteria according to
code
1
2
Select relevant
welding
inspection tools
Check root
Training
Hours
Delivery
Mode
inspection
Inquisitive in
seeking advice
to confirm
acceptance &
rejection criteria
from superior
Open to
comments on
weld
imperfection
Ensure safety
when
performing
bend test
Assessment Criteria
2
3
4
5
40
1
2
3
selected
Root penetration
checked
Weldment profile
for butt weld
checked
Type of surface
defect Identified
Welding
specimen visual
and testing
carried out
Acceptance &
rejection criteria
confirmed
Demonstration
Observation
Case study
94
Work Activities
Related Knowledge
3
4
5
5.1
8. Compile
work
completion
checklist
1
2
Attitude / Safety /
Environmental
Related Skills
Delivery
Mode
Assessment Criteria
penetration for
butt weld only
Check weldment
profile for butt
weld
Identify type of
surface defect
Carry out welding
specimen test
face bend (FB),
side bend test
Seek advice on
acceptance &
rejection criteria
from superior
Welding checklist
over
1
Training
Hours
Fill-up welding
checklist
Compile and submit
report to superior
Precise in filling
welding
checklist
Integrity in
compiling report
4
4
1
2
Lecture
Group Discussion
1
2
Observation
Case study
1
2

up complete
Report compile and
submitted to
superior for hand
over
95
Core Abilities
1.01
1.02
1.11
2.01
2.03
2.04
2.05
2.11
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.13
3.15
3.16
5.01
5.02
4.01
4.02
4.03
4.04
4.05
6.01
6.02
6.03
6.05
6.06
6.07

Communicate clearly
Understand systems
Social Skills
1.
2.
3.
4.
5.
6.
Learning Skills
Self-discipline
Teamwork
96

ITEMS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

Code and standard (API 1104)
Code and standard (ISO)
Base metal pipe: 6"to 8" NPS schedule 80 (minimum range)
Safety shoe
Coverall
Leather gloves
Fire extinguisher
Muffler / ear plug
First aid kit
Hazard signage
Material standard
Electrode quiver
1: 1
1: 1
1: 1
1: 1
1: 1
1
1
1
1
1: 1
1: 1
1: 1
1: 1
1: 5
1: 1
1 : 15
1 : 15
1: 1
1: 1
As required
1 : 15
1 : 15
1: 1
1: 1
1: 1
1 : 15
1:
1:
1
5
97
ITEMS
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Hydraulic press
Spark lighter
arrester
back arrester
arrester
Band saw machine
Power saw machine
Welding checklist
1:
1:
1:
1:
15
15
15
1
1:
15
1:
15
1:
1:
1:
1:
1:
1:
15
15
15
5
2
1
98
References
REFERENCES
1
2
3
4
5
6
7
8
9
10
11
978-0871715067
99

Sub Sector
Job Area
SHIELDED METAL ARC WELDING (SMAW) 6GR

The person who is competent in this CU shall be able to perform shielded metal arc welding (SMAW) 6GR positions on carbon steel
material. Upon completion of this competency unit, trainees will be able to:-
1.
2.
3.
4.
5.
6.
7.
8.
Learning Outcomes
Competency Unit ID

MC-024-3:2012-E01
Work Activities
Related Knowledge
1. Carry out
safety
assessment at
work area
Safety induction in
accordance to Occupational
Safety and Health Act
(OSHA), Factory and
Machinery Act, Regulation,
1
Hazard identification,
risk assessment and
risk control
(HIRARC)
1.1
Safety hazard and
Training
460 Hours
Credit Values
46
Duration
Attitude / Safety /
Training
Delivery
Assessment Criteria
Environmental
Hours
Mode
Level
Related Skills
3
4
Demonstrate safe
working habit and
consciousness in
workshop
Adhere to
worksite safety
requirement,
regulations
Alert in ensuring
safe working
environment
Responsible and
24
1
2
Lecture
Group
Discussion
Welding hazards
identified which
includes:
1.1 Safety hazard
1.2 Health hazard
1.3 Environmental
hazard
2 Welding risk
assessment
conducted
3 Proper
protection
100
Work Activities
Related Knowledge
protection
Slipping or tripping,
floor protection
hazard
1.1.2.1
Fire/ spark/
heat protection
1.1.2.2
Fire
extinguisher
type
1.1.2.3
Elements of fire
1.1.2.4
Flammable
hazard (ex:
painting, oil,
gas, etc)
1.1.2.5
Fire watcher
1.1.5 Eye injuries
1.2
Health hazard and
protection
1.2.1 Ergonomic in
gases and
protection
1.2.3 Welder health
condition
1.2.4 Personnel
Protective
Equipment (PPE)
Attitude / Safety /
Environmental
Related Skills
1.1.1
5
6
7
accountable in
performing
welding task
Transparent in
reporting to
relevant authority
Ensure
housekeeping
Ensure proper
PPE worn at work
site
Training
Hours
Delivery
Mode
Assessment Criteria
addressed
according to risk
assessment
result which
covers:
3.1 Safety hazard
protection
3.2 Health hazard
protection
3.3 Environmental
hazard
protection
4 Welding risk
control carried
out which
covers:
4.1 Procedure to
obtain Permit To
Work (PTW)
4.2 Lock out, tack
out (LOTO)
4.3 Welding area
emergency
response plan
(ERP)
4.4 First aid
treatment
procedure
conducted such
as:
4.4.1 Cardio
Pulmonary
Resuscitatio
101
Work Activities
Related Knowledge
ultraviolet radiation)
Environmental
hazard
and emergency
escape route
1.3.3 Extreme
temperature
(Hotwork/ coldwork)
1.3.6 Radiation /
ultraviolet protection
1.3.7 Noise hazard
1.3.7.1
Noise exposure
1.3.7.2
Noise
protection
1.3.8.1
Electrical
protection
1.3.8.2
Electrical shock
2
Safety operating
procedure
2.1
Procedure to obtain
Permit To Work
(PTW)
2.2
Lock out, tack out
(LOTO)
2.3
First aid treatment
procedure
2.3.1 Cardio Pulmonary
Resuscitation
1.3
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
4.4.2
4.4.3
n (CPR)
Minor cut
injuries
Bone
fracture first
aid
treatment
102
Work Activities
Related Knowledge
2.3.2
2.3.3
2.3.4
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
(CPR)
Minor cut injuries
Bone fracture first
aid treatment
Emergency
response plan
(ERP)
1.
1.1
1.2
1.3
2
2.1
2.2
2.3
3
3.1
3.2
Identify welding
hazards which
covers:
Safety hazard
Health hazard
Environmental
hazard
Conduct welding
risk assessment to
address proper
protection within
work area which
covers:
Safety hazard
protection
Health hazard
protection
Environmental
hazard protection
Carry out welding
risk control by:
Execute procedure
to obtain Permit To
Work (PTW)
Execute lock out,
24
1 Case study
2. Observation
103
Work Activities
Related Knowledge
3.3
3.4
3.4.1
3.4.2
3.4.3
2. Comply to
work
instruction
and relevant
Welding
Procedure
Specification
(WPS)
1
2
3
4
5
6
7
8
8.1
9
10
Welding terminology
Welding drawing and
symbol
WPS content
Procedure
(PQR)
Welding codes and
standards
Joint design
Material type and
grade (eg. material
mill certificate)
Welding position
For butt weld - 6GR
Preheat requirement
Post-weld heat
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
tack out (LOTO)

procedure
Identify welding
area emergency
response plan
(ERP)
Able to conduct
first aid treatment
procedure such as:
Cardio Pulmonary
Resuscitation
(CPR)
Minor cut injuries
Bone fracture first
aid treatment
1
2
3
Meticulous in
interpreting WPS
content
Refer to superior
for any
uncertainties
Conform to WPS
requirements
30
1
2
Lecture
Group
Discussion
1
2
3
4
5
6
7
8
Welding terminology
described
Welding drawing and
symbol interpreted
WPS content
interpreted
Procedure
(PQR) familiarised
Code and standard
complied
Joint design
interpreted
Type of material
identified
Welding position
interpreted
104
Work Activities
Related Knowledge
11
12
13
14
15
16
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
treatment (PWHT)
requirement
SMAW process
Consumable
specification,
classification and
type
Electrical
polarity, travel speed
Welding parameters
table
Role of Destructive
Testing (DT)
assessment
Role of NonDestructive Testing
(NDT)
10
11
12
13
14
1
2
3
4
Describe welding
terminology
Interpret welding
drawing and
symbol
Interpret WPS
content
Familiarise
Procedure
Qualification
Record (PQR)
Comply to welding
codes and
10
1
2
Reheat requirement
identified
PWHT requirement
identified
SMAW process
determined
Consumable
specification,
classification and
type identified
Electrical
characteristics
identified
Welding parameter
table interpreted
Case study
Observation
105
Work Activities
Related Knowledge
6
7
8
8.1
9
10
11
12
13
14
3. Verify base
metal material
used
1
1.1
Carbon Steel
material
Material mill
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
standards
Able to interpret
joint design
Able to identify
type of material
Able to interpret
welding position
For butt weld 6GR
Able to identify
preheat
requirement
Able to identify
PWHT requirement
Able to determine
SMAW process
Able to identify
consumable
specification,
classification and
type
Able to identify
electrical
polarity, travel
speed
Interpret welding
parameter table
1
Meticulous in
verifying based
metal material in
1
2
Lecture
Group
Discussion
Carbon steel
material
confirmed to
106
Work Activities
Related Knowledge
Related Skills
certificate
Material standard
Heat number
Chemical
composition
1.1.4 Mechanical
properties
1.1.5 Material form pipes of dissimilar
thicknesses with
restricted ring plate
1.1.6 Material size
2
Material physical
rust, ovality, etc)
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
accordance to
material mill
certificate
1.1.1
1.1.2
1.1.3
Assessment Criteria
1
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
Confirm carbon
steel material to
relevant WPS
Affirm content of
material mill
Material standard
Heat number
Chemical
composition
Mechanical
Properties
Material form pipes of dissimilar
thicknesses with
restricted ring
plate
1
2
relevant WPS
Content of
material mill
certificate
affirmed
Material
condition
confirmed
Demonstration
Observation
107
Work Activities
Related Knowledge
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
1.1.6 Materials sizes

2
Confirm material
physical condition
(eg. Dent, rust,
ovality, etc)
4. Verify
consumable
as specified
1
1.1
1.2
1.3
2
3
4
Electrode
specification/
classification
Core wire
Electrode size
baking procedure
Electrode baking
oven
Electrode holding
oven
Cautious practice
when handling
hot electrode
from baking oven
Lecture
1.1
1.2
1.3
2
Confirm electrode
specification/
classification such
as:
Core wire
Electrode size
Carry out electrode
handling/baking
procedure if
required
Setting up oven
temperature for
1
2
3
Demonstration
Observation
Case study
Electrode
specification/
classification
confirmed
Electrode
handling/baking
procedure
carried out if
required
Oven
temperature for
electrode baking
setup if required
Temperature for
holding oven
setup if required
108
Work Activities
Related Knowledge
4
5. Check SMAW
equipment
and
accessories
functionality
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
SMAW welding
machine (electrical
driven transformer)
Power supply switch
Power source cable
Earth cable
Electrical driven
transformer
SMAW welding
machine (engine
driven)
Diesel engine
Electric generator
set
Earth cable
Accessories:
Welding cable
Electrode holder
Work cable
Work Clamp
Heating torch with
propane gas /
heating element
Clampmeter/
tongmeter
Contactless
pyrometer
Temperature
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
baking
Setting up
temperature for
holding oven
1
Ensure welding
machine validity
is within
calibration period
Ensure welding
machine in
functioning and
safe operating
condition
16
1
2
Lecture
Group
Discussion
3
4
5
SMAW welding
machine
functionality
affirmed
Complete
welding
accessories
installed to
welding machine
Relevant
welding PPE
worn
Complete and
proper welding
tools ensured
Status of
welding machine
calibration
confirmed
Machine arc
stability assured
109
Work Activities
Related Knowledge
3.9
3.10
3.11
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
5
6
7
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
indicating crayon/
chalk
Cutting lens goggle
Welding shield
Welding gauntlet
Marking tools and
hand tools:
Marking chalk
Steel ruler
Center punch
L square
Chisel
Chalk line
Chipping hammer
Portable grinding
machine
specification
Wire brush/ power
brush
Type of files
Ball peen hammer
Brush/broom
Electrode quiver
Status of welding
Machine calibration
Arc stability
technique
1
2
Affirm SMAW
welding machine
functionality
Assure complete
24
1
2
3
Demonstration
Observation
Case study
110
Work Activities
Related Knowledge
3
4
5
6. Perform
SMAW
process
1
2
Joint Configuration
Joint preparation marking
and cutting
2.1
Mechanical cutting
2.2
Oxy-acetylene gas
cutting
angle & bevel angle
4 Root face
5 Root gap /opening
6 Fit-up / jig & fixture setup
7 Tack weld
8 Surface cleaning
9 Welding position - 6GR
machine
11 Arc blow effect
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
welding
accessories
machine
Ensure complete
and proper welding
tools for use
Confirm status of
welding machine
calibration
Assure welding arc
stability
1
2
3
4
Ensure PPE in
good usage
condition
Ensure PPE are
worn accordingly
Cautious when
dispensing hot
electrode butt
Ensure glove free
from oil base and
any moisture
during electrode
handling
Electrode to be
handled
according to
manufacturer
recommendation
Ensure proper
welding
40
1
2
Lecture
Group
Discussion
1
2
3
4
5
6
7
8
9
Joint
configuration
identified
Weld joint
marking and
cutting prepared
Angle check
carried out
Root face
identified
Root gap
/opening
identified
Fit-up / jig &
fixture set up
SMAW machine
operated
Arc striking test
performed
Tack weld
111
Work Activities
Related Knowledge
Attitude / Safety /
Environmental
Related Skills
15
16
17
18
19
20
21
22
23
Hot pass
Hot pass cleaning
Interpass
Interpass cleaning
Capping
Weldment cleaning
Gouging technique
Grinding technique
testing (PT/MT)
24 Back welding/ back filled
down procedure
1
2
2.1
2.2
3
4
5
6
7
Identify joint
configuration
Prepare weld joint
Carry out
mechanical cutting
cutting
Carry out check
Angle (included
angle & bevel
angle
Identify root face
Identify root gap
/opening
fixture
Operate SMAW
Training
Hours
Delivery
Mode
environment
condition (eg.
under shade from
rain and
barricade from
heavy wind, etc)
Ensure grinding
work are carried
out safely
176
1
2
3
Demonstration
Observation
Project
Assessment Criteria
carried out
10 Surface cleaning
carried out
11 Welding
performed in
position 6GR
12 Pre-heating
carried out as
required
13 Welding
parameters set
14 Root pass /
penetration
carried out
15 Root pass
cleaning
executed
16 Hot pass carried
out
17 Hot pass
cleaning execute
18 Interpass carried
out
19 Interpass
cleaning
executed
20 Capping
executed
21 Weldment
cleaning carried
out
22 Post-heating
carried out as
112
Work Activities
Related Knowledge
Related Skills
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
machine
Carry out arc
Carry out tack weld
Carry out surface
cleaning
Setup welding
position 6GR
Carry out preheating as required
Set welding
parameters
Carry out root pass
/ penetration
Execute root pass
cleaning
Carry out hot pass
Execute hot pass
cleaning
Carry out interpass
Execute interpass
cleaning
Execute capping
Carry out weldment
cleaning
Carry out postheating as required
Carry out welding
machine shut down
procedure
Carry out
housekeeping
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
required
Environmental
requirement
carried out
during
performing
SMAW process
24 Welding
machine shut
down procedure
executed
25 Housekeeping
carried out
113
Work Activities
7. Perform visual
inspection and
testing
(destructive
test)
Related Knowledge
Attitude / Safety /
Environmental
Related Skills
1
2
3
4

Root inspection
Weldment profile
and causes such as:
4.1
4.2
Incomplete
penetration
4.3
Undercut
4.4
Arc strike
4.5
Spatter
4.6
Crack
4.7
Slag inclusion
4.8
Porosity
4.9
Overlap
4.10 Lack of fusion
(surface)
4.11 Underfill
4.12 Burn-through
& angular)
5.1
bend (RB), face
bend (FB), side bend
test
criteria according to code
3
4
Meticulous in
checking visual
inspection
Inquisitive in
seeking advice to
confirm
acceptance &
rejection criteria
from superior
Open to
comments on
weld imperfection
Ensure safety
when performing
bend test
Training
Hours
40
Delivery
Mode
1
2
Lecture
Group
Discussion
Assessment Criteria
2
3
4
5
1
2
Select relevant
welding inspection
tools
Check root
40
1
2
3
Relevant
welding
inspection
tools selected
Root
penetration
checked
Weldment
profile for butt
weld checked
Type of
surface defect
Identified
Welding
specimen
visual and
testing carried
out
Acceptance &
rejection
criteria
confirmed
Demonstration
Observation
Case study
114
Work Activities
Related Knowledge
3
4
5
5.1
8. Compile work
completion
checklist
1
2
Attitude / Safety /
Environmental
Related Skills
Delivery
Mode
Assessment Criteria
penetration for butt

weld only
Check weldment
profile for butt weld
Identify type of
surface defect
Carry out welding
specimen test
bend (RB), face
bend (FB), side
bend test
Seek advice on
acceptance &
rejection criteria
from superior
Welding checklist
over
1
2
1
2
Training
Hours
Fill-up welding checklist

Compile and submit
report to superior
Precise in filling
welding checklist
Integrity in
compiling report
1
2
Lecture
Group
Discussion
1
2
Observation
Case study
1
2
Welding
checklist fill up
complete
Report compile
and submitted to
superior for hand
over
115
Core Abilities
1.01
1.02
1.11
2.01
2.03
2.04
2.05
2.11
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.13
3.15
3.16
5.01
5.02
4.01
4.02
4.03
4.04
4.05
6.01
6.02
6.03
6.05
6.06
6.07

Communicate clearly
Understand systems
Social Skills
1.
2.
3.
4.
5.
6.
Learning Skills
Self-discipline
Teamwork
116

ITEMS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

Base metal pipe dissimilar thickness 8" schedule 80 and schedule 120, with
restricted ring 6mm thickness
Safety shoe
Coverall
Leather gloves
Fire extinguisher
Muffler / ear plug
First aid kit
Hazard signage
Material standard
Electrode quiver
Hydraulic press
1:
1:
1:
1
1
1
1
1
1: 1
1: 1
1: 1
1: 1
1: 5
1: 1
1 : 15
1 : 15
1: 1
1: 1
As required
1 : 15
1 : 15
1: 1
1: 1
1: 1
1 : 15
1:
1:
1:
1:
1
5
15
15
117
ITEMS
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

Spark lighter
arrester
back arrester
arrester
Band saw machine
Power saw machine
Welding checklist
1:
1:
15
1
1:
15
1:
15
1:
1:
1:
1:
1:
1:
15
15
15
5
2
1
118
References
REFERENCES
1
2
3
4
5
6
7
8
9
10
11
978-0871715067
119

Sub Sector
Job Area
SUBMERGED ARC WELDING (SAW) 1G

The person who is competent in this CU shall be able to operate submerged arc welding (SAW) 1G position on carbon steel material. Upon
completion of this competency unit, trainees will be able to:-
1.
2.
3.
4.
5.
6.
7.
8.
9.
Learning Outcomes

Check SAW equipment and accessories functionality
Operate SAW process
MC-024-3:2012-E02
Competency Unit ID
Work Activities
Related Knowledge
1. Carry out
safety
assessment
at work area
Safety induction in
accordance to Occupational
Safety and Health Act
(OSHA), Factory and
Machinery Act, Regulation,
1
Hazard
assessment and risk
control (HIRARC)
Level
3
Attitude / Safety /
Environmental
Related Skills
Demonstrate
safe working
habit and
consciousness
in workshop
Adhere to
worksite safety
requirement,
regulations
Alert in ensuring
safe working
Training
Duration
Training
Hours
24
248 Hours
Credit Values
Delivery
Mode
1
2
Lecture
Group
Discussion
25
Assessment Criteria
Welding hazards
identified which
includes:
1.1 Safety hazard
1.2 Health hazard
1.3 Environmental
hazard
2
Welding risk
assessment
conducted
120
Work Activities
Related Knowledge
Safety hazard and

protection
floor protection
hazard
1.1.2.1
Fire/ spark/
heat protection
1.1.2.2
Fire
extinguisher
type
1.1.2.3
Elements of fire
1.1.2.4
Flammable
hazard (ex:
painting, oil,
gas, etc)
1.1.2.5
Fire watcher
1.1.5 Eye injuries
1.2
Health hazard and
protection
1.2.1 Ergonomic in
gases and
protection
1.2.3 Welder health
condition
1.2.4 Personnel
Protective
Equipment (PPE)
Attitude / Safety /
Environmental
Related Skills
1.1
6
7
environment
Responsible
and accountable
in performing
welding task
Transparent in
reporting to
relevant
authority
Ensure
housekeeping
Ensure proper
PPE worn at
work site
Training
Hours
Delivery
Mode
Assessment Criteria
Proper protection
addressed
according to risk
assessment result
which covers:
3.1 Safety hazard
protection
3.2 Health hazard
protection
3.3 Environmental
hazard protection
4
Welding risk control

carried out which
covers:
Permit To Work
(PTW)
(LOTO)
4.3 Welding area
emergency
response plan
(ERP)
procedure
conducted such as:
4.4.1 Cardio
Pulmonary
Resuscitation
(CPR)
4.4.2 Minor cut
121
Work Activities
Related Knowledge
Arc burn (Intense

ultraviolet radiation)
1.3
Environmental
hazard
and emergency
escape route
1.3.3 Extreme
temperature
(Hotwork/
coldwork)
1.3.6 Radiation /
ultraviolet
protection
1.3.7 Noise hazard
1.3.7.1
Noise exposure
1.3.7.2
Noise
protection
1.3.8.1
Electrical
protection
1.3.8.2
Electrical shock
2
Safety operating
procedure
2.1
Procedure to obtain
Permit To Work
(PTW)
2.2
Lock out, tack out
(LOTO)
2.3
First aid treatment
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
1.2.5
4.4.3
injuries
Bone fracture
first aid
treatment
122
Work Activities
Related Knowledge
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
procedure
Cardio Pulmonary
Resuscitation
(CPR)
2.3.2 Minor cut injuries
2.3.3 Bone fracture first
aid treatment
2.3.4 Emergency
response plan
(ERP)
2.3.1
1.
1.1
1.2
1.3
2
2.1
2.2
2.3
3
3.1
Identify welding
hazards which
covers:
Safety hazard
Health hazard
Environmental
hazard
Conduct welding
risk assessment to
address proper
protection within
work area which
covers:
Safety hazard
protection
Health hazard
protection
Environmental
hazard protection
Carry out welding
risk control by:
Execute procedure
24
1
2
Case study
Observation
123
Work Activities
Related Knowledge
3.2
3.3
3.4
3.4.1
3.4.2
3.4.3
2. Comply to
work
instruction
and relevant
Welding
Procedure
Specification
(WPS)
1
2
3
4
5
6
7
Welding terminology
Welding drawing
and symbol
WPS content
Procedure
(PQR)
Welding codes and
standards
Joint design
Material type and
grade (eg. material
mill certificate)
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
to obtain Permit To
Work (PTW)
Execute lock out,
tack out (LOTO)
procedure
Identify welding
area emergency
response plan
(ERP)
Able to conduct
first aid treatment
procedure such
as:
Cardio Pulmonary
Resuscitation
(CPR)
Minor cut injuries
Bone fracture first
aid treatment
1
2
3
Meticulous in
interpreting WPS
content
Refer to superior
for any
uncertainties
Conform to WPS
requirements
30
1
2
Lecture
Group
Discussion
1
2
3
4
5
6
7
Welding terminology
described
Welding drawing and
symbol interpreted
WPS content interpreted
Procedure Qualification
Record (PQR)
familiarised
Code and standard
complied
Joint design interpreted
Type of material
identified
124
Work Activities
Related Knowledge
8
8.1
9
10
11
12
13
14
15
16
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
Welding position
For butt weld 1G
Preheat requirement
Post-weld heat
treatment (PWHT)
requirement
SMAW process
Consumable
specification,
classification and
type
Electrical
polarity, travel
speed
Welding parameters
table
Role of Destructive
Testing (DT)
assessment
Role of NonDestructive Testing
(NDT)
9
10
11
12
13
14
1
2
3
4
Describe welding
terminology
Interpret welding
drawing and
symbol
Interpret WPS
content
Familiarise
10
1
2
Welding position
interpreted
Reheat requirement
identified
PWHT requirement
identified
SMAW process
determined
Consumable
specification,
classification and type
identified
Electrical characteristics
identified
Welding parameter table
interpreted
Case study
Observation
125
Work Activities
Related Knowledge
Related Skills
5
6
7
8
8.1
9
10
11
12
13
14
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
Procedure
Qualification
Record (PQR)
Comply to welding
codes and
standards
Able to interpret
joint design
Able to identify
type of material
Able to interpret
welding position
For butt weld 1G
Able to identify
preheat
requirement
Able to identify
PWHT
requirement
Able to determine
SMAW process
Able to identify
consumable
specification,
classification and
type
Able to identify
electrical
polarity, travel
speed
Interpret welding
126
Work Activities
Related Knowledge
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
parameter table
3. Check SAW
equipment
and
accessories
functionality
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
SAW welding
machine (electrical
driven transformer)
Power supply switch
Power source cable
Earth cable
Electrical driven
transformer
SAW welding
machine (engine
driven)
Diesel engine
Generator set
Earth cable
Accessories:
Welding cable
Flux hopper
Slide rail
Electrode wire spool
Electrode wire reel
Carriage control unit
(including control
guide)
Work cable
Work clamp
Heating torch with
propane gas /
heating element
Clampmeter/
tongmeter
Contactless
Ensure welding
machine validity
is within
calibration
period
Ensure welding
machine in
functioning and
safe operating
condition
1
2
Lecture
Group
Discussion
1
2
3
4
5
6
SAW welding machine

functionality affirmed
Complete welding
accessories installed to
welding machine
Relevant welding PPE
worn
Complete and proper
welding tools ensured
Status of welding
machine calibration
confirmed
assured
127
Work Activities
Related Knowledge
3.12
3.13
3.14
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
5
6
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
pyrometer
Temperature
indicating crayon/
chalk
Cutting lens goggle
Welding shield
Marking tools and
hand tools:
Marking chalk
Steel ruler
Center punch
L square
Chisel
Chalk line
Chipping hammer
Portable grinding
machine
type of material
Wire brush/ power
brush
Type of files
Ball peen hammer
Brush/broom
Status of welding
Machine calibration
1
2
Affirm SAW
welding machine
functionality
Assure complete
welding
1
2
3
Demonstration
Observation
Case study
128
Work Activities
Related Knowledge
3
4
5
6
4. Verify base
metal
material
used
1
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
2
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
accessories
machine
Use relevant PPE
for welding
Ensure complete
and proper
welding tools for
use
Confirm status of
welding machine
calibration
Assure machine
arc stability
1
Carbon Steel
material
Material mill
certificate
Material standard
Heat number
Chemical
composition
Mechanical
properties
Material form plate and large
diameter pipe
Material size
Material physical
rust, ovality, etc)
Meticulous in
verifying based
metal material in
accordance to
material mill
certificate
1
2
Lecture
Group
Discussion
1
2
3
Confirm carbon
Carbon steel
material confirmed
to relevant WPS
Content of material
mill certificate
affirmed
Material condition
confirmed
Demonstration
129
Work Activities
Related Knowledge
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
2
5. Verify
consumable
as specified
1
1.1
1.2
1.3
2
3
Electrode
specification/
classification
Wire electrode
Wire electrode size
Flux (fused or
agglomerated and
granulated)
Wire Electrode
handling
Flux handling/baking
procedure
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
Observation
steel / stainless
steel material to
relevant WPS
Affirm content of
material mill
Material standard
Heat number
Chemical
composition
Mechanical
Properties
Material form plate and large
diameter pipe
Material size
Confirm material
physical condition
(eg. Dent, rust,
ovality, etc)
1
Cautious
practice when
handling hot
electrode from
baking oven
Lecture
Electrode
specification/
classification
confirmed
Flux
handling/baking
procedure carried
out
Oven temperature
setup for flux
baking requirement
130
Work Activities
Related Knowledge
1.1
1.2
1.3
2
3
1
2
2.1
2.2
3
4
5
6
7
8
Training
Hours
Delivery
Mode
Assessment Criteria
Flux baking oven

1
6. Operate
SAW
process
Attitude / Safety /
Environmental
Related Skills
Joint configuration
Joint preparation
marking and cutting
Mechanical cutting
Oxy-acetylene gas
cutting
Check Angle
(included angle &
bevel angle)
Root face
setup
Tack weld
Surface cleaning
Welding position -
Confirm electrode
specification/
classification such
as:
Wire electrode
Wire electrode
size
Flux (fused or
agglomerated and
granulated)
Carry out flux
handling/baking
procedure
Setting up oven
temperature for
flux baking
1
2
3
4
Ensure PPE in
good usage
condition
Ensure PPE are
worn accordingly
Cautious when
dispensing hot
electrode butt
Ensure glove
free from oil
base and any
moisture during
electrode
handling
Electrode to be
40
1
2
3
1
2
Demonstration
Observation
Case study
Lecture
Group
Discussion
Joint configuration
identified
2 Weld joint marking and
cutting prepared
3 Angle check carried out
4 Root face identified
5 Root gap /opening
identified
6 Fit-up / jig & fixture set
up
7 SAW machine operated
8 Arc striking test
performed
9 Tack weld carried out
10 Surface cleaning
131
Work Activities
Related Knowledge
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Attitude / Safety /
Environmental
Related Skills
1G plate
Operation of SAW
machine
Arc blow effect
Parameter setting
Root pass
Hot pass
Hot pass cleaning
Interpass
Interpass cleaning
Capping
Weldment cleaning
Root pass back
gouging
Root pass back
grinding
Root pass back
welding
Post-Weld Heat
Treatment (PWHT)
Welding machine
shut down
procedure
Good housekeeping
1
2
2.1
2.2
Identify joint
configuration
Prepare weld joint
Carry out
mechanical cutting
cutting
Training
Hours
Delivery
Mode
handled
according to
manufacturer
recommendation
Ensure proper
welding
environment
condition (eg.
under shade
from rain and
barricade from
heavy wind, etc)
Ensure grinding
work are carried
out safely
40
1
2
3
Demonstration
Observation
Project
Assessment Criteria
carried out
11 Welding performed in
position - 1G
12 Pre-heating carried out
as required
13 Welding parameters set
carried out
executed
16 Hot pass carried out
executed
18 Interpass carried out
executed
20 Capping executed
carried out
22 Root pass back gouging
carried out
23 Root pass back grinding
carried out
24 Root pass back welding
carried out
25 Defective profile rectified
26 Post-heating carried out
as required
Environmental
requirement carried out
during operating SAW
process
132
Work Activities
Related Knowledge
Related Skills
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Carry out check

Angle (included
angle & bevel
angle)
Identify root face
fixture
Prepare start and
stop running plate
Operate SAW
machine
Carry out arc
Carry out tack
weld
Carry out surface
cleaning
Setup welding
position - 1G plate
required
Set the
parameters
Carry out root
pass
Execute root pass
cleaning
Carry out hot pass
Execute hot pass
cleaning
Carry out interpas
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria

down procedure
executed
29 Housekeeping carried
out
133
Work Activities
Related Knowledge
19
20
21
22
23
24
25
26
7. Perform
visual
inspection
and testing
(destructive
test)
1
2
3
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
Welding inspection
kit
Root inspection
Weldment profile
Type of welding
defect and causes
such as:
Incomplete
penetration
Undercut
Arc strike
Spatter
Crack
Slag inclusion
Porosity
Attitude / Safety /
Environmental
Related Skills
Training
Hours
Delivery
Mode
Assessment Criteria
Execute interpass
cleaning
Execute capping
Carry out
weldment cleaning
Carry out root
pass back gouging
Carry out root
pass back grinding
Carry out root
pass back welding
Carry out welding
machine shut
down procedure
Carry out
housekeeping
1
2
Meticulous in
checking visual
inspection
Inquisitive in
seeking advice
to confirm
acceptance &
rejection criteria
from superior
Open to
comments on
weld
imperfection
Ensure safety
when performing
bend test
40
1
2
Lecture
Group
Discussion
1
2
3
4
5
Relevant welding
inspection tools
selected
Root penetration
checked
Weldment profile
for butt weld
checked
Type of surface
defect Identified
Welding
specimen visual
and testing
carried out
Acceptance &
rejection criteria
134
Work Activities
Related Knowledge
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
5
5.1
Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
confirmed
Overlap
Lack of fusion
(surface)
Underfill
Burn-through
Misalignment (linear
& angular)
Throat thickness
(fillet)
Unequal leg length
(fillet)
Concavity (fillet)
Convexity (fillet)
Welding specimen
test
bend (RB), face
bend (FB), side
bend test
Acceptance &
rejection criteria
according to code
1
2
3
4
Select relevant
welding inspection
tools
Check root
penetration for butt
weld only
Check weldment
profile for butt weld
Identify type of
surface defect
40
1
2
3
Demonstration
Observation
Case study
135
Work Activities
Related Knowledge
5
5.1
8. Carry out
back
gouging,
grinding and
back welding
as required
in
accordance
with test
specimen
1
2
3
4
5
1
2
3
1
3
4
1
2
Apply gouging
technique where
applicable (exclude
stainless steel)
Apply grinding
technique
Apply back welding
Apply weldment
cleaning
Welding checklist
over
1
2
1
2
Training
Hours
Delivery
Mode
Assessment Criteria
Carry out welding

specimen test
bend (RB), face
bend (FB), side
bend test
Seek advice on
acceptance &
rejection criteria
from superior
Gouging technique
Grinding technique
testing (PT/MT)
Back welding
Weldment cleaning
9. Compile
work
completion
checklist
Attitude / Safety /
Environmental
Related Skills
Fill-up welding checklist

Compile and submit
report to superior
Conform to WPS
repair procedure
Perform gouging
and grinding with
care
Practice
housekeeping
Precise in filling
welding checklist
Integrity in
compiling report
Lecture
1
2
1
2
3
Demonstration
Observation
Case study
1
2
Lecture
Group
Discussion
1
2
Observation
Case study
Gouging technique
applied to test
specimen
Grinding technique
applied to test
specimen
Back welding
technique applied to
test specimen
Weldment cleaning
applied to test
specimen

up complete
Report compile and
submitted to
superior for hand
over
136
Core Abilities
1.01
1.02
1.11
2.01
2.03
2.04
2.05
2.11
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.13
3.15
3.16
5.01
5.02
4.01
4.02
4.03
4.04
4.05
6.01
6.02
6.03
6.05
6.06
6.07

Communicate clearly
Understand systems
Social Skills
1.
2.
3.
4.
5.
6.
Learning Skills
Self-discipline
Teamwork
137

ITEMS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

Code and standard (ASME IX, AWS, API, ISO, etc.)
Base metal - plate (9mm and above)
Safety shoe
Coverall
Leather gloves
Fire extinguisher
Muffler / ear plug
First aid kit
Hazard signage
Material standard
Welding electrode wire
Flux baking oven
SAW welding machine (electrical driven transformer) and accessories
Hydraulic press
Spark lighter
1 : 1
1 : 1
1 : 1
1 : 1
1 : 1
1 : 1
1 : 1
1 : 1
1 : 1
1 : 5
1 : 1
1 : 15
1 : 15
1 : 1
As required
1 : 15
1 : 1
1 : 1
1 : 15
1
1
1
1
1
1
:
:
:
:
:
:
1
5
15
15
15
1
138
ITEMS
27.
28.
29.
30.
31.
32.
33.
arrester
back arrester
arrester
Band saw machine
Power saw machine
Welding checklist
15
15
1
1
1
1
1
1
:
:
:
:
:
:
15
15
15
5
2
1
139
References
REFERENCES
1
2
3
4
5
6
7
8
9
10
11
978-0871715067
140
Training Hour Summary

SECTOR
SUBSECTOR
JOBAREA
JOBLEVEL
CUID
MC024
3:2012C01
MC024
3:2012C02
MC024
3:2012C03
MC024
3:2012E01
MC024
3:2012E02
:
:
:
:
MACHINERY AND EQUIPMENT

THREE(3)
CompetencyUnit
Training
Hour
SHIELDED METAL ARC WELDING (SMAW) FOR

FILLET WELD 1F, 2F, 3F, 4F, BUTT WELD 1G AND 2G
580
SHIELDED METAL ARC WELDING (SMAW) FOR 3G

AND 4G
652
SHIELDED METAL ARC WELDING (SMAW) FOR 5G

AND 6G (UP-HILL AND DOWN-HILL)
636
SHIELDED METAL ARC WELDING (SMAW) 6GR
460
SUBMERGED ARC WELDING (SAW) 1G
248
TotalTrainingProgramHours
141
2576

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Copyright DSD 2012

Department of Skills Development (DSD)

STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN

First Publish 2012

All rights reserved

STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN

Jabatan Pembangunan Kemahiran

STANDARD PRACTICE ............................................................................................................................................................ 3

OCCUPATIONAL STRUCTURE ................................................................................................................................. 5

DEFINITION OF COMPETENCY LEVEL.................................................................................................................... 6

MALAYSIAN SKILL CERTIFICATION......................................................................................................................... 7

Training delivery ................................................................................................................................................................... 7

JOB COMPETENCIES ................................................................................................................................................ 7

WORKING CONDITIONS ........................................................................................................................................... 7

EMPLOYMENT PROSPECTS .................................................................................................................................... 7

Malaysian Market ................................................................................................................................................................. 7

TRAINING, INDUSTRIAL/PROFESSIONAL RECOGNITION, OTHER QUALIFICATIONS AND ADVANCEMENT .. 8

SOURCES OF ADDITIONAL INFORMATION ............................................................................................................ 9

3. DEFINITION OF COMPETENCY LEVEL

Competent in performing a range of varied

Malaysia Skills Certificate Level 2:

Competent in performing a significant range

Malaysia Skills Certificate Level 3:

Competent in performing a broad range of

Malaysia Skills Diploma Level 4:

Competent in performing a broad range of

Malaysia Skills Advanced Diploma

Competent in applying a significant range of

MALAYSIAN SKILL CERTIFICATION

Shielded Metal Arc Welding (SMAW) 6GR

Oil and Gas

American Society of Mechanical Engineers (ASME)

8. TRAINING, INDUSTRIAL/PROFESSIONAL RECOGNITION, OTHER QUALIFICATIONS AND

9. SOURCES OF ADDITIONAL INFORMATION

Department of Occupational Safety and Health (DOSH)

Department of Standards Malaysia (Standards Malaysia)

American Welding Society (AWS)

American National Standard Institute (ANSI)

American Society for Testing and Materials (ASTM)

British Standards International (BSI) Group

International Organization for Standardization

International Labour Organisation (ILO)

SHIELDED METAL ARC WELDING (SMAW) PROCESS LEVEL 3

En. Mohd Herman Bin Rosli

En. Mansor Bin Ibrahim

En. Awaldin Bin Mohd Arif

En. Azaddin Bin A. Aziz

En. Lokman Bin Zakaria

En. Hamzah Bin Mohamed Kasa

En. Mohd Salleh Bin Mohd Noh

En. Zahidi Bin Zainuddin

En. Wan Yusof Bin Wan Hasan

En. Mohd Ali Bin Moh Salleh

En. Mohd Sufie Bin Mohamed

En. Mohd Ali Man Shah Bin Abu

Johor State Occupational Safety and Health officer

En. Syed Mahathir Bin Syed Azman

En. Ahmad Azran Bin Ranaai