CURRICULUM of COMPETENCY UNIT (CoCU)

Sub Sector WELDING TECHNOLOGY AND FABRICATION

Job Area SHIELDED METAL ARC WELDING (SMAW)
Competency Unit Title 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. Carry out safety assessment at work area

2. Comply to work instruction and relevant Welding Procedure Specification (WPS)
3. Verify base metal material used
Learning Outcomes 4. Verify consumable as specified
5. Check SMAW equipment and accessories functionality
6. Perform SMAW process
7. Perform visual inspection and testing (destructive test)
8. Carry out back gouging, grinding and back welding as required in accordance with test specimen
9. Compile work completion checklist

Training
Competency Unit ID MC-024-3:2012-C02 Level 3
Duration
652 Hours Credit Values 65
Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
1. Carry out Safety induction in 1 Demonstrate 24 1 Lecture 1 Welding hazards
safety as- accordance to safe working 2 Group Discussion identified which
sessment at Occupational Safety and habit and includes:
work area Health Act (OSHA), Factory consciousness 1.1 Safety hazard
and Machinery Act, in workshop 1.2 Health hazard
Regulation, Guideline and 2 Adhere to 1.3 Environmental
Code of Practice which worksite safety hazard
covers: requirement,
1 Hazard regulations 2 Welding risk
identification, risk 3 Alert in ensuring assessment
assessment and safe working conducted
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risk control environment
(HIRARC) 4 Responsible 3 Proper protection
1.1 Safety hazard and and accountable addressed
protection in performing according to risk
1.1.1 Slipping or tripping, welding task assessment result
floor protection 5 Transparent in which covers:
1.1.2 Fire and explosion reporting to 3.1 Safety hazard
hazard relevant protection
1.1.2.1 Fire/ spark/ authority 3.2 Health hazard
heat protection 6 Ensure protection
1.1.2.2 Fire housekeeping 3.3 Environmental
extinguisher 7 Ensure proper hazard protection
type PPE worn at
1.1.2.3 Elements of work site 4 Welding risk control
fire carried out which
1.1.2.4 Flammable covers:
hazard (ex: 4.1 Procedure to obtain
painting, oil, Permit To Work
gas, etc) (PTW)
1.1.2.5 Fire watcher 4.2 Lock out, tack out
1.1.3 Working at height (LOTO)
1.1.4 Pressure system 4.3 Welding area
1.1.5 Eye injuries emergency
1.2 Health hazard and response plan
protection (ERP)
1.2.1 Ergonomic in 4.4 First aid treatment
welding activities - procedure
body posture conducted such as:
1.2.2 Welding fumes, 4.4.1 Cardio
gases and Pulmonary
protection Resuscitation
1.2.3 Welder health (CPR)
condition 4.4.2 Minor cut
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Work Activities Related Knowledge Related Skills Assessment Criteria
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1.2.4 Personnel injuries
Protective 4.4.3 Bone fracture
Equipment (PPE) first aid
1.2.5 Arc burn (Intense treatment
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
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Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
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)
1 Identify welding 24 1 Demonstration
hazards which 2 Observation
covers:
1.1 Safety hazard
1.2 Health hazard
1.3 Environmental
hazard

2 Conduct welding
risk assessment to
address proper
protection within
work area which
covers:
2.1 Safety hazard
protection
2.2 Health hazard
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Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
protection
2.3 Environmental
hazard protection

3 Carry out welding

risk control by:
3.1 Execute
procedure to
obtain Permit To
Work (PTW)
3.2 Execute lock out,
tack out (LOTO)
procedure
3.3 Identify welding
area emergency
response plan
(ERP)
3.4 Able to conduct
first aid treatment
procedure such
as:
3.4.1 Cardio Pulmonary
Resuscitation
(CPR)
3.4.2 Minor cut injuries
3.4.3 Bone fracture first
aid treatment
2. Comply to 1 Welding terminology 1 Meticulous in 30 1 Lecture 1 Welding
work instruc- 2 Welding drawing interpreting 2 Group Discussion terminology
tion and rel- and symbol WPS content described
evant Weld- 3 WPS content 2 Refer to 2 Welding drawing
ing Proced- 4 Procedure superior for any and symbol
ure Specific- Qualification Record uncertainties interpreted
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Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
ation (WPS) (PQR) 3 Conform to 3 WPS content
5 Welding codes and WPS interpreted
standards requirements 4 Procedure
6 Joint design Qualification Record
7 Material type and (PQR) familiarised
grade (eg. material 5 Code and standard
mill certificate) complied
8 Welding position 6 Joint design
8.1 For butt weld - 3G, interpreted
4G 7 Type of material
9 Preheat identified
requirement 8 Welding position
10 Post-weld heat interpreted
treatment (PWHT) 9 Reheat requirement
requirement identified
11 SMAW process 10 PWHT requirement
12 Consumable identified
specification, 11 SMAW process
classification and determined
type 12 Consumable
13 Electrical specification,
characteristics - classification and
ampere, volt, type identified
polarity, travel 13 Electrical
speed characteristics
14 Welding parameters identified
table 14 Welding parameter
15 Role of Destructive table interpreted
Testing (DT)
assessment
16 Role of Non-
Destructive Testing
(NDT)
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Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
1 Describe welding 10 1 Case study
terminology 2 Observation
2 Interpret welding
drawing and
symbol
3 Interpret WPS
content
4 Familiarise
Procedure
Qualification
Record (PQR)
5 Comply to welding
codes and
standards
6 Able to interpret
joint design
7 Able to identify
type of material
8 Able to interpret
welding position
8.1 For butt weld - 3G,
4G
9 Able to identify
preheat
requirement
10 Able to identify
PWHT
requirement
11 Able to determine
SMAW process
12 Able to identify
consumable
specification,
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Environmental Hours Mode
classification and
type
13 Able to identify
electrical
characteristics -
ampere, volt,
polarity, travel
speed
14 Interpret welding
parameter table
3. Verify base 1 Carbon Steel and 1 Meticulous in 8 1 Lecture 1 Carbon steel /
metal mater- Stainless Steel verifying based 2 Group Discussion stainless steel
ial used material metal material in material confirmed
1.1 Material mill accordance to to relevant WPS
certificate material mill 2 Content of material
1.1.1 Material standard certificate mill certificate
1.1.2 Heat number affirmed
1.1.3 Chemical 3 Material condition
composition confirmed
1.1.4 Mechanical
Properties
1.1.5 Material form -
plate
1.1.6 Material size
2 Material physical
condition (eg. Dent,
rust, ovality, etc)
1 Confirm carbon 8 1 Demonstration
steel / stainless 2 Observation
steel material to
relevant WPS
1.1 Affirm content of
material mill
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Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
certificate such as:
1.1.1 Material standard
1.1.2 Heat number
1.1.3 Chemical
composition
1.1.4 Mechanical
Properties
1.1.5 Material form -
plate
1.1.6 Material size
2 Confirm material
physical condition
(eg. Dent, rust,
ovality, etc)
4. Verify con- 1 Electrode 1 Cautious 8 1 Lecture 1 Electrode
sumable as specification/ practice when specification/
specified classification handling hot classification
1.2 Core wire electrode from confirmed
1.3 Electrode size baking oven 2 Electrode
1.4 Flux coating (basic, handling/baking
rutile and cellulose) procedure carried
2 Electrode handling / out if required
baking procedure 3 Oven temperature
3 Electrode baking for electrode baking
oven setup if required
4 Electrode holding 4 Temperature for
oven holding oven setup
1 Confirm electrode 8 1 Demonstration if required
specification/ 2 Observation
classification such 3 Case study
as:
1.2 Core wire
1.3 Electrode size
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Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
1.4 Flux coating
(basic, rutile and
cellulose)
2 Carry out
electrode
handling/baking
procedure if
required
3 Setting up oven
temperature for
baking
4 Setting up
temperature for
holding oven
5. Check 1 SMAW welding machine 1 Ensure welding 16 1 Lecture 1 SMAW welding
SMAW (electrical driven machine validity 2 Group Discussion machine
equipment transformer) is within functionality
and ac- 1.1 Power supply calibration affirmed
cessories switch period 2 Complete welding
functionality 1.2 Power source cable 2 Ensure welding accessories
1.3 Earth cable machine in installed to welding
1.4 Electrical driven functioning and machine
transformer safe operating 3 Relevant welding
2 SMAW welding machine condition PPE worn
(engine driven) 4 Complete and
2.1 Diesel engine proper welding tools
2.2 Generator set ensured
2.3 Earth cable 5 Status of welding
3 Accessories: machine calibration
3.1 Welding cable confirmed
3.2 Electrode holder 6 Machine arc
3.3 Work cable stability assured
3.4 Work Clamp
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Environmental Hours Mode
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
per type of material
4.10 Wire brush/ power
brush
4.11 Type of files
4.12 Ball peen hammer
4.13 Brush/broom
5 Electrode quiver
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Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
6 Status of welding
Machine calibration
7 Machine arc stability
1 Affirm SMAW 24
welding machine
(electrical driven
transformer)
functionality
2 Assure complete
welding
accessories
installed to
welding machine
3 Use relevant PPE
for welding
4 Ensure complete
and proper
welding tools for
use
5 Confirm status of
welding machine
calibration
6 Assure machine
arc stability
7. Perform 1 Joint Configuration 1 Ensure PPE in 40 1 Lecture 1 Joint configuration
SMAW pro- 2 Joint preparation good usage 2 Group Discussion identified
cess marking and cutting condition 2 Weld joint marking
2.1 Mechanical cutting 2 Ensure PPE are and cutting
2.2 Oxy-acetylene gas worn prepared
cutting accordingly 3 Angle check carried
2.3 Plasma cutting 3 Cautious when out
3 Check Angle (included dispensing hot 4 Root face identified
angle & bevel angle electrode butt 5 Root gap /opening
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Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
4 Root face 4 Ensure glove identified
5 Root gap /opening free from oil 6 Fit-up / jig & fixture
6 Fit-up / jig & fixture setup base and any set up
7 Tack weld moisture during 7 SMAW machine
8 Surface cleaning electrode operated
9 Welding position - 3G handling 8 Arc striking test
and 4G 5 Electrode to be performed
10 Operation of SMAW handled 9 Tack weld carried
machine according to out
11 Arc blow effect manufacturer 10 Surface cleaning
12 Parameter setting recommendatio carried out
13 Root pass / penetration n 11 Welding performed
14 Root pass cleaning 6 Ensure proper in position - 3G and
15 Hot pass welding 4G
16 Hot pass cleaning environment 12 Pre-heating carried
17 Interpass condition (eg. out as required
18 Interpass cleaning under shade 13 Welding parameters
19 Capping from rain and set
20 Weldment cleaning barricade from 14 Root pass /
21 Welding machine shut heavy wind, etc) penetration carried
down procedure 7 Ensure grinding out
22 Good housekeeping work are carried 15 Root pass cleaning
1 Identify joint out safely 352 1 Demonstration executed
configuration 8 Ensure usage of 2 Observation 16 Hot pass carried out
2 Prepare weld joint gauntlet for 4G 3 Project 17 Hot pass cleaning
2.1 Carry out position execute
mechanical 18 Interpass carried
cutting out
2.2 Carry out oxy- 19 Interpass cleaning
acetylene gas executed
cutting 20 Capping executed
2.3 Carry out 21 Weldment cleaning
plasma cutting carried out
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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
3 Carry out check 22 Post-heating carried
Angle (included out as required
angle & bevel 23 Attitude/ Safety/
angle Environmental
4 Identify root face requirement carried
5 Identify root gap out during
/opening performing SMAW
6 Setup fit-up / jig & process
fixture 24 Welding machine
7 Operate SMAW shut down
machine procedure executed
8 Carry out arc 25 Housekeeping
striking test run to carried out
obtain arc stability
9 Carry out tack
weld
10 Carry out surface
cleaning
11 Setup welding
position - 3G and
4G
12 Carry out pre-
heating as
required
13 Set the
parameters
14 Carry out root
pass / penetration
15 Execute root pass
cleaning
16 Carry out hot pass
17 Execute hot pass
cleaning
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Environmental Hours Mode
18 Carry out
interpass
19 Execute interpass
cleaning
20 Execute capping
21 Carry out
weldment cleaning
22 Carry out post-
heating as
required
23 Carry out welding
machine shut
down procedure
24 Carry out
housekeeping
8. Perform 1 Welding inspection kit 1 Meticulous in 40 1 Lecture 1 Relevant welding
visual in- 2 Root inspection checking visual 2 Group Discussion inspection tools
spection and 3 Weldment profile inspection selected
testing (de- 4 Type of welding defect 2 Inquisitive in 2 Root penetration
structive and causes such as: seeking advice checked
test) 4.1 Irregular weld profile to confirm 3 Weldment profile
4.2 Incomplete acceptance & for butt weld
penetration rejection criteria checked
4.3 Undercut from superior 4 Type of surface
4.4 Arc strike 3 Open to defect Identified
4.5 Spatter comments on 5 Welding
4.6 Crack weld specimen visual
4.7 Slag inclusion imperfection and testing
4.8 Porosity 4 Ensure safety carried out
4.9 Overlap when 6 Acceptance &
4.10 Lack of fusion performing rejection criteria
(surface) bend test confirmed
4.11 Underfill
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Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
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 Select relevant 40 1 Demonstration
welding inspection 2 Observation
tools 3 Case study
2 Check root
penetration for
butt weld only
3 Check weldment
profile for butt
weld
4 Identify type of
surface defect
5 Carry out welding
specimen test
5.1 For butt weld -
root bend (RB),
face bend (FB),
side bend test
6 Seek advice on
acceptance &
rejection criteria
from superior
9. Carry out 1 Gouging technique 1 Conform to 4 1 Lecture 1 Gouging technique
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 Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
back gou- 2 Grinding technique WPS repair applied to test
ging, grind- 3 Surface inspection and procedure specimen
ing and back testing (PT/MT) 2 Perform 2 Grinding technique
welding as 4 Back welding gouging and applied to test
required in 5 Weldment cleaning grinding with specimen
accordance 1 Apply gouging care 8 1 Demonstration 3 Back welding
with test technique where 3 Practice 2 Observation technique applied to
specimen applicable (exclude housekeeping 3 Case study test specimen
stainless steel) 4 Weldment cleaning
2 Apply grinding applied to test
technique specimen
3 Apply back welding
4 Apply weldment
cleaning
10. Compile 1 Welding checklist 1 Precise in filling 4 1 Lecture 1 Welding checklist fill
work com- 2 Work completion hand welding 2 Group Discussion up complete
pletion over checklist 2 Report compile and
checklist 2 Integrity in submitted to
1 Fill-up welding compiling report 4 1 Observation superior for hand
checklist 2 Case study over
2 Compile and submit
report to superior

Employability Skills
Core Abilities Social Skills
1.01 Identify and gather information 1 Communication Skills
1.02 Document information, procedures or processes 2 Interpersonal Skills
1.11 Apply thinking skills and creativity 3 Learning Skills
2.01 Interpret and follow manuals, instructions and SOP’s
4 Multitasking and prioritizing
2.03 Communicate clearly
2.04 Prepare brief reports and checklists using standard forms 5 Self-discipline
2.05 Read/interpret flowcharts and pictorial information 6 Teamwork
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Core Abilities Social Skills
2.11 Convey information and ideas to people
3.01 Apply cultural requirements to the workplace
3.02 Demonstrate integrity and apply ethical practices
3.03 Accept responsibility for own work and work area
3.04 Seek and act constructively upon feedback about performance
3.05 Demonstrate safety skills
3.06 Respond appropriately to people and situations
3.07 Resolve interpersonal conflicts
3.13 Develop and maintain team harmony and resolve conflicts
3.15 Liase to achieve identified outcomes
3.16 Identify and assess client/customer needs
5.01 Implement project/work plans
5.02 Inspect and monitor work done and/or in progress
4.01 Organize own work activities
4.02 Set and revise own objectives and goals
4.03 Organize and maintain own workplace
4.04 Apply problem solving strategies
4.05 Demonstrate initiative and flexibility
6.01 Understand systems
6.02 Comply with and follow chain of command
6.03 Identify and highlight problems
6.05 Analyse technical systems
6.06 Monitor and correct performance of systems
6.07 Develop and maintain networks

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Tools, Equipment and Materials (TEM)
ITEMS RATIO (TEM : Trainees)
1. Welding procedure specification (WPS) 1: 1
2. Procedure Qualification Record (PQR) 1: 1
3. Code and standard (ASME IX) 1: 1
4. Permit To Work (PTW) form 1: 1
5. Base metal plate: plate 6mm to 12mm (minimum range) 1: 1
6. Safety shoe 1: 1
7. Coverall 1: 1
8. Leather gloves 1: 1
9. Fire extinguisher 1: 5
10. Muffler / ear plug 1: 1
11. First aid kit 1 : 15
12. Hazard signage 1 : 15
13. Material mill certificate 1: 1
14. Material standard 1: 1
15. Welding electrode (2.5mm - 4.0mm) As required
16. Electrode baking oven 1 : 15
17. Electrode holding oven 1 : 15
18. SMAW welding machine (electrical driven transformer) and accessories 1: 1
19. Marking tools and hand tools 1: 1
20. Electrode quiver 1: 1
21. Welding inspection kit 1 : 15
22. Welding bay c/w accessories (eg. Power supply, lighting, welding curtain, 1: 1
fume extractor, welding table with positioner, etc)
23. Jig & fixture fit-up clamp 1: 5
24. Hydraulic press 1: 15
25. Guided bend test jig 1: 15
26. High speed cutting machine 1: 15
27. Spark lighter 1: 1
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ITEMS RATIO (TEM : Trainees)
28. Oxy-acetylene gas cutting (manual) and accessories with flash back
arrester 1: 15
29. Oxy-acetylene gas cutting machine (semi-auto) and accessories with flash
back arrester 1: 15
30. Oxy-acetylene pipe cutting machine and accessories with flash back
arrester 1: 15
31. Band saw machine 1: 15
32. Power saw machine 1: 15
33. Gouging torch and accessories 1: 5
34. Air compressor and receiver 1: 2
35. Welding checklist 1: 1

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References

REFERENCES

1 Sacks & Bohnart,2007,Welding Principles & Practices,3rd edition, 1221, Avenue of the Americas, New York, NY 10020 USA, Mc Graw Hill, ISBN: 978-
0077238773
2 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
3 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
4 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
5 Griffin, Roden, Briggs, 1985, Pipe Welding Techniques, 4th edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-0827322486
6 Ivan H. Griffin, Edward M. Roden and Charles W. Briggs,1984, Basic Arc Welding4th edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-
0827321311
7 ASM International, 1983, Metal Reference Book, 2nd edition, Material Park, Ohio, 44073 USA, American Society For Metals, ISBN:978-0871701565
8 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
9 Gower A. Kennedy, 1982, Welding Technology, 2nd edition, Lethbridge Community College, Alberta, New York, USA, Howard W. Sams & Son Inc., ISBN: 978-
0672979903
10 Frank R. Schell, 1977, Welding Procedures: Electric Arc, 1st edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-0827316034
11 Giachino, Weeks, Johnson, 1974, Welding Technology, 2nd edition, Chicago, 60637 USA, American Technical Society, ISBN: 978-0826930637

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