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) 6GR
The person who is competent in this CU shall be able to perform shielded metal arc welding (SMAW) 6GR positions on carbon steel ma-
terial. 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. Compile work completion checklist

Training
Competency Unit ID MC-024-3:2012-E01 Level 3 460 Hours Credit Values 46
Duration
Attitude / Safety / Training Delivery
Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
1. Carry out Safety induction in 1 Demonstrate safe 24 1 Lecture 1 Welding hazards
safety assess- accordance to Occupational working habit and 2 Group identified which
ment at work Safety and Health Act consciousness in Discussion includes:
area (OSHA), Factory and workshop 1.1 Safety hazard
Machinery Act, Regulation, 2 Adhere to 1.2 Health hazard
Guideline and Code of worksite safety 1.3 Environmental
Practice which covers: requirement, hazard
1 Hazard identification, regulations 2 Welding risk
risk assessment and 3 Alert in ensuring assessment
risk control safe working conducted
(HIRARC) environment 3 Proper
1.1 Safety hazard and 4 Responsible and protection
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protection accountable in addressed
1.1.1 Slipping or tripping, performing according to risk
floor protection welding task assessment
1.1.2 Fire and explosion 5 Transparent in result which
hazard reporting to covers:
1.1.2.1 Fire/ spark/ relevant authority 3.1 Safety hazard
heat protection 6 Ensure protection
1.1.2.2 Fire housekeeping 3.2 Health hazard
extinguisher 7 Ensure proper protection
type PPE worn at work 3.3 Environmental
1.1.2.3 Elements of fire site hazard
1.1.2.4 Flammable protection
hazard (ex: 4 Welding risk
painting, oil, control carried
gas, etc) out which
1.1.2.5 Fire watcher covers:
1.1.3 Working at height 4.1 Procedure to
1.1.4 Pressure system obtain Permit To
1.1.5 Eye injuries Work (PTW)
1.2 Health hazard and 4.2 Lock out, tack
protection out (LOTO)
1.2.1 Ergonomic in 4.3 Welding area
welding activities - emergency
body posture response plan
1.2.2 Welding fumes, (ERP)
gases and 4.4 First aid
protection treatment
1.2.3 Welder health procedure
condition conducted such
1.2.4 Personnel as:
Protective 4.4.1 Cardio
Equipment (PPE) Pulmonary
1.2.5 Arc burn (Intense Resuscitatio
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ultraviolet radiation) n (CPR)
1.3 Environmental 4.4.2 Minor cut
hazard injuries
1.3.1 Adequate access 4.4.3 Bone
and emergency fracture first
escape route aid
1.3.2 Confined space treatment
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
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
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Work Activities Related Knowledge Related Skills Assessment Criteria
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(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 Case study
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
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)
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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 terminology
work instruc- 2 Welding drawing and interpreting WPS 2 Group described
tion and relev- symbol content Discussion 2 Welding drawing and
ant Welding 3 WPS content 2 Refer to superior symbol interpreted
Procedure 4 Procedure for any 3 WPS content
Specification Qualification Record uncertainties interpreted
(WPS) (PQR) 3 Conform to WPS 4 Procedure
5 Welding codes and requirements Qualification Record
standards (PQR) familiarised
6 Joint design 5 Code and standard
7 Material type and complied
grade (eg. material 6 Joint design
mill certificate) interpreted
8 Welding position 7 Type of material
8.1 For butt weld - 6GR identified
9 Preheat requirement 8 Welding position
10 Post-weld heat interpreted
treatment (PWHT) 9 Reheat requirement
requirement identified
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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 speed 13 Electrical
14 Welding parameters characteristics
table identified
15 Role of Destructive 14 Welding parameter
Testing (DT) table interpreted
assessment
16 Role of Non-
Destructive Testing
(NDT)
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
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7 Able to identify
type of material
8 Able to interpret
welding position
8.1 For butt weld -
6GR
9 Able to identify
preheat
requirement
10 Able to identify
PWHT requirement
11 Able to determine
SMAW process
12 Able to identify
consumable
specification,
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 1 Meticulous in 4 1 Lecture 1 Carbon steel
metal material material verifying based 2 Group material
used 1.1 Material mill metal material in Discussion confirmed to
certificate accordance to relevant WPS
1.1.1 Material standard material mill 2 Content of
1.1.2 Heat number certificate material mill
1.1.3 Chemical certificate
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composition affirmed
1.1.4 Mechanical 3 Material
properties condition
1.1.5 Material form - confirmed
pipes of dissimilar
thicknesses with
restricted ring plate
1.1.6 Material size
2 Material physical
condition (eg. Dent,
rust, ovality, etc)
1 Confirm carbon 8 1 Demonstration
steel material to 2 Observation
relevant WPS
1.1 Affirm content of
material mill
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 -
pipes of dissimilar
thicknesses with
restricted ring
plate
1.1.6 Materials sizes
2 Confirm material
physical condition
(eg. Dent, rust,
ovality, etc)
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4. Verify 1 Electrode 1 Cautious practice 8 1 Lecture 1 Electrode
consumable specification/ when handling specification/
as specified classification hot electrode classification
1.1 Core wire from baking oven confirmed
1.2 Electrode size 2 Electrode
1.3 Flux coating (basic, handling/baking
rutile and cellulose) procedure
2 Electrode handling / carried out if
baking procedure required
3 Electrode baking 3 Oven
oven temperature for
4 Electrode holding electrode baking
oven setup if required
1 Confirm electrode 8 1 Demonstration 4 Temperature for
specification/ 2 Observation holding oven
classification such 3 Case study setup if required
as:
1.1 Core wire
1.2 Electrode size
1.3 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 SMAW 1 SMAW welding 1 Ensure welding 16 1 Lecture 1 SMAW welding
equipment machine (electrical machine validity 2 Group machine
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Work Activities Related Knowledge Related Skills Assessment Criteria
Environmental Hours Mode
and accessor- driven transformer) is within Discussion functionality
ies functional- 1.1 Power supply switch calibration period affirmed
ity 1.2 Power source cable 2 Ensure welding 2 Complete
1.3 Earth cable machine in welding
1.4 Electrical driven functioning and accessories
transformer safe operating installed to
2 SMAW welding condition welding machine
machine (engine 3 Relevant
driven) welding PPE
2.1 Diesel engine worn
2.2 Electric generator 4 Complete and
set proper welding
2.3 Earth cable tools ensured
3 Accessories: 5 Status of
3.1 Welding cable welding machine
3.2 Electrode holder calibration
3.3 Work cable confirmed
3.4 Work Clamp 6 Machine arc
3.5 Heating torch with stability assured
propane gas /
heating element
3.6 Clampmeter/
tongmeter
3.7 Contactless
pyrometer
3.8 Temperature
indicating crayon/
chalk
3.9 Cutting lens goggle
3.10 Welding shield
3.11 Welding gauntlet
4 Marking tools and
hand tools:
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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
specification
4.10 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 Arc stability
technique
1 Affirm SMAW 24 1 Demonstration
welding machine 2 Observation
functionality 3 Case study
2 Assure complete
welding
accessories
installed to welding
machine
3 Ensure complete
and proper welding
tools for use
4 Confirm status of
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Work Activities Related Knowledge Related Skills Assessment Criteria
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welding machine
calibration
5 Assure welding arc
stability
7. Perform 1 Joint Configuration 1 Ensure PPE in 40 1 Lecture 1 Joint
SMAW pro- 2 Joint preparation marking good usage 2 Group configuration
cess and cutting condition Discussion identified
2.1 Mechanical cutting 2 Ensure PPE are 2 Weld joint
2.2 Oxy-acetylene gas worn accordingly marking and
cutting 3 Cautious when cutting prepared
3 Check Angle (included dispensing hot 3 Angle check
angle & bevel angle electrode butt carried out
4 Root face 4 Ensure glove free 4 Root face
5 Root gap /opening from oil base and identified
6 Fit-up / jig & fixture setup any moisture 5 Root gap
7 Tack weld during electrode /opening
8 Surface cleaning handling identified
9 Welding position - 6GR 5 Electrode to be 6 Fit-up / jig &
10 Operation of SMAW handled fixture set up
machine according to 7 SMAW machine
11 Arc blow effect manufacturer operated
12 Parameter setting recommendation 8 Arc striking test
13 Root pass / penetration 6 Ensure proper performed
14 Root pass cleaning welding 9 Tack weld
15 Hot pass environment carried out
16 Hot pass cleaning condition (eg. 10 Surface cleaning
17 Interpass under shade from carried out
18 Interpass cleaning rain and 11 Welding
19 Capping barricade from performed in
20 Weldment cleaning heavy wind, etc) position – 6GR
21 Gouging technique 7 Ensure grinding 12 Pre-heating
22 Grinding technique work are carried carried out as
23 Surface inspection and out safely required
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testing (PT/MT) 13 Welding
24 Back welding/ back filled parameters set
25 Welding machine shut 14 Root pass /
down procedure penetration
26 Good housekeeping carried out
1 Identify joint 176 1 Demonstration 15 Root pass
configuration 2 Observation cleaning
2 Prepare weld joint 3 Project executed
2.1 Carry out 16 Hot pass carried
mechanical cutting out
2.2 Carry out oxy- 17 Hot pass
acetylene gas cleaning execute
cutting 18 Interpass carried
3 Carry out check out
Angle (included 19 Interpass
angle & bevel cleaning
angle executed
4 Identify root face 20 Capping
5 Identify root gap executed
/opening 21 Weldment
6 Setup fit-up / jig & cleaning carried
fixture out
7 Operate SMAW 22 Post-heating
machine carried out as
8 Carry out arc required
striking test run to 23 Attitude/ Safety/
obtain arc stability Environmental
9 Carry out tack weld requirement
10 Carry out surface carried out
cleaning during
11 Setup welding performing
position – 6GR SMAW process
12 Carry out pre- 24 Welding
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Environmental Hours Mode
heating as required machine shut
13 Set welding down procedure
parameters executed
14 Carry out root pass 25 Housekeeping
/ penetration carried out
15 Execute root pass
cleaning
16 Carry out hot pass
17 Execute hot pass
cleaning
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 visual 1 Welding inspection kit 1 Meticulous in 40 1 Lecture 1 Relevant
inspection and 2 Root inspection checking visual 2 Group welding
testing (de- 3 Weldment profile inspection Discussion inspection
structive test) 4 Type of welding defect 2 Inquisitive in tools selected
and causes such as: seeking advice to 2 Root
4.1 Irregular weld profile confirm penetration
4.2 Incomplete acceptance & checked
penetration rejection criteria 3 Weldment
4.3 Undercut from superior profile for butt
4.4 Arc strike 3 Open to weld checked
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Environmental Hours Mode
4.5 Spatter comments on 4 Type of
4.6 Crack weld imperfection surface defect
4.7 Slag inclusion 4 Ensure safety Identified
4.8 Porosity when performing 5 Welding
4.9 Overlap bend test specimen
4.10 Lack of fusion visual and
(surface) testing carried
4.11 Underfill out
4.12 Burn-through 6 Acceptance &
4.13 Misalignment (linear rejection
& angular) criteria
5 Welding specimen test confirmed
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
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Environmental Hours Mode
bend test
6 Seek advice on
acceptance &
rejection criteria
from superior
9. Compile work 1 Welding checklist 1 Precise in filling 4 1 Lecture 1 Welding
completion 2 Work completion hand welding checklist 2 Group checklist fill up
checklist over 2 Integrity in Discussion complete
compiling report 2 Report compile
1 Fill-up welding checklist 4 1 Observation and submitted to
2 Compile and submit 2 Case study superior for hand
report to superior over

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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
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 (AWS D1.1) 1: 1
4. Permit To Work (PTW) form 1 1
5. Base metal pipe dissimilar thickness 8" schedule 80 and schedule 120,
with restricted ring 6mm thickness 1: 1
1: 1
6. Safety shoe 1: 1
7. Coverall 1: 1
8. Leather gloves 1: 5
9. Fire extinguisher 1: 1
10. Muffler / ear plug 1 : 15
11. First aid kit 1 : 15
12. Hazard signage 1: 1
13. Material mill certificate 1: 1
14. Material standard As required
15. Welding electrode (2.5mm - 4.0mm) 1 : 15
16. Electrode baking oven 1 : 15
17. Electrode holding oven 1: 1
18. SMAW welding machine (electrical driven transformer) and accessories 1: 1
19. Marking tools and hand tools 1: 1
20. Electrode quiver 1 : 15
21. Welding inspection kit
22. Welding bay c/w accessories (eg. Power supply, lighting, welding curtain, 1: 1
fume extractor, welding table with positioner, etc) 1: 5
23. Jig & fixture fit-up clamp 1: 15
24. Hydraulic press 1: 15
25. Guided bend test jig 1: 15
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ITEMS RATIO (TEM : Trainees)
26. High speed cutting machine 1: 1
27. Spark lighter
28. Oxy-acetylene gas cutting (manual) and accessories with flash back 1: 15
arrester
29. Oxy-acetylene gas cutting machine (semi-auto) and accessories with flash 1: 15
back arrester
30. Oxy-acetylene pipe cutting machine and accessories with flash back 1: 15
arrester 1: 15
31. Band saw machine 1: 15
32. Power saw machine 1: 5
33. Gouging torch and accessories 1: 2
34. Air compressor and receiver 1: 1
35. Welding checklist

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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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