New 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 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. 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-C01 Level 3
Duration
580 Hours Credit Values 58
New
New Attitude / Safety / New Delivery
New Work Activities New Related Knowledge New Related Skills Training New Assessment Criteria
Environmental Mode
Hours
1. Carry out Safety induction in 1 Demonstrate safe 24 1 Lecture 1 Welding hazards
safety as- accordance to working habit and 2 Group Discussion identified which
sessment at Occupational Safety consciousness in includes:
work area and Health Act (OSHA), workshop 1.1 Safety hazard
Factory and Machinery 2 Adhere to worksite 1.2 Health hazard
Act, Regulation, safety requirement, 1.3 Environmental
Guideline and Code of regulations hazard
Practice which covers: 3 Alert in ensuring 2 Welding risk
1 Hazard safe working assessment

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Hours
identification, environment conducted
risk assessment 4 Responsible and 3 Proper protection
and risk control accountable in addressed
(HIRARC) performing welding according to risk
1.1 Safety hazard task assessment
and protection 5 Transparent in result which
1.1.1 Slipping or reporting to relevant covers:
tripping, floor authority 3.1 Safety hazard
protection 6 Ensure protection
1.1.2 Fire and housekeeping 3.2 Health hazard
explosion 7 Ensure proper PPE protection
hazard worn at work site 3.3 Environmental
1.1.2.1 Fire/ spark/ hazard protection
heat 4 Welding risk
protection control carried
1.1.2.2 Fire out which covers:
extinguisher 4.1 Procedure to
type obtain Permit To
1.1.2.3 Elements of Work (PTW)
fire 4.2 Lock out, tack out
1.1.2.4 Flammable (LOTO)
hazard (ex: 4.3 Welding area
painting, oil, emergency
gas, etc) response plan
1.1.2.5 Fire (ERP)
watcher 4.4 First aid
1.1.3 Working at treatment
height procedure
1.1.4 Pressure conducted such
system as:
1.1.5 Eye injuries 4.4.1 Cardio
1.2 Health hazard Pulmonary
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Hours
and protection Resuscitation
1.2.1 Ergonomic in (CPR)
welding 4.4.2 Minor cut
activities - body injuries
posture 4.4.3 Bone fracture
1.2.2 Welding fumes, first aid
gases and treatment
protection
1.2.3 Welder health
condition
1.2.4 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
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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
(CPR)
2.3.2 Minor cut
injuries
2.3.3 Bone fracture
first aid
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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)
procedure
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Hours
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 1 Meticulous in 30 1 Lecture 1 Welding
work instruc- terminology interpreting WPS 2 Group Discussion terminology
tion and rel- 2 Welding drawing content described
evant Weld- and symbol 2 Refer to superior 2 Welding drawing
ing Proced- 3 WPS content for any and symbol
ure Specifica- 4 Procedure uncertainties interpreted
tion (WPS) Qualification 3 Conform to WPS 3 WPS content
Record (PQR) requirements interpreted
5 Welding codes 4 Procedure
and standards Qualification
6 Joint design Record (PQR)
7 Material type familiarised
and grade (eg. 5 Code and
material mill standard
certificate) complied
8 Welding position 6 Joint design
8.1 For fillet weld - interpreted
1F, 2F, 3F, 4F 7 Type of material
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Hours
8.2 For butt weld - identified
1G, 2G 8 Welding position
9 Preheat interpreted
requirement 9 Reheat
10 Post-weld heat requirement
treatment identified
(PWHT) 10 PWHT
requirement requirement
11 SMAW process identified
12 Consumable 11 SMAW process
specification, determined
classification and 12 Consumable
type specification,
13 Electrical classification and
characteristics - type identified
ampere, volt, 13 Electrical
polarity, travel characteristics
speed identified
14 Welding 14 Welding
parameters table parameter table
15 Role of interpreted
Destructive
Testing (DT)
assessment
16 Role of Non-
Destructive
Testing (NDT)
1 Describe welding 10 1 Case study
terminology 2 Observation
2 Interpret welding
drawing and
symbol
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Hours
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 fillet weld -
1F, 2F, 3F, 4F
8.2. For butt weld -
1G, 2G
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
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Hours
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 mater- and Stainless verifying based 2 Group Discussion stainless steel
ial used Steel material metal material in material
1.1 Material mill accordance to confirmed to
certificate material mill relevant WPS
1.1.1 Material certificate 2 Content of
standard material mill
1.1.2 Heat number certificate
1.1.3 Chemical affirmed
composition 3 Material
1.1.4 Mechanical condition
properties confirmed
1.1.5 Material form -
plate and pipe
1.1.6 Material size
2 Material physical
condition (eg.
Dent, rust,
ovality, etc)

1 Confirm carbon 4 1 Case study

steel / stainless 2 Observation
steel material to
relevant WPS
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Hours
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 -
plate and pipe
1.1.6 Material size
2 Confirm material
physical condition
(eg. Dent, rust,
ovality, etc)
4. Verify con- 1 Electrode 1 Cautious practice 8 1 Lecture 1 Electrode
sumable as specification/ when handling hot specification/
specified classification electrode from classification
1.1 Core wire baking oven confirmed
1.2 Electrode size 2 Electrode
1.3 Flux coating handling/baking
(basic, rutile and procedure carried
cellulose) out if required
2 Electrode 3 Oven
handling / baking temperature for
procedure electrode baking
3 Electrode baking setup if required
oven 4 Temperature for
4 Electrode holding oven
holding oven setup if required
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Hours
1 Confirm electrode 8 1 Demonstration
specification/ 2 Observation
classification such 3 Case study
as:
4.1 Core wire
4.2 Electrode size
4.3 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 1 SMAW welding 1 Ensure welding 16 1 Lecture 1 SMAW welding
SMAW machine machine validity is 2 Group Discussion machine
equipment (electrical driven within calibration functionality
and ac- transformer) period affirmed
cessories 1.1 Power supply 2 Ensure welding 2 Complete welding
functionality switch machine in accessories
1.2 Power source functioning and installed to
cable safe operating welding machine
1.3 Earth cable condition 3 Relevant welding
1.4 Electrical driven PPE worn
transformer 4 Complete and
2 SMAW welding proper welding
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Hours
machine (engine tools ensured
driven) 5 Status of welding
2.1 Diesel engine machine
2.2 Electric calibration
generator set confirmed
2.3 Earth cable 6 Machine arc
3 Accessories: stability assured
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 lens
goggle
3.10 Welding shield
3.11 Welding gauntlet
3.12 Visor / face
shield
4 Marking tools
and hand tools:
4.1 Marking chalk
4.2 Steel ruler
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Hours
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 Welding arc
stability
1 Use relevant PPE 8 1 Demonstration
2 Affirm SMAW 2 Observation
welding machine 3 Case study
functionality
3 Assure complete
welding
accessories
installed to
welding machine
4 Ensure complete
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Hours
and proper
welding tools for
use
5 Confirm status of
welding machine
calibration
6 Acquire welding
arc stability
6. Perform 1 Joint Configuration 1 Ensure PPE in 24 1 Lecture 1 Joint
SMAW pro- 2 Joint preparation good usage 2 Group Discussion configuration
cess marking and cutting condition identified
2.1 Mechanical 2 Ensure PPE are 2 Weld joint
cutting worn accordingly marking and
2.2 Oxy-acetylene 3 Cautious when cutting
gas cutting dispensing hot prepared
2.3 Plasma cutting electrode butt 3 Angle check
3 Check Angle (included 4 Ensure glove free carried out
angle & bevel angle from oil base and 4 Root face
4 Root face any moisture identified
5 Root gap /opening during electrode 5 Root gap
6 Fit-up / jig & fixture handling /opening
setup 5 Electrode to be identified
7 Tack weld handled according 6 Fit-up / jig &
8 Surface cleaning to manufacturer fixture set up
9 Welding position - 1F, recommendation 7 SMAW machine
2F, 3F, 4F, 1G and 6 Ensure proper operated
2G welding 8 Arc striking test
10 Operation of SMAW environment performed
machine condition (eg. 9 Tack weld
11 Arc blow effect under shade from carried out
12 Welding parameter rain and barricade 10 Surface
setting from heavy wind, cleaning
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Hours
13 Root pass / etc) carried out
penetration 7 Ensure grinding 11 Welding
14 Root pass cleaning work are carried performed in
15 Hot pass out safely position - 1F,
16 Hot pass cleaning 2F, 3F, 4F, 1G
17 Interpass and 2G
18 Interpass cleaning 12 Pre-heating
19 Capping carried out as
20 Weldment cleaning required
21 Welding machine shut 13 Welding
down procedure parameters set
22 Good housekeeping 14 Root pass /
1 Identify joint 300 1 Demonstration penetration
configuration 2 Observation carried out
2 Prepare weld joint 3 Project 15 Root pass
2.1 Carry out cleaning
mechanical executed
cutting 16 Hot pass
2.2 Carry out oxy- carried out
acetylene gas 17 Hot pass
cutting cleaning
2.3 Carry out plasma executed
cutting 18 Interpass
3 Carry out check carried out
Angle (included 19 Interpass
angle & bevel cleaning
angle) executed
4 Identify root face 20 Capping
5 Identify root executed
gap /opening 21 Weldment
6 Setup fit-up / jig & cleaning carried
fixture out
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Environmental Mode
Hours
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 requirement
weld carried out
10 Carry out surface during
cleaning performing
11 Setup welding SMAW process
position - 1F, 2F, 24 Welding
3F, 4F, 1G and machine shut
2G down procedure
12 Carry out pre- executed
heating as 25 Housekeeping
required carried out
13 Set welding
parameters
14 Carry out root
pass / penetration
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
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Hours
cleaning
22 Carry out post-
heating as
required
23 Carry out welding
machine shut
down procedure
24 Carry out
housekeeping
7. Perform 1 Welding 1 Meticulous in 40 1 Lecture 1 Relevant
visual inspec- inspection kit checking visual 2 Group Discussion welding
tion and test- 2 Root inspection inspection inspection
ing 3 Weldment profile 2 Inquisitive in tools selected
(destructive 4 Type of welding seeking advice to 2 Root
test) defects and confirm penetration
causes such as: acceptance & checked
4.1 Irregular weld rejection criteria 3 Weldment
profile from superior profile for butt
4.2 Incomplete 3 Open to weld and fillet
penetration comments on weld weld checked
4.3 Undercut imperfection 4 Type of
4.4 Arc strike 4 Ensure safety surface defect
4.5 Spatter when performing Identified
4.6 Crack nick break test and 5 Welding
4.7 Slag inclusion bend test specimen
4.8 Porosity visual and
4.9 Overlap testing carried
4.10 Lack of fusion out
(surface) 6 Penetrant test
4.11 Under fill for fillet weld
4.12 Burn-through conducted
4.13 Misalignment 7 Acceptance &
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Hours
(linear & rejection
angular) criteria
4.14 Throat thickness confirmed
(fillet)
4.15 Unequal leg
length (fillet)
4.16 Concavity (fillet)
4.17 Convexity (fillet)
5 Welding
specimen test
5.1 For fillet weld : -
nick break test,
fracture test,
macro
examination
5.2 For butt weld -
root bend (RB),
face bend (FB),
side bend test
(SB)
6 Penetrant test
(PT)
7 Acceptance &
rejection criteria
according to
code
1 Select relevant 50 1 Demonstration
welding 2 Observation
inspection tools 3 Case study
2 Check root
penetration for
butt weld only
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Hours
3 Check weldment
profile for butt
weld and fillet
weld
4 Identify type of
surface defect
5 Carry out welding
specimen test
5.1 For fillet weld : -
nick break test,
facture test,
macro
examination
5.2 For butt weld -
root bend (RB),
face bend (FB),
side bend test
(SB)
6 Conduct
penetrant test for
fillet weld
7 Seek advice on
acceptance &
rejection criteria
from superior
8. Carry out 1 Gouging 1 Conform to WPS 4 1 Lecture 1 Gouging
back gou- technique repair procedure technique
ging, grind- 2 Grinding 2 Perform gouging, applied to test
ing and back technique grinding and back specimen
welding as 3 Surface welding with care 2 Grinding
required in inspection and 3 Practice technique
accordance testing (PT/MT) housekeeping applied to test
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Hours
with test spe- 4 Back welding specimen
cimen 5 Weldment 3 Back welding
cleaning technique
1 Apply gouging 18 applied to test
technique where 1 Demonstration specimen
applicable 2 Observation 4 Weldment
(exclude stainless 3 Case study cleaning
steel) applied to test
2 Apply grinding specimen
technique
3 Apply back
welding
4 Apply weldment
cleaning
9. Compile work 1 Welding 1 Precise in filling 4 1 Lecture 1 Welding
completion checklist welding checklist 2 Group Discussion checklist fill up
checklist 2 Work 2 Integrity in complete
completion compiling report 2 Report
hand over compile and
submitted to
1 Fill-up welding 4 1 Observation superior for
checklist 2 Case study hand over
2 Compile and
submit report to
superior

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New Employability Skills
New Core Abilities New 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 5 Self-discipline
2.04 Prepare brief reports and checklists using standard forms 6 Teamwork
2.05 Read/interpret flowcharts and pictorial information
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 Liaise 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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New Tools, Equipment and Materials (TEM)
New ITEMS New 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 Code and standard (ASME IX) 1 : 1
5 Permit To Work (PTW) form 1 : 1
6 Base metal plate: plate 6mm to 12mm (minimum range) 1 : 1
7 Base metal pipe: 4"to 6" NPS schedule 40 (minimum range) 1 : 1
8 Safety shoe 1 : 1
9 Coverall 1 : 1
10 Leather gloves 1 : 1
11 Fire extinguisher 1 : 5
12 Muffler / ear plug 1 : 1
13 First aid kit 1 : 15
14 Hazard signage 1 : 15
15 Material mill certificate 1 : 1
16 Material standard 1 : 1
17 Welding electrode (2.5mm - 4.0mm) As required
18 Electrode baking oven 1 : 15
19 Electrode holding oven 1 : 15
20 SMAW welding machine and accessories 1 : 1
21 Marking tools and hand tools 1 : 1
22 Electrode quiver 1 : 1
23 Welding inspection kit 1 : 15
24 Welding bay c/w accessories (eg. Power supply, lighting, welding curtain,
fume extractor, welding table with positioner, etc) 1 : 1
25 Jig & fixture fit-up clamp 1 : 5
26 Hydraulic press 1 : 15
27 Guided bend test jig 1 : 15
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New ITEMS New RATIO (TEM : Trainees)
28 High speed cutting machine 1 : 15
29 Spark lighter 1 : 1
30 Plasma cutting (for stainless steel) 1 : 15
31 Oxy-acetylene gas cutting (manual) and accessories with flash back 1 : 15
arrester
32 Oxy-acetylene gas cutting machine (semi-auto) and accessories with flash 1 : 15
back arrester
33 Oxy-acetylene pipe cutting machine and accessories with flash back 1 : 15
arrester
34 Band saw machine 1 : 15
35 Power saw machine 1 : 15
36 Gouging torch and accessories 1 : 5
37 Air compressor and receiver 1 : 2
38 Welding checklist 1 : 1
39 Macro test equipment (cutter, polisher and etching acid) and accessories 1 : 15

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New References

New 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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