Level 3 City & Guilds NVQ in Fabrication and Welding · PDF file · 2017-12-14The Level 3 NVQ in Fabrication and Welding Engineering is intended for those who will be ... pipe and

Level 3 City & Guilds NVQ in Fabrication and Welding Engineering

www.city-and-guilds.co.ukJune 2004

Scheme Handbook1681

City & Guilds is the UK’s leading provider of vocational qualifications, offering over 500 awards across a wide range of industries, and progressing from entry level to the highest levels of professional achievement. With over 8500 centres in 100 countries, City & Guilds is recognised by employers worldwide for providing qualifications that offer proof of the skills they need to get the job done. The City & Guilds Group includes City & Guilds Pitman Qualifications, specialising in IT, office-based qualifications and English as a second language awards, and ILM (the Institute of Leadership & Management) providing management qualifications, learning materials and membership services. Land based qualifications are offered through NPTC, also part of the City & Guilds Group. City & Guilds also manages the Engineering Council Examinations on behalf of the Engineering Council. General information about City & Guilds is available on our website www.city-and-guilds.co.uk or from our Customer Relations team at the address below or by phoning 020 7294 2800 or e-mailing [email protected] & Guilds fully supports the principle of equal opportunities and we are committed to satisfying this principle in all our activities and published material. A copy of our equal opportunities policy statement ‘Access to assessment’ is available on our website or from the Customer Relations team.City & Guilds publications are available from our Publication Sales department at the address below or by phoning 020 7294 2850 or faxing 020 7294 3387

First published 2004©2004 The City and Guilds of London Institute All rights reserved.City & Guilds is a trademark of the City and Guilds of London Institute.Every effort has been made to ensure that the information contained in this publication is true and correct at the time of going to press. However, City & Guilds’ products and services are subject to continuous development and improvement and the right is reserved to change products and services from time to time. City & Guilds cannot accept liability for loss or damage arising from the use of information in this publication.City & Guilds1 Giltspur StreetLondon, EC1A 9DDT +44 (0)20 7294 2468F +44 (0)20 7294 2400www.city-and-guilds.co.uk

Contents Page

Foreword 3

The Award 4

Qualification Structure – Fabrication and Welding Level 3 4

Assessment Requirements 7

National Occupational Standards and Evidence Recording Sheets 15

Key Skills Signposting 253

Further Information 257

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Foreword

This document provides details of the requirements specific to this N/SVQ qualification which includes:� the requirements for occupational competence for all those involved in

assessing performance� specific assessment requirements and � the National Occupational Standards.

It is designed to be used in conjunction with the following documents (also on the website):the N/SVQ Candidate Guide and Logbookand the N/SVQ Centre Guide.

The guide does not contain details of centre and scheme approval - these may be found in the document: ‘Providing City and Guilds qualifications’ (stock code EN-00-1111) available free of charge from the Sales Department or your regional/national City & Guilds office (see Further information section of this document).

Details of general regulations, registration and certification procedures, including fees, are included in the City & Guilds Directory of N/SVQ Awards. This information also appears on City & Guilds web site http://www.city-and-guilds.co.uk

The following documents also include information on policy and guidance on quality assurance within NVQs and assessors and verifiers should be aware of the contents.

• City & Guilds policy document ‘Ensuring Quality’ – aimed at those involved in the assessment and verification of City & Guilds awards. Issued 3-4 times a year (available from Sales Department) NB Edition 12 – December 2001 summarises policy from all previous editions)

• Joint Awarding Body Guidance on Internal Verification of NVQs, issued November 2001, published by the DfES, also available on City & Guilds web site.

General NVQ information

Centres should refer to the City & Guilds Centre Guide for NVQs, included on this CD-ROM, for information on NVQs, the people involved, the assessment process and model recording forms.

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Level 3 NVQ in Fabrication and WeldingEngineering

The Award

The Level 3 NVQ in Fabrication and Welding Engineering is intended for those who will be required to undertake the production of welded and fabricated items within engineering.The aim is to show that candidates have acquired the skills to carry out practical activities and an understanding of the technology to meet the needs of the industry. The qualification covers manual and mechanised welding, sheet metalwork, platework, structural steelwork, pipe and tube fabrication and composite fabrication.

The award will be appropriate for those following a modern apprenticeship and also those undertaking retraining and career progression.

There are 55 units within the qualification. All candidates must take the THREE core units plus a specified number of optional units from one of the seven occupational pathways to achieve the award. Additional units may be taken, for which the candidate will receive a Certificate of Unit Credit.

The Units have been contextualised by EMTA from the National Engineering Competency Standards (ECS).

Qualification Structure

Mandatory units for all pathways (all three units must be completed)

Unit 1: Complying with Statutory Regulations and Organisational Safety RequirementsUnit 2: Using and Interpreting Engineering Drawings and DocumentsUnit 3: Working Efficiently and Effectively in Engineering

Pathways

1 Manual Welding

Must complete any ONE unit from the following:Unit 4: Welding Materials by the Manual Metal Arc ProcessUnit 5: Welding Materials by the Manual MIG/MAG and other Continuous Wire ProcessesUnit 6: Welding Materials by the Manual TIG and Plasma Arc Welding ProcessUnit 7: Welding Materials by the Manual Gas Welding ProcessUnit 8: Welding Pipe/Tube using Multiple Manual Arc Welding ProcessesUnit 9: Welding Plate using Multiple Manual Arc Welding Processes

2 Welding Machine Setting and Operating

Must complete any ONE unit from the following:Unit 10: Preparing Mechanised Arc Welding Equipment for ProductionUnit 11: Preparing Resistance Spot, Seam and Projection Welding Machines for ProductionUnit 12: Preparing Laser Welding Machines for ProductionUnit 13: Preparing Electron Beam Welding Machines for ProductionUnit 14: Preparing Friction Welding Machines for ProductionUnit 15: Preparing Brazing Machines for Production

Plus ONE more unit from the following:Unit 16: Welding Materials with Mechanised Arc Welding EquipmentUnit 17: Welding Materials using Resistance Spot, Seam and Projection Welding Machines

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Unit 18: Welding Materials using Laser Welding MachinesUnit 19: Welding Materials using Electron Beam Welding MachinesUnit 20: Welding Materials using Friction Welding MachinesUnit 21: Joining Materials using Brazing Machines

3 Sheet Metalworking (3 mm or less)

Must complete the following units:Unit 22: Marking Out Components for MetalworkUnit 23: Cutting Sheetmetal to Shape using Hand and Machine ToolsUnit 24: Forming Sheetmetal using Hand and Machine Tools

Plus TWO more units from the following:Unit 25: Producing Sheetmetal AssembliesUnit 26: Heat Treating Materials for Fabrication ActivitiesUnit 27: Developing and Marking Out Templates for Metalwork

Plus ONE more unit from the following:Unit 28: Joining Fabricated Components using Mechanical FastenersUnit 29: Bonding Engineering Materials using AdhesivesUnit 30: Joining Materials by Resistance Spot WeldingUnit 31: Producing Fillet Welded Joints using a Manual Welding Process

4 Plateworking (3 mm upwards)

Must complete ONE unit from the following:Unit 22: Marking Out Components for MetalworkUnit 27: Developing and Marking Out Templates for Metalwork

Plus ONE unit from:Unit 32: Cutting Plate and Sections using Shearing MachinesUnit 33: Cutting and Shaping Materials using Portable Thermal Cutting EquipmentUnit 34: Cutting Materials using Saws and Abrasive Discs

Plus TWO more units from the following:Unit 35: Bending and Forming Plate using Press Brakes or Bending MachinesUnit 36: Forming Platework using Power Rolling MachinesUnit 37: Producing and Finishing Holes using Drilling MachinesUnit 38: Producing Platework Assemblies

Plus TWO more units from the following:Unit 28: Joining Fabricated Components using Mechanical FastenersUnit 31: Producing Fillet Welded Joints using a Manual Welding ProcessUnit 39: Slinging, Lifting and Moving Materials and Components

5 Structural Steelwork


Plus ONE unit from the following:Unit 32: Cutting Plate and Sections using Shearing MachinesUnit 33: Cutting and Shaping Materials using Portable Thermal Cutting EquipmentUnit 34: Cutting Materials using Saws and Abrasive Discs

Plus TWO more units from the following:Unit 37: Producing and Finishing Holes using Drilling Machines

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Unit 40: Forming Structural Sections using MachinesUnit 41: Producing Structural Steel Ancillary ComponentsUnit 42: Producing Major Structural Components/Sub-assemblies

Plus TWO more units from the following:Unit 28: Joining Fabricated Components using Mechanical FastenersUnit 31: Producing Fillet Welded Joints using a Manual Welding ProcessUnit 39: Slinging, Lifting and Moving Materials and Components Unit 43: Erecting Structural Steelwork

6 Pipe and Tube Fabrication


Plus ONE more unit from the following:Unit 33: Cutting and Shaping Materials using Portable Thermal Cutting EquipmentUnit 34: Cutting Materials using Saws and Abrasive Discs

Plus TWO more units from the following:Unit 37: Producing and Finishing Holes using Drilling MachinesUnit 44: Forming Pipework by Machine BendingUnit 45: Producing Pipe Fabrications

Plus ONE more unit from the following:Unit 28: Joining Fabricated Components using Mechanical FastenersUnit 29: Bonding Engineering Materials using AdhesivesUnit 46: Producing Socket and Flange Fillet Welded Joints in Pipe using a Manual Welding

Process

7 Composite Fabrication

Must complete TWO units from the following:Unit 47: Producing Components by Fibre Reinforced Plastic (FRP) MouldingUnit 48: Producing Components by Acrylic MouldingUnit 49: Producing Components from Carbon FibreUnit 50: Producing Components from Glass FibreUnit 51: Producing Composite AssembliesUnit 52: Producing Components by Vacuum FormingUnit 53: Trimming Composite Mouldings using Hand ToolsUnit 54: Joining Plastics using Manual Welding ProcessesUnit 55: Bonding Composite Mouldings

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Assessment Requirements for Awards within the Engineering Sector

Introduction

The purpose of the assessment strategy is to

• assist assessors, internal verifiers and external verifiers• encourage and promote consistent assessment of the qualification• promote cost effective assessment strategies• promote the use of external quality control of assessment methods

The assessment strategy also specifies

• the qualifications and experience required for assessors and verifiers• the assessment environment and standard of equipment that should be used• access to the qualification• the evidence required to support competent performance against the standards• carrying out assessments• assessing knowledge and understanding

Section A General Requirements

The assessment strategy for City and Guilds awards based on EMTA units is detailed below. It applies throughout the standards and must be used as the basis for all individual assessments. In the implementation of all EMTA standards, reference should be made back to this strategy when specifying the assessment requirements for each unit or element of competence. The internal and external verifier will seek evidence that the requirements have been fulfilled by candidates and assessors at all times.

Scope of the Award

Evidence of competence must be assessed against the requirements of the relevant National Occupational Standards. For this award, the relevant standards are contextualised versions of the Engineering Competence Standards (ECS).

Qualification Structure

The qualification structure for this award requires candidates to complete common mandatory units, followed by a choice of pathways. Candidates may then be required to complete further mandatory units within their chosen pathway, followed by a number of optional units from a provided selection. The range of optional units allows for any variations in the occupation in different organisations and across the sector.

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Assessor Requirements

Assessment must be carried out by competent assessors who hold, or are working towards, the nationally recognised Assessor units (A1/A2) (formerly D32/D33).

Assessors must be able to demonstrate that they have sufficient technical competence to evaluate and judge evidence for this award. This will be demonstrated either by holding a relevant technical qualification or by proven suitable experience of the technical areas to be assessed. The assessor’s competence must, at the very least, be at the same level as that required of the candidate(s) in the units being assessed.

Specific technical requirements for assessors of this qualification are outlined on page 11.

Assessors must also know:

• the content and meaning of the National Occupational Standards against which assessments are to be carried out• the appropriate Regulatory Body’s system of vocational qualifications• the relevant Awarding Body’s documentation and system of vocational qualifications within which the assessment is taking place.

Verifier Requirements

Internal Verifiers must hold, or be working towards, the nationally recognised Internal Verifier unit (V1) (formerly D34), and would be expected to be familiar with, and preferably hold, the nationally recognised Assessor units.

External Verifiers must hold, or be working towards, the nationally recognised External Verifier unit (V2) (formerly D35), and would be expected to be familiar with, and preferably hold, the nationally recognised Assessor units, and possibly even the nationally recognised Internal Verifier unit.

Verifiers, both internal and external, will also be expected to be fully conversant with the standards against which the assessments and verification are to be carried out, the appropriate Regulatory Body’s system of vocational qualifications, and the relevant Awarding Body’s documentation and system of vocational qualifications within which the assessment and verification is taking place.

Additionally verifiers, both internal and external, should be technically familiar with the skill area being verified.

Specific technical requirements for verifiers of this qualification are outlined on page 11.

Witness testimony

Where observation of process is used to obtain the performance evidence, this observation must be carried out against the standards. Best practice would require that such observation is carried out by a qualified assessor. If this is not practicable then alternative sources of evidence may be used.

For example, the observation may be carried out against the standards by someone else in close contact with the candidate. This could be a supervisor, colleague, mentor or manager, who may be regarded as a suitable witness to the candidate’s competency. However, the witness must be technically competent in the process or skills that they are providing testimony for to at least the same level of expertise as that required of the candidate. It will be the responsibility of the assessor to make sure that any witness testimonies accepted as evidence of a candidate’s competency are reliable and technically valid.

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Assessment Environment

Evidence for this award should be obtained from the working environment where the work activities or work outcomes to be assessed are clearly attributable to the candidate. However, in certain circumstances, replication of work activities may be acceptable.Where replication is considered necessary, assessors must be confident that the environment replicates the workplace to such an extent that competencies gained will be fully transferable to the workplace. In this case assessors must clearly identify those aspects of the workplace that are critical to performance, and make sure that they have been replicated satisfactorily. Where replication is involved, assessors must obtain agreement with internal and external verifiers before assessing any candidates.

Examples of critical aspects could be:

• environmental conditions such as, noise levels, lighting conditions and the presence of hazards• the use of industrial equipment and procedures• pressure of work such as time constraints and repetitive activities• carrying out work on actual work pieces and the consequences of making mistakes• customer/supplier/departmental relationships

Access to Assessment

There are no entry qualifications or age limits required for these qualifications unless this is a legal requirement of the process or the environment. Assessment is open to any candidate who has the potential to reach the standards laid down for this qualification. However centres should refer to the statement on access to assessment in the City & Guilds Centre Guide for NVQs on not entering for similar awards at the same level.

Aids or appliances which are designed to alleviate disability may be used during assessment providing they do not compromise the standard required.

Carrying Out Assessments

EMTA strongly recommends that the majority of assessment evidence for the mandatory units is gathered during the performance of the optional units. Evidence should be obtained as a whole, where practically possible, since competent performance in the optional units is often dependent on competence in the mandatory units. Although it is possible to achieve this qualification with the minimum number of optional units, organisations may wish their candidates to be assessed for more than this.

Where key skills are required, these may be included as additional units and assessed in conjunction with the mandatory and optional units, where this is appropriate.

The standards were developed to cover a range of activities. The evidence produced for this award will, therefore, depend on the candidate’s choice of ‘scope’ items in the standard, which are intended to help the candidate to seek the appropriate information and to acquire the necessary skills, techniques and knowledge before being able to demonstrate competent performance.

Where the scope section gives a choice (for example ‘any three from five’), assessors should note that candidates do not need to cover the other (in this example, two) items, particularly where these additional items may relate to other activities or methods which are not part of the candidate’s normal workplace activity or area of expertise.

Performance Evidence Requirements

Performance evidence must be the main form of evidence gathered.

In order to demonstrate consistent, competent performance for a unit, a minimum of three different evidence examples of performance evidence will be required, to show that the tasks reflected by the unit

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title have been carried out to the stated standards. The number of items required in each of the scope statements specified for a unit (e.g., four from a choice of six) must all be covered. It is possible that some of the scope items may be covered more than once. If, however, the three examples of performance evidence are not sufficient to cover all the specified scope items, then further examples of performance evidence will be required to ensure this coverage is achieved.

Assessors must make sure that the evidence provided reflects the candidate’s competence and not just the achievement of the training programme.

Items of performance evidence often contain features that apply to more than one unit, and can be used as evidence in any unit where appropriate.

Performance evidence may be either:

• products of the candidate’s work, such as items that have been produced or worked on, documents produced as part of a work activity, records or photographs of the product or

• evidence of the way the candidates carried out the activities such as witness testimonies, assessor observations or authenticated candidate reports of the activity undertaken

Competent performance is more than just carrying out a series of individual set tasks. Many of the units contain statements that require the candidate to provide evidence that proves they are capable of combining the various features and techniques. Where this is the case, separate fragments of evidence would not provide this combination of features and techniques and will not, therefore, be acceptable as demonstrating competent performance.

If there is any doubt as to what constitutes suitable evidence, the external verifier should be consulted.

Assessing Knowledge and Understanding

Knowledge and understanding are key components of competent performance, but it is unlikely that performance evidence alone will provide enough evidence in this area. Where the candidate’s knowledge and understanding (and the handling of contingency situations) is not apparent from performance evidence, it must be assessed by other means and be supported by suitable evidence.

Knowledge and understanding can be demonstrated in a number of different ways, but it is suggested that the most appropriate methods for this qualification are oral questioning and practical demonstrations. Assessors should ask enough questions to be able to determine that the candidate has an appropriate level of knowledge and understanding as required by the unit.

Where oral questioning is used the assessor must retain a record of the questions asked, together with the candidate’s answers.

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Section B Qualification-Specific Requirements for the N/SVQ in Fabrication and Welding Level 3

Scope of the Award

This qualification is for people who are occupied primarily in welding and/or fabrication, and who have a high level of technical skill and knowledge in that activity. They will be expected to demonstrate safe working practices and procedures at all times and work with minimum supervision, taking personal responsibility for the quality and accuracy of the work they carry out.

Candidates for this qualification will have gained a high level of skill ability and acquired sound knowledge and understanding of the relevant techniques, materials, tools and equipment used, in order to enable them to carry out the activities, solve related problems, correct any faults and ensure the work output meets the required specification standard.

Specific Technical Requirements for Assessors

Assessors of this qualification should have a minimum of three years’ relevant skills experience, and should have a thorough working knowledge of welding and fabrication processes, techniques, and procedures used.

Specific Technical Requirements for Verifiers

Verifiers should have some relevant skills experience, and should have held a position of engineering responsibility. They should have sufficient technical knowledge to enable them to verify that assessments have been carried out to the technical and safety standards required, and to ask relevant questions of assessors or candidates, where necessary.

Specific Evidence Requirements

Candidates must carry out at least THREE separate assessment tasks. The unit guidance and scope for each unit indicate in detail what evidence is required. There is a specific Unit Checklist provided for EACH unit in this guide.

Completing the Unit checklists

The candidate must carry out at least three separate assessment tasks. The location of all items of evidence, that must cover ALL of the criteria given in the standards, should entered on the checklist provided after each unit under the ‘Performance Evidence’ columns. These locations must be identified in a way that allows the verifiers (internal and external) to easily trace and audit the evidence e.g. Page 6 – could refer to the position in the portfolio of the inspection sheet covering ‘Weld Quality B and C and Dimensional Accuracy. Drawing 1 could provide the specification for the same task. Also Job 1234 could refer to an actual product.Note that it may not be possible to cover all of the required criteria by completing three tasks. In such cases supplementary work may be needed to cover this shortfall, this will be referenced in the fourth column’

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In addition to the unit checklist, the required evidence must also contain

• Actual product evidence where practical – e.g. taking into account its weight, size and or if it is an actual production item for customer use. Photographs or videos may be used in lieu provided they show the skill areas in sufficient detail for the verifiers (internal and external) to make a decision regarding the practical standards achieved

• A work sheet (company or centre devised) that clearly lays down the required product specification in terms of materials, tolerances and any time restrictions plus a drawing. Note i) it is not necessary for the candidate to personally reproduce drawings, method descriptors etc. unless these items do not exist.ii) in cases of industrial confidentiality or sensitivity then it may be permissible to exclude certain items from the evidence, but a description of the general nature of the work/activity must be provided. In cases of doubt the EV should be consulted about the validity of a proposed assessment before the candidate commences any such work.

• An inspection sheet or report that clearly identifies that the product has been reliably tested against the specification. If there are any discrepancies of a non-critical nature then the assessment may be deemed acceptable provided that there is a statement to this effect signed by a duly appointed and responsible person.

• A brief report, prepared by the candidate, that identifies any hazards or difficulties associated with the work and how these were dealt with. It should also highlight any specific requirements or special skill areas that were involved e.g. non standard tools, tool and work holding methods (use of jigs and fixtures etc.) Note that where relevant some aspects of this could also form part of the required knowledge evidence e.g. items 8 and 9 of this unit.

Knowledge evidence

Where the required knowledge and understanding cannot be obviously and positively inferred from an assessor or expert witness observing the practical tasks, then the candidate must be formally questioned using either short written answer or oral types of questions.The questions should only relate to the specific areas defined by the criteria for this unit. e.g. if only AC equipment is used then the questions should not ask for setting details etc. of DC equipment. (Note that this knowledge may well form part of an all round underpinning knowledge programme but in such cases it would be assessed separately.

Assessors must carefully plan all types of questioning procedures beforehand. The actual questions (oral and written) must be kept under secure conditions and only made available to the candidates during the assessment process. The candidates will retain a copy of their results, including comments made by the assessor during oral questioning. (See the separate information section regarding the use of oral questioning techniques).Assessors must make the questions available to verifiers so that the latter can compare them against the results sheets held by the candidates.

The knowledge evidence should be referenced in a similar fashion to that used for performance evidence.

Note that it is not necessary to assess the knowledge criteria on three separate occasions

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Level 3 NVQ in Fabrication and Welding Engineering Knowledge evidence recording sheet(this should be copied for each unit)

Method(s) usedKnowledgereference Written Oral Inferred

Candidate’sEvidence location

AssessorReference

ResultDate

assessed

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2

3

4

5

6

7

8

9

10

11

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Name Signature

Candidate: Date:

Assessor: Date:

Internal Verifier Date:

External Verifier Date:

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National Occupation Standards – Fabrication and Welding Level 3

Supplied by SEMTA

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Unit 1 Complying With Statutory Regulations and Organisational Safety Requirements

Unit Summary

This unit identifies the competencies you need to deal with statutory and organisational safety requirements in accordance with approved regulations, codes of practice and procedures. You will be required to comply with all relevant regulations that apply to your area of work as well as your general responsibilities as defined in the Health and Safety at Work Act. You will also need to be able to identify the relevant qualified first aiders or appointed person and know the location of the first aid facilities. You will have an understanding of the procedures to beadopted in the case of accidents involving injury and in situations where there are dangerous occurrences or hazardous malfunctions of equipment, processes or machinery. You will also need to be fully conversant with the organisation’s procedures for fire alerts and the evacuation of premises.

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

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

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

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Performance statements:

You must:a. Comply with your duties and obligations as defined in the Health and Safety at Work Act b. Present yourself in the workplace suitably prepared for the activities to be undertakenc. Follow organisational accident and emergency proceduresd. Recognise and control hazards in the workplacee. Use correct manual lifting and carrying techniquesf. Apply safe working practices and procedures

Scope of the unit:The numbers of scope items specified (below) indicate the minimum requirements for this Occupational Standard.

You must:1. Demonstrate your understanding of your duties and obligations to health and safety by carrying out all of the following:

● apply in principle your duties and responsibilities as an individual under the Health and Safety at Work Act and relevant current legislation

● identifying within your organisation, appropriate sources of information and guidance on health and safety issues, to include:

o Eye protection and personal protective equipment o COSHH regulationso Risk assessments

● identifying the warning signs and labels of the main groups of hazardous or dangerous substances● complying with the appropriate Statutory Regulations at all times

2. Comply with all emergency requirements to include:● identifying the appropriate qualified first aiders or appointed person and the location of first aid facilities● identifying the procedures to be followed in the event of injury to self or others● following organisational procedures in the event of fire and the evacuation of premises● identifying the procedures to be followed in the event of dangerous occurrences or hazardous

malfunctions

3. Identify the hazards and risks that are associated with all of the following:● your working environment ● the tools and equipment that you use ● materials and substances that you use● using working practices that do not follow laid down procedures

4. Demonstrate two methods of manual lifting and carrying techniques:lifting alone with assistance of others ● with mechanical assistance

5. Apply safe working practices in an industrial environment to include all of the following:● maintaining a tidy workplace with exits and gangways free from obstructions● using tools and equipment safely and only for the purpose intended● observing organisational safety rules, signs and hazard warnings● taking measures to protect others from harm by any work you are carrying out

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Knowledge statements:

You must have knowledge and understanding of :

1. The roles and responsibilities of yourself and others under the Health and Safety at Work Act 1974 and current legislation (e.g. The Management of Health and Safety at Work Regulations; Workplace Health and Safety and Welfare Regulations; Personal Protective Equipment at Work Regulations; Manual Handling Operations Regulations; Provision and use of Work Equipment Regulations; Display Screen at Work Regulations)

2. The specific regulations and safe working practices and procedures that apply to your work activities3. The warning signs for the seven main groups of hazardous substances defined by Classification, Packaging and

Labelling of Dangerous Substances Regulations4. How to locate relevant health and safety information for your tasks and the sources of expert assistance when

help is needed5. What constitutes a hazard in the workplace (such as moving parts of machinery, electricity, slippery and

uneven surfaces, dust and fumes, handling and transporting, contaminants and irritants, material ejection, fire, working at height, environment, pressure/stored energy systems, volatile or toxic materials, unshielded processes)

6. What are your responsibilities for dealing with hazards and reducing risks in the workplace (such as hazard spotting and safety inspections; the use of hazard check lists, carrying out risk assessments, COSHHassessments and safe systems of working)

7. What are the risks associated with your working environment, the tools, materials and equipment that you use, spillages of oil and chemicals, not reporting accidental breakages of tools or equipment and not following laid down working practices and procedures

8. What first aid facilities exist within your work area and within the organisation in general and the procedures to be followed in the case of accidents involving injury

9. What constitutes dangerous occurrences and hazardous malfunctions and why these must be reported even when no one was injured

10. The procedures for sounding the emergency alarms, evacuation procedures and escape routes to be used and the need to report your presence at the appropriate assembly point

11. What the organisational policy is with regard to fire fighting procedures, the common causes of fire and what you can do to help prevent them

12. What protective clothing and equipment is available for your areas of activity13. How to safely lift and carry loads and the manual and mechanical aids available14. How to prepare and maintain safe working areas, standards and procedures to ensure good housekeeping15. The importance of safe storage of tools, equipment, materials and products16. The extent of your own responsibility and whom you should report to, in the event of problems that you cannot resolve

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Performance Evidence 1

PerformanceEvidence 2


Additional Performance Evidence

(if required)Evidence TypeDateHealth & Safety (understanding ALL application of duties and equipment)H & S at Work ActPPECOSHHrisk assessmentshazardous substancesstatutory regulationsEmergency Requirements (ALL)first aider/facilitiesinjury proceduresfire proceduresdanger/hazard proceduresEnvironmental Hazards/Risks (ALL)working environmenttools & equipmentmaterials and substancesbad working practicesManual Lifting & Carrying Techniques (TWO)lifting alonewith assistance of otherswith mechanical assistanceSafe Working Practices (ALL)tidy workplacetools & equipmentsafety/hazard warningsprotect others

Knowledge and understanding reference:

Candidate: Date:

Assessor: Date:

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Unit 2 Using & Interpreting Engineering Drawings & Documents

Unit Summary

This unit identifies the competencies you need to make effective use of text, numeric and graphical information by interpreting and using technical information extracted from engineering drawings, technical manuals, reference tables, specifications and charts in accordance with approved procedures. You will be required to extract the necessary information from the various drawings and related documents in order to establish and carry out the work requirements and to make valid decisions about the quality and accuracy of the work produced in accordance with approved procedures.

Your responsibilities will require you to comply with organisational policy and procedures for obtaining and using the drawings and related specifications. You will be expected to report any problems with the use and interpretation of the drawings and specifications that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of the types of drawings and documents used and provide an informed approach to applying instructions and procedures. You will be able to read and interpret the drawings and documents used and will know about the conventions, symbols and abbreviations in adequate depth to provide a sound basis for carrying out the activities to the required specification.

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You must:a. Use the approved source to obtain the required drawings and specificationsb. Correctly interpret the drawings and specificationsc. Identify, extract and interpret the required informationd. Use the information obtained to ensure that work output meets the specificatione. Deal promptly and effectively with any problems within your control and report those which cannot be solvedf. Report any inaccuracies or discrepancies in drawings and specifications


You must: 1. Use approved sources to obtain the necessary drawings and related specifications and carry out all of the following:

● check the currency and validity of the drawings and documents used● exercise care and control over the documents at all times● correctly extract all necessary data in order to carry out the required tasks● seek out additional information where there are gaps or deficiencies in the information obtained● deal with or report any problems found with the drawings/specifications● make valid decisions based on the evaluation of the engineering information gained● return all drawings and related specifications to the approved location on completion of the work● complete all necessary production documentation

2. Use information extracted from engineering drawings to include one or more types of drawing from the following:

● detailed component drawings● general assembly drawings● repair drawings ● fluid power drawings● wiring/circuit diagrams ● installation drawings

● modification drawings● sub-assembly drawings● schematic diagrams● fabrication drawings ● welding drawings

3. Use information extracted from related documentation to include two from the following:● job instructions● drawing instructions● test schedules● manufacturers instructions● weld procedure specifications

● reference tables/charts● national, international and organisational standards● planning documentation● quality control documents

4. Extract information that includes three of the following: ● materials or components required● dimensions● tolerances ● build quality

installation requirements

● surface texture requirements ● location/orientation of parts● process or treatments required● assembly sequence

● weld type and size● operations required ● connections to be made

● circuit characteristics (such as pressure, flow, current, voltage, speed)

23



You must have knowledge and understanding of:

1. The information sources used for the drawings and specifications that you use in your work activities2. How drawings and documents are obtained and how to check that they are current and valid3. How to use other sources of information to support the drawings (such as electronic component pin

configuration specifications, standard reference charts for limits and fits, tapping drill reference charts, bend allowances required for material thickness, electrical conditions required for specific welding rods)

4. The procedures for reporting discrepancies in the drawings or documents and for reporting lost or damaged drawings/documents

5. Care and control procedures for the drawings and documents and the importance of returning them to the designated location on completion of the work activities

6. The basic drawing conventions that are used and why there needs to be different types of drawings7. The types of drawings used and how they interrelate (such as isometric and orthographic, first and third angle,

assembly drawings, circuit and wiring diagrams, block and schematic diagrams)8. Imperial and metric systems of measurement, tolerancing and fixed reference points9. The meaning of the different symbols and abbreviations found on the drawings that you use (such as surface

finish, electronic components, weld symbols, linear and geometric tolerances, pressure and flow characteristics)10. Care and control procedures for drawings and specifications and how damage or graffiti on drawings can lead to

scrapped work 11. The extent of your own responsibility, when to act on your own initiative to find, clarify and evaluate information

and whom you should report to if you have problems that you cannot solve

24





Additional Performance Evidence (if required)

Evidence TypeDateNecessary Drawings & Specifications (ALL)check currency & validitycare & controlextract dataadditional informationproblemsdecisionsreturn drawings etcproduction documentationInformation Extracted from Engineering Drawings (ONE OR MORE)componentassemblyrepairfluid powerwiring/circuitinstallationmodificationsub-assemblyschematicfabricationweldingInformation Extracted from Related Documentation (TWO)job instructionsdrawing instructionstest schedulesmanufacturers instructionsweld procedure spec’sreference tables/chartsstandardsplanning docsquality control docsExtract Information (THREE)materials/componentsdimensionstolerancesbuild qualityinstallationcircuit characteristicssurface texturelocation/orientation of partsprocess or treatmentsassembly sequenceweld type/sizeoperationsconnections


Candidate: Date:

Assessor: Date:

25

Unit 3 Working Efficiently & Effectively in Engineering

Unit Summary

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

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

In order to be efficient and effective in the workplace you will also be required to demonstrate that you can create and maintain effective working relationships with colleagues and line management, review objectives and targets for your personal development, contribute to and communicate any opportunities for improvements that could be made to working practices and procedures.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to working efficiently and effectively in an engineering environment. You will understand the need to work efficiently and effectively and its application, and will know about the areas you need to consider when preparing and tidying up the work area, how to contribute to improvements, deal with problems, maintain effective working relationships and agree your development objectives and targets in adequate depth to provide a sound basis for carrying out the activities safely and correctly. You will understand the safety precautions required when carrying out engineering activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

26



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Prepare the work area to carry out the engineering activityc. Check there are sufficient supplies of materials and/or consumables and that they meet work requirementsd. Ensure completed products or resources are stored in the appropriate location on completion of the activitiese. Tidy up the work area on completion of the engineering activityf. Deal promptly and effectively with problems within you control and report those that cannot be resolvedg. Contribute and communicate opportunities for improvement to working practices and procedures h. Maintain effective working relationships with colleaguesi. Review personal training and development as is appropriate to the job role

Scope of the unit:The numbers of scope items specified (below) indicate the minimum requirements for this Occupational Standard.You must:1. Prepare to carry out the engineering activity taking into consideration all of the following as is applicable to the work to be undertaken:

● the work area is free from hazards and suitably prepared for the activities to be undertaken ● any required safety procedures are implemented● any necessary personal protection equipment is obtained and is in a usable condition● tools and equipment required are obtained and checked that they are in a safe and useable condition● all necessary drawings, specifications and associated documentation is obtained● job instructions are obtained and understood● the correct materials or components are obtained ● storage arrangements for work are appropriate

appropriate authorisation to carry out the work is obtained

2. Complete work activities to include all of the following:● completing all necessary documentation accurately

and legibly● returning tools and equipment ● returning drawings and work instructions

● identifying where appropriate any unusable tools, equipment and components

● arranging for disposal of waste materials

3. Contribute to organisational procedures for identifying opportunities for improvement to one of the following:● working practices● working methods● quality● safety

● tools and equipment● suppliers● internal communication● customer service

● training and development● teamwork● other

4. Deal with problems affecting the engineering process to include two of the following:● materials● tools and equipment● drawings

● job specification● quality● people

● timescales● safety● activities or procedures

5. Maintain effective working relationships to include two of the following:● colleagues within own working group● colleagues outside normal working group

● line management● external contacts

6. Review personal development objectives and targets to include one of the following:● dual or multi skilling● training on new equipment / technology● increased responsibility

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

● other specific requirements

27



You must have a knowledge and understanding of:

1. The safe working practices and procedures to be followed whilst preparing and tidying up your work environment2. The correct use of any equipment used to protect the health and safety of you and your colleagues3. The procedure for ensuring that all documentation relating to the work being carried out is available and current

prior to starting the activity4. The action that should be taken if documentation received is incomplete and / or incorrect5. The procedure for ensuring all tools and equipment are available prior to undertaking the activity6. The checks to be carried out to ensure tools and equipment are in full working order prior to undertaking the

activity7. The action that should be taken if tools and equipment are not in full working8. The checks to be carried out to ensure all materials required are correct and complete prior to undertaking the

activity9. The action that should be taken if materials do not meet the requirements of the activity10. Who to inform when the work activity has been completed11. The information and / or documentation they require to confirm the activity has been completed12. What materials, equipment and tools can be re-used13. How any waste materials and / or products are transferred, stored and disposed of14. Where tools and equipment should be stored and located15. The importance of making a contribution to improving working practices16. The procedure and format for making suggestions for improvements17. What the benefits are to you and the organisation if improvements can be identified18. The importance of maintaining effective working relationships within the workplace19. The procedures to deal with and report any problems that can affect working relationships20. The type of difficulties that can occur in working relationships21. The regulations that affect how you should be treated at work (such as Equal Opportunities Act, Race and Sex

Discrimination, Working Time Directive)22. The benefits of continuous personal development23. The training opportunities that are available in the workplace24. The importance of why your training and development should be reviewed25. Who to discuss training and development issues with26. The extent of your own responsibility and whom you should report to if you have any problems that you cannot

resolve

28






Evidence TypeDatePreparation for Engineering Activity (ALL)work area free of hazardssafety proceduresPPEtools/equipmentdrawings/specs/docsjob instructionsmaterials/componentsstorageauthorisationWork Activities (ALL)necessary docsreturn tools/equipmentreturn drawingsunusable tools/componentswaste materialsIdentify Opportunities for improvement (ONE)working practicesworking methodsqualitysafetytools/equipmentsuppliersinternal communicationcustomer servicetraining/developmentteamworkotherProblems Affecting Engineering Process (TWO)materialstools/equipmentdrawingsjob specificationqualitypeopletimescalessafetyactivities/proceduresMaintain Effective Working Relationships (TWO)own working groupoutside own working groupline managementexternal contactsPersonal Development Objectives (ONE)dual or multi-skillingnew equipment/technologyresponsibilitycompany working policiesother


Candidate: Date:

Assessor: Date:

29

Unit 4 Welding materials by the manual metal arc process

Unit Summary

This unit identifies the competencies you need to prepare and operate manual metal arc welding equipment in accordance with approved welding procedures. You will be required to set up and check the welding equipment and associated workholding and manipulating devices required. In setting up the equipment you will need to connect all the required leads/cables, electrode holder and workpiece earthing arrangements ready for use, and set and adjust the welding conditions in line with the welding procedure specification. You must operate the equipment safely and correctly and make any necessary adjustments to settings in order to produce the welded joints to the required specification.

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

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

30



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant joining procedure and job instructionsc. Check that the joint preparation complies with the specificationd. Check that joining and related equipment and consumables are as specified and fit for purposee. Make the joints as specified using the appropriate thermal joining techniquef. Produce joints of the required quality and of specified dimensional accuracyg. Shut down the equipment to a safe condition on completion of joining activitiesh. Deal promptly with excess and waste materials and temporary attachments, in line with approved and agreed proceduresi. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Set up, check, adjust and use manual metal-arc welding and related equipment to include either:

alternating current equipment (AC)direct current equipment (DC)

2. Use two types and two sizes of electrode from the following:rutilebasicnickel alloy

cellulosicstainless steelother electrodes

3. Produce welded joints which incorporate both:butt weldsfillet welds

4. Produce joints in two forms of specified materials from different material groups to include the following:platesection

pipe/tubeother forms

5. Weld joints according to approved welding procedures in good access situations in the following BS EN287 positions:

Vertical upwards (PF) butt weldand four other positions chosen from:

Flat (PA)Horizontal (PC)Overhead (PE)

Horizontal vertical (PB)Vertical downwards (PG)Inclined tube/pipe (H-LO45 or J-LO45)

6. Produce welded components which: achieve a weld quality equivalent to Level B of BS EN 25817/ISO 5817 except for excess weld metal,

excessive convexity, excess throat thickness and excessive penetration for which Level C shall apply (for aluminium, EN30042/ISO10042 applies)

meet the required dimensional accuracy within specified tolerances

31




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

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

3. Principles of MMA welding, the equipment and its operation (fusion welding principles, characteristics of the metal arc, AC and DC power sources, typical equipment and power ranges, care of equipment, terminology used in welding)

4. Extracting information required from drawings and welding procedure specifications (interpretation of welding symbols; scope, content and application of the welding procedure specification)

5. Types and classification of electrodes (flux coverings, correct control, storage and drying of electrodes) 6. Types and features of welded joints in plate, tube and sections (fillet and butt welds, single and multi-run welds,

welding positions, weld quality) 7. Problems that can occur with the welding activities and how these can be overcome (causes of distortion and

methods of control, effects of welding on materials and sources of weld defects; methods of prevention) 8. Methods of setting up the joint to achieve correct location of components and control of distortion (edge

preparation, use of jigs/fixtures; manipulators and positioners, tack welding, size and spacing in relationship to material thickness and component size, use of temporary attachments, pre-setting)

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

10. The techniques of operating the welding equipment to produce a range of joints in the various joint positions (fine tuning parameters, correct manipulation of electrode, safe closing down of the welding equipment)

11. The organisational quality systems used and weld standards to be achieved 12. Weld inspection and test procedures used including destructive and non-destructive methods 13. Personal approval tests and their applicability to your work14. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

32






Evidence typeDate Equipment (either)ACDCElectrode type (two different types and two different sizes required)rutilebasicnickel alloycelluosicstainless steelother (specify)Electrode sizeJoint (both required for each joint)butt weldfillet weldMaterial (two different types required)platesectionpipe/tubeother (specify)Joint position (PF and four others required)PFPAPCPEPBPGH-LO45 or J-LO45Weld quality Level B BS EN 25817/ISO 5817 requiredgeneralWeld quality Level C BS EN 25817/ISO 5817 (aluminium EN 30042/ISO 10042) requiredexcess weld metalexcess convexityexcess throat thicknessexcessive penetrationDimensional accuracy achieved within tolerances


Candidate: Date:

Assessor: Date:

33

Unit 5 Welding Materials by the Manual MIG/MAG & other Continuous Wire Processes

Unit Summary

This unit identifies the competencies you need to prepare and operate manual MIG, MAG and other cored wire arc welding equipment in accordance with approved welding procedures. You will be required to set up and check the welding equipment and associated workholding and manipulating devices required. In setting up the equipment you will need to connect all the required leads/cables, hoses, shielding gas supply and wire feed mechanisms ready for use, and set and adjust the welding conditions in line with the welding procedure specification. You must operate the equipment safely and correctly and make any necessary adjustments to settings in order to produce the welded joints to the required specification.

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

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

34



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant joining procedure and job instructionsc. Check that the joint preparation complies with the specificationd. Check that joining and related equipment and consumables are as specified and fit for purposee. Make the joints as specified using the appropriate thermal joining techniquef. Produce joints of the required quality and of specified dimensional accuracyg. Shut down the equipment to a safe condition on completion of joining activitiesh. Deal promptly with excess and waste materials and temporary attachments, in line with approved and agreed

procedures i. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Set up, check, adjust and use welding and related equipment for one of the following welding processes:

MIG MAGCored wire

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

3. Produce welded joints which incorporate both of the following: butt weldsfillet welds

4. Produce joints in two forms of specified materials from different material groups to include the following: platesection

sheet (<3mm)pipe/tube

other forms


Vertical upwards (PF) butt weld and four other positions chosen from:


Horizontal vertical (PB)Vertical downwards (PG)Inclined pipe/tube (H-LO 45 or J-LO45)


excessive convexity, excess throat thickness and excessive penetration for which Level C shall apply (for aluminium EN 30042/ISO 10042 applies)


35




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

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

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

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


6. Types and classification of consumables (wires, shielding gases -inert and active; control and storage of consumables)

7. Types and features of welded joints in plate, sheet and tube (fillet and butt welds, single and multi-run welds, welding positions, weld quality)

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

9. Methods of setting up the joint to achieve correct location of components and control of distortion (edge preparation; correct joint set-up; cleanliness of materials used; use of jigs/fixtures, manipulators and positioners; tack welding, size and spacing in relationship to material thickness and component size; use of temporary attachments; pre-setting)

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

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

12. The organisational quality systems used and weld standards to be achieved13. Weld inspection and test procedures used including destructive and non-destructive methods14. Personal approval tests and their applicability to your work15. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

36






(if required)Evidence TypeDateWelding Processes (ONE)MIGMAGCored wireConsumables (BOTH)wire types & sizes (two different types and two different sizes required)shielding gases (2)Produce Welded Joints (BOTH)butt weldsfillet weldsProduce Joints in TWO forms of Specified Material from Different Material Groups platesectionsheet (<3mm)pipe/tubeother formsApproved Welding Procedures in BS EN287 Positions (PF & FOUR others)PFPAPCPEPBPGH-LO45 or J-LO45Weld Quality Level B BS EN 25817/ISO 5817 requiredgeneralWeld Quality Level C BS EN 25817/ISO 5817 (aluminium EN 30042/ISO 10042) requiredexcess weld metalexcess convexityexcess throat thicknessexcessive penetrationDimensional Accuracyachieved within tolerances


Candidate: Date:

Assessor: Date:

37

Unit 6 Welding Materials by the Manual TIG and Plasma Arc Welding Process

Unit Summary

This unit identifies the competencies you need to prepare and operate manual TIG or Plasma Arc welding equipment in accordance with approved welding procedures. You will be required to set up and check the welding equipment and associated workholding and manipulating devices required. In setting up the equipment you will need to connect all the required leads/cables, hoses and torch ready for use, and set and adjust the welding conditions in line with the welding procedure specification. You must operate the equipment safely and correctly and make any necessary adjustments to settings in order to produce the welded joints to the required specification.


Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying welding procedures and instructions. You will understand the TIG or Plasma Arc welding process, and its application, and will know about the equipment, materials and consumables in adequate depth to provide a sound basis for setting up and operating the equipment, recognising and correcting faults and ensuring the work output is produced to the required specification. Visual inspection and non-destructive testing of your completed work is implied. You will understand the safety precautions required when working with the welding equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

38




proceduresi. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Set up, check, adjust and use welding and related equipment for one of the following manual welding processes:

TIG Plasma-arc

2. Use consumables appropriate to the material, application and electrodes to include both of the following: two different sizes of electrodetwo types of filler wire from different material groups

3. Produce welded joints which incorporate the following:butt welds

and eitherfillet welds OR welds made autogenously (without filler wire)

4. Produce joints in two forms of specified materials from different material groups to include the following:platesectionother forms

pipe/tubesheet




Horizontal vertical (PB)Vertical downwards (PG)Inclined pipe/tube (H-LO45 or J-LO45)


excessive convexity, excess throat thickness and excessive penetration for which Level C shall apply (for aluminium EN 30042/ISO 10042 applies)


39




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

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

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

4. Principles of TIG or Plasma-arc welding, the equipment and its operation (fusion welding principles, characteristics of the arc, power sources, typical equipment and power ranges, care of equipment, control systems, filler wires, gas supply and control, terminology used in welding)


6. Types and classification of consumables (wires, shielding gasses, electrodes; control and storage of consumables)7. Types and features of welded joints in plate and tube (fillet and butt welds, single and multi-run welds, welding

positions, weld quality)8. Problems that can occur with the welding activities and how these can be overcome (causes of distortion and

methods of control, effects of welding on materials and sources of weld defects; methods of prevention)9. Methods of setting up the joint to achieve correct location of components and control of distortion (edge

preparation, use of jigs/fixtures; manipulators and positioners, tack welding, size and spacing in relationship to material thickness and component size, use of temporary attachments, pre-setting)

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

11. The techniques of operating the welding equipment to produce a range of joints in the various joint positions (fine tuning parameters, correct manipulation of torch, safe closing down of the welding equipment)


40






(if required)Evidence TypeDateManual Welding Processes (ONE)TIGPlasma-arcConsumables (BOTH)electrode (two different sizes)filler wire (two types)Produce Welded Jointsbutt welds andfillet welds ORautogenously made weldsProduce Joints in TWO forms of specified material from different material groups platesectionpipe/tubesheetother formsApproved Welding Procedures in BS EN287 Positions (PF & FOUR others)PFPAPCPEPBPGH-LO45 or J-LO45Weld Quality Level B BS EN 25817/ISO 5817 requiredgeneralWeld Quality Level C BS EN 25817/ISO 5817 (aluminium EN 30042/ISO 10042) requiredexcess weld metalexcess convexityexcess throat thicknessexcessive penetrationDimensional Accuracyachieved within tolerances


Candidate: Date:

Assessor: Date:

41

Unit 7 Welding Materials by the Manual Gas Welding Process

Unit Summary

This unit identifies the competencies you need to prepare and operate manual gas welding equipment in accordance with approved welding procedures. You will be required to set up and check the welding equipment and associated workholding and manipulating devices required. In setting up the equipment you will need to connect all the required regulators/gauges, flashback arrestors, hoses and welding torch ready for use, and set and adjust the gas pressures/welding conditions in line with the welding procedure specification. You must operate the equipment safely and correctly and make any necessary adjustments to settings in order to produce the welded joints to the required specification.


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

42






You must:1. Set up, check, adjust and use gas welding and related equipment to include all of the following:

correct handling and storage of cylindersconnecting regulators, hoses and valvesconnecting the welding torch and selecting and fitting the correct size nozzlefitting a flash back arrestorsetting appropriate gas pressuresusing the correct procedure for lighting, adjusting and extinguishing the welding flame

2. Use a range of filler wire to include: two different sizes two types of wire from different material groups

3. Produce welded joints which incorporates the following: butt welds

And eitherfillet welds OR welds made autogenously (without filler wire)

4. Produce joints in two forms of specified materials from different material groups to include the following:platesection

other formspipe/tube

sheet (<3mm)




Horizontal vertical (PB)Vertical downwards (PG)Inclined pipe/tube (H-LO45 or J-LO45)

6. Produce welded components which:achieve a minimum weld quality equivalent to Level B of BS EN 25817/ISO 5817 except for excess

weld metal, excessive convexity, excess throat thickness and excessive penetration for which Level C shall apply (for aluminium EN30042/ISO10042 applies)


43




1. The safe working practices and procedures to be observed when working with gas welding equipment (general workshop and site safety; cylinder handling and storage; appropriate personal protective equipment; fire and explosion prevention; protecting other workers; safety in enclosed/confined spaces; fume control; accident procedure; statutory requirements; risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with gas welding and how they can be minimised (high pressure cylinders and gas supply systems; naked flames; fumes and gases; explosive gas mixtures; oxygen enrichment; spatter; hot slag and metal, grinding and mechanical metal/slag removal; elevated working, enclosed spaces)


4. Principles of gas welding, the equipment and its operation (gas welding principles, supply of compressed gases, characteristics of welding flames, typical equipment, care of equipment, terminology used in gas welding)


6. Types and classification of filler rods and fluxes; control and storage of consumables7. Types and features of welded joints in sheet, plate and tube (fillet and butt welds, single and multi-run welds,

welding positions, weld quality)8. Problems that can occur with the welding activities and how these can be overcome (causes of distortion and

methods of control, effects of welding on materials and sources of weld defects; methods of prevention) 9. Methods of setting up the joint to achieve correct location of components and control of distortion (correct joint

set-up; cleanliness of materials used; edge preparation; use of jigs/fixtures, manipulators and positioners; tack welding, size and spacing in relationship to material thickness and component size, use of temporary attachments, pre-setting)

10. Setting up the welding equipment and checks that need to be made to ensure that it is safe and ready to use (connection of hoses, torch, flash-back arrestors, hose check valves and regulators; checking connections for leaks; setting welding parameters)

11. The techniques of operating the welding equipment to produce a range of joints in the various joint positions (selection of nozzle, application of flux, manipulation of torch and filler rods, safe closing down of the welding equipment)


44






(if required)Evidence TypeDateSet Up, Check, Adjust & Use Equipment (ALL)cylinders-handling & storageregulators, hoses & valveswelding torch & nozzleflash back arrestorsetting gas pressureswelding flameFiller Wire (TWO different sizes and types)sizetypeProduce Welded Jointsbutt weldsfillet welds ORwelds made autogenouslyProduce Joints in TWO forms of specified material from different material groups platesectionpipe/tubesheet (<3mm)other formsApproved Welding Procedures in BS EN287 Positions (PF & FOUR others)PFPAPCPEPBPGH-LO45 or J-LO45Weld Quality Level B BS EN 25817/ISO 5817 requiredgeneralWeld Quality Level C BS EN 25817/ISO 5817 (aluminium EN 30042/ISO 10042) requiredexcess weld metalexcess convexityexcess throat thicknessexcessive penetrationDimensional Accuracyachieved within tolerances


Candidate: Date:

Assessor: Date:

45

Unit 8 Welding Pipe/Tube using Multiple Manual Arc Welding Processes

Unit Summary

This unit identifies the competencies you need to produce full penetration butt welds in pipe or tube using manual welding processes such as manual metal arc (MMA), MIG, MAG, TIG, Plasma or cored wire welding equipment in accordance with instructions and/or approved welding procedures. It covers the use of multiple welding processes such as root TIG and fill with MMA or MMA root and flux core fill. You will be required to check that all the workholding equipment and manipulating devices required are available and in a usable condition. You will be expected to set up the welding equipment ensuring that all the leads/cables, hoses and wire feed mechanisms are securely connected and free from damage. In preparing to weld you will need to set and adjust the welding conditions in line with the welding procedure specification. You must operate the equipment safely and correctly and make any necessary adjustments to settings in order to produce the welded joints to the required specification.

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

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

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You must:1. Set up, check, adjust and use welding and related equipment for two or more of the following welding processes:

Manual Metal ArcMIG/MAG

TIGPlasma arc

Cored wire

2. Use consumables specified in the welding procedure specification for the following:the root run(s)the fill and capping runs

3. Produce full penetration butt joints in both of the following: small bore pipe / tube (50mm diameter or less)large bore pipe / tube (above 50mm diameter)

5. Weld butt joints according to approved welding procedures in good access situations in the following BS EN287 positions :

Inclined (H-LO 45 or J-LO 45)

and three other positions chosen from:Flat (PA) rotatingHorizontal (PC)Vertical Upwards (PF)Vertical Downwards (PG)

5. Produce welded components which: achieve a minimum weld quality equivalent to Level B of BS EN 25817/ISO 5817 except for excess


meet the required dimensional accuracy within specified tolerance

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


3. The hazards associated with the selected welding process and how they can be minimised (live electrical components, poor earthing, arc radiation, fumes and gases, gas supply leaks, spatter, hot slag and metal; grinding and mechanical metal/slag removal; elevated working; enclosed spaces; slips, trips and falls)

4. The manual welding process selected and an awareness of the different types of welding equipment (basic principles of fusion welding, AC and DC power sources, ancillary equipment, power ranges, care of equipment, terminology used in welding, flame setting)

5. Extracting information required from drawings and welding procedure specifications (interpretation of welding symbols, scope, content and application of the welding procedure specification)

6. The consumables associated with the chosen welding process (types of electrodes and or filler metal and their application; types of shielding gas and their application, gas supply and control; correct control, storage and drying of electrodes and filler wire)

7. The types and features of welded joints in plate, fillet and butt welds (single and multi-run welds, welding positions, weld quality)

8. Methods of setting up and restraining the joint to achieve correct location of components and control of distortion (edge preparation, use of jigs and fixtures, manipulators and positioners, tack welding size and spacing in relationship to material thickness and component size, use of temporary attachments, pre-setting)

9. Preparing the welding equipment and checks that need to be made to ensure that it is safe and ready to use (electrical connections, power return and earthing arrangements; equipment calibration, setting welding parameters)

10. The techniques of operating the welding equipment to produce a range of joints in the various joint positions (fine tuning parameters, correct manipulation of the welding gun or electrode, safe closing down of the welding equipment)

11. The importance of complying with job instructions and the welding procedure specification12. Problems that can occur with the welding activities and how these can be overcome (causes of distortion and

methods of control, effects of welding on materials and sources of weld defects; methods of prevention)13. The organisational quality systems used and weld standards to be achieved, weld inspection and test procedures

used including visual and non-destructive tests.14. Personal approval tests and their applicability to your work15. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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(if required)Evidence TypeDateSet Up, Check, Adjust & Use welding equipment (TWO or more)Manual Metal ArcMIG/MAGTIGPlasma ArcCored WireConsumables (both)root runsfill & capping runsProduce Full Penetration Butt Joints (both)small bore pipe/tube <50mm)large bore pipe/tube (>50mm)Weld Butt Joints according to BS EN287 (H-LO 45 or J-LO 45 & THREE others)H-LO 45 or J-LO 45PAPCPFPGWeld Quality Level B BS EN 25817/ISO 5817 requiredgeneralWeld Quality Level C BS EN 25817/ISO 5817 (aluminium EN30042/ISO10042) requiredexcess weld metalexcess convexityexcess throat thicknessexcessive penetrationDimensional Accuracyachieved within tolerances


Candidate: Date:

Assessor: Date:

49

Unit 9 Welding Plate using Multiple Manual Arc Welding Processes

Unit Summary

This unit identifies the competencies you need to produce full penetration butt welds in plate or section materials using multiple manual welding processes such as manual metal arc (MMA), MIG, MAG, TIG, Plasma or cored wire welding equipment in accordance with instructions and/or approved welding procedures. You will be expected to produce welds using two or more welding processes such as root TIG and fill with MMA or MMA root and flux core fill. You will be required to check that all the workholding equipment and manipulating devices required are available and in a usable condition. You will be expected to set up the welding equipment ensuring that all the leads/cables, hoses and wire feed mechanisms are securely connected and free from damage. In preparing to weld you will need to set and adjust the welding conditions in line with the welding procedure specification. You must operate the equipment safely and correctly and make any necessary adjustments to settings in order to produce the welded joints to the required specification.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying multiple welding procedures and instructions. You will understand the welding processes used and their application, and will know about the equipment, materials and consumables used in adequate depth to provide a sound basis for setting up and operating the equipment, recognising and correcting faults and ensuring the work output is produced to the required specification. Visual inspection and non-destructive testing of your completed work is implied. You will understand the safety precautions required when working with the welding equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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You must:1. Set up, check, adjust and use welding and related equipment for two or more of the following welding processes:


TIGPlasma Arc

Cored wire

2. Use consumables specified in the welding procedure specification for the following: the root run(s)the fill and capping runs

3. Produce full penetration butt joints in one the following types of material: carbon range of steel platestainless platenon-ferrous plate

5. Weld butt joints according to approved welding procedures in good access situations in the following BSEN287 positions :

vertical upwards (PF)

and four other positions chosen from:Flat (PA) Horizontal (PC)Horizontal Vertical (PB)Vertical Downwards (PG)Overhead (PE or PD)

5. Produce welded components which: achieve a minimum weld quality equivalent to Level B of BS EN 25817/ISO 5817 except for excess



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


3. The hazards associated with the selected welding process and how they can be minimised (live electrical components, poor earthing, arc radiation, fumes and gases, gas supply leaks, spatter, hot slag and metal; grinding and mechanical metal/slag removal; elevated working; enclosed spaces; slips, trips and falls)



6. The consumables associated with the chosen welding process (types of electrodes and or filler metal and their application; types of shielding gas and their application, gas supply and control; correct control, storage and drying of electrodes and filler wire)

7. The types and features of welded joints in plate, fillet and butt welds (single and multi-run welds, welding positions, weld quality)


9. Preparing the welding equipment and checks that need to be made to ensure that it is safe and ready to use (electrical connections, power return and earthing arrangements; equipment calibration, setting welding parameters)



methods of control, effects of welding on materials and sources of weld defects; methods of prevention) 13. The organisational quality systems used and weld standards to be achieved, weld inspection and test procedures

used including visual and non-destructive tests14. Personal approval tests and their applicability to your work15. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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(if required)Evidence TypeDateSet Up, Adjust & Use Welding Equipment (TWO or more)Manual Metal ArcMIG/MAGTIGPlasma ArcCored WireConsumables (both)root run (s)fill & capping runsProduce Full penetration Butt Joints (ONE)carbon range of steel platestainless platenon-ferrous plateWeld Butt Joints according to BS EN287 positions (PF & FOUR others)PAPCPBPGPE or PDWeld Quality Level B BS EN 25817/ISO 5817 requiredgeneralWeld Quality Level C BS EN 25817/ISO 5817 (aluminium EN30042/ISO10042) requiredexcess weld metalexcess convexityexcess throat thicknessexcessive penetrationDimensional Accuracyachieved within tolerances


Candidate: Date:

Assessor: Date:

53

Unit 10 Preparing Mechanised Arc Welding Equipment for Production

Unit Summary

This unit identifies the competencies needed to prepare a mechanised MIG/MAG, cored wire, Submerged Arc, TIG or Plasma Arc welding installation for production in accordance with approved procedures. You will be required to set up and check both the welding installation and all associated mechanical and electrical apparatus forming part of the mechanised or automated installation. This will include setting up of handling and loading equipment, workholding arrangements, traversing mechanisms, transfer mechanisms and safety equipment as is applicable to the machine type. In setting up the welding conditions you will be expected to set the electrical conditions, wire feed rate, welding speed, shielding gas supply system and, where applicable, flux dispensing and recovery mechanisms. You must produce trial welds and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification and solving machine related problems during production will also form part of your role.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying mechanised welding procedures. You will understand the welding process carried out, and its application, and will know about the equipment, relevant materials and consumables in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant joining procedure specification and job instructions for the work to be producedc. Check that the equipment is as specified and in usable conditiond. Obtain the required components and check that the joint preparation complies with the specificatione. Set up the handling, work-holding and associated equipment to achieve correct joint positioning f. Select and prepare the appropriate consumables in line with the joining procedure specificationg. Set and adjust the machine operating conditions to achieve joints of the required quality and within specified dimensional accuracyh. Check that all safety mechanisms are in place and that the equipment is operating satisfactorilyi. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Ensure the arc welding equipment is suitable for production by carrying out all of the following checks:

the equipment is correctly maintained and in a safe and usable conditionthe equipment is correctly calibratedall electrical and mechanical systems function smoothlyequipment shut down systems function correctly

6. Prepare and set-up one of the following arc welding installations for two different joint configurations in the specified materials, forms and positions, according to work instructions and the welding procedure specification:

● MIG/MAG● Cored wire● TIG

● Submerged Arc● Plasma Arc

6. Set up the welding equipment and parameters in accordance with the welding procedure specification to include setting all of the following as is applicable to the machine type:

electrical parameterswire feed ratesafety devices

welding speed consumables

shielding gas supply systemflux dispensing and recovery mechanisms

4. Set up the work piece to achieve correct joint fit-up and alignment to include setting and checking all of the following as is applicable to the machine type:

handling and loading equipmentworkholding arrangementstransfer mechanisms

preparation of materials and joint faces is to specification traversing mechanismssafety mechanisms

5. Prove the installation is operating correctly and is ready for production by producing specified trial welds and checking all of the following:

● visual appearance of weld● dimensional accuracy

● quality of weld● machine settings are as specified

6. Solve problems in production relating to all of the following as is applicable:● machine performance● joint set-up● condition of materials being joined● consumables

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1. The safe working practices and procedures to be observed when setting and operating arc welding installations (working with machinery; the use of appropriate personal protective equipment; machine guards; ventilation and fume extraction; protecting other workers from the effects of the welding arc; machine safety devices; stopping the machine in an emergency; closing the machine down on completion of activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with mechanised arc welding machines and how they can be minimised (dangers from the electric arc; live electrical components; fumes and gases; hot slag and metal; grinding and mechanical metal/slag removal; moving parts of machinery)

3. The basic principles of the relevant mechanised arc welding process (using heat to join metals by fusion; forming a weld; use of filler metal; principal features of a welded joint; process principles, parameters, heat input; how variation in the parameters influences the weld features, quality and output; terminology used in welding)

4. The key components and features of the equipment (power source; power range; electrical parameters such as arc voltage, current, and duty cycle; wire dispensing and feed mechanisms; flux dispensing and recovery and shielding gas supply; calibration of equipment)

5. Mechanised and automated welding basics (types of installations; machine functions: loading, handling, clamping and transfer of components; traversing components or welding head)

6. Extracting necessary information from the component drawings and welding procedure specifications.7. Non-consumable electrodes, types, sizes, profiles, selection and maintenance8. Types and application of electrodes; the selection, control, handling and storage of filler wires, fluxes and shielding

gases9. Types of joints applicable and the edge preparation required10. Problems that can occur with the welding activities and how these can be overcome (causes of distortion and

methods of control, welding characteristics of parent metals and sources of weld defects; methods of prevention)11. Methods of setting up the joint to achieve correct location of components and control of distortion (work holding

methods such as use of jigs/fixtures; component alignment; joint setting to give correct penetration)12. Setting up the welding equipment to the welding procedure specification (setting electrical conditions and filler wire

feed rate; flux dispensing rate; gas flow; welding speed)13. Checking the machine functions to the required specification (running pre-production trials to prove that the

installation is working satisfactorily)14. Organisational quality systems (standards to be achieved; production records to be kept)15. Personal approval tests and their applicability to your work16. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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(if required)Evidence TypeDateCheck Arc Welding Equipment (ALL)safe & usablecorrectly calibratedsystems function smoothlyshut down systemsPrepare ONE of the Arc Welding Installations for TWO different Joint ConfigurationsMIG/MAGTIGCored WireSubmerged ArcPlasma ArcSet Up Equipment & Parameters (ALL)electrical parameterswire feed ratesafety deviceswelding speedconsumablesshielding gas supply systemflux dispensing & recoverySet up work piece to achieve correct joint fit-up & alignment (ALL as applicable) handling & loading equipmentworkholding arrangementstransfer mechanismspreparation of materials & joint facestraversing mechanismssafety mechanismsProduce Trial Welds and check (ALL)visual appearancedimensional accuracyqualitymachine settingsSolve Problems in Production (ALL)machine performancejoint set-upcondition of materialsconsumables


Candidate: Date:

Assessor: Date:

57

Unit 11 Preparing Resistance Spot, Seam and Projection Welding Machines for Production

Unit Summary

This unit identifies the competencies you need to prepare a resistance spot, seam or projection welding installation for production in accordance with approved procedures. You will be required to set up and check both the welding equipment and all associated mechanical and electrical apparatus forming part of the mechanised or automated installation. This will include setting up of handling and loading equipment, workholding arrangements, traversing mechanisms, transfer mechanisms and safety equipment as is applicable to the machine type. In setting up the welding conditions you will be expected to set the welding current, welding and squeeze times, electrode pressure cycle, and welding speed for seam or spot pitch. You must produce trial welds and prove the machine is working satisfactorily before declaring the equipment ready for production. Making adjustments to settings to achieve specification and solving machine related problems during production will also form part of your role.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying resistance-welding procedures. You will understand the welding process carried out, and its application, and will know about the equipment, relevant materials and consumables in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant joining procedure specification and job instructions for the work to be producedc. Check that the equipment is as specified and in usable conditiond. Obtain the required components and check that the joint preparation complies with the specificatione. Set up the handling, work-holding and associated equipment to achieve correct joint positioning f. Select and prepare the appropriate consumables in line with the joining procedure specificationg. Set and adjust the machine operating conditions to achieve joints of the required quality and within specified

dimensional accuracyh. Check that all safety mechanisms are in place and that the equipment is operating satisfactorilyi. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Ensure the resistance welding equipment is suitable for production by carrying out all of the following checks:


2. Set up, check, adjust and use one of the following types of resistance welding installations:● spot welding ● seam welding ● projection welding

3. Set up the welding installation and parameters in accordance with the welding procedure specification to include setting up all of the following as is applicable to the type of installation:

● welding current● welding and squeeze times● electrode pressure cycle

● welding speed (seam)● weld pitch (spot)

4. Set up the work piece to achieve correct joint fit-up and alignment to include setting and checking all of the following as is applicable to the type of installation:

● handling and loading equipment● traversing mechanisms● safety mechanisms

● preparation of materials and joint faces is to specification● work holding arrangements● transfer mechanisms

5. Set up the equipment to produce welded components in the specified materials and forms that cover both of the following:

● two different material thicknesses two different joint configurations

6. Prove the installation is operating correctly and is ready for production by producing specified trial welds and checking all of the following as is applicable to the application:

● visual appearance of weld area● dimensional accuracy

● weld quality● machine settings are as specified

7. Solve problems in production relating to all of the following as is applicable:machine performancecondition of electrode

joint set-upcondition of materials being joined

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1. The specific safety precautions to be taken when setting and operating resistance welding installations (working with machinery; the use of appropriate personal protective equipment; machine guards; operation of machine safety devices; stopping the machine in an emergency; closing down the machine on completion of the welding activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with resistance welding machines and how they can be minimised (dangers from live internal electrical components, fumes, hot metal, expulsion of hot particles, moving parts of machines)

3. The basic principles of resistance welding (heat and pressure to join metals; heating effect of welding current; principle features of the welded joint; heat input; welding and pressure cycles; how variations in the parameters influences the weld features; terminology used in welding)

4. The key components and features of the resistance welding equipment used (power source; welding head; power range; electrical parameters such as voltage, current, electrode pressure and welding time; systems for parameter control)

5. Mechanised and automated resistance welding basics (types of installation; machine functions; control systems; safety features; loading, handling, clamping and transfer of components)

6. Extracting information from drawing and welding procedure specifications7. Types of electrodes used in resistance welding, contact profiles and maintenance requirements of the electrodes8. Types of joints applicable to resistance welding and the surface preparation required9. Methods of setting up the joints to achieve correct location of components (work holding arrangements;

component location and contact)10. Setting up the welding equipment to the welding procedure specification (setting welding conditions, time and

pressure cycles; welding speed)11. Checking that the equipment functions to the required specification (running pre-production trials to prove that the

installation is working satisfactorily)12. Problems that can occur with the welding activities and how these can be overcome (welding characteristics of

relevant materials and sources of weld defects; methods of prevention)13. Organisational quality systems (standards to be achieved; production records to be kept)14. Personal approval tests and their applicability to your work15. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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(if required)Evidence TypeDateCheck Resistance Welding Equipment (ALL)safe & usablecorrectly calibratedsystems function smoothlyshut down systemsSet up, Check, Adjust & Use Resistance Welding Installations (ONE)spot weldingseam weldingprojection weldingSet up Welding Installation & Parameters (ALL as applicable )welding currentwelding & squeeze timeselectrode pressure cyclewelding speed (seam)weld pitch (spot)Set up work piece for correct joint fit-up and alignment (checking ALL as applicable)handling and loading equipmenttraversing mechanismssafety mechanismspreparation of materials & joint facesworkholding arrangementstransfer mechanismsSet up Equipment to Produce Welded Components (BOTH TWO different thicknesses & configurations)thicknessjoint configurationProduce & Check Trial Welds (ALL as applicable)visual appearancedimensional accuracyweld qualitymachine settingsProblems in Production (ALL as applicable)machine performancecondition of electrodejoint set-upcondition of materials


Candidate: Date:

Assessor: Date:

61

Unit 12 Preparing Laser Welding Machines for Production

Unit Summary

This unit identifies the competencies needed to prepare laser welding machines for production in accordance with approved procedures. You will be required to set up and check both the welding installation and all associated mechanical and electrical apparatus forming part of the mechanised or automated installation. This will include setting up of handling and loading equipment, workholding arrangements, transfer mechanisms and safety equipment as is applicable to the machine type. In setting up the welding conditions you will be expected to set the optical system, beam characteristics, beam alignment, electrical parameters, welding speed and, where applicable, the shielding gas system. You must produce trial welds and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification and solving machine related problems during production will also form part of your role.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying laser welding procedures. You will understand the welding process carried out, and its application, and will know about the equipment, relevant materials and consumables in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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You must:1. Ensure the laser welding equipment is suitable for production by carrying out all of the following checks:

the equipment is correctly maintained and in a safe and usable conditionthe condition of the optical system meets safe operational requirements the equipment is correctly calibrated (where applicable)all electrical and mechanical systems function smoothlyequipment shut down systems function correctly

2 Set up the welding equipment and parameters in accordance with instructions and the welding procedure specification to include setting all of the following as is applicable to the type of installation:

● optical system● beam characteristics● beam alignment

● electrical parameters● welding speed● shielding gas system (where applicable)

3 Set up the components to achieve correct joint fit-up and alignment to include setting and checking all of the following as is applicable to the type of installation:

● surface preparation and condition of joint faces is according to specification● handling and loading equipment● workholding arrangements● traversing or manipulating devices● transfer mechanisms● safety mechanisms

4. Set up the equipment to produce welded components which covers both of the following: ● two different components● two different material groups

5 Prove the installation is operating correctly and is ready for production by producing specified trial welds and checking all of the following as is applicable to the application:



6. Solve problems in production relating to all of the following as is applicable: ● machine performance● joint set-up

● condition of materials being joined● consumables

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1. The safe working practices and procedures to be observed when setting and operating laser welding installations (working with machinery; care when working with laser beams; protecting other workers; the use of appropriate personal protective equipment; machine guards; ventilation and fume extraction; machine safety devices; stopping the machine in an emergency; closing the machine down on completion of activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with laser welding machines and how they can be minimised (dangers from laser beams; live electrical components; fumes and gases; hot metal; moving parts of machinery)

3. The basic principles of laser welding (using a laser beam to join metals by fusion; forming a weld; use of filler metal; principal features of a welded joint; process principles, nature of the laser beam; methods of generating a laser beam; guiding and optical focussing, laser optics, parameters, heat input; use of shielding gases, how variation in the parameters influences the weld features and penetration, quality and output; terminology used in welding)

4. The key components and features of the equipment (types of laser beam generator, beam characteristics, power ranges; beam guiding and focusing arrangements; power sources; materials and thickness capabilities; facilities for manipulating the components for welding; safety features; shielding gas supply and control)

5. Mechanised and automated welding basics (types of installations; machine functions; loading, handling, clamping and transfer of components; traversing components for welding; control of machine functions; safety features)

6. Extracting information required from drawings and welding procedure specifications7. Types of joints applicable and the edge preparation required8. Problems that can occur with the welding activities and how these can be overcome (causes of distortion and

methods of control, welding characteristics of parent materials and sources of weld defects; methods of prevention; effect of metal vapour on beam characteristics, penetration and weld shape)

9. Methods of setting up the components to achieve correct beam alignment, penetration and control of distortion; manipulation and work holding equipment to present the joint correctly relative to the beam)

10. Setting up the welding equipment to the welding procedure specification (electrical and optical conditions; focal distance; welding speed)

11. Checking that the machine functions to the required specification (running pre-production trials to prove that the installation is working satisfactorily)

12. Organisational quality systems (standards to be achieved; production records to be kept)13. Personal approval tests and their applicability to your work14. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

64






(if required)Evidence TypeDateCheck Laser Welding Equipment (ALL)safe & usableoptical system safecorrectly calibratedsystems function smoothlyshut down systemsSet up Welding Equipment & Parameters (ALL as applicable)optical systembeam characteristicsbeam alignmentelectrical parametersshielding gas systemwelding speedSet up & Check Components for correct joint fit-up and alignment (ALL as applicable)surface preparation & condition of joint faceshandling & loading equipmentworkholding arrangementstraversing or manipulating devicestransfer mechanismssafety mechanismsSet up equipment to produce Welded Components (BOTH two different joints and two different groups)componentsmaterial groupsProduce & Check Trial Welds (ALL as applicable)visual appearancedimensional accuracyweld qualitymachine settingsSolve Problems in Production (ALL as applicable)machine performanceconsumablesjoint set-upcondition of materials


Candidate: Date:

Assessor: Date:

65

Unit 13 Preparing Electron Beam Welding Machines for Production

Unit Summary

This unit identifies the competencies needed to prepare electron beam welding machines for production in accordance with approved procedures. You will be required to set up and check both the welding installation and all associated mechanical and electrical apparatus forming part of the mechanised or automated installation. This will include setting up of handling and loading equipment, workholding arrangements, transfer mechanisms and safety equipment as is applicable to the machine type.

In setting up the welding conditions you will be expected to set the electrical parameters, beam characteristics, beam alignment, welding speed, vacuum pressure and chamber safety devices. You must produce trial welds and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification and solving machine related problems during production will also form part of your role.


Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying electron beam welding procedures. You will understand the welding process carried out, and its application, and will know about the equipment, relevant materials and consumables in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

66






You must:1. Ensure the electron beam equipment is suitable for production by carrying out all of the following checks:

the equipment is correctly maintained and in a safe and usable conditionthe equipment is correctly calibrated

● the chamber interior is in a clean condition● the electron gun is clean● door faces and seals are sound● the chamber vacuum system operates correctly

● the accuracy of optical or other beam positioning devices

● the smooth operation of in chamber mechanical equipment

● equipment shut down systems function correctly● the X –ray check list is complied with

6. Set up the welding equipment and parameters in accordance with instructions and the welding procedure specification to include setting all of the following as is applicable to the type of installation:

● beam alignment● electrical parameters

● beam characteristics● welding speed

● chamber pressure● chamber safety devices

6. Set up the components to achieve correct joint fit-up and alignment to include setting and checking all of the following as is applicable to the type of installation:

● handling and loading equipment● workholding arrangements● traversing or manipulating devices● transfer mechanisms

● surface preparation and condition of joint faces is according to specification

● safety mechanisms

4. Set up the equipment to produce welded components which covers both of the following:● two different components● two different material groups




6. Solve problems in production relating to all of the following as is applicable:● machine performance● joint set-up


67




1. The safe working practices and procedures to be observed when setting and operating electron beam welding installations (working with machinery; care in presence of high voltages; the use of appropriate personal protective equipment; machine guards; ventilation and fume extraction; machine safety devices; x-ray dosimeters; closing the machine down on completion of activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with electron-beam welding machines and how they can be minimised (dangers from the mains and high voltage supplies; live electrical components; emission of x-rays, fumes and gases; hot metal; moving parts of machinery)

3. The basic principles of electron beam welding (using an electron beam in vacuum to join metals by fusion; forming a weld; principal features of a welded joint; and penetration process principles, nature of the electron beam; generation and control of an electron beam; parameters, heat input; how variation in the parameters influences the weld features and penetration, quality and output; terminology used in welding)

4. The key components and features of the equipment (electron gun and control of beam power and characteristics, vacuum chamber and its construction, vacuum system and controls, in-chamber manipulating equipment; power sources and power range, materials and thickness capabilities, safety features; facilities for locating chamber and work handling)

5. Extracting information required from drawings and welding procedure specifications6. Types of joints applicable and the edge preparation required7. Problems that can occur with the welding activities and how these can be overcome (magnetic effect of

component on beam/joint alignment; effect of metal vapour on beam characteristics and penetration; effects of increase in chamber pressure, welding characteristics of parent materials and sources of weld defects; methods of prevention)

8. Methods of setting up the components to achieve correct location and beam alignment; types of in-chamber manipulating equipment

9. Setting up the welding equipment to the welding procedure specification (setting electrical conditions; beam characteristics, welding speed)

10. Checking the machine functions to the required specification (running pre-production trials to prove that the installation is working satisfactorily)

11. Organisational quality systems (standards to be achieved; production records to be kept)12. Personal approval tests and their applicability to your work13. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

68






(if required)Evidence TypeDateCheck Electron Beam Equipment (ALL)safe & usablecorrectly calibratedchamber interior cleanelectron gun cleandoor faces & sealschamber vacuum systemaccuracy of beam devicesin chamber mech’ equip’shut down systemsx-ray check list complianceSet up Welding Equipment & Parameters (ALL as applicable)beam alignmentelectrical parametersbeam characteristicswelding speedchamber pressurechamber safety devicesSet up & Check Components to achieve correct joint fit-up and alignment (ALL as applicable)handling & loading equip’workholding arrangementstraversing or manipulating devicestransfer mechanismssurface preparation & condition of joint facessafety mechanismsSet up equipment to produce Welded Components (BOTH two different joints and two different groups)componentsmaterial groupsProduce & Check Trial Welds (ALL as applicable)visual appearancedimensional accuracyweld qualitymachine settingsSolve Problems in Production (ALL as applicable)machine performanceconsumablesjoint set-upcondition of materials


Candidate: Date:

Assessor: Date:

69

Unit 14 Preparing Friction Welding Machines for Production

Unit Summary

This unit identifies the competencies needed to prepare friction welding machines for production in accordance with approved procedures. You will be required to set up and check both the welding installation and all associated mechanical and electrical apparatus forming part of the mechanised or automated installation. This will include setting up of handling and loading equipment, workholding arrangements, in-process monitoring features, transfer mechanisms and safety equipment as is applicable to the machine type.

In setting up the welding conditions you will be expected to set the electrical conditions, process cycle times, rotational/orbiting speed and weld and forge travel. You must produce trial welds and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification and solving machine related problems during production, will also form part of your role.


Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying friction welding procedures. You will understand the welding process carried out, and its application, and will know about the equipment, relevant materials and consumables in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

70






You must:1. Ensure the friction welding equipment is suitable for production by carrying out all of the following checks:


6. Set up the welding equipment and parameters in accordance with the welding procedure specification to include setting all of the following as is applicable to the type of installation:

● friction and forge cycle times● friction and forge loads (forces)● frictional burn-off characteristics and forge displacement● rotational speed or other appropriate friction conditions● braking effort

6. Set up the components to achieve correct joint fit-up and alignment to include setting and checking all of the following as is applicable to the type of installation:

● surface preparation and condition of joint faces is according to specification● handling and loading equipment● workholding devices● transfer mechanisms● safety devices

4. Set up the equipment to produce welded components which covers both of the following: ● two different components● two different material groups


● visual appearance of weld● dimensional accuracy● quality of weld

● machine settings are as specified● in-process monitoring and data acquisition


● condition of prepared materials being joined● consumables

71




1. The safe working practices and procedures to be observed when setting and operating friction welding installations (working with machinery; the use of appropriate personal protective equipment; machine guards; ventilation and fume extraction; machine safety devices; stopping the machine in an emergency; closing the machine down on completion of activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with friction welding machines and how they can be minimised (dangers from live electrical components; fumes; hot metal; moving parts of machinery and components)

3. The basic principles of friction welding (using heat generated by friction to join metals by welding; rotational and orbital methods of heat generation, forming a weld; use of filler metal; principal features of a welded joint; welding cycle, parameters, heat input; how variation in the settings influences the weld features, quality and output; terminology used in welding)

4. The key components and features of the equipment (types of machines; constructional features; mechanical features, drive train, driven and stationary component holding devices, force generation, and control systems, in-process monitoring features, data acquisition and sensors; braking systems; welding cycle control; feedback and recording)

5. Mechanised and automated welding basics (types of installations; machine functions: loading, handling, clamping and transfer of components; control of machine functions; safety features)

6. Extracting information required from drawings and welding procedure specifications7. Preparation of joint faces; finish, tolerances8. Problems that can occur with the welding activities and how these can be overcome (welding characteristics of

parent materials and sources of weld defects; methods of prevention9. Setting up the welding equipment to the welding procedure specification (setting welding cycle; heating and forging

forces, rotational speed)10. Checking the machine functions to the required specification (running pre-production trials to prove that the

installation is working satisfactorily)11. Organisational quality systems (standards to be achieved; production records to be kept, methods of testing friction

welds and principles of quality control in production)12. Personal approval tests and their applicability to your work13. The extent of your responsibility and whom you should report to if you have problems that you cannot resolve

72






(if required)Evidence TypeDateCheck Friction Welding Equipment (ALL)safe & usablecorrectly calibratedelectrical & mechanical systems function smoothlyshut down systemsSet up Welding Equipment & Parameters (ALL as applicable)friction & forge cycle timesfriction & forge loads (forces)frictional burn-off and forge displacementrotational speedbraking effortSet up Components to achieve correct joint fit-up and alignment (ALL as applicable)surface preparationhandling & loadingworkholding devicestransfer mechanismssafety devicesSet up equipment to produce Welded Components (BOTH two different joints and two different groups)componentsmaterial groupsProduce & Check Trial Welds (ALL)visual appearancedimensional accuracyweld qualitymachine settingsin process monitoringSolve Problems in Production (ALL as applicable)machine performanceconsumablesjoint set-upcondition of materials


Candidate: Date:

Assessor: Date:

73

Unit 15 Preparing Brazing Machines for Production

Unit Summary

This unit identifies the competencies needed to prepare torch, inductance, resistance or furnace brazing installations for production in accordance with approved procedures. You will be required to set up and check both the brazing installation and all associated mechanical and electrical apparatus forming part of the mechanised or automated installation. This will include setting up of handling and loading equipment, workholding arrangements, traversing mechanisms, transfer mechanisms and safety equipment as is applicable to the machine type.

In setting up the brazing conditions you will be expected to set the brazing temperature controls, brazing time, flame conditions, flux dispensing arrangements, filler metal placement controls and brazing atmosphere controls as is applicable to the machine type. You must produce trial joints and prove the machine is working satisfactorily before declaring the installation ready for production. Making adjustments to settings to achieve specification and solving machine related problems during production, will also form part of your role.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying mechanised brazing procedures. You will understand the brazing process carried out, and its application, and will know about the equipment, relevant materials and consumables in adequate depth to provide a sound basis for setting up the equipment, correcting faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

74






You must:1. Ensure the brazing machine is suitable for production by carrying out all of the following checks:


2. Prepare and set-up one of the following brazing installations for two different joint configurations in the specified materials, forms and positions, according to work instructions and the welding procedure specification:

● Torch● Induction

● Resistance● Furnace

3. Set up the welding equipment and parameters in accordance with the welding procedure specification toinclude setting all of the following as is applicable to the machine type:

brazing temperature controlbrazing time flame conditionflux dispensing arrangements

filler metal placementbrazing atmosphere controlsafety devices

4. Set up the work piece to achieve correct joint fit-up and alignment to include setting and checking all of the following as is applicable to the machine type:

handling and loading equipmentworkholding arrangementstransfer mechanisms

preparation of materials and joint faces is to specification traversing and indexing mechanismssafety mechanisms

5. Prove the installation is operating correctly and is ready for production by producing specified trial joints and checking all of the following:

● visual appearance of braze● dimensional accuracy

● quality of braze● machine settings are as specified



75




1. The safe working practices and procedures to be observed when setting and operating brazing installations (working with machinery; the use of appropriate personal protective equipment; machine guards; ventilation and fume extraction; machine safety devices; stopping the machine in an emergency; closing the machine down on completion of activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with brazing machines and how they can be minimised (dangers from relevant equipment sources; fumes and gases; hot metal; moving parts of machinery)

3. The basic principles of the relevant brazing process (principal features of brazed joints; wetting and capillary flow, role of fluxes/atmospheres; parameters, heat input; how variation in the parameters influences the quality and output; terminology used in brazing)

4. The key components and features of the relevant brazing equipment5. Mechanised and automated brazing basics (types of installations; machine functions: loading, handling, clamping,

manipulating and transfer of components)6. Extracting information required from drawings and procedure specifications7. Types and forms of filler metal; specification; control and storage of consumables8. Types of joints applicable and the surface preparation required; methods of applying filler metal9. Problems that can occur with the brazing activities and how these can be overcome, sources of brazing defects

and methods of prevention10. Methods of setting up the joint to achieve correct location of components (work holding methods for component

location)11. Setting up the equipment to the brazing procedure specification12. Checking the machine functions to the required specification (running pre-production trials to prove that the

installation is working satisfactorily and producing joints of the specified quality)13. Methods of flux removal and cleaning14. Organisational quality systems (standards to be achieved; production records to be kept; testing of brazed joints)15. Personal approval tests and their applicability to your work16. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

76






(if required)Evidence TypeDateCheck Brazing Machine (ALL)safe & usablecorrectly calibratedelectrical & mechanical systems function smoothlyshut down systemsSet up ONE of these Installations for TWO different Joint ConfigurationsTorchInductionResistanceFurnaceSet up Welding Equipment & Parameters (ALL as applicable)brazing temp’ controlbrazing timeflame conditionflux dispensingfiller metal placementbrazing atmosphere cont’safety devicesSet up & check work piece to achieve correct joint fit-up and alignment (ALL)handling & loadingworkholding arrangementstransfer mechanismspreparation of materialstraversing & indexingsafety mechanismsProduce & Check Trial Joints (ALL)visual appearance of brazedimensional accuracyquality of brazemachine settingsSolve Problems in Production (ALL as applicablemachine performanceconsumablesjoint set-upcondition of materials


Candidate: Date:

Assessor: Date:

77

Unit 16 Welding Materials with Mechanised Arc Welding Equipment

Unit Summary

This unit identifies the competencies you need to operate one type of mechanised MIG/MAG, cored wire, Submerged Arc, TIG, or Plasma Arc welding installation that has already been prepared for production in accordance with approved instructions, or welding procedures. You will be expected to check that the equipment has been approved for production and that sufficient supplies of all the required materials and consumables are present and correct, and ready for production operations to be performed.

You must operate the installation safely and correctly in accordance with instructions and approved procedures and achieve a weld quality and tolerances that meet the product specification. The production output may be inspected by visual and non-destructive testing methods to check that the specified quality is being achieved. You must continuously monitor the operation of the installation, and make any necessary adjustments to equipment settings in line with your permitted authority in order to produce the welded joints to the required specification. Meeting production requirements will be an important issue and your production records must show consistent and satisfactory performance.

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

Your underpinning knowledge will provide a sound basis for your work, enabling you to adopt an informed approach to applying welding procedures and instructions. You will have an understanding of how the welding process works and is applied in mechanised form, and will know about the equipment, materials and consumables in adequate depth to provide a sound background to the process operation and for carrying out the welding activities to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

78



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant joining procedure and work instructionsc. Confirm that the machine is set up and operating correctly, ready for the joining operations to be carried outd. Check that the parent material, components, consumables and joint preparation comply with specificationse. Carry out and monitor the machine operations in accordance with specifications and job instructionsf. Achieve joints of the required quality and specified dimensional accuracyg. Make sure that the rate of output is as specifiedh. Deal promptly and effectively with problems within your control and report those that you cannot solvei. Shut down the equipment to a safe condition on conclusion of the joining activities


You must:1. Confirm that the installation is ready for production operations to include checking all of the following:

the installation has been approved for productionsupplies of components and consumables are adequate and correctly preparedmachine settings comply with instructions and the welding procedure specificationall machine functions operate correctlyall safety equipment is in place and functioning correctly

2. Operate one of the following mechanised arc welding processes in the specified materials, forms and positions:

MIG/MAGCored WireTIG

Submerged ArcPlasma Arc

3. Produce welded components covering both of the following: two different joint configurationstwo different material groups

4. Monitor the process operation and machine functions, and make adjustments as required to parameters and mechanisms within your permitted authority and tolerances to include adjusting all of the following:

electrical parameterswelding speedflux dispensing and recovery mechanismssafety deviceswire feed rategas shielding systemmechanical functions (handling, loading, workholding, transfer)

5. Produce welded components which: achieve a weld quality equivalent to the relevant level of EN 25817/ISO 5817 as required by the

application standard (for aluminium, EN 30042/ISO 10042 applies)meet the required dimensional accuracy within specified tolerances

79




1. The safe working practices and procedures to be observed when operating mechanised arc welding installations(working with machinery; the use of personal protective equipment; protecting others from the effects of the electric arc; appropriate machine guards; operation of machine safety devices; stopping the machine in an emergency; closing the machine down on completion of activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with arc welding machines and how they can be minimised (dangers from the electric arc; live electrical components; fumes and gases; hot metal; grinding and mechanical metal/slag removal; moving parts of machinery)

3. The principles of mechanised and automated welding (types of installations; machine functions; control systems; safety features

4. The key components and features of the equipment used (power source; electrical parameters such as arc voltage, current, wire dispensing and feed mechanisms; flux dispensing and recovery; shielding gas supply; control and storage of consumables; how variations in the parameters influence weld features, quality and output)

5. Extracting the necessary information from drawings and welding procedure specifications, welding symbols and abbreviations used

6. Operation of the machine controls and their function; care of equipment7. Setting up and aligning the work piece, and the equipment to be used8. Monitoring the installation during the welding process; recognition of problems and action to be taken9. Problems that can occur with the welding activities (distortion, material and weld defects)10. Self inspection of completed work, methods and equipment to be used11. Organisational quality systems (standards to be achieved; production records to be kept)12. Personal approval tests and their applicability to your work13. The extent of your own responsibility and whom you should report to if you have problems that you cannot

resolve

80






(if required)Evidence TypeDateCheck Installation (ALL)approved for productionadequate suppliesmachine settingsmachine functionssafety equipmentOperate Mechanised Arc Welding Processes (ONE)MIG/MAGCored WireTIGSubmerged ArcPlasma ArcProduce Welded Components (BOTH two different joints and two different groups)joint configurationsmaterial groupsMonitor process Adjust Parameters & Mechanisms (ALL)electrical parameterswelding speedflux dispensing and recovery mechanismssafety deviceswire feed rategas shielding systemmechanical functionsWeld Quality to Relevant Level BS EN 25817/ISO 5817 (aluminium EN30042/ISO10042) requiredgeneralDimensional Accuracyachieved within tolerances


Candidate: Date:

Assessor: Date:

81

Unit 17 Welding Materials using Resistance Spot, Seam and Projection Welding Machines

Unit Summary

This unit identifies the competencies you need to operate resistance spot, seam or projection welding installations, which have already been prepared for production in accordance with approved instructions, or welding procedures. You will be expected to check that the installation has been approved for production and that sufficient supplies of all required materials and consumables are present and correct, and ready for production operations to be performed.

You must operate the installation safely and correctly in accordance with instructions and approved procedures and achieve a weld quality and tolerances that meet the product specification. The production output may be inspected by visual and non-destructive testing methods to check that the specified quality is being achieved. You must continuously monitor the operation of the installation and make any necessary adjustments to equipment settings in line with your permitted authority in order to produce the welded joints to the required specification. Meeting production requirements will be an important issue and your production records must show consistent and satisfactory performance.


Your underpinning knowledge will provide a sound basis of your work, enabling you to adopt an informed approach to applying welding procedures and instructions. You will have an understanding of how the resistance welding process works and is applied in mechanised form, and will know about the equipment, materials and consumables in adequate depth to provide a sound background to the process operation and for carrying out the activities to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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You must:1. Confirm that the installation is ready for operation to include checking all of the following:

● the installation has been approved for production● supplies of components and consumables are adequate and correctly prepared● machine settings comply with instructions and the welding procedure specification● all machine functions operate correctly● all safety equipment is in place and functioning correctly

2. Operate one of the following resistance welding installations:● spot welding● seam welding● projection welding

3. Produce welded components in the specified materials and forms that cover both of the following:● two different material thicknesses● two different joint configurations

4. Monitor the process operation, electrode condition and machine function and make adjustments to required parameters and mechanisms to include all of the following as is appropriate to machine type:

● welding current● welding and squeeze times● electrode pressure cycle● welding speed (seam)● weld pitch (spot)● mechanical functions

5. Produce welded components which: ● achieve a weld quality as specified in the application standard ● spot and projection welds are correctly located ● seam welds are of the correct dimensions● meet the required dimensional accuracy within specified tolerance

83




1. The specific safety precautions to be taken when operating resistance welding installations (working withmachinery; the use of appropriate personal protective equipment machine guards; operation of machine safety devices; stopping the machine in an emergency; closing down the machine on completion of the welding activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with resistance welding machines and how they can be minimised (dangers from live internal electrical components, fumes, hot metal, expulsion of hot particles, moving parts of machines)

3. The basic principles of resistance welding; terminology used in welding4. Mechanised and automated welding basics (types of installation; machine functions; control systems; safety

features)5. The key components and features of the equipment used (power source; electrical parameters such as arc voltage,

current, electrode pressure and welding time; systems for parameter control; how variation in the parameters influence weld features, quality and output)

6. Extracting information required from drawings and welding procedure specifications7. Operation of the machine controls and their function; clamping and transfer of components, equipment care

procedures8. Setting up and aligning the workpiece9. Monitoring the installation during the welding process; recognition of problems and action to be taken10. Problems that can occur with the welding activities, materials and weld defects11. Self inspection of completed work12. Organisational quality systems (standards to be achieved; production records to be kept)13. Personal approval tests and their applicability to your work14. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

84






(if required)Evidence TypeDateCheck Installation (ALL)approved for productionadequate suppliesmachine settingsmachine functionssafety equipmentOperate Resistance Welding Installations (ONE)spot weldingseam weldingprojection weldingProduce Welded Components (BOTH two different joints and two different thicknesses)material thicknessjoint configurationAdjust Parameters & Mechanisms (ALL as applicable)welding currentwelding & squeeze timeselectrode pressure cyclewelding speed (seam)weld pitch (spot)mechanical functionsProduce Welded Componentsachieve specified weld qualitycorrectly locate spot & projection weldscorrect dimensions of seam weldsrequired dimensional accuracy


Candidate: Date:

Assessor: Date:

85

Unit 18 Welding Materials using Laser Welding Machines

Unit Summary

This unit identifies the competencies you need to operate laser welding installations, which have already been prepared for production in accordance with approved instructions, or welding procedures. You will be expected to check that the installation has been approved for production and that sufficient supplies of all required materials and consumables are present and correct, and ready for production operations to be performed.



Your underpinning knowledge will be provide a sound basis of your work, enabling you to adopt an informed approach to applying welding procedures and instructions. You will have an understanding of how the laser welding process works and is applied in mechanised form, and will know about the equipment, materials and consumables in adequate depth to provide a sound background to the process operation and for carrying out the activities to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

86







2. Produce welded components covering both of the following:● two different components● two different material groups

3 Monitor the process operation and machine function and make adjustments as required to parameters and mechanisms to include all of the following as is appropriate to machine type:

● electrical parameters● welding speed● weld alignment and characteristics● beam tracking● beam characteristics (focal spot) ● gas shielding (where applicable)● mechanical mechanisms for workholding, traversing and transfer

4. Produce welded components which: ● achieve a weld quality equivalent to the relevant level of EN/ISO 13919 as required by the application standard● meet the required dimensional accuracy within specified tolerances

87




1. The safe working practices and procedures to be observed when operating laser welding installations (working with machinery; care when working with laser beams; the use of appropriate personal protective equipment; protecting other workers; machine guards; operation of machine safety devices; stopping the machine in an emergency; closing the machine down on completion of activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with laser welding machines and how they can be minimised (dangers from the laser beam; live electrical components; fumes and gases; hot metal; moving parts of machinery)

3. Principles of laser welding; terminology used in welding4. The key components and features of the equipment (types of laser beam generators, beam characteristics, power

ranges; beam guiding and focussing arrangements; power sources; materials and thickness capabilities; facilities for manipulating the components for welding; safety features; shielding gas supply and control)

5. Mechanised and automated welding basics (types of installations; machine functions; safety features)6. Extracting information required from drawings and welding procedure specifications7. Operation of the machine; controls and their function; care of equipment8. Setting up and aligning the workpiece9. Monitoring the installation during the welding process; recognition of problems and action to be taken10. Problems that can occur with the welding activities: materials and weld defects11. Self inspection of completed work12. Organisational quality systems (standards to be achieved; production records to be kept)13. Personal approval tests and their applicability to your work14. The extent of your responsibility and whom you should report to when you have problems you cannot resolve

88






(if required)Evidence TypeDateCheck Installation (ALL)approved for productionadequate suppliesmachine settingsmachine functionssafety equipmentProduce Welded Components (BOTH two different components and two different groups)componentsmaterial groupsAdjust Parameters & Mechanisms (ALL as applicable)electrical parameterswelding speedweld alignment and characteristicsbeam trackingbeam characteristicsgas shieldingmechanical mechanismsWeld Quality to relevant Level of EN/ISO 13919 requiredgeneralDimensional Accuracyachieved within tolerances


Candidate: Date:

Assessor: Date:

89

Unit 19 Welding Materials using Electron Beam Welding Machines

Unit Summary

This unit identifies the competencies you need to operate electron beam welding installations, which have already been prepared for production in accordance with approved instructions, or welding procedures. You will be expected to check that the installation has been approved for production and that sufficient supplies of all required materials and consumables are present and correct, and ready for production operations to be performed.



Your underpinning knowledge will provide a sound basis of your work, enabling you to adopt an informed approach to applying welding procedures and instructions. You will have an understanding of how the electron beam welding process works and is applied in mechanised form, and will know about the equipment, materials and consumables in adequate depth to provide a sound background to the process operation and for carrying out the activities to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

90






● the installation has been approved for production● supplies of components and consumables are adequate and correctly prepared● machine settings comply with instructions and the welding procedure specification● all machine functions operate correctly ● all safety equipment is in place and functioning correctly


4. Monitor the process operation and machine function and make adjustments as required to parameters and mechanisms to include all of the following as is appropriate to machine type:

● electrical parameters● welding speed● chamber pressure● weld alignment and characteristics● beam tracking ● mechanical functions

4. Produce welded components which: ● achieve a weld quality equivalent to the relevant level of EN/ISO 13919 as required by the application standard● meet the required dimensional accuracy within specified tolerances

91




1. The safe working practices and procedures to be observed when operating electron beam welding installations (working with machinery; care in presence of high voltage; the use of appropriate personal protective equipment; protecting other workers; machine guards; operation of machine safety devices; x-ray dosimeters; closing the machine down on completion of activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with electron beam welding machines and how they can be minimised (dangers from the mains and high voltage supplies; live electrical components; emission of x-rays, fumes and gases; hot metal; moving parts of machinery)

3. Principles of electron-beam welding; terminology used in welding4. The key components and features of the equipment (electron gun and control of beam power and characteristics;

vacuum chamber and its construction; vacuum system and controls; in-chamber manipulating equipment; power sources and power range; material and thickness capabilities; safety features; facilities for loading chamber and work handling)

5. Extracting information required from drawings and welding procedure specifications6. Operation of the machine; controls and their function; care of equipment7. Setting up and aligning the workpiece8. Monitoring the installation during the welding process; recognition of problems and action to be taken9. Problems that can occur with the welding activities (materials and weld defects; beam instability, loss of alignment,

increase in chamber pressure)10. Self inspection of completed work11. Organisational quality systems (standards to be achieved; production records to be kept)12. Personal approval tests and their applicability to your work13. The extent of your responsibility and whom you should report to when you have problems you cannot resolve

92






(if required)Evidence TypeDateCheck Installation (ALL)approved for productionadequate suppliesmachine settingsmachine functionssafety equipmentProduce Welded Components (BOTH two different components and two different groups)componentsmaterial groupsAdjust Parameters & Mechanisms (ALL as applicable)electrical parameterswelding speedchamber pressureweld alignment and characteristicsbeam trackingmechanical functionsWeld Quality to the relevant Level of EN/ISO 13919 requiredgeneralDimensional Accuracyachieved within tolerances


Candidate: Date:

Assessor: Date:

93

Unit 20 Welding Materials using Friction Welding Machines

Unit Summary

This unit identifies the competencies you need to operate friction welding installations, which have already been prepared for production in accordance with approved instructions, or welding procedures. You will be expected to check that the installation has been approved for production and that sufficient supplies of all required materials and consumables are present and correct, and ready for production operations to be performed.

You must operate the installation safely and correctly in accordance with instructions and approved procedures and achieve a weld quality and tolerances that meet the product specification. The production output may be inspected by visual and non-destructive testing methods to check that the specified quality is being achieved. You must continuously monitor the operation of the installation using the in-process monitoring features of the welding machine and make any necessary adjustments to equipment settings in line with your permitted authority in order to produce the welded joints to the required specification. Meeting production requirements will be an important issue and your production records must show consistent and satisfactory performance.


Your underpinning knowledge will provide a sound basis of your work, enabling you to adopt an informed approach to applying welding procedures and instructions. You will have an understanding of how the friction welding process works and is applied in mechanised form, and will know about the equipment, materials and consumables in adequate depth to provide a sound background to the process operation and for carrying out the activities to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

94








3. Monitor the process operation and machine functions and make adjustments as required to settings and mechanisms to include all of the following as is appropriate to machine type:

● friction and forge cycle time● friction and forge loads (forces)● rotational speed or other friction conditions, e.g. orbital● frictional burn-off characteristics and forge displacement● weld appearance (correct upset)● braking effort

4. Produce welded components which: ● achieve a weld quality as specified in the application standard or specification● meet the required dimensional accuracy within specified tolerances

95




1. The safe working practices and procedures to be observed when operating friction welding installations (working with machinery; the use of appropriate personal protective equipment; machine guards; operation of machine safety devices; stopping the machine in an emergency; closing the machine down on completion of activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with friction welding machines and how they can be minimised (dangers from live electrical components; fumes; hot metal; moving parts of machinery and components)

3. Principles of friction welding; terminology used in welding4. The key components and features of the equipment (types of machines; constructional features, mechanical

features, drive train, driven and stationary component holding devices, force generation and control systems, braking systems; welding cycle control; feedback and recording)

5. Mechanised and automated welding basics; types of installations; machine functions; safety features6. Extracting information required from drawings and welding procedure specifications7. Operation of the machine; controls and their function; care of equipment8. Setting up and aligning the workpiece9. Monitoring the installation during the welding process; the various types of monitoring features used on friction

welding machines; recognition of problems and action to be taken10. Problems that can occur with the welding activities: materials and weld defects11. Self inspection of completed work12. Organisational quality systems (standards to be achieved; feedback from machine; corrective actions; production

records to be kept)13. Personal approval tests and their applicability to your work14. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

96






(if required)Evidence TypeDateCheck Installation (ALL)approved for productionadequate suppliesmachine settingsmachine functionssafety equipmentProduce Welded Components (BOTH two different components and two different groups)componentsmaterial groupsAdjust Settings & Measurements (ALL as applicable)friction & forge cycle timefriction & forge loadsrotational speed or other frictional conditionsfrictional burn-offweld appearance (correct upset)braking effortWeld Quality Specified to Level requiredgeneralDimensional Accuracyachieved within tolerances


Candidate: Date:

Assessor: Date:

97

Unit 21 Joining Materials using Brazing Machines

Unit Summary

This unit identifies the competencies you need to operate torch, inductance, resistance or furnace brazing installations that have already been prepared for production in accordance with approved instructions or procedures. You will be expected to check that the equipment has been approved for production and that sufficient supplies of all the required materials and consumables are present and correct, and ready for production operations to be performed.

You must operate the installation safely and correctly in accordance with instructions and approved procedures and achieve a joint quality and tolerances that meet the product specification. You must continuously monitor the operation of the installation, and make any necessary adjustments to equipment settings in line with your permitted authority in order to produce the brazed joints to the required specification. Meeting production requirements will be an important issue and your production records must show consistent and satisfactory performance.

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

Your underpinning knowledge will provide a sound basis for your work, enabling you to adopt an informed approach to applying brazing procedures and instructions. You will have an understanding of how the brazing process works and is applied in mechanised form, and will know about the equipment, materials and consumables in adequate depth to provide a sound background to the process operation and for carrying out the brazing activities to the required specification. You will understand the safety precautions required when working with the machine and its associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

98





You must:1. Confirm that the installation is ready for production operations to include checking all of the following:

the installation has been approved for productionsupplies of components and consumables are adequate and correctly preparedmachine settings comply with instructions and the brazing procedure specificationall machine functions operate correctlyall safety equipment is in place and functioning correctly

2 Operate one of the following mechanised brazing processes in the specified materials, forms and positions:

torchinductionfurnaceresistance

3. Produced brazed assemblies covering both of the following: two different joint configurationstwo different material groups

4. Monitor the process operation and machine functions, and make adjustments as required to parameters and mechanisms within your permitted authority and tolerances to include adjusting all of the following as applicable to the machine type:

brazing temperaturebrazing timeflux and filler metal dispensingbrazing atmosphereflame conditionmechanical functions (handling, loading, workholding, transfer) safety devices

5. Produce brazed components or assemblies which: achieve the quality specified in the application standardmeet the required dimensional accuracy within specified tolerances

99




1. The safe working practices and procedures to be observed when operating brazing installations (working with machinery; the use of appropriate personal protective equipment; machine guards; operation of machine safety devices; stopping the machine in an emergency; closing the machine down on completion of activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with brazing machines, and how they can be minimised (dangers from relevant equipment sources; fumes and gases; hot metal; moving parts of machinery)

3. Principles of the relevant brazing process; terminology used in brazing4. The key components and features of the equipment5. Mechanised and automated brazing basics (types of installations; machine functions; safety features)6. Extracting information required from drawings and brazing procedure specifications7. Operation of the machine controls and their function; care of equipment; control and storage of consumables8. Setting up and aligning the work pieces9. Monitoring the installation during the brazing process; recognition of problems and action to be taken10. Problems that can occur with the brazing activities: materials, filler metals and joint defects11. Self inspection of completed work12. Organisational quality systems (standards to be achieved; production records to be kept)13. Personal approval tests and their applicability to your work14. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

100






(if required)Evidence TypeDateCheck Installation (ALL)approved for productionadequate suppliesmachine settingsmachine functionssafety equipmentOperate Mechanised Brazing Processes (ONE)TorchInductionFurnaceResistanceProduce Brazed Assemblies (BOTH two different joints and two different groups)joint configurationsmaterial groupsMonitor and adjust Parameters & Mechanisms (ALL as applicable)brazing temperaturebrazing timeflux & filler metal dispensingbrazing atmosphereflame conditionmechanical functionssafety devicesProduce Brazed Components to Quality Level SpecifiedgeneralDimensional Accuracywithin required tolerances


Candidate: Date:

Assessor: Date:

101

Unit 22 Marking Out Components for Metalwork

Unit Summary

This unit identifies the competencies you need to mark out sheet and plate work (including simple templates), and rolled sections in accordance with approved procedures. You will be required to select the required materials to use and the appropriate marking out tools and equipment based on the information presented to you and the accuracy to be achieved. Marking out will be the preparation required for cutting, shaping and forming sheet materials, plate and sections as is appropriate to the application and will include marking out workpiece datums, centre lines, angles and curved details, cutting and bending details including bending allowances and hole centring and outlining details.

Materials to be marked out may include ferrous and non-ferrous. Certain materials will require you to take the grain flow into account to avoid later production process problems.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying marking out procedures. You will understand the marking out process, and its application, and will know about the materials as well as the care and use of tools in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the safety procedures required when using marking mediums, and when carrying out the marking out activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

102



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Obtain and use the correct information for marking outc. Obtain the appropriate marking out equipment and check that it is in a usable conditiond. Prepare suitable datums and marking out surfacese. Mark out using appropriate methodsf. Check that the marking out complies with the specificationg. Deal promptly and effectively with problems within your control and report those that cannot be resolved


You must:1. Mark out sheet, plate or section materials on two appropriate materials from the following:

hot rolled mild steel (black)cold rolled mild steel (bright)coated mild steel (tinned or galvanised)stainless steel

aluminium● brass● copper

● lead● titanium● non-metallic materials

2. Mark out sheet or plate for three of the following forms/shapes of component: flat covers and platessquare and radial bendssquare/rectangular/box sectionscylindrical sections (e.g. trunking, pipes, tanks)frames or structures

fish plates, gussets bracketsstructural support pads, bed platescolumns, beams or strutssimple seatings (e.g. boiler saddles, tank cradles)

3. Mark out directly onto sheet or plate from drawings using all of the following tools and instruments:scriberpunchrule and tapestraight edge square

● protractor● dividers or trammels● chalk, bluing or paint● laser (where applicable)

4. Mark out material to include five of the following features: datum and centre linessquare/rectangular profilesanglescircles

● curved profiles● cutting and bending detail (including allowances)● hole centring and outlining (circular and linear)

5. Produce marked out component which meet all of the following quality and accuracy standards:company/customer standards and codes of practice

• dimensionally accurate (to drawing or specification)• clearly defined for required processes• uses recognised marking out conventions

103




1. The specific safety precautions to be taken when working in a fabrication environment with sheet, plate or rolled section materials (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)

2. The personal protective clothing and equipment that needs to be worn when carrying out the fabrication activities (leather gloves, eye protection, safety helmets etc.)

3. The correct methods of moving or lifting sheet, plate and rolled section materials4. The hazards associated with marking out fabricated components and how they can be minimised (such as working

in a fabrication environment, lifting and handling sheet/fabricated components, slivers/burrs on sheet materials, using marking out mediums, using laser marking out equipment)

5. The procedures to be adopted to obtain the necessary drawings and job instructions6. How to extract information from engineering drawings and related specifications to include symbols and

conventions to appropriate BS or ISO standards in relation to work undertaken7. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference

points and system of tolerancing8. Visualising how to produce a three dimensional shape from the two dimensional material9. The preparations that need to be carried out on the material prior to marking out to enhance clarity and accuracy,

and safety10. Principles of marking out, developing basic shapes (flat, rectangular and cylindrical) from flat sheet, plate or rolled

section materials11. The effective use and care of tools/instruments12. Use of marking out conventions, datum edges/lines and centre lines13. The material characteristics and process considerations that need to be taken into account when marking out

sheet, plate or rolled section materials14. How to calculate and mark out true lengths, bend allowances and circumferences15. Geometrical construction methods for straight and radius bends, curved or circumference sections, pyramid or

cone sections16. Ways of laying out the shapes/patterns to maximise the use of plate or sheet material17. Setting and adjusting tools, such as squares and protractors18. Methods of marking out large or long shapes19. Marking out and transferring information from templates20. How to transfer information to the underside of the sheet or plate21. The importance of using tools only for the purpose intended, the care that is required when using the equipment

and tools, the proper way of preserving and storing tools and equipment between operations.22. The need for clear and dimensional accuracy in marking out to specifications/drawings23. The sort of things that can go wrong in marking out fabrication components, and how these can be avoided24. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve25. Reporting lines and procedures, line supervision and technical experts

104






Evidence TypeDateMark out sheet, plate or section materials (on TWO of the following)hot rolled mild steel (black)cold rolled mild steel (bright)coated mild steelstainless steelaluminiumbrasscopperleadtitaniumnon-metallic materialsMark out sheet or plate (THREE of the following forms)flat covers & platessquare & radial bendssquare/rectangular/boxcylindrical sectionsframes or structuresfish plates, gussetsbracketsstructural support pads, bed platescolumns beams or strutssimple seatingsMark onto sheet or plate from drawings (USING ALL)scriberpunchrule & tapestraight edgesquareprotractordividers or trammelschalk bluing or paintlaser (where applicable)Mark out material to include FIVE of the following featuresdatum & centre linessquare/rectangular profilesanglescirclescurved profilescutting & bending detailhole centring & outliningProduce marked out components which meet Quality & Accuracy Standards (ALL)company/customerdimensionally accurateclearly defineduses recognised conventions


Candidate: Date:

Assessor: Date:

105

Unit 23 Cutting Sheetmetal to Shape using Hand and Machine Tools

Unit Summary

This unit identifies the competencies you need to cut and shape sheetmetal (up to and including 3 mm) in order to fabricate clips, brackets, covers, trunking and similar components (including templates) in accordance with approved procedures. You will be required to select the appropriate equipment to use for the material and thickness and the accuracy required to be achieved and will use hand tools, hand power tools and machinery as is applicable. The cutting and shaping will involve producing straight cuts, external curved contours, cut-ins, notches and round and square holes.

Materials to be cut and shaped may include ferrous and non-ferrous. This will call for care in selecting the right tools so as to avoid damage to the tools and danger to oneself.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying sheetmetal cutting and shaping procedures. You will understand the processes, the equipment and their application, and will know about the materials in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the safety precautions required when working with fabrication tools and machinery. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

106



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow relevant specifications for the component to be produced c. Obtain the appropriate tools and equipment for the shaping operations and check they are in a safe and usable conditiond. Shape the materials using appropriate methods and techniquese. Check that all the required shaping operations have been completed to the required specificationf. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Cut and finish material to the marked out shape using six of the following tools:

tin snipsbench shearsguillotinehacksawband sawhand power tools (drill, nibbling)

● pillar drill● files● punch/cropping machine● trepanning● nibbling machine

2. Perform operations to produce all of the following shapes:straight cutscut-ins (straight and curved)notches

● external curved contours● round holes● square holes

3. Use sheetmetal of various thickness up to and including 3 mm for two appropriate materials and two thicknesses from the following:

hot rolled mild-steel (black)cold rolled mild steel (bright)coated mild steel (e.g. tinned, galvanised)stainless steelaluminium

● brass● copper● lead● titanium

4. Produce cut and shaped components which meet all the following quality and accuracy standards:company/customer standards requirements dimensionally accurate (to drawing or specifications)

● free from distortion● free from sharp edges, slivers or burrs

107




1. The specific safety precautions to be taken when working with sheetmetal equipment and materials in a fabrication environment (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)


2. The correct methods of moving or lifting sheetmetal3. Safe working practices and procedures that need to be observed when using manual and power operated tools4. The hazards associated with fabrication work and how they can be minimised, such as using dangerous or badly

maintained tools and equipment, operating guillotines and when using hand and bench shears 5. The procedures for obtaining the necessary drawings and specifications and how to check that they are the latest

issue6. How to extract information from engineering drawings and related specifications to include symbols and conventions

to appropriate BS or ISO Standards in relation to work undertaken7. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference

points and system of tolerancing8. How to interpret the marking out conventions on the materials to be cut and shaped such as cutting lines, centre

lines, etc9. The tools and techniques available for cutting and shaping sheetmetal such as tin snips, bench shears, guillotines,

portable power tools, bench drills, saws etc10. What preparations you may have to carry out on the material prior to cutting it11. The material characteristics and process considerations that need to be taken into account when cutting and shaping

sheetmetal12. The use and care of tools and equipment including checks that need to be made to ensure that the tools are fit for

purpose (sharp, undamaged, plugs and cables secure and free from damage, machine guards or safety devices operating correctly)

13. Tool cutting characteristics14. Setting and adjusting tools and equipment, the use of back stops on guillotines etc15. The importance of using tools or equipment only for the purpose intended, the care that is required when using the

tools or equipment, the proper way of preserving tools or equipment between operations16. The sort of things that can go wrong with cutting and shaping sheetmetal and how these can be avoided17. The importance of using the machine guards and safety protection equipment at all times18. Inspection techniques that can be applied to check shape and dimensional accuracy are to specification and within

acceptable limits19. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve20. Reporting lines and procedures, line supervision and technical experts

108






(if required)Evidence TypeDateCut & Finish Material Using Tools (SIX)tin snipsbench shearsguillotinehacksawband sawhand power toolspillar drillfilespunch/cropping machinetrepanningnibbling machineProduce Shapes (ALL)straight cutscut-ins (straight and curved)notchesexternal curved contoursround holessquare holesUse sheetmetal of various thicknesses 3mm for TWO appropriate materials & TWO thicknesseshot rolled mild steelcold rolled mild steelcoated mild steelstainless steelaluminiumbrasscopperleadtitaniumProduce Components to meet Quality & Accuracy Standardscompany/customer requirementsdimensionally accuratefree from distortionfree from sharp edges, slivers or burrs


Candidate: Date:

Assessor: Date:

109

Unit 24 Forming Sheetmetal using Hand and Machine Tools

Unit Summary

This unit identifies the competencies you need to form sheetmetal (up to and including 3mm) using hand tools and machine tools in accordance with approved procedures. You will be required to select the appropriate equipment to use based on the operations required, material to be formed and accuracy to be achieved and this will include such things as hammers and stakes, formers, bending machines, rolling machines, wiring and swaging machines. The components/shapes to be produced will include bends/upstands, folds, box sections, wired edges, cylinders and curved sections, square to round trunking, lobsterback trunking, and stretching and shrinking of materials to form cowlings and rounded covers, curved panels with balled corners, concertina ducting or trunking.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying sheet metalwork forming procedures. You will understand the forming processes, the equipment used and its application, and will know about the materials and forming techniques in adequate depth to provide a sound basis for carrying out the activities, correcting faults and producing the components to the required specification. You will understand the safety precautions required when working with the forming machines and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

110



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the correct component drawing and any other related specifications for the component to be producedc. Determine what has to be done and how this will be achievedd. Use the appropriate tools and equipment for the pressure shaping operations and check that they are in a safe and usable conditione. Shape the materials to the required specification using appropriate methods and techniquesf. Check that all the required shaping operations have been completed to the required standardg. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Ensure that the tools and equipment to be used are appropriate to the application and in a safe and usable condition by carrying out all of the following checks:

● hand tools are in a usable condition (hammer shafts secure; stakes, formers and striking faces free from defects and damage)the appropriate machine is selected for the operation being performed the machine guards and safety devices are in position and function correctlyforming tools are appropriate and in a serviceable condition (secure, correct shape, free from damage)machine settings are suitable for the material thickness and operations to be performed

2. Use three of the following types of forming equipment/techniques:● hammers/panel beating equipment● stakes and formers● bending machine (hand or powered)● rolling machine (hand or powered)

● wheeling machine ● jenny/wiring machine● swaging machine● spot heating techniques

3. Perform forming operations which produces seven of the following shapes: ● bends/upstands● folds● box sections● wired edges● swages ● curved panels ● cylindrical sections

● cowlings and rounded covers● square to round trunking● lobsterback trunking● domed corners● concertina ducting or trunking● ribbed components

4. Produce components made from two different materials from the following: ● bright mild-steel ● tinned steel● galvanised plate● stainless steel● titanium/special steels

● aluminium● brass● copper● lead

5. Produce components which meet all of the following quality and accuracy standards: ● dimensional accuracy is within specification tolerances

finished components meet the required shape/geometry (to the template profile)completed components are free from excessive tooling marks, deformation or cracking

111




1. The specific safety precautions to be taken when working with sheetmetal equipment and materials in a fabrication environment (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)

2. The personal protective clothing and equipment that needs to be worn when carrying out the fabrication activities (leather apron and gloves, eye protection, safety helmets etc.)

3. The correct methods of moving or lifting sheet or plate materials4. The hazards associated with sheetmetal work and how they can be minimised, such as handling sheet/fabricated

components, using machinery, using dangerous or badly maintained tools and equipment5. How to obtain the necessary drawings, specifications and work instructions6. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing8. Marking out conventions used in sheetmetal work and how to recognise cutting detail and bending and folding

lines9. Hand tools used in sheetmetal forming activities and typical operations that they are used for (range of hammers,

stakes, formers, sand bags)10. The various machine tool forming equipment that can be used to produce a range of shapes (such as bends, box

sections, cylinders and curved sections, wired edges and swages)11. Methods of stretching and shrinking materials and the tools, equipment and techniques used12. How to set up the various machine to produce the required forms (setting up of rolls; setting fingers on bending

machines; setting forming tools for swaging)13. Ways of limiting distortion, marking, creases, flats (in curved sections)14. How the materials are to be prepared for the forming operations and why some materials may require a heating

process prior to forming15. The characteristics of the various materials used with regard to the bending and forming process16. Tool and equipment care and maintenance procedures17. Organisational quality control procedures and recognition of pressure forming defects18. Dimensional and forming inspection checks that need to be carried out and the tools and equipment to be used19. Limitations of the various forming processes and accuracy that may realistically be achieved20. Ways of avoiding and correcting inaccuracies in forming activities21. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

112


PerformanceEvidence 1




Evidence TypeDateCheck Tools & Equipment (ALL)hand tools useableappropriate machinemachine guardsappropriate forming toolssuitable machine settingsUse Forming Equipment/Techniques (THREE)hammers/panel beatingstakes & formersbending machine rolling machine wheeling machinejenny/wiring machineswaging machinespot heating techniquesProduce shapes (SEVEN)bends/upstandsfoldsbox sectionswired edgesswagescurved panelscylindrical sectionscowlings & rounded coverssquare to round trunkinglobsterback trunkingdomed cornersconcertina ducting/trunkingribbed componentsProduce Components from different materials (TWO)bright mild steeltinned steelgalvanised platestainless steeltitanium/special steelsaluminiumbrasscopperleadProduce Components to Quality & Accuracy Standards (ALL)dimensional accuracyrequired shape/geometryno excessive tooling marks


Candidate: Date:

Assessor: Date:

113

Unit 25 Producing Sheetmetal Assemblies

Unit Summary

This unit identifies the competencies you need to produce Sheetmetal (up to and including 3mm) assemblies in accordance with approved procedures. You will be required to correctly interpret specifications and drawings, bring together and assemble and join, in the right order, Sheetmetal components and/or light sections in order to construct completed fabricated assemblies or sub-assemblies such as ducting, tanks, cylindrical sections, conical sections, reduction pieces etc. You will be required to lay out and secure the various component parts of the structure using mechanical fastenings, resistance welding or self securing methods in the correct order and ensure they are assembled in a manner that is fit for purpose.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying Sheetmetal fabrication techniques and their assembly and fixing procedures. You will understand the techniques used and the requirements of the manufacturing and assembling procedures and their application. You will know about the methods of assembling the components of the required strength, that are fit for purpose in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with Sheetmetal components and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

114



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant instructions, assembly drawings and any other specificationsc. Ensure that the specified components are available and that they are in a usable conditiond. Use the appropriate methods and techniques to assemble the components in their correct positionse. Secure the components using the specified connectors and securing devicesf. Check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specificationg. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must: 1. Carry out all of the following during the sheetmetal assembly operations:

correctly prepare and set-up the components and faces to be joineduse the correct datum facesuse the specified or appropriate fixing methodcorrectly align the components and faces to be joinedassemble/fabricate the sheetmetal components in the correct order or mannerproduce an assembly which meets the required specification

2. Produce five of the following sheetmetal assemblies: framestanksductingguardshoods

panels sectional trunkingsquare, rectangular and box sectionscylindrical sectionsconical sections

reduction piecestransformerssegmented bendssteel and composite material

assemblies

3. Use four of the following types of components in the assemblies produced: sheetmetal coverspre-fabricated square/rectangular componentspre-fabricated cylindrical/conical componentsbrackets

flangespipeslight rolled section (angle, channel or tee section)

stiffeners and frame components

4. Assemble sheetmetal components using two of the following methods: ● temporary tack welding● soldering or brazing● resistance spot welding● riveting (hollow or solid)

● adhesive bonding● flanged and mechanically fastened (bolts, screws)● self securing joints (knocked up, paned down, swaged, joggled)

5. Produce sheetmetal assemblies which meet all of the following quality and accuracy standards: ● all components are correctly assembled and aligned in accordance with the specification● overall dimensions are within specification tolerances● assemblies meet appropriate geometric tolerances (square, straight, angles free from twists)● where appropriate pitch of erection holes meet specification requirements● completed assemblies have secure and firm joints, are clean and free from burrs or flash

115




1. The specific safety precautions to be taken when working in a fabrication environment and when producing sheetmetal assemblies (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)

2. The personal protective clothing and equipment that needs to be worn when carrying out the fabrication activities (leather gloves, eye protection, safety helmets, ear protection etc.)

3. Safe working practices and procedures needed for producing sheetmetal assemblies4. The correct methods of moving or lifting bulky fabrications5. The hazards associated with sheetmetal fabrication and assembly work and how they can be minimised (such using

dangerous or badly maintained tools and equipment, lifting and handling long and heavy components, cuts, slips trips and falls)

6. How to obtain the necessary drawings and joining specifications7. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing9. How to interpret marking out conventions; cutting lines, centre lines, etc10. The preparations that need to be carried out on the components prior to assembling them11. The various methods of securing the assembled components (the range of mechanical fastening devices that are

used (such as nuts and bolts, screws, special fasteners, resistance and tack welding methods and techniques, adhesive bonding of components and self secured joints such as knocked up, paned down, swaged and joggled)

12. How to set up and align the various components and the tools and equipment that is used13. Methods of temporarily holding the joints together to aid the assembly activities (clamps, rivet clamps)14. The use and care of tools and equipment, and control procedures15. The importance of using tools or equipment only for the purpose intended, the care that is required when using the

tools or equipment, the proper way of preserving tools or equipment between operations16. The sort of things that can go wrong when producing sheetmetal assemblies, and how these can be avoided 17. Inspection techniques that can be applied to check shape (including straightness) and dimensional accuracy are to

specification and within acceptable limits18. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve19. Reporting lines and procedures, line supervision and technical experts

116






Evidence TypeDateSheetmetal Assembly Operations (ALL)set up components & facesuse correct datum facesappropriate fixing methodalign components & facesassemble/fabricate components in orderassembly meets specificationProduce Sheetmetal Assemblies (FIVE)framestanksductingguardshoodspanelssectional trunkingsquare/rectangular/box sectionscylindrical sectionsconical sectionsreduction piecestransformerssegmented bendssteel & compositeUse Types of Components (FOUR)sheetmetal coverspre-fab’ square/rectangularpre-fab’ cylindrical/conicalbracketsflangespipeslight rolled section stiffenersAssemble Sheetmetal Components using TWO of these methodstemporary tack weldingsoldering or brazingresistance spot weldingriveting (hollow or solid)adhesive bondingflanged & mechanically fastenedself securing jointsMeet Quality & Accuracy Standards (ALL)correctly assembled and aligneddimensions within tolerancesappropriate geometric tolerancesappropriate pitch of erectionsecure & firm joints, free from burrs or flash


Candidate: Date:

Assessor: Date:

117

Unit 26 Heat Treating Materials for Fabrication Activities

Unit Summary

This unit identifies the competencies you need to heat treat ferrous and non-ferrous materials in order to assist with the fabrication activities in accordance with approved procedures. You will be required to identify and use the appropriate materials, apply the appropriate processes and use tools and equipment based on the information presented to you to achieve the required condition. The heat treatment processes will include hardening, tempering, annealing and normalising/stress relieving and can be applied to the fabricator’s tools such as punches, chisels and scribers or the component/materials to be worked on.

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

Your underpinning knowledge will provide a good understanding of your work, and provide a sound approach to applying the heat treatment procedures. You will understand the principles of heat treatment, and their application, and will know about the effects on the structure of the materials and their characteristics in sufficient depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the process is carried out to the required specification. You will be required to demonstrate safe working practices throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

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You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Ensure the materials to be processed are suitably prepared for the processing operations to be carried outc. Check and monitor that the processing equipment is set up and maintained at satisfactory operating conditions throughout the processing operationsd. Carry out the process in accordance with operating procedures and the workpiece specification requirementse. Ensure that the processed workpiece achieves the required characteristics and meets the processing specificationf. Deal promptly and effectively with problems within your control and report those that you cannot solveg. Dispose of waste and excess materials in line with agreed organisational proceduresh. Shut down the processing equipment to a safe condition on completion of the processing activities


You must:1. Carry out all the following during the heat treatment activities:

● use the correct heat treatment procedure and quality documentation● follow relevant COSHH and risk assessment procedures● apply the required heat treatment processes safely and correctly● ensure the safety of self and others while carrying out the processes● leave the work area in a safe condition on completion of the activities

2. Carry out two of the following heat treatment processes/techniques:● hardening● tempering● annealing● pre-heating● normalising/stress relieving

3. Apply the appropriate heat treatment process to two of the following:● ferrous components/sections● ferrous high carbon tools (punches, chisels, scribes)● hot steel rivets● non-ferrous sheet or plate● titanium

4. Carry out heat treatment processes to the following quality and accuracy standards: ● tools are of the correct hardness for the application and, where appropriate, suitably tempered ● hardened materials are free from cracks● materials/components are suitably treated to permit working● distortion is limited and controlled

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1. The specific safety precautions to be taken and safe working practices to be employed when carrying out the heat treatment of materials in a fabrication environment (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)

2. The personal protective clothing and equipment that needs to be worn when working on heat treatment processes (gloves, eye protection, etc.)

3. The handling precautions and correct methods of moving materials, particularly when hot4. The hazards associated with heat treatment processes and fabrication and how they can be minimised (such as

handling sheet/fabricated components, handling hot materials, overheating quenching oils)5. Reasons for heat treating materials6. The various heat treatment processes, methods and procedures that may be applied7. The type of equipment that can be used to carry out the various heat treatment processes (furnaces, black smiths

heart, gas torches)8. Handling techniques for hot metal components9. How the materials need to be prepared in readiness for the heat treatment operations10. The type of materials that can be heat treated and the processes that may be applied11. Materials and their characteristics and how their structure can be modified12. The various cooling and quenching techniques that are applied to the processes and why it is important to use the

correct process (water, oil, sand, air)13. The use of quenching oils and the need to maintain the oil temperature below the oil flash point14. Information sources on heat treatment temperatures, tempering colours, soak times required and quenching/cooling

mediums to be used15. The various testing techniques that can be used to check the correct condition has been achieved (simple file tests to

check hardening or annealing has been achieved)16. Ways of limiting distortion during the heat treatment process17. Quality control procedures and recognition of defects18. Limitations of the various processes19. Organisational procedures for disposing of and recycling of waste20. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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(if required)Evidence TypeDateDuring Heat Treatment Activities (ALL)correct procedure and documentationfollow relevant COSHH and risk assessment proceduressafe & correct processesensure safety of self & othersleave work area safe afterCarry out heat treatment processes/techniques (TWO)hardeningtemperingannealingpre-heatingnormalising/stress relievingApply Appropriate Heat Treatment Process to materials (TWO)ferrous componentsferrous high carbon toolshot steel rivetsnon-ferrous steel or platetitaniumCarry Out Processes to Quality & Accuracy Standards (ALL)tools of correct hardness & tempered where necessarymaterials free from cracksmaterial/components suitably treateddistortion limited/controlled


Candidate: Date:

Assessor: Date:

121

Unit 27 Developing and Marking Out Templates for Metalwork

Unit Summary

This unit identifies the competencies you need for developing and marking out templates prior to cutting and/or shaping the material in accordance with approved procedures. You will be required to select the appropriate materials and equipment to use based on the information presented to you and the accuracy required to be achieved. The templates produced may be used for marking out, setting of fabrications or pipe arrangements or preparing (setting) heavy plate for rolling.

Your responsibilities will require you to comply with organisational policy and procedures for the marking out and template making activities, seeking out relevant information and reporting any problems with the equipment, materials or template making activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to template making. You will understand the marking out and template making process and its application, and will knowabout the equipment, materials and processes to be carried out in sufficient depth to provide a sound basis for carrying out the activities, correcting faults and producing the templates to the required specification. You will understand the safety precautions required when carrying out the template making activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Obtain and use the correct information for marking outc. Obtain the appropriate marking out equipment and check that it is in a usable conditiond. Prepare suitable datums and marking out surfacese. Mark out using appropriate methodsf. Check that the marking out complies with the specificationg. Deal promptly and effectively with problems within your control and report those that cannot be resolved


You must:1. Mark out plate or pipe setting for two of the following:

angular settinglarge radius sectionplate settingburner template

2. Mark out templates for six of the following:radiused and mitred cornersconcentric conesoffset conestruncated conessquare/rectangular to roundfishtail segmented bends (lobsterback)

ball corner or spherical sectionfish platesbed platesgusset platesstructural componentssimple seating (tank cradles)

3. Use all of the following tools and instruments to mark out directly from drawings onto Sheetmetal: scriberpunchrule or tapestraight edge

squareprotractordividers or trammels

4. Mark out material to include all of the following features:datums and centre-linessquare and rectangular profilesanglescircles and curved profiles

cutting detail and allowancesbend/fold allowanceshole centres and outlining (linear)hole centres and outlining (on pitch circles)

5. Developed templates meet all the following quality and accuracy standards: template profile complies with drawing or job requirementsdimensional accuracy meets drawing/specificationsuitably marked or labelled to identify purposemarking out uses recognised conventions

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1. The specific safety precautions to be taken when working in a fabrication environment with sheet or plate materials (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)


3. The correct methods of moving or lifting sheet or plate materials4. The hazards associated with fabrication work and how they can be minimised (such as handling sheet/fabricated

components; using dangerous or badly maintained tools and equipment)5. How to obtain the necessary drawings, template specifications and job instructions6. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing8. Principles and techniques for marking out templates 9. Geometrical methods for developing of complex shapes (such as square to round, lobsterback sections) from sheet

metal10. How to produce a three dimensional shape from the two dimensional material11. Use of marking out conventions, datum edges/lines and centre lines12. The preparations that need to be carried out on the material prior to marking out to enhance clarity and accuracy,

and safety13. The component material characteristics and process considerations that need to be taken into account when

marking out templates14. Allowances for joint and weld preparations for different materials and thicknesses15. How to calculate true lengths, bend allowances and circumferences16. The effective use and care of tools/instruments17. How to mark out and preserve the template for maximum clarity, accuracy and ease of transfer18. Ways of laying out the shapes/patterns to maximise the use of plate or sheet material19. Setting and adjusting tools, such as squares and protractors20. How to transfer information to the underside of the sheet or plate21. The importance of using tools only for the purpose intended; the care that is required when using the equipment

and tools; the proper way of preserving and storing tools and equipment between operations22. The need for clear and dimensional accuracy in marking out to specifications/drawings23. The sort of things that can go wrong in marking out templates and how these can be avoided 24. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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Evidence TypeDateMark Out Plate or Pipe Setting (TWO)angular settinglarge radius sectionplate settingburner templateMark Out Templates (SIX)radiused & mitred cornersconcentric conesoffset conestruncated conessquare/rectangular to roundfishtailsegmented bends (lobsterback)ball cornerfish platesbed platesgusset platesstructural componentssimple seating (tank cradles)Use Tools & Instruments to Mark Directly from Drawings onto Sheetmetal (ALL)scriberpunchrule or tapestraight edgesquareprotractordividers or trammelsMark Out Material to Include Features (ALL)datums & centre linessquare & rectangular profilesanglescircles & curved profilescutting detail & allowancesbend/fold allowanceshole centres and outlining (linear)hole centres and outlining (on pitch circles)Develop Templates to Meet Quality & Accuracy Standards (ALL)profile complies with job requirementsdimensional accuracy meets specifictaionsuitably marked/labelledrecognised marking out conventions


Candidate: Date:

Assessor: Date:

125

Unit 28 Joining Fabricated Components using Mechanical Fasteners

Unit Summary

This unit identifies the competencies you need to undertake the preparation and making of joints between fabricated components using mechanical means in accordance with approved procedures. You will be required to produce suitable and appropriate joints using appropriate methods for the materials to be joined that meet the specified conditions and subsequent operating conditions to be demanded of the joint. Particular attention will be needed in the preparation and finishing of the materials so that the finished component is fit for purpose and meets the level of accuracy required. The mechanical fastenings used will include rivets, self-tapping screws, bolts and screwed fittings, anchor nuts and proprietary fasteners as is appropriate to the application and/or specification. The joint will be of two or more materials and may include non-metallic materials and joints of dissimilar metals.

Your responsibilities will require you to comply with organisational policy and procedures, or those of the fastener manufacturers. You will be expected to seek out the relevant information and to report any problems with the mechanical fasteners or the joining activities that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your actions and the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to the joining activities carried out. You will understand the basic characteristics of the materials to be joined, the various processes used and the appropriate procedures that go with them in adequate depth to provide a sound basis for achieving a sound and cohesive joint that is fit for purpose.

You will understand the safety precautions required when working with the tools and equipment, especially those for use in hot metal processes and the safeguards necessary for undertaking the using processes. You will be required to demonstrate safe working practices throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

126



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant instructions, assembly drawings and any other specificationsc. Ensure that the specified components are available and that they are in a usable conditiond. Use the appropriate methods and techniques to assemble the components in their correct positionse. Secure the components using the specified connectors and securing devicesf. Check the completed assembly to ensure that all operations have been completed and the finished assembly meets

the required specificationg. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must: 1. Carry out all of the following during the joining process:

correctly prepare the faces of the materials to be joinedselect the appropriate/specified fixingscorrectly align the materials and faces to be joinedassemble the components in the correct order or manner

● produce a joint that meets the requirements of the specification

2. Produce assemblies which include six of the following:flat and flanged joints on flat or curved surfacessquare/rectangular trunkingcircular trunking

● access flanges and cover plates● tanks and tank covers

● joints with gasket or sealant● pipes ● structural components● long or critical alignments● permanent and temporary assemblies

3. Use four of the following assembly methods and techniques:riveting using cold or/and hot rivetsriveting using pop/blind rivets self-tapping screwsuse of proprietary fasteners crimping

● assembling using bolt fittings● using screw fittings to tapped components● nuts and (spot welded) screw studs● locking methods and devices● clinching

4. Join the components in three of the following joining positions, access and environmental conditions:horizontalverticaloverheadin workshop conditionsinternal and confined spaces

5. Produce joints to all of the following quality and accuracy standards as is applicable to the application:joints are accurately assembled and aligned in accordance with the specificationsjoints are secure and firm bolted and screwed joints are tightened to the correct torqueriveted joints are free from excessive material deformation and hammer marks

● pitch of holes meet the specification● completed joints are clean and free from burrs

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1. The specific safety precautions to be followed when working in a fabrication environment and when carrying out joining activities using fabricated components (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)

2. The personal protective clothing and equipment that needs to be worn when carrying out the joining activities (leather gloves, eye protection, safety helmets etc.)

3. The hazards associated with the joining operations and how they can be minimised (such as handling sheet/fabricated components, using hot metal riveting techniques, handling and using sealants and cleaning agents, dangerous or badly maintained tools and equipment)

4. How to obtain the necessary drawings and joining procedure specifications5. How to extract information from engineering drawings and related specifications to include symbols and conventions

to appropriate BS or ISO standards in relation to work undertaken6. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference

points and system of tolerancing7. The use of manufacturers’ specifications for the types of fasteners used8. The advantages and disadvantages of the different forms and methods of mechanical join9. The various joining processes that are used and the tools and equipment that is required10. The preparations that need to be carried out on the materials/components prior to joining them (such as, materials to

be degreased, dry and clean, with hole and flanges de-burred)11. How to set up and align the joints prior to fixing and the tools and methods that can be used (such as clamps, rivet

gripping tools, temporary fixings, jacking and supporting devices)12. How to produce a secure joint using blind rivets and the type of riveting tools that are available13. How to produce a good hot or cold riveted joint and the use of the various riveting tools14. How to determine the length of the rivets required to give a properly formed rivet head15. The range of bolts and screwed fasteners that are to be used; why it is important to use the correct type of washer;

sequence of tightening bolts on flanged joints; and the tools and equipment used to ensure they are tightened to the required torque

16. The various types of proprietary fasteners that are used on fabricated assemblies (such as anchor nuts, clinch nuts, welded studs etc.)

17. The materials used and their joining characteristics, electrochemical reaction between dissimilar metals and means of reducing the effects, use of gasket material

18. Checks that need to be carried out on the tools and equipment prior to use to ensure that they are in a safe and usable condition (such as condition of plugs and leads on power tools, condition of striking faces on hammers, condition of riveting tools and rivet snaps)

19. Equipment setting, operating and care procedures; why equipment and tools need to be correctly set up and in good condition

20. The importance of using the tools only for the purpose intended; the care that is required when using the equipment and tools; the proper way of preserving and storing tools and equipment between operations.

21. Quality control and test procedures for detection of defects in joints, visual, feel and measurement checks22. The sort of things that can go wrong with the joining operations and how these can be avoided23. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve24. Reporting lines and procedures, line supervision and technical experts

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Evidence TypeDateCarry out Joining Processes (ALL)prepare faces of materialsselect appropriate fixingscorrectly align materials and facesassemble in correct ordermeet requirements of spec’Produce Assemblies with (SIX)flat & flanged jointssquare/rectangular trunkingcircular trunkingaccess flanges & cover platestanks & tank coversjoints with gasket or sealantpipesstructural componentslong or critical alignmentsperm’ & temp’ assembliesUse Assembly Methods & Techniques (FOUR)riveting using cold/hot rivetsriveting using pop/blind rivetsself-tapping screwsuse of proprietary fastenerscrimpingassembling using bolt fittingsscrew fittings to tapped componentsnuts & screw studslocking methods & devicesclinchingJoin Components (THREE)horizontalverticaloverheadin workshop conditionsinternal & confined spacesProduce Joints to Applicable Quality & Accuracy Standards (ALL)joints accurately assembled & alignedjoints secure & firmbolts/joints to correct torqueriveted joints: no excessive material deformationpitch of holes to spec’completed joints clean


Candidate: Date:

Assessor: Date:

129

Unit 29 Bonding Engineering Materials using Adhesives

Unit Summary

This unit identifies the competencies you need to undertake the joining of engineering materials using adhesive bonding processes in accordance with approved procedures. You will be required to identify and select suitable or specified bonding agents for the materials to be joined that meet the specified conditions and subsequent operating conditions to be demanded of the joint. Particular attention will be needed in the preparation of the materials and the application of the bonding agent as well as the means of securing the joint until the setting or curing process has been completed so that the finished component meets the level of accuracy required. The adhesive bonding agents used will include impact adhesives, cold curing adhesives, rubber mastic, solvent adhesives, epoxy resins and thermally cured adhesives. The joint will be of two or more materials and may include metallic and/or non-metallic materials and joints of dissimilar materials.

Your responsibilities will require you to comply with organisational policies and procedures, and/or those of the bonding agent manufacturers. You will be expected to seek out the relevant information and to report any problems with the bonding agents, materials or bonding activities that you cannot resolve yourself, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to the adhesive bonding activities carried out. You will understand the basic characteristics of the materials to be joined, the bonding agents used and the procedures that go with them in adequate depth to provide a sound basis for carrying out the activities safely and correctly and for achieving a sound and cohesive joint fit for purpose. You will need to understand the precautions required when working with the various bonding agents and safeguards necessary for undertaking the process. You will be required to demonstrate safe working practices throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

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You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant bonding procedure specification and job instructionsc. Check that the materials to be bonded and bonding agents comply with the specificationd. Correctly prepare the parent materials and bonding agents in line with the bonding specificatione. Carry out the bonding operations using the specified processes and techniques to position and bond the materials in their correct locations f. Ensure that any equipment used to maintain surface contact during the bonding activities is set up and used correctlyg. Achieve bonds of the required quality and within the specified dimensional accuracy h. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all of the following during the adhesive bonding process:

correctly prepare the materials for bondingselect the right constituents and bonding methodscheck the surfaces to be bonded mate properly to make a sound joint possible ensure the joint is rigidly secure during the curing periodremove surplus material and clean up at the appropriate time

2. Carry out adhesive bonding activities using two of the following types of material:metallic non-metallic combinations

3. Use two of the following types of adhesives:impact adhesivescold curing adhesives

● rubber mastic ● solvent adhesives

● epoxy resins● thermally cured adhesives

4. Produce bonded joints in three of the following types of component: flat and flanged joints on flat surfacesflat and flanged joints on curved surfacesvertical componentshorizontal components rectangular trunking

circular trunkingaccess flanges, panels and cover platestanks and tank coverspipe work

5. Use a range of bonding equipment and devices to include four of the following:mixing vesselsspatulas, brushes, knivesspray equipment

jigsformers clamps

pressesweights temporary fixtures (clips, wiring)

6. Use a range of preparation and cleaning agents to include two of the following:detergents solvents petroleum products acids

7. Produce bonded joints which comply with all of the following quality and accuracy standards: components are dimensionally accurate and of the correct orientationjoints meet the required application standard completed joints are clean and free from surplus adhesivethe completed joint has the required appearance

131




1. The specific safety precautions to be taken when bonding engineering materials using adhesives in a fabrication environment (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)

2. The personal protective clothing and equipment that needs to be worn when carrying out bonding as part of the fabrication activities (gloves, eye protection, safety helmets, respiratory protection etc.)

3. The importance of good workshop practice and house keeping, ventilation and fume control equipment, first aid procedures and actions, hazardous substances and relevant sections of COSHH

4. The correct methods of moving or lifting sheet or plate materials5. The hazards associated with bonding fabricated components and how they can be minimised6. How to obtain the necessary drawings and joining specifications7. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing9. The material preparations that are required and the equipment and consumables that are used10. The importance of working to organisational and bonding agent manufacturers’ instructions whilst carrying out the

bonding activities11. The methods and techniques used for bonding the materials (such as gluing, impact, chemical and thermal reaction

techniques)12. The basic characteristics of the adhesives that are to be used adhesives13. The use and precautions to be taken when using adhesives and solvents14. Maintenance and care of tools and equipment15. Methods of degreasing components and producing a keying surface16. Type and suitability of adhesives, setting or curing requirements and time, strength an appearance17. Common causes of defects associated with the bonding processes and how to avoid them18. The effects of the environment on the bonding process such as temperature, humidity, cleanliness19. How to identify, select, use, and clean, the appropriate bonding agent holding vessels, brushes, stirrers and

spatulas, scrapers, knives, clamps and weights20. The importance of cleaning up after use to ensure everything can be used again and minimising the need for

replacement of equipment21. Reasons for checking components are assembled in the correct sequence, are positioned dimensionally accurately

and to the correct orientation in accordance with the specifications prior to bonding22. How to check that completed joints are firm, sound and fit for purpose23. Procedures for cleaning off surplus adhesive and tidying up the appearance of joints24. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve25. Line supervision and technical experts

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Evidence TypeDateAdhesive Bonding Process (ALL)correctly prepare materialsselect right constituentscheck surfacesensure joint rigidly secureremove surplus materialCarry out bonding using types of material (TWO)metallicnon-metalliccombinationsUse Types of Adhesive (TWO)impact adhesivescold curing adhesivesrubber masticsolvent adhesivesepoxy resinsthermally cured adhesivesProduce Bonded Joints (THREE)flat & flanged joints on flat surfacesflat & flanged joints on curved surfacesvertical componentshorizontal componentsrectangular trunkingcircular trunkingaccess flanges, panels etctanks & tank coverspipe workUse a Range of Bonding Equipment & Devices (FOUR)mixing vesselsspatulas, brushes, knivesspray equipmentjigsformersclampspressesweightstemporary fixturesUse a Range of Preparation & Cleaning Agents (TWO)detergentssolventspetroleum productsacidsProduce Bonded Joints to Quality & Accuracy Standards (ALL)dimensionally accuratemeet application standardjoints are cleanjoints have req’ appearance


Candidate: Date:

Assessor: Date:

133

Unit 30 Joining Materials by Resistance Spot Welding

Unit Summary

This unit identifies the competencies you need to set up and use portable, and simple fixed spot welding machines in accordance with approved instructions, or welding procedures. You will be expected to check that the equipment is fit for purpose, the electrodes are correctly profiled, and that the component parts are in the correct condition for spot welding. In preparing the equipment you will need to set the welding current, welding and squeeze times and electrode pressure. You must operate the equipment safely and correctly and make any necessary adjustments to the equipment settings and parameters within permitted tolerances in order to achieve weld quality and tolerances that meet the specification.

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

Your underpinning knowledge will provide a sound basis of your work, enabling you to adopt an informed approach to applying spot welding procedures and instructions. You will have an understanding of how the resistance spot welding process works, and will know about the equipment, materials and consumables in adequate depth to provide a sound background to the process operation and for carrying out the activities to the required specification. You will understand the safety precautions required when working with the welding equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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You must:1. Ensure the resistance spot welding equipment is fit for purpose by carrying out all of the following checks:

● equipment range is suitable for the operations to be performed● portable equipment power leads are undamaged and securely connected● electrodes are of the correct type, size and profile● all equipment mechanical and electrical systems operate correctly● supplies of components are adequate and suitably prepared● appropriate safety screens are available

2. Set up, check, adjust and operate one of the following resistance spot welding machines: ● portable spot welding machines● fixed simple spot welding machines

3 Set up the equipment parameters in accordance with instructions and the welding procedure specification to include setting all of the following:

● electrode tip diameter/profile● welding current● welding and squeeze times● electrode pressure

4. Monitor the process operation and make adjustments to parameters in order to produce welded components covering both of the following:

● two different components● two different material thicknesses

5. Produce welded components which meet all the following requirements: ● achieve a weld quality as specified in the application standard ● spot welds are correctly pitched out ● welded components meet the required dimensional accuracy within specified tolerances

135




1. The specific safety precautions to be taken when operating resistance welding equipment (working with machinery, the use of appropriate personal protective equipment; the use of safety screens; operation of equipment safety devices; closing down the equipment on completion of the welding activities; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)

2. The hazards associated with resistance welding equipment and how they can be minimised (dangers from live internal electrical components, fumes, hot metal, expulsion of hot particles, moving parts of machines)

3. The basic principles of resistance welding (heat and pressure to form a weld heating effect of welding current; principal features of the welded joint; heat input; welding and pressure cycles; terminology used in welding)

4. The key components and features of the equipment used (power source; welding head; power range; electrical parameters such as arc voltage, current, electrode pressure and welding time; systems for parameter control; how variation in the parameters influence weld features, quality and output)

5. Extracting information required from drawings and procedure specifications6. Operation of the equipment controls and their function; equipment care procedures7. Monitoring the equipment during the welding process; fine tuning parameters to maintain quality; recognition of

problems and action to be taken8. Problems that can occur with the welding activities, materials and weld defects9. Self inspection of completed work10. Organisational quality systems (standards to be achieved; production records to be kept)11. Personal approval tests and their applicability to your work12. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

136






(if required)Evidence TypeDateCheck Resistance Spot Welding Equipment (ALL)suitable equipment rangeportable power leads okayelectrodes correct size type and profilesystems operate correctlyadequate suppliesappropriate safety screensSet up, check, adjust, operate resistance spot welding machines (ONE)portablefixed simpleSet up Equipment Parameters (ALL)electrode tip diameter/profilewelding currentwelding & squeeze timeselectrode pressureMonitor Process Operation & Adjust Parameters (two different components and two different thicknesses)componentsmaterial thicknessesProduce Welded Components to Requirementsachieve specified weld qualityspot welds correctly pitched outdimensional accuracy within tolerances


Candidate: Date:

Assessor: Date:

137

Unit 31 Producing Fillet Welded Joints using a Manual Welding Process

Unit Summary

This unit identifies the competencies you need to produce fillet welds in plate, sheet or sections and/or fillet welded joints in pipe/tube using a manual welding process such as manual metal arc, MIG, MAG, TIG, flux cored wire, inert shield or gas welding equipment in accordance with instructions and/or approved welding procedures. You will be required to check that all the workholding equipment and manipulating devices required are available and in a usable condition. You will be expected to check the welding equipment to ensure that all the leads/cables, hoses and wire feed mechanisms are securely connected and free from damage.

In preparing to weld you will need to set and adjust the welding conditions in line with the instructions or welding procedure specification. You must operate the equipment safely and correctly and make any necessary adjustments to settings in line with your permitted authority in order to produce the welded joints to the required specification. You will be required to demonstrate your capability to produce the fillet welds of the required quality and this could be through tests according to BS 4872 or EN 287.

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

Your underpinning knowledge will provide a sound basis for your work, and will provide an understanding of how the particular welding process works. You will know about the equipment, materials and consumables in adequate depth to provide a sound background for the welding operations to be performed, and for ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the welding equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

138








TIGPlasma Arc

Cored wireGas welding

2. Use consumables as specified in the welding procedure specification covering either:two types of electrode from:� rutile� basic� cellulosic � nickel alloy � stainless steel� other

two types of filler wire from different material groups3. Produce fillet welded joints in two of the following forms of material:

platesectionspipe/tube

sheetother

4. Weld joints according to approved welding procedures in good access situations in two of the following BS EN287 positions:

Flat (PA)Horizontal (PC)Horizontal Vertical (PB)Vertical Upwards (PF)Vertical Downwards (PG)Overhead (PE or PD)

5. Produce fillet welded joints which: achieve a minimum weld quality requirements applicable to fillet welds equivalent to those given in the

relevant European/International Standards (e.g. EN 25817/ISO 5187 and EN30042/ISO 10042) as required by the application standard or specification


139



You must have knowledge and understanding of: (as is applicable to the welding process selected)

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


3. The hazards associated with the selected welding process and how they can be minimised (live electrical components, poor earthing, arc radiation, fumes and gases, gas supply leaks, spatter, hot slag and metal, grinding and mechanical metal/slag removal; elevated working, enclosed spaces, slips, trips and falls)


5. Extracting information required from drawings and welding procedure specifications (interpretation of welding symbols, scope, content and application of the welding procedure specification

6. The consumables associated with the chosen welding process (types of electrodes and or filler metal and their application, types of shielding gas and their application, gas supply and control; correct control, storage and drying of electrodes and filler wire)

7. The types and features of welded joints in pipe (fillet and butt welds, single and multi-run welds, welding positions, weld quality)


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



methods of control, effects of welding on materials and sources of weld defects; methods of prevention)13. The organisational quality systems used and weld standards to be achieved; weld inspection and test procedures


140






(if required)Evidence TypeDateSet up check, adjust & Use Welding & Related Equipment (ONE)Manual Metal ArcMIG/MAGTIGPlasma ArcCored WireGas WeldingUse Consumables as Specified (EITHER TWO types of electrodes OR TWO Types of Filler Wire from different Material Groups)rutilebasiccellulosicnickel alloystainless steelotherFiller wire 1Filler wire 2Produce Fillet Welded Joints (TWO)platesectionspipe/tubesheetotherWeld Joints to Approved Procedures in BS EN287 Positions (TWO)PAPCPBPFPGPD or PEProduce Fillet Welded Joints to Relevant Standards (e.g. EN 25817/ISO 5187 & EN30042/ISO 10042)generalRequired Dimensional Accuracywithin specified tolerance


Candidate: Date:

Assessor: Date:

141

Unit 32 Cutting Plate and Sections using Shearing Machines

Unit Summary

This unit identifies the competencies you need for cutting and shaping metal plate and sections (3 mm thickness and above) for fabrications using guillotines and section cropping machines, in accordance with approved procedures. You will be required to select the appropriate equipment and machine settings to use for the material and thickness and the accuracy required to be achieved. Materials to be cut and shaped may include ferrous and non-ferrous and will includeparallel cuts, square cuts, and cuts that are at an angle. These cuts will be achieved by working to marking out and by setting the machines back stop when multiple cutting is required. This will call for care in selecting the right tools so as to avoid damage to the materials and tools, and danger to oneself.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying metal shearing procedures. You will understand the shearing processes, the equipment and its application, and will know about the process in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the safety precautions required when working with shearing machines and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

142



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the machine is set up and ready for the machining activities to be carried outc. Manipulate the machine tool controls safely and correctly in line with operational procedures d. Produce components to the required quality and within the specified dimensional accuracye. Carry out quality sampling checks at suitable intervals f. Deal promptly and effectively with problems within your control and report those that cannot be solvedg. Shut down the equipment to a safe condition on conclusion of the machining activities


You must:1. Confirm that the equipment is safe and fit for purpose by carrying out all of the following checks:

the appropriate equipment/machine is selected for the operation being performed the machine guards and safety devices are in position and function correctlycutting blades are in a serviceable condition (sharp, free from damage or chips)machine settings are suitable for the material thickness and operations to be performed

2. Cut metal plate using both of the following types of shearing machine: guillotinessection cropping machine

3. Cut materials using both of the following techniques:to markingsusing machine back-stop for multiple cutting

4. Perform operations that produce straight and accurate cuts which includes all of the following:● parallel cuts● square cuts● angular cuts

5. Cut plate, sections or bars for one appropriate material and for two different thicknesses: black mild steel

● stainless steel● aluminium

● brass or copper ● tin plate● other specific materials

6. Produce cut components which meet all of the following quality and accuracy standards: ● dimensional accuracy is within the tolerances specified on the drawing/specification ● cut components are free from excessive distortion● cut edges are neat and free from false tool cuts and shearing slivers● angled cuts are within specification requirements

143




1. The specific safety precautions to be taken when working in a fabrication environment and when working with shearing machines (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)


3. Safe working practices and procedures for operating machine tools4. The correct methods of moving or lifting heavy plate and the equipment to be used5. The hazards associated with fabrication work and shearing operations and how they can be minimised (such as using

dangerous or badly maintained tools and equipment; lifting and handling plate; operating machinery)6. How to obtain the necessary drawings and specifications7. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing9. How to interpret marking out conventions; cutting lines, centre lines, etc10. the various shearing machine cutting methods and techniques (such as cutting to marking out; using machine back-

stops; setting plate at an angle to the machine slides)11. Material handling and preparation methods (such as degreasing, de-burring, straightening)12. The material cutting characteristics and process considerations that need to be taken into account when shearing

plate material13. The method of setting and adjusting guillotine blades for the material thickness14. Tool and equipment care and control procedures and how to recognise when the cutting blades require changing15. The importance of using tools or equipment only for the purpose intended; the care that is required when using the

tools or equipment; the proper way of preserving tools or equipment between operations16. The safety mechanisms and devices that are on the machine and why they must always be used (machine guards,

interlocks, safety operating devices17. The things that can go wrong when shearing materials and how these can be avoided18. Inspection techniques that can be applied to check shape and dimensional accuracy are to specification and within


144






(if required)Evidence TypeDateCheck Equipment safe and fit for purpose (ALL)equipment is appropriate for tasksafety devices functioncutting blades serviceablemachine settings suitableCut Metal Plate (BOTH types of machine)guillotinessection cropping machinesCut Materials (BOTH techniques)to markingsusing machine back-stop for multiple cuttingProduce Straight & Accurate Cuts (ALL)parallel cutssquare cutsangular cutsCut Plate, Sections or Bars for ONE Appropriate Material & for TWO different Thicknessesblack mild steelstainless steelaluminiumbrass or coppertin plateother specific materialsProduce Cut Components to Quality & Accuracy Standards (ALL)dimensional accuracy within tolerancesno excessive distortioncut edges are neat and free from false cuts and sliversangled cuts within specification requirements


Candidate: Date:

Assessor: Date:

145


Unit Summary

This unit identifies the competencies you need for cutting and shaping metal plate and sections (3 mm thickness and above) for fabrications using guillotines and section cropping machines, in accordance with approved procedures. You will be required to select the appropriate equipment and machine settings to use for the material and thickness and the accuracy required to be achieved. Materials to be cut and shaped may include ferrous and non-ferrous and will include parallel cuts, square cuts, and cuts that are at an angle. These cuts will be achieved by working to marking out and by setting the machines back stop when multiple cutting is required. This will call for care in selecting the right tools so as to avoid damage to the materials and tools, and danger to oneself.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying metal shearing procedures. You will understand the shearing processes, the equipment and its application, and will know about the process in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the safety precautions required when working with shearing machines and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

146



You must:h. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesi. Confirm that the machine is set up and ready for the machining activities to be carried out j. Manipulate the machine tool controls safely and correctly in line with operational procedures k. Produce components to the required quality and within the specified dimensional accuracyl. Carry out quality sampling checks at suitable intervals m. Deal promptly and effectively with problems within your control and report those that cannot be solvedn. Shut down the equipment to a safe condition on conclusion of the machining activities



the appropriate equipment/machine is selected for the operation being performed the machine guards and safety devices are in position and function correctlycutting blades are in a serviceable condition (sharp, free from damage or chips)machine settings are suitable for the material thickness and operations to be performed

2. Cut metal plate using both of the following types of shearing machine: guillotinessection cropping machine

3. Cut materials using both of the following techniques:to markingsusing machine back-stop for multiple cutting

4. Perform operations that produce straight and accurate cuts which includes all of the following:● parallel cuts● square cuts● angular cuts

5. Cut plate, sections or bars for one appropriate material and for two different thicknesses: black mild steel

● stainless steel● aluminium

● brass or copper ● tin plate● other specific materials

6. Produce cut components which meet all of the following quality and accuracy standards: ● dimensional accuracy is within the tolerances specified on the drawing/specification ● cut components are free from excessive distortion● cut edges are neat and free from false tool cuts and shearing slivers● angled cuts are within specification requirements

147




21. The specific safety precautions to be taken when working in a fabrication environment and when working with shearing machines (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)


23. Safe working practices and procedures for operating machine tools24. The correct methods of moving or lifting heavy plate and the equipment to be used25. The hazards associated with fabrication work and shearing operations and how they can be minimised (such as using

dangerous or badly maintained tools and equipment; lifting and handling plate; operating machinery)26. How to obtain the necessary drawings and specifications27. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing29. How to interpret marking out conventions; cutting lines, centre lines, etc30. the various shearing machine cutting methods and techniques (such as cutting to marking out; using machine back-

stops; setting plate at an angle to the machine slides)31. Material handling and preparation methods (such as degreasing, de-burring, straightening)32. The material cutting characteristics and process considerations that need to be taken into account when shearing

plate material33. The method of setting and adjusting guillotine blades for the material thickness34. Tool and equipment care and control procedures and how to recognise when the cutting blades require changing35. The importance of using tools or equipment only for the purpose intended; the care that is required when using the

tools or equipment; the proper way of preserving tools or equipment between operations36. The safety mechanisms and devices that are on the machine and why they must always be used (machine guards,

interlocks, safety operating devices37. The things that can go wrong when shearing materials and how these can be avoided38. Inspection techniques that can be applied to check shape and dimensional accuracy are to specification and within


148






(if required)Evidence TypeDateCheck Equipment safe and fit for purpose (ALL)equipment is appropriate for tasksafety devices functioncutting blades serviceablemachine settings suitableCut Metal Plate (BOTH types of machine)guillotinessection cropping machinesCut Materials (BOTH techniques)to markingsusing machine back-stop for multiple cuttingProduce Straight & Accurate Cuts (ALL)parallel cutssquare cutsangular cutsCut Plate, Sections or Bars for ONE Appropriate Material & for TWO different Thicknessesblack mild steelstainless steelaluminiumbrass or coppertin plateother specific materialsProduce Cut Components to Quality & Accuracy Standards (ALL)dimensional accuracy within tolerancesno excessive distortioncut edges are neat and free from false cuts and sliversangled cuts within specification requirements


Candidate: Date:

Assessor: Date:

149

Unit 33 Cutting and Shaping Materials using Portable Thermal Cutting Equipment

Unit Summary

This unit identifies the competencies you need for cutting and shaping plate (3mm thickness and above), rolled sections, pipe and tube for fabrications using portable thermal cutting equipment in accordance with approved procedures. The equipment to be used will include hand held gas cutting equipment, plasma cutting equipment and simple portable machines running on tracks. You will be required to assemble and set up the appropriate equipment to be used for the material and thickness to be cut, the type of operation to be carried out and the accuracy required to be achieved. Materials to be cut and shaped may include mild steel, stainless steel, special steels and other appropriate materials and will include guided cuts, vertical cuts, overhead cuts, external curved contours, round and square holes and demolition work as is appropriate. This will call for care in selecting the right equipment and tools so as to avoid damage to the material and tools, and danger to oneself

Your responsibilities will require you to comply with organisational policy and procedures for the cutting operations, seeking out relevant information for the thermal cutting activities undertaken and to report any problems with the equipment, materials, consumables or cutting activities that you cannot personally resolve yourself, or are outside your personal responsibilities, to the relevant authority. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and the quality and accuracy of the work that you produce.

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying thermal-cutting procedures. You will understand the processes, and will know about the equipment and its application, and the materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will need to understand the safety precautions required when working with the thermal cutting equipment, especially those with regard to fire and potential explosion, and the safeguards necessary for undertaking the activities safely and correctly. You will be expected to demonstrate safe working practices throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

150



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the machine is set up and ready for the machining activities to be carried out c. Manipulate the machine tool controls safely and correctly in line with operational procedures d. Produce components to the required quality and within the specified dimensional accuracye. Carry out quality sampling checks at suitable intervals f. Deal promptly and effectively with problems within your control and report those that cannot be solvedg. Shut down the equipment to a safe condition on conclusion of the machining activities



the equipment selected is suitable for the operations to be performedregulators, hoses and valves are securely connected and free from leaks and damagethe correct gas nozzle is fitted to the cutting torchthat a flash back arrestor is fitted to gas equipmentappropriate gas pressures are setthe correct procedure is used for lighting, adjusting and extinguishing the cutting flamehoses are safely routed and protected at all timesgas cylinders are handled and stored safely and correctly

2. Use two of the following thermal cutting methods:hand held Oxy-fuel gas-cutting equipmenthand held plasma gas-cutting equipmentsimple portable track driven cutting equipment (electrical or mechanical)

3. Perform thermal cutting operations to produce six of the following features: down-hand straight cuts freehandstraight cuts track guidedvertical cutsoverhead cuts

square/rectangular shapesirregular shapesangled cutsexternal curved contours

round holes square holesrough cutting (demolition)bevelled edge – weld

preparations

4. Produce thermal cuts in four of the following forms of material (metal of 3mm and above and two different thickness:

platebar

rolled sectionspipe/tube

structures

5. Produce cut profiles for one type of material from the following:mild steelstainless steel

special steelsother appropriate metal

6. Produce thermally cut components which meet all of the following quality and accuracy standards:● dimensional accuracy is within the tolerances specified on the drawing/specification or within +/- 1.5mm● angled cuts are within specification requirements (perpendicular/angularity)● cuts are clean and smooth with minimal drag lines

151




1. The specific safety precautions to be taken when working with thermal cutting equipment in a fabrication environment (general workshop and site safety, appropriate personal protective equipment, fire and explosion prevention, protecting other workers, safety in enclosed/confined spaces; fume control; accident procedure; statutory regulations)

2. The personal protective clothing and equipment that needs to be worn when working with fabrications and thermal cutting equipment (leather aprons and gloves, eye protection, safety helmets etc.)

3. The correct methods of moving or lifting plate materials and components4. The hazards associated with thermal cutting and how they can be minimised (naked flames, fumes and gases,

explosive gas mixtures, oxygen enrichment, spatter, hot metal, elevated working, enclosed spaces)5. Safe working practices and procedures for using thermal equipment in line with British Compressed Gas

Association (BCGA) codes of practice, to include setting up procedures, permit to work procedures and emergency shut down procedures

6. How to obtain the necessary drawings and thermal cutting specifications7. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing9. The thermal cutting process (basic principles of thermal cutting and related equipment; the various techniques and

their limitation; care of the equipment to ensure that it is safe and ready to use10. The various types of thermal cutting equipment available and typical applications11. The accessories that can be used with hand held thermal cutting equipment to aid cutting operations (such as

guides, trammels, templates) arrangements for attaching cutting aids to the equipment12. The gases used in thermal cutting, gas identification and colour codes, their particular characteristics and safety

procedures13. How to set up the thermal cutting equipment (connection of hoses, regulators and flash back arrestors, selection

of cutting torch and nozzle size in relationship to material thickness and operations performed)14. Preparations prior to cutting (checking connections for leaks, setting gas pressures, setting up the

material/workpiece, checking cleanliness of materials used)15. The holding methods that are used to aid thermal cutting and equipment that can be used16. Setting of operating conditions; flame control and the effects of mixtures and pressures associated with thermal

cutting.17. The correct procedure for lighting and extinguishing the flame, and the importance of following the procedure18. Procedures to be followed for cutting specific materials, and why these procedures must always be adhered to19. Material thermal cutting characteristics and material preparation requirements20. The terminology used in thermal cutting in relation to the operations being performed21. The problems that can occur with thermal cutting and how they can be avoided; causes of distortion during

thermal cutting and methods of controlling distortion22. The effects of oil, grease, scale or dirt on the cutting process23. The causes of cutting defects, how to recognise them and methods of correction and prevention24. Quality requirements of the type of work being undertaken25. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

152






Evidence TypeDateCheck equipment safe and fit for purpose (ALL)suitable equipment selectedregulators, valves & hoses securely connectedcorrect gas nozzle fittedflash back arrestor fittedappropriate gas pressurescorrect procedure for flamehoses safely routed and protectedsafe handling/storing of gas cylindersUse Thermal Cutting Methods (TWO)Oxy-fuel gasplasma gasportable track drivenPerform Thermal Cutting Operations to produce features (SIX)down-hand straight cuts freehandstraight cuts track guidedvertical cutsoverhead cutssquare/rectangular shapesirregular shapesangled cutsexternal curved contoursround holessquare holesrough cutting (demolition)bevelled edgeProduce Thermal Cuts in different forms (FOUR) (metal of 3mm and above and two different thickness)platebarrolled sectionspipe/tubestructuresProduce Cut Profiles (ONE)mild steelstainless steelspecial steelsother appropriate metalProduce Thermally Cut Components to Quality & Accuracy Standards (ALL)dimensional accuracy within tolerancesangled cuts within specification requirementscuts are clean & smooth


Candidate: Date:

Assessor: Date:

153

Unit 34 Cutting Materials using Saws and Abrasive Discs

Unit Summary

This unit identifies the competencies you need to cut and shape materials using saws and abrasive discs in accordance with approved procedures. You will be required to select the appropriate equipment for the operations to be carried out and check that it is in a safe and usable condition. In carrying out the cutting and shaping operations you will be expected to use both saws and abrasive discs to cut and shape the materials to the required accuracy and specification.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying cutting procedures when using saws and abrasive discs. You will understand the suitability of the cutting processes, and their applications, and will know about the characteristics of the materials and the appropriate processes and techniques in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the safety precautions required when carrying out the cutting and shaping activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

154





You must:1. Ensure that the equipment is fit for purpose and used safely by carrying out all of the following:

selecting the appropriate equipment/machine for the operation being performed checking the machine guards and safety devices are in position and function correctlychecking cutting discs/blades are in a serviceable condition (free from damage or chips; sharp)isolating the equipment from its power supply whilst changing blades or discs using the equipment safely and correctly and only for its intended purpose

2. Use two of the following types of cutting equipment:● machine saw● band saw

● hand held portable abrasive disc● radiac abrasive disc

3. Carry out all of the following cutting and shaping activities:● straight sawing● abrasive disc cutting● contour shaping using saws

4. Cut and shape components which contain all of the following features:● straight parallel cuts● square cuts

● curved contours● angled/mitred cuts

5. Produce components that comply with all of the following quality and accuracy standards:● dimensional accuracy is within specification tolerances● cuts are square and clean and free from excessive burrs● angled cuts are within specification requirements

6. Cut and shape three of the following forms of material:● flat plate● solid bar (square, round, hexagonal etc)● rolled sections (angle, channel, RSJ )● pipe/tube● rail section● non-ferrous materials

155




1. The specific safety precautions to be taken when working in a fabrication environment and when working with power operated saws and abrasive disc cutting machines (statutory regulations, risk assessment procedures and COSHH regulations)


3. Safe working practices and procedures to be observed when working with the machines including emergency shutdown procedures

4. The correct methods of moving or lifting heavy plate or rolled sections5. The hazards associated with fabrication work and cutting operations and how they can be minimised (such using

dangerous or badly maintained tools and equipment; airborne particles; hot metal; burrs and sharp edges)6. How to obtain the necessary drawings, specifications and work instructions7. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing9. How to interpret marking out conventions (cutting lines, centre lines, etc.)10. The range of machine saws available (such as power hacksaws, circular saws and band saws)11. The abrasive cutting equipment available to include hand held portable machines and bench type radiac cutting

machines12. The selection and fitting of abrasive cutting discs, cutting disc identification markings and how to identify the correct

type of disc for the type of material being cut13. Statutory regulations regarding the fitting and use of abrasive discs14. The material cutting characteristics and process considerations that need to be taken into account when cutting

materials15. The use and care of tools and equipment such as checking that trailing leads, plugs and sockets are in a safe and

usable condition16. The use of safety screens to protect other uses from flying sparks whilst using abrasive cutting discs17. The importance of ensuring that the machine guards are correctly fitted and positioned before using the equipment18. How to set and adjust power saws for the various operations being performed19. The importance of using tools or equipment only for the purpose intended; the care that is required when using the

tools or equipment; the proper way of preserving tools or equipment between operations20. The things that can go wrong when cutting materials using saws or abrasive discs, and how these can be avoided21. Inspection techniques that can be applied to check shape and dimensional accuracy is to specification and within

acceptable limits22. The extent of your own responsibility and who you should report to if you have problems that you cannot resolve23. Reporting lines and procedures, line supervision and technical experts

156






(if required)Evidence TypeDateCheck Equipment is fit for purpose (ALL)appropriate for tasksafety devices functioncutting discs serviceableisolate to change discsuse safely as intendedUse Cutting Equipment (TWO)machine sawband sawportable abrasive discradiac abrasive discCarry out cutting & shaping activities (ALL)straight sawingabrasive disc cuttingcontour shaping with sawsCut & shape components with features (ALL)straight parallel cutssquare cutscurved contoursangled/mitred cutsProduce Components to Quality & Accuracy Standards (ALL)dimensional accuracy within tolerancescuts square & clean and free from excessive burrsangled cuts within specification requirementsCut & Shape Material (THREE)flat platesolid bar (square, round hexagonal etc.)rolled sections (angle, channel, RSJ)pipe/tuberail sectionnon-ferrous materials


Candidate: Date:

Assessor: Date:

157

Unit 35 Bending and Forming Plate using Press Brakes or Bending Machines

Unit Summary

This unit identifies the competencies you need for bending and forming plate (of 3mm and above) for fabrications using power operated equipment such as press brakes, bending machines and power presses in accordance with approved procedures. You will be required to select the appropriate bending and forming equipment and set it up for the operations being performed. This will involve setting up appropriate backstops or plate positioning devices, fitting of appropriate bending tools/formers taking account of material thickness and the accuracy required to be achieved. You will also need to ensure that all the required safety devices are operating correctly and that the machine guards are in place and correctly adjusted.

Materials to be bent and formed may include ferrous and non-ferrous, and tasks will include producing bends of various angles, producing box and tray sections, setting plate ends for rolling operations, and producing curved sections. This will call for care in selecting the right tools so as to avoid damage to the tools and danger to oneself.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying the power pressing procedures required. You will understand the processes, and will know about the equipment and its application, the tooling and materials, in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will need to understand the safety precautions required when working with power operated presses and the safeguards necessary for undertaking the activities safely and correctly. You will be required to demonstrate safe working practices and procedures throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

158



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Confirm that the equipment is set up correctly and is ready for use c. Manipulate the machine controls safely and correctly in line with operational proceduresd. Produce components to the required specificatione. Carry out quality sampling checks at suitable intervalsf. Deal promptly and effectively with problems within your control and report those that cannot be solvedg. Shut down the equipment to a safe condition on conclusion of the machining activities


You must:1. Confirm that the equipment is safe to use and fit for purpose by carrying out all of the following checks:

the appropriate machine is selected for the operation being performed the machine guards and safety devices are in position and function correctlyforming tools are appropriate and in a serviceable condition (secure, correct shape, free from damage)machine settings are suitable for the material thickness and operations to be performed

2. Operate one of the following types of power operated bending equipment:press brakespowered bending machinepower press

3. Perform operations that produce all of the following :bends at 90°bends of various angles using various bend radiiset plate endsbox square and rectangular sectionscurved plates

4. Bend and form metal plate of 3mm or more thickness for one appropriate material and two thicknesses:black mild-steelstainless steelaluminiumspecial metals

5. Produce components that conform to all of the following quality and accuracy standards:bend position and dimensional accuracy is within the specification tolerancesthe form or sharpness of the bend conforms to best practice and or specification without deformation or crackingthe bend conforms to the required shape/geometry (to the template profile)

159




1. The specific safety precautions to be taken when working with power operated bending and forming equipment such as press brakes or/and bending machines in a fabrication environment (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)

2. The correct protective clothing, and handling precautions to be taken, when working with heavy platework3. The correct methods of moving or lifting sheet or plate materials4. The hazards associated with power operated bending and forming processes, and how they can be minimised (such

as handling heavy sheet materials and components; operating moving equipment; using faulty or badly maintained tools and equipment)

5. The safe working practices and procedures required for operating power operated bending machines6. How to obtain the necessary drawings and bending specifications7. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing9. Marking out conventions applicable to the bending process (centre lines; bending lines)10. The various types of power operated bending machines that are used and typical applications11. How to prepare and set-up the machine for a range of different bends (angled bends; box sections; plate edge

setting; curved sections)12. The types of bending tools that are used for the various operations and how they are secured and set to the

machines tool holding device13. Ways of limiting distortion, marking and creases in the finished workpiece14. The preparations that need to be carried out on the materials prior to bending them15. The basic characteristics of the materials with regard to the bending operations undertaken16. Why some materials may require a heating process before bending begins17. The need to take care of the bending tools and equipment; how to recognise faulty or damaged forming tools; how

bending and forming tools should be stored18. The sort of problems that can occur with the bending and forming activities, and how they can be avoided19. The organisational quality control procedures that are used, and how to recognise defects in the bends that you

produce20. How to make dimensional and forming inspection checks, and the tools and equipment that can be used21. Accuracy and limitations of processes22. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

160






(if required)Evidence TypeDateCheck Equipment (ALL)appropriate for tasksafety devices functionappropriate and serviceable forming toolssuitable machine settingsOperate Power Operated Bending Equipment (ONE)press brakespowered bending machinepower pressProduce the following (ALL)bends of 90ºbends of various angles using various bend radiiset plate endsbox square & rectangular sectionscurved platesBend and Form Metal Plate of 3mm or more Thickness (ONE Material – TWO Thicknesses)black mild steelstainless steelaluminiumspecial metalsProduce Components to Quality & Accuracy Standards (ALL)bend position/dimensional accuracy within tolerancesform/sharpness of bend conforms to best practicebend conforms to required shape/geometry


Candidate: Date:

Assessor: Date:

161

Unit 36 Forming Platework using Power Rolling Machines

Unit Summary

This unit identifies the competencies you need to bend and form plate for fabrications in accordance with approved procedures using power operated pinch or pyramid rolls which may be hand adjusted or console controlled. You will be required to select the most appropriate type and size of power rolling machine based on the operations to be performed and the thickness and size of the material to be rolled. Setting up the rolls will involve setting and adjusting the gap between feed and forming rolls to suit plate thickness, positioning side roller and adjusting to suit required radius, checking and setting parallelism of rollers and applying suitable pressure to rollers throughout the forming operation.

You will be expected to carry out or direct the rolling operations for their effective use to form the material to the required profile without flats or deformities. You will also need ensure that all the required safety devices are operating correctly and that the machine guards are in place and correctly adjusted. Materials to be rolled may include ferrous and non-ferrous and will include operations such as rolling cylinders and cones, producing curved sections, counter curved sections, pipe sections and straightening plate. This will call for care in selecting the right machines so as to avoid damage to the tools and danger to oneself.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying the power rolling procedures required. You will understand the process and its application, and will know about the equipment and materials in adequate depth to provide a sound basis for setting up the equipment, correcting faults and carrying out the activities to the required specification. You will need to understand the safety precautions required when working with power rolls and the safeguards necessary for undertaking the activities safely and correctly. You will be required to demonstrate safe working practices and procedures throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

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● the rolls are appropriate for the material used and operations being performed● the machine guards and safety devices are in position and operating correctly● rolls are appropriate for the operation and in a serviceable condition (suitable diameter; free from damage)● roll settings are suitable for the material thickness and operations to be performed ● equipment for supporting the plate at the start of the rolling operations is in place

2. Use one of the following types of power rolling machine:● powered rolls hand adjusted● powered rolls console adjusted● different roll sizes (diameter) and power

3. Perform rolling operations that produce five of the following:● cylinders● cones● segments of a cylindrical tank● curved section or sector of an otherwise flat plate● counter curved sections● pipe sections● flattening or straightening plate

4. Carry out rolling operations on one type of material from the following:● carbon steel● stainless steel● aluminium● special metals

5. Produce rolled components that conform to all of the following quality and accuracy standards:● dimensional accuracy is within the specification tolerances● the rolled section conforms to best practice and or specification without deformation or cracking● the component conforms to the required shape/geometry (to the template profile)

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1. The specific safety precautions to be taken when working with rolling machines in a fabrication environment (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)

2. Checks that need to be carried out to ensure that the power rolls are safe and in a fit condition to use3. The personal protective clothing and equipment that needs to be worn when working with heavy platework (gloves,

eye protection, safety helmets etc.)4. The handling precautions and correct methods of moving or lifting sheet or plate materials5. The hazards associated with fabrication work and how they can be minimised, such as handling sheet/fabricated

components, using hot metal techniques, using dangerous or badly maintained tools and equipment, moving parts of power rolling machines

6. How to obtain the necessary drawings, specifications and job instructions.)7. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing9. Marking out conventions used in platework and how to recognise the bending, forming and cutting lines10. The basic principle of operation of the power rolling machine used and the type of work it can perform11. How to select an appropriate machine for the operations to be performed (roll size; power of machine)12. How to set up the machine to produce the required form (cylinders, cones, curved sections, straightening plates13. Techniques of rolling (including pre-setting plate edges, adjusting pressure throughout the rolling operations,

checking component for parallelism or form throughout the operations)14. How to release the rolls and remove the workpiece when rolling cylindrical and conical sections15. Ways of limiting distortion, marking, creases and flats in curved sections16. How the materials need to be prepared prior to rolling, and the effects of raw material scale or burrs on the finished

article17. Material characteristics with regard to forming using rolling machines18. The care and maintenance procedures that need to be observed to ensure the machines are in a serviceable

condition19. The organisational quality control procedures and how to recognise rolling defects20. The inspection checks that need to be carried out and the tools and equipment that are used21. The accuracy that can be achieved by rolling and limitations of the rolling processes22. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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(if required)Evidence TypeDateCheck Equipment (ALL)rolls are appropriatemachine guards functionrolls are serviceableroll settings suitableplate supporting equipment in placeUse Power Rolling Machines (ONE)powered rolls hand adjustedpowered rolls consoled adjusteddifferent roll sizes & powerPerform rolling operation to produce the following (FIVE)cylindersconessegments of a cylindrical tankcurved sectioncounter curved sectionpipe sectionsflattening or straightening plateCarry out rolling operations on material (ONE type)carbon steelstainless steelaluminiumspecial metalsProduce rolled components to quality & accuracy standards (ALL)dimensional accuracy within tolerancesrolled section to best practicecomponent is required shape/geometry (to template profile)


Candidate: Date:

Assessor: Date:

165

Unit 37 Producing and Finishing Holes using Drilling Machines

Unit Summary

This unit identifies the competencies you need to produce holes using drilling machines in sheet, plate, rolled section or pipe in accordance with approved procedures. You will be required to select the appropriate drilling equipment to use based on the operations to be performed and the size of the component worked on. You will be expected to use appropriate workholding methods and techniques to secure the workpiece for the drilling operations and this will include the use of jigs, clamps, machine vice and other appropriate holding devices. In drilling the holes you will need to accurately position the drill bits and use appropriate speeds and feeds to drill and finish the holes to the required specification. Drilling and finishing operations will include through holes, blind holes, counter-bored holes, countersunk holes, spot facing, reaming and tapping.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying the drilling and finishing procedures. You will understand the drilling equipment used and its application, together with the material characteristics and the appropriate tooling for carrying out the drilling and finishing process. You will know about the basic principles and requirements of securing the work piece prior to carrying out the process in adequate depth to provide a sound basis for carrying out the drilling activities, correcting faults and ensuring the work output meets the required specification. You will understand the safety precautions required when carrying out the drilling and finishing activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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You must:1. Ensure that the equipment is fit for purpose and used safely by carrying out all of the following:

selecting the appropriate drilling equipment/machine for the operation being performed checking the machine guards and safety devices are in position and function correctlychecking drill bits and cutting tools are in a serviceable condition (free from damage or chips; sharp)isolating the equipment from its power supply whilst changing drill bits securely clamping/restraining the components during the drilling operations

● using the equipment safely and correctly and only for its intended purpose

2. Use two of the following drilling machines: ● hand held drilling machine ● pillar/bench drill radial arm drill

3. Use two of the following workholding devices:● jigs/fixtures ● machine vice clamps

4. Carry out five of the following drilling and finishing operations:● drilling through holes● drilling holes to a depth● counter-boring holes● countersinking holes ● reaming holes● tapered reaming

● centre drilling● spot facing ● trepanning holes● tapping holes● jig or template drilling● component alignment drilling

5. Produce drilled and finished components which meet all of the following quality and accuracy standards as is applicable to the process:

dimensional and positional accuracy is within specification tolerancesdrilled holes are correctly formed and free from excessive tool marksreamed holes are of the correct fit and have a smooth surface finish free from tool markstapped holes are of the correct type, threads are correctly formed and have a good fitcounter-bores, countersinks and spot facings meet job requirements

6. Produce drilled holes in three of the following material types:● ferrous sheet metal● stainless steel sheet metal● non-ferrous sheet metal● ferrous plate or components

● stainless steel plate or components● non-ferrous plate or components● non-metallic materials● composite materials

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1. The specific safety precautions to be taken when working in a fabrication environment and when carrying out drilling and finishing operations on materials used in fabricating (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)


3. The correct methods of moving or lifting materials4. The safe working practices and procedures to be used when using portable power operated tools and drilling

machines, including emergency stop procedures for the machines5. The hazards associated with drilling work and how they can be minimised (such as using dangerous or badly

maintained tools and equipment; insecure or poorly clamped workpieces; airborne metal particles; sharp edges and splinters)

6. How to obtain the necessary drawings, specifications and work instructions7. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing9. How to interpret marking out conventions (cutting lines; centre lines, etc.)10. The various types and application of drilling machines (including portable power tools, bench and pedestal machines

and radial arm machines)11. The range of drilling and hole finishing tools available (including twist drills, reamers, counter-bore tools, countersink

tools, spot facing tools, taps)12. The methods of holding and securing the drills and finishing tools into the machine spindle (chucks, taper shank

sleeves, collet chucks)13. The methods of holding and securing workpieces for drilling (including jigs and fixtures, machine vices, clamps and

restraining devices)14. Methods used to align the drill with the workpiece and the use of centre drills and pilot drills15. How to check that the drill hole is in the correct position before drilling to the full diameter, and how to correct a drill

that has been started off centre16. The selection of speeds and feeds for drilling, reaming and finishing operations17. The selection of cutting fluids and compounds for drilling, reaming and tapping of holes18. Setting and adjusting tools and equipment, use of depth stops etc19. The material characteristics and process considerations that need to be taken into account when carrying out drilling

operations20. The care and control of tools and equipment; checking portable power tool leads, plugs and sockets are in a safe and

usable condition21. The importance of using tools or equipment only for the purpose intended; the care that is required when using the

tools or equipment; the proper way of preserving tools or equipment between operations22. The things that can go wrong with drilling operations, and how these can be avoided23. Inspection techniques that can be applied to check the dimensional accuracy and finish is to specification and within


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Evidence TypeDateCheck Equipment (ALL)appropriate drilling equipmentsafety devices functiondrill bits etc serviceableisolate equipment while changing drill bitssecurely clamping during drillinguse equipment safelyUse Drilling Machines (TWO)hand heldpillar/bench drillradial arm drillUse Workholding Devices (TWO)jigs/fixturesmachine viceclampsCarry Out Drilling & Filling Operations (FIVE)drilling through holesdrilling holes to a depthcounter-boring holescountersinking holesreaming holestapered reamingcentre drillingspot facingtrepanning holestapping holesjig or template drillingcomponent alignment drillingProduce Drilled & Finished Components to Quality & Accuracy Standards (ALL as applicable)dimensional & positional accuracydrilled holes correctly formedreamed holes correct fit and smooth surface finishtapped holes correct typecounter-bores/countersinks spot facings to requirementsProduce Drilled Holes In Material Types (THREE)ferrous sheet metalstainless steel sheet metalnon-ferrous sheet metalferrous platestainless steel platenon-ferrous platenon-metallic materialscomposite materials


Candidate: Date:

Assessor: Date:

169

Unit 38 Producing Platework Assemblies

Unit Summary

This unit identifies the competencies you need to produce heavy platework (3mm thick plate and above) assemblies in accordance with approved procedures. You will be required to correctly interpret specifications and drawings, bring together and assemble and join, in the right order, plate work components and sections in order to construct completed fabricated assemblies or sub-assemblies such as square and rectangular plate structures, covers and side plates, tanks, pressure vessels, cylindrical sections, conical sections, reduction pieces, simple and complex boiler seatings etc. You will be required lay out and secure the various component parts of the structure using mechanical fastenings, temporary tack welding, flanged and mechanically fastened or adhesive bonding techniques in the correct order and ensuring they are assembled in a manner that is fit for purpose.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying platework fabrication techniques and their assembly and fixing procedures. You will understand the techniques used and the requirements of the manufacturing and assembling procedures, and their application. You will know about the methods of assembling the components of the required strength, that are fit for purpose, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with heavy platework components and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant instructions, assembly drawings and any other specificationsc. Ensure that the specified components are available and that they are in a usable conditiond. Use the appropriate methods and techniques to assemble the components in their correct positionse. Secure the components using the specified connectors and securing devicesf. Check the completed assembly to ensure that all operations have been completed and the finished assembly

meets the required specificationg. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must: 1. Carry out all of the following during the platework assembly operations:

correctly prepare and set-up the components and faces to be joineduse the correct datum facesuse the specified or appropriate fixing methodcorrectly align the components and faces to be joinedassemble/fabricate the platework components in the correct order or mannerproduce an assembly which meets the required specification

2. Produce five of the following platework assemblies:framestankscovers and side platessquare, rectangular and box sections cylindrical conical

reduction piecestransformerssegmented bendssteel and composite material assembliessimple or complicated seatings (tank or boiler seats)

3. Use four of the following types of components in the assemblies produced: plates or coverspre-fabricated square/rectangular componentspre-fabricated cylindrical/conical componentsbrackets

flangespipesrolled section components (angle, channel or tee

section)

4. Assemble platework components using two of the following methods: ● temporary tack welding● riveting (hot or cold)● flanged and mechanically fastened (nuts and bolts)● adhesive bonding

5. Produce platework assemblies which meet all of the following quality and accuracy standards: ● all components are correctly assembled and aligned in accordance with the specification● overall dimensions are within specification tolerances● assemblies meet appropriate geometric tolerances (square, straight, angles free from twists)● where appropriate, pitch of erection holes meet specification requirements● completed assemblies have secure and firm joints, and are clean and free from burrs or flash

171




1. The specific safety precautions to be taken when working in a fabrication environment and when producing platework assemblies (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)


3. Safe working practices and procedures needed for producing platework assemblies4. The correct methods of moving or lifting bulky and heavy fabrications5. The hazards associated with platework fabrication and assembly work and how they can be minimised (such using

dangerous or badly maintained tools and equipment; lifting and handling long and heavy components; cuts, slips trips and falls)



points and system of tolerancing9. How to interpret marking out conventions (cutting lines; centre lines, etc.)10. The preparations that need to be carried out on the components prior to assembling them11. The various methods of securing the assembled components (nuts and bolts; tack welding methods and

techniques; hot and cold riveting; adhesive bonding of components)12. How to set up and align the various components and the tools and equipment that is used13. Methods of temporarily holding the joints together to aid the assembly activities (clamps, rivet clamps, jacks and

wedges)14. The use and care of tools and equipment, and control procedures15. The importance of using tools or equipment only for the purpose intended; the care that is required when using

the tools or equipment; the proper way of preserving tools or equipment between operations16. The sort of things that can go wrong when producing platework assemblies, and how these can be avoided17. Inspection techniques that can be applied to check shape (including straightness) and dimensional accuracy is to


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Evidence TypeDateCarry Out During Platework Assembly Operations (ALL)correctly prepare & set upuse correct datum facesuse specified fixing methodcorrectly align componentsassemble/fabricate components in orderproduce assembly to required specificationProduce Platework Assemblies (FIVE)framestankscovers & side platessquare, rectangular & box sectionscylindricalconicalreduction piecestransformerssegmented bendssteel & composite material assembliessimple/complicated seatingsUse Types of Components (FOUR)plates or coverspre-fab square/rectangularpre-fab cylindrical/conicalbracketsflangespipesrolled section components (angle, channel or tee section)Assemble Platework Components (TWO)temporary tack weldingriveting (hot or cold)flanged/mechanically fastened (nuts & bolts)adhesive bondingProduce Platework Assemblies to Quality & Accuracy Standards (ALL)correctly assembleddimensions within tolerancesmeet appropriate geometrictolerancespitch of erection holes to specificationsecure & firm joints, clean and free from burrs or flash


Candidate: Date:

Assessor: Date:

173

Unit 39 Slinging, Lifting and Moving Materials and Components

Unit Summary

This unit identifies the competencies you need to move loads by slinging and lifting in accordance with approved procedures. You will be required to use correctly specified items of lifting gear, which will include hand, and/or power operated cranes and winches, and associated lifting accessories. You must check that the lifting equipment is within current authorisation dates, is undamaged and within the permitted safe working load. You will be expected to correctly estimate the weight of the load to be moved and attach the appropriate slings to suitable or designated lifting points on the load in order to achieve a safe and balanced lift. You must check the area that the load will move through to ensure that it is free from obstructions and is safe for the load to be moved. You will also be expected to able to give the correct hand and verbal signals during the lifting activities.

Your responsibilities will require you to comply with organisational policy and procedures for the slinging, signalling and lifting activities undertaken and to report any problems with the slinging and lifting equipment or the lifting activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and the safety and integrity of the materials being moved.

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying slinging, signalling and lifting procedures. You will understand the slinging, signalling and lifting techniques used, and their application, and will know about the lifting equipment and accessories for lifting, in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will need to understand the safety precautions required when slinging and lifting components and the safeguards that are necessary for undertaking the activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

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You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Position the moving equipment so that the weight of the load is evenly distributed c. Attach the appropriate handling equipment securely to the load, using approved methods to eliminate slippaged. Confirm that the load is secure before movinge. Move the load over the selected, suitable routef. Position and release the load safely in its intended final location


You must:7. Ensure that the equipment to be used is suitable for the components being lifted and in a safe and usable

condition by checking all of the following: ● equipment is certified and is compliant, within current test dates● all lifting equipment registers are up to date ● all slings are free from obvious defects ● the lifting equipment selected is suitable and has a sufficient SWL for the application● the identification number and SWL are clearly marked on the equipment selected ● the equipment selected is suitable for the environment of operation

2. Use two of the following lifting and moving methods and technique:● crane● winch● powered lifting equipment

● lifting appliances● pulling appliances● multi sheaved block combinations

● hand operated lifting equipment

● jacks, skates & trolleys

3. Use two of the following slinging methods: ● single leg slings ● two-leg slings ● three-and-four leg slings

4. Move two of the following types of loads:● sheet materials● pipes, bars, joists etc. (single and in bundles)● fragile ● hot/radiant

● components with evenly distributed weight● components with unevenly distributed weight● awkward shaped● corrosive/chemical

5. Move loads safely and correctly that are re-positioned in two of the following positions:● to differing elevations● as part of an assembly ● through complex rigging operations

● along the same elevation● turn a load

6. Calculate loads in three of the following sheave block combinations:● single● two singles● a double and single

● two doubles● a treble and double

7. Find the weight of the materials/loads to be moved using all of the following as is applicable:● check against documentation● calculation from drawings

● by estimation● by converting metric-imperial

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1. The specific safety precautions to be taken when slinging and lifting loads and the need for ensuring load security (general workshop and site safety, appropriate personal protective equipment, protecting other workers during the lifting operations; accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)

2. The hazards associated with slinging and lifting of loads, and how they can be minimised3. An understanding of ACOP for safe use of lifting equipment and Lifting Operation and Lifting Equipment

Regulations (LOLER)4. The specific requirements for the marking of lifting equipment and the specific method used in the organisation in

which you are working5. The range of equipment that is to be used for the lifting operations such as hand and power operated cranes,

winches pulling equipment6. The lifting equipment accessories that are to be used (such as slings, chains, wire ropes, eye bolts)7. Checks that should be made on the lifting equipment prior to use, and things that you should look for8. How to carry out in-service inspections of the equipment and what to do should any defective equipment be

identified9. How to determine the approximate weight of the load to be moved10. Factors which affect the selection of the lifting equipment and lifting accessories (such as weight, type of load,

operating environment)11. How to calculate loads on winches/lead ropes on multi-sheaved rigs 12. How to identify the included angle when using multi-leg slings13. How to check that the lifting equipment is capable of lifting the load to be moved14. How to determine the centre of gravity of the load and determine suitable slinging and lifting points15. How to plan and prepare a route for moving loads and the things that you will need to take into account16. The specific requirements for the organisation of lifting operations17. Signalling techniques used to communicate with crane drivers to include both hand signals and verbal commands18. How lifting equipment should be stored, handled and maintained.19. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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Evidence TypeDateCheck Equipment (ALL)certified & compliantregisters are up to dateslings free from defectis suitable & has sufficient SWLID No & SWL clearly markedsuitable for environmentUse Lifting & Moving Methods & Techniques (TWO)cranewinchpowered lifting equipmentlifting appliancespulling appliancesmulti sheaved blockhand operatedjacks, skates & trolleysUse Slinging Methods (TWO)single leg slingstwo leg slingsthree & four leg slingsMove Types of Load (TWO)sheet materialspipes, bars, joists etcfragilehot/radiantevenly distributed weightunevenly distributed weightawkward shapedcorrosive/chemicalMove Loads Safely & Correctly that are Repositioned (TWO)to differing elevationsas part of an assemblythrough complex rigging operationsalong the same elevationturn a loadCalculate Loads in Sheave Block Combinations (THREE)singletwo singlesa double & a singletwo doublesa treble & a doubleFind Weight of Materials/Load to be moved (ALL)check against documentationcalculation from drawingsby estimationby converting metric-imperial


Candidate: Date:

Assessor: Date:

177

Unit 40 Forming Structural Sections using Machines

Unit Summary

This unit identifies the competencies you need to bend and form rolled sectional material using presses, bending machines and power rolls in accordance with approved procedures. You will be required to select the most appropriate type and size of machine, based on the operations to be performed and the type and section of material being used. In producing the components you will be required to operate the equipment safely and correctly, or direct operations for its effective use to form the material to the required profile without flats or deformities. The operations to be performed will include bending beams, curved beams, circular sections, counter curved sections, twisted beams and straightening of beams.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to forming structural section material using power machine procedures. You will understand the equipment being used, the forming principles, and their application, and will know about the processes involved and their limitations in sufficient depth to provide a sound basis for carrying out the activities, correcting any faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the forming machines and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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the appropriate machine is selected for the operation being performed the machine guards and safety devices are in position and function correctlyforming tools are appropriate and in a serviceable condition (secure, correct shape, free from damage)machine settings are suitable for the material thickness and operations to be performed

2. Use one of the following types of machines:● power press● hammer machines● section bending machine● powered rolls● special purpose machines

3. Produce formed structural sections which contain four of the following features:right angled bendsangular bendscurved beamscircular sectionscounter curved sections twisted sectionstraightening

4. Bend and form structural components made from three of the following forms of material: ● rolled steel joists (RSJ)● angle section● channel section

● structural tubes/pipes● extrusions● other specific components

5. Produce structural components which meet all of the following quality and accuracy standards:bend position and dimensional accuracy is within the specification tolerancesthe form or sharpness of the bend conforms to best practice and/or specification without deformation or crackingthe bend conforms to the required shape/geometry (to the template profile)

179




1. The specific safety precautions to be taken when working with power operated bending and forming equipment such as presses, bending machines and rolling machines in a fabrication environment

2. The general workshop and site safety requirements, statutory regulations; risk assessment procedures and COSHH regulations

3. The correct protective clothing and handling precautions to be taken when working with structural section materials (gloves, eye protection, safety helmets, ear protection)

4. The handling precautions and correct methods of moving or lifting heavy structural section (RSJs, etc.)5. The hazards associated with power operated bending processes and how they can be minimised (such as handling

heavy structural materials and components; operating moving equipment; using faulty or badly maintained tools and equipment)

6. The safe working practices and procedures required for operating power operated bending and forming machines7. How to obtain the necessary structural drawings and bending procedure specifications8. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing10. Marking out conventions applicable to the bending process (centre lines; bending lines)11. The various types of power operated bending machines that are used for structural section materials, and typical

applications12. How to prepare and set up the machine for a range of different bends (angled bends, curved sections, twisted

sections and straightening of sections)13. The types of bending tools that are used for the various operations and how they are secured and set to the

machine’s tool holding device14. Ways of limiting distortion, marking and creases in the finished workpiece15. The preparations that need to be carried out on the materials prior to bending them16. The basic characteristics of the materials with regard to the bending operations undertaken17. Why some materials may require a heating process before bending begins18. The need to take care of the bending tools and equipment; how to recognise faulty or damaged forming tools; how

bending and forming tools should be stored19. The problems that can occur with the bending and forming activities, and how they can be avoided20. The organisational quality control procedures that are used, and how to recognise defects in the bends that you

produce21. How to make dimensional and forming inspection checks, and the tools and equipment that can be used22. Accuracy and limitations of processes23. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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(if required)Evidence TypeDateCheck Equipment (ALL)appropriate machinemachine guards in position safety devices functionforming tools appropriatemachine settings suitableUse Machines (ONE)power presshammer machinessection bending machinepowered rollsspecial purpose machinesProduce Formed Structural Sections Containing Features (FOUR)right angled bendsangular bendscurved beamscircular sectionscounter curved sectionstwisted sectionstraighteningBend & Form Structural Components made from Material (THREE forms)rolled steel joists (RSJ)angle sectionchannel sectionstructural tubes/pipesextrusionsother specific componentsProduce Structural Components to Quality & Accuracy Standards (ALL)bend position and dimensional accuracy within tolerancesform or sharpness of bend to best practicebend to required shape/geometry


Candidate: Date:

Assessor: Date:

181

Unit 41 Producing Structural Steel Ancillary Components

Unit Summary

This unit identifies the competencies you need to cut and shape plate and section materials to produce structural steel components such as fish plates, gussets, brackets, support pads and bed plates in accordance with approved procedures. You will be required to interpret drawings, mark out simple shapes and hole positions, cut out and shape plate and sections, drill and prepare structural components ready for the assembly of major structural components.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying structural steel shaping and fabrication procedures. You will understand the fabrication processes, the equipment and its application, and will know about the materials and how to produce structural component parts in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the safety precautions required when working with fabrication tools and machinery. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

182



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow relevant specifications for the component to be produced c. Obtain the appropriate tools and equipment for the shaping operations and check they are in a safe and

usable conditiond. Shape the materials using appropriate methods and techniquese. Check that all the required shaping operations have been completed to the required specificationf. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Ensure that you carry out all of the following during the manufacturing activities:

use the tools and equipment safely and correctly and only for its intended purposemark out the components accurately using recognised conventionsset up and hold the components firmly during the shaping operationsproduce the components to the correct size and shape ensure all holes are of the correct size and are at the correct centres for fixings

2. Cut and shape material to the marked out shape using four of the following methods:shearing/croppingsawingburningdrillingbending

3. Produce structural steel components to include three of the following:● fish tails● gussets● brackets● support pads

● flanges● bed plates● tie bars● stiffening plates

4. Produce structural steel components from both of the following:● steel plate (3mm or more thickness)● rolled steel section

5. Produce cut and shaped structural steel components which meet all the following quality and accuracy standards:

company/customer standards requirements dimensionally accurate (to drawing or specifications)

● free from distortion● free from sharp edges, slivers or burrs

183




1. The specific safety precautions to be taken when working in a fabrication environment and when cutting plate or rolled sections to shape (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)


3. The correct methods of moving or lifting plate and rolled section materials4. Safe working practices and procedures that need to be observed when using manual and power operated tools5. The hazards associated with fabrication work and how they can be minimised (such as using dangerous or badly

maintained tools and equipment; operating shearing machines; handling plate and fabricated components; using hot metal techniques)

6. The procedures for obtaining the necessary drawings and specifications and how to check that they are the latest issue

7. How to extract information from engineering drawings and related specifications to include symbols and conventions to appropriate BS or ISO standards in relation to work undertaken

8. How to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing

9. How to produce a three dimensional shape from the two dimensional material10. The preparations that need to be carried out on the material prior to marking out to enhance clarity, accuracy and

safety11. Principles of marking out and the tools and equipment that are used12. Use of marking out conventions (datums, cutting detail, centre lines etc.)13. How to calculate and mark out true lengths, bend allowances and circumferences14. Ways of laying out the shapes/patterns to maximise the use of plate or sheet materials15. Marking out and transferring information from templates and how to transfer information to the underside of the

plate16. The tools and techniques available for cutting and shaping plate and section materials (such as shearing machines,

saws, burning equipment, drills, presses and rolling machines etc.)17. The material characteristics and process considerations that need to be taken into account when cutting and shaping

plate and section materials18. The use and care of tools and equipment including checks that need to be made to ensure that the tools are fit for

purpose (cutting tools are sharp and undamaged; plugs and cables secure and free from damage; machine guards or safety devices operating correctly)

19. How to produce weld preparations and the type of preparations required for different joints and material thicknesses20. Setting and adjusting tools and equipment; use of back stops on guillotines etc21. The importance of using tools or equipment only for the purpose intended; the care that is required when using the

tools or equipment; the proper way of preserving tools or equipment between operations22. Safety and control procedures for shaping plate and rolled steel sections23. The sort of things that can go wrong with cutting and shaping plate and section materials, and how these can be

avoided24. The use of machine guards and safety protection equipment25. Inspection techniques that can be applied to check shape and dimensional accuracy is to specification and within


184






(if required)Evidence TypeDateCarry out during manufacturing activities (ALL)use tools safelymark out accuratelyset up & hold firmly correct size & shapeensure holes correct sizeCut & shape material to marked out shape (FOUR)shearing/croppingsawingburningdrillingbendingProduce structural steel components to include (THREE)fish tailsgussetsbracketssupport padsflangesbed platestie barsstiffening platesProduce structural steel components from (BOTH)steel plate ( 3mm thick)rolled steel sectionProduce cut & shaped structural steel components to quality & accuracy standards (ALL)company/customer standardsdimensionally accuratefree from distortionfree from sharp edges, slivers or burrs


Candidate: Date:

Assessor: Date:

185

Unit 42 Producing Major Structural Components/Sub-assemblies

Unit Summary

This unit identifies the competencies you need to produce major structural components such as beams, columns, portals, roof trusses, lattice braced framework, castellated beams using sections and fabricated components to specification and in accordance with approved procedures. You will be required lay out and secure parts of the structure for welding or fixing using mechanical fastenings in the correct order, and ensuring they are assembled in a manner that is fit for purpose.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to producing structural components, their assembly and fixing procedures. You will understand the techniques used and the requirements of the manufacturing and assembling procedures and their application. You will know about the methods of producing structural components of the required strength, that are fit for purpose, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with structural components and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

186






You must: 1. Carry out all of the following during the structural assembly operations:

correctly prepare and set up the components and faces to be joineduse the correct datum facesuse the specified or appropriate fixing methodcorrectly align the components and faces to be joinedassemble/fabricate the structural components in the correct order or mannerproduce an assembly which meets the required specification

2. Produce three of the following structural assemblies:● beams● columns● portals● roof trusses● lattice braced frameworks ● castellated beams

● flanged components● bulk heads● staircases● safety cages● hand rails● seatings

3. Use four of the following types of components in the assemblies produced: ● structural sections● fabricated beams ● fish plates● brackets

● support plates● bed plates● guards, hand rails● platforms and ladders

4. Assemble the components using two of the following methods: ● bolted● riveted

● temporary tack welded● adhesive bonding

5. Produce assemblies which meet all of the following quality and accuracy standards: ● all components are correctly assembled and aligned in accordance with the specification● overall dimensions are within specification tolerances● assemblies meet appropriate geometric tolerances (square, straight, angles free from twists)● where appropriate, pitch of erection holes meets specification requirements● completed assemblies are secure, clean and free from burrs or flash

187




1. The specific safety precautions to be taken when working in a fabrication environment and when producing structural components (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)


3. Safe working practices and procedures needed for producing structural components4. The correct methods of moving or lifting heavy fabrications or rolled steel sections5. The hazards associated with fabrication work and structural component operations and how they can be minimised

(such using dangerous or badly maintained tools and equipment, lifting and handling log and heavy components, slips trips and falls)



points and system of tolerancing9. How to interpret marking out conventions; cutting lines, centre lines, etc10. The preparations that need to be carried out on the components prior to assembling them11. The various methods of securing the assembled components (the range of nuts and bolts used including close

tolerance location bolts; tack welding methods and techniques; adhesive bonding of components)12. How to set up and align the various components and the tools and equipment that is used13. The material cutting characteristics and process considerations that need to be taken into account when producing

structural components14. The use and care of tools and equipment, and control procedures15. The importance of using tools or equipment only for the purpose intended; the care that is required when using the

tools or equipment; the proper way of preserving tools or equipment between operations16. The things that can go wrong when producing structural components/assemblies, and how these can be avoided17. Guards and safety protection equipment18. Inspection techniques that can be applied to check shape (including straightness) and dimensional accuracy are to


188






Evidence TypeDateCarry out during structural assembly operations (ALL)correctly prepare & set up componentsuse correct datum facesuse specified fixing methodcorrectly align components and facesassemble in correct orderproduce assembly to required specificationProduce Structural Assemblies (THREE)beamscolumnsportalsroof trusseslattice braced frameworkscastellated beamsflanged componentsbulkheadsstair casessafety cageshand railsseatingsUse Types of Components in Assemblies (FOUR)structural sectionsfabricated beamsfish platesbracketssupport platesbed platesguards/hand railsplatforms & laddersAssemble Components (TWO methods)boltedrivetedtemporary tack weldedadhesive bondedProduce Assemblies to Quality & Accuracy Standards (ALL)correctly assembleddimensions within tolerancesappropriate geometric tolerancespitch of erection holes to specification requirementsassemblies secure & clean


Candidate: Date:

Assessor: Date:

189

Unit 43 Erecting Structural Steelwork

Unit Summary

This unit identifies the competencies you need to erect and assemble pre-fabricated structural steelwork such as support structures, building frames and roofs, mezzanine platforms, rigs, access staging and platforms to specification and in accordance with approved procedures. You will be required to determine, from the drawings and specifications, what has to be done and how best it can be achieved safely, within the time frames allowed and appropriate to the environment and site conditions.

Your responsibilities will require you to comply with organisational policy and procedures for the safe erection of the structure and the associated assembly activities to be undertaken and to report any problems with the component parts, equipment or construction activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying structural assembly and erection procedures. You will understand the principles and processes associated with the erection and assembly of the structures, and their application. You will know about the ways of handling structural steelwork, the means of fixing them in position as well as the care and use of the tools and equipment in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the finished structure is produced to the required specification. You will understand the safety precautions required when working at height and with structural components and their associated tools and equipment. You will be required todemonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

190



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Determine what has to be done and how this will be achievedc. Select the appropriate construction elements and check that they are in a usable conditiond. Position and secure the construction elements in line with the specificatione. Securely fix any necessary temporary support facilitiesf. Take appropriate measures to protect the finished constructiong. Deal promptly and effectively with problems within your control and report those that cannot be solved



comply with health and safety and site regulations at all timesuse the correct construction drawings and interpret them correctlycorrectly prepare the components and faces to be erected and assembleduse the correct datum faceserect and assemble the structural components in the correct order or mannercorrectly align the components and faces to be joined use the specified or appropriate fixing method and ensure all bolts are tightened to the required torqueproduce an assembly which meets the required specification

2. Erect structural steelwork for one of the following: ● building frames and roofs● support structures

● mezzanine platforms● rigs

● access staging and platforms

3. Use four of the following types of components in the assemblies produced: ● columns● beams ● roof trusses● frames

● bed plates● staircases● bulkheads● roof sheeting/cladding

● fish plates● brackets● support plates

● guards and hand rails● safety cages● platforms and ladders

4. Use all of the following during the erection and assembly activities: ● hand tools and equipment (podger, crow bar, spanners, torque wrenches)● assembly and alignment techniques and procedures (levels, plumb lines, laser equipment)● mechanical fastening techniques and procedures (bolted, riveted)● slinging and lifting techniques (ropes, chains, cranes)● temporary staging or mobile platforms

5. Erect structural steelwork on either of the following sites: new construction siteexisting construction

6. Produce constructions which meet all of the following quality and accuracy standards: ● all components are correctly assembled and aligned in accordance with the specification● overall dimensions are within specification tolerances● assemblies meet appropriate geometric tolerances (square, straight, angles, free from twists)● completed assemblies meet specification

191




1. The specific safety precautions to be taken when working in a steel construction/erection environment and when erecting structural components (general site safety, appropriate personal protective equipment, accident procedure; working at height and statutory regulations relating to it, risk assessment procedures and COSHH regulations)

2. The personal protective clothing and equipment that needs to be worn when carrying out the erection activities (leather gloves, eye protection, safety helmets, ear protection, safety harness etc.)

3. Safe working practices and procedures needed for erecting structural components4. The correct methods of moving or lifting heavy structural sections5. The hazards associated with erecting structural components and how they can be minimised (such as using

dangerous or badly maintained tools and equipment, lifting and handling log and heavy components, working at height, slips trips and falls)

6. How to obtain the necessary construction and site drawings and joining specifications7. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing9. The preparations that need to be carried out on the components prior to erecting and assembling them10. Equipment and temporary installations that may be required to support the structure during the erection activities11. The various methods of securing the assembled components (the range of nuts and bolts used including close

tolerance location bolts; temporary tack welding methods and techniques)12. How to set-up and align the various components and the tools and equipment that is used13. The use and care of tools and equipment, and control procedures14. The importance of using tools or equipment only for the purpose intended; the care that is required when using

the tools or equipment; the proper way of preserving tools or equipment between operations15. The things that can go wrong when erecting structural components/assemblies, and how these can be avoided16. Inspection techniques that can be applied to check the construction is to specification and within acceptable limits17. The extent of your own responsibility and whom you should report to if you have problems that you cannot solve18. Reporting lines and procedures, line supervision and technical experts

192






Evidence TypeDateCarry Out during Structural Assembly Operations (ALL)comply with health & safetyuse and interpret correct construction drawingscorrectly prepare componentsuse correct datum faceserect in correct ordercorrectly align componentsappropriate fixing methodproduce assembly to required specificationErect Structural Steelwork (ONE)building frames & roofssupport structuresmezzanine platformsrigsaccess staging & platformsUse Types of Components in Assemblies (FOUR)columnsbeamsroof trussesframesbed platesstaircasesbulkheadsroof sheeting/claddingfish platesbracketssupport platesguards & hand railssafety cagesplatforms & laddersUse during Erection & Assembly Activities (ALL)hand tools & equipmentassembly/alignment techniquesmechanical fastening techniquesslinging & lifting techniquestemporary staging/mobile platformsErect Structural Steelwork on the following sites (EITHER)new construction siteexisting constructionProduce Constructions to Quality & Accuracy Standards (ALL)correctly assembleddimensions within tolerancesappropriate geometric tolerancesassemblies meet specification


Candidate: Date:

Assessor: Date:

193

Unit 44 Forming Pipework by Machine Bending

Unit Summary

This unit identifies the competencies you need to bend and form pipes using pipe-bending machines in accordance with approved procedures. You will be required to select the most appropriate type and size of machine and former, based on the pipe type, size and operations to be performed. In producing the components you will be required to operate the equipment safely and correctly, or direct operations for their effective use, to bend and form the pipe to the required profile without flats or deformations. The pipe bending and forming operations to be performed will include bending at right angles, bending to other angles, producing offsets, producing bridge sets, producing curved sections and producing expansion loops.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to forming pipework using machine procedures. You will understand the equipment being used, the forming principles, and their application, and will know about the processes involved and their limitations in sufficient depth to provide a sound basis for carrying out the activities, correcting any faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the forming machines and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

194






the appropriate machine is selected for the operation being performed the machine guards and safety devices are in position and function correctlyforming tools are appropriate and in a serviceable condition (secure, correct diameter, free of damage)machine settings are suitable for the pipe diameter, material thickness and operations to be performed

2. Use one of the following types of pipe bending machines:● hand operated manual bending machines (small diameter pipe)● hydraulic operated bending machines● powered pipe bending machines● CNC bending machines● power press with different former radii and sizes (pipe diameter)

3. Bend and form one of the following types of pipework: small bore lubrication/fuel pipingcable ducting pipeworkheavy duty pipes

structural pipeshigh pressure pipes

4. Produce pipework forms that includes four of the following:right angled bendsangular bends

● offsets

● bridge sets● expansion loops● curved sections

5. Bend and form pipes made from one of the following types of material: ferrous steel non-ferrous ● special metals

5. Produce pipe bends and forms which comply with all of the following quality and accuracy standards as is applicable:

● meet drawing, specification, template or job requirements● meet customer requirements● have the required dimensional accuracy within specified tolerances

the form or sharpness of the bend conforms to best practice and or specification without deformation or crackingthe bend conforms to the required shape/geometry (to the template profile)

195




1. The specific safety precautions to be taken when working with pipe bending equipment bending machines in a fabrication environment


3. The safe working practices and procedures required for operating power operated bending and forming machines4. The specific personal protective equipment that needs to be worn when carrying out the pipe bending activities

(gloves, eye protection, safety helmets, ear protection etc.)5. The handling precautions and correct methods of moving or lifting long lengths or heavy pipes6. The hazards associated with the pipe bending activities and how they can be minimised (handling long pipe lengths;

using power operated bending equipment; using dangerous or badly maintained tools and equipment; using heating equipment)



9. Principles and methods of marking out pipework and the type of equipment used (direct marking; use of templates; use of set wires; marking out conventions applicable to the bending process (centre lines; bending lines)

10. Allowances that need to be made in the marking out for the bending and forming activities11. How to prepare the pipes in readiness for the bending and forming activities (visually checking for defects, cleaning

the materials, removing burrs and sharp edges)12. The characteristics of the various materials that are to be used with regard to the bending operations and why some

materials may require the addition of heat to aid the bending process13. The various types of pipe bending machines used to bend and form the pipe (including the use of hand bending

machines, hydraulic bending equipment, power operated equipment and heating methods)14. How to prepare and set up the machine for a range of different bends (angled bends, curved sections, twisted

sections and straightening of sections)15. How to produce the various bends required (such as angled bends, dog-leg sets, bridge sets and expansion loops)16. Ways of limiting distortion, wrinkles, marking and creases in the finished workpiece17. The problems that can occur with the bending and forming activities, and how they can be avoided18. The organisational quality control procedures that are used, and how to recognise defects in the bends that you

produce19. How to make dimensional and forming inspection checks and the tools and equipment that can be used20. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

196






(if required)Evidence TypeDateCheck Equipment safe and fit for purpose (ALL)appropriate machine usedsafety devices functionforming tools appropriatemachine settings suitableUse Pipe Bending Machines (ONE)hand operated manualhydraulic operatedpoweredCNCpower press with different former radii and sizesBend & Form Pipework (ONE)small bore lubrication/fuelcable ductingheavy dutystructuralhigh pressureProduce Pipework Forms (FOUR)right angled bendsangular bendsoffsetsbridge setsexpansion loopscurved sectionsBend & Form Pipes made from the following materials (ONE)ferrous non-ferrousspecial metalsProduce Pipe Bends & Forms to quality & accuracy standards (ALL)meet drawing, specification, template or job requirementsmeet customer requirementsdimensional accuracy within tolerancesbend conforms to best practicebend conforms to required shape/geometry


Candidate: Date:

Assessor: Date:

197


Unit Summary

This unit identifies the competencies you need to bend and form pipes using pipe-bending machines in accordance with approved procedures. You will be required to select the most appropriate type and size of machine and former, based on the pipe type, size and operations to be performed. In producing the components you will be required to operate the equipment safely and correctly, or direct operations for their effective use, to bend and form the pipe to the required profile without flats or deformations. The pipe bending and forming operations to be performed will include bending at right angles, bending to other angles, producing offsets, producing bridge sets, producing curved sections and producing expansion loops.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to forming pipework using machine procedures. You will understand the equipment being used, the forming principles, and their application, and will know about the processes involved and their limitations in sufficient depth to provide a sound basis for carrying out the activities, correcting any faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the forming machines and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

198



You must:h. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesi. Confirm that the equipment is set up correctly and is ready for use j. Manipulate the machine controls safely and correctly in line with operational proceduresk. Produce components to the required specificationl. Carry out quality sampling checks at suitable intervalsm. Deal promptly and effectively with problems within your control and report those that cannot be solvedn. Shut down the equipment to a safe condition on conclusion of the machining activities



the appropriate machine is selected for the operation being performed the machine guards and safety devices are in position and function correctlyforming tools are appropriate and in a serviceable condition (secure, correct diameter, free of damage)machine settings are suitable for the pipe diameter, material thickness and operations to be performed

2. Use one of the following types of pipe bending machines:● hand operated manual bending machines (small diameter pipe)● hydraulic operated bending machines● powered pipe bending machines● CNC bending machines● power press with different former radii and sizes (pipe diameter)

3. Bend and form one of the following types of pipework: small bore lubrication/fuel pipingcable ducting pipeworkheavy duty pipes

structural pipeshigh pressure pipes

4. Produce pipework forms that includes four of the following:right angled bendsangular bends

● offsets

● bridge sets● expansion loops● curved sections

5. Bend and form pipes made from one of the following types of material: ferrous steel non-ferrous ● special metals

5. Produce pipe bends and forms which comply with all of the following quality and accuracy standards as is applicable:

● meet drawing, specification, template or job requirements● meet customer requirements● have the required dimensional accuracy within specified tolerances

the form or sharpness of the bend conforms to best practice and or specification without deformation or crackingthe bend conforms to the required shape/geometry (to the template profile)

199




1. The specific safety precautions to be taken when working with pipe bending equipment bending machines in a fabrication environment


3. The safe working practices and procedures required for operating power operated bending and forming machines4. The specific personal protective equipment that needs to be worn when carrying out the pipe bending activities

(gloves, eye protection, safety helmets, ear protection etc.)5. The handling precautions and correct methods of moving or lifting long lengths or heavy pipes6. The hazards associated with the pipe bending activities and how they can be minimised (handling long pipe lengths;

using power operated bending equipment; using dangerous or badly maintained tools and equipment; using heating equipment)



9. Principles and methods of marking out pipework and the type of equipment used (direct marking; use of templates; use of set wires; marking out conventions applicable to the bending process (centre lines; bending lines)

10. Allowances that need to be made in the marking out for the bending and forming activities11. How to prepare the pipes in readiness for the bending and forming activities (visually checking for defects, cleaning

the materials, removing burrs and sharp edges)12. The characteristics of the various materials that are to be used with regard to the bending operations and why some

materials may require the addition of heat to aid the bending process13. The various types of pipe bending machines used to bend and form the pipe (including the use of hand bending

machines, hydraulic bending equipment, power operated equipment and heating methods)14. How to prepare and set up the machine for a range of different bends (angled bends, curved sections, twisted

sections and straightening of sections)15. How to produce the various bends required (such as angled bends, dog-leg sets, bridge sets and expansion loops)16. Ways of limiting distortion, wrinkles, marking and creases in the finished workpiece17. The problems that can occur with the bending and forming activities, and how they can be avoided18. The organisational quality control procedures that are used, and how to recognise defects in the bends that you

produce19. How to make dimensional and forming inspection checks and the tools and equipment that can be used20. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

200






(if required)Evidence TypeDateCheck Equipment safe and fit for purpose (ALL)appropriate machine usedsafety devices functionforming tools appropriatemachine settings suitableUse Pipe Bending Machines (ONE)hand operated manualhydraulic operatedpoweredCNCpower press with different former radii and sizesBend & Form Pipework (ONE)small bore lubrication/fuelcable ductingheavy dutystructuralhigh pressureProduce Pipework Forms (FOUR)right angled bendsangular bendsoffsetsbridge setsexpansion loopscurved sectionsBend & Form Pipes made from the following materials (ONE)ferrous non-ferrousspecial metalsProduce Pipe Bends & Forms to quality & accuracy standards (ALL)meet drawing, specification, template or job requirementsmeet customer requirementsdimensional accuracy within tolerancesbend conforms to best practicebend conforms to required shape/geometry


Candidate: Date:

Assessor: Date:

201

Unit 45 Producing Pipe Fabrications

Unit Summary

This unit identifies the competencies you need to produce pipe fabrications such as flanged pipes, elbows, tee pieces, reduction pieces and segmented bends to specification and in accordance with approved procedures. You will be required to cut, form, lay out and secure parts of the pipe fabrication in the correct orientation and configuration for fixing using tack welding or mechanical securing methods as is specified or appropriate to the application and in a manner that is fit for purpose.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach producing fabricated pipe components and their assembly and fixing procedures. You will understand the techniques used and the requirements of the manufacturing and assembling procedures and their application. You will know about the methods of producing pipe components of the required strength, that are fit for purpose and meet the requirements of pressure tests etc, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with pipe fabrications/components and their associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

202







fabricate the pipe components in the correct order and mannerproduce suitable weld preparations on the pipe endscorrectly prepare and set up the pipe components and faces to be joinedcheck that the fabrication has the required configuration use the specified or appropriate fixing methodproduce a pipe fabrication which meets the required specification

2. Produce three of the following pipe fabrications/assemblies:● flanged pipe● straight reduction piece● elbow● equal tee piece ● reduction tee piece ● segmented bend

3. Produce pipe fabrications from one of the following materials: ● ferrous ● non-ferrous● non-metallic

4. Assemble the components using two of the following methods: ● bolted● riveted● self secured (knocked up, paned down, swaged, joggled)● temporary tack welded● adhesive bonding

5. Produce pipe fabrications which meet all of the following quality and accuracy standards: ● all components are correctly assembled and aligned in accordance with the specification● overall dimensions are within specification tolerances● assemblies meet appropriate geometric tolerances (square, straight, angles free from twists)● where appropriate, pitch of flange holes meet specification requirements● assemblies are leak and pressure tested (where appropriate)● completed assemblies are secure, clean and free from burrs or flash

203




1. The specific safety precautions to be taken when working in a pipe fabrication environment and when producing fabricated pipe components (general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations)

2. The personal protective clothing and equipment that needs to be worn when carrying out the pipe fabrication activities (leather gloves, eye protection, safety helmets, ear protection etc.)

3. Safe working practices and procedures needed for producing fabricated pipe components4. The correct methods of moving or lifting long or heavy pipe fabrications5. The hazards associated with pipe fabrication work and assembly operations and how they can be minimised (such

using dangerous or badly maintained tools and equipment; lifting and handling long and heavy components; slips, trips and falls)

6. How to obtain the necessary pipe fabrication drawings and joining specifications7. How to extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing9. How to interpret marking out conventions (cutting lines; centre lines, etc.)10. The preparations that need to be carried out on the pipe components prior to assembling them11. The various methods of securing the pipe components (temporary tack welding methods and techniques, self

securing methods such as knocked up, paned down, swaged and joggled, adhesive bonding of components)12. How to prepare the pipe ends ready for welding (clean, correct shape, appropriate weld preparations)13. How to set-up and align the various components and the tools and equipment that is used (jigs, fixtures, templates)14. The material cutting characteristics and process considerations that needs to be taken into account when producing

pipe fabrications15. The use and care of tools and equipment, and control procedures16. The importance of using tools or equipment only for the purpose intended; the care that is required when using the

tools or equipment; the proper way of preserving tools or equipment between operations.17. The things that can go wrong when producing pipe fabrications and assemblies, and how these can be avoided18. Inspection techniques that can be applied to check shape (including roundness, straightness and dimensional

accuracy) is to specification and within acceptable limits19. How to pressure test completed assemblies and the tools, equipment and techniques that are used 20. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve21. Reporting lines and procedures, line supervision and technical experts

204






(if required)Evidence TypeDateCarry Out During Structural Assembly Operations (ALL)fabricate pipe components in correct order/mannersuitable weld preparations on pipe endsprepare and set up pipe components correctlycheck fabrication configurationappropriate fixing methodmeet required specificationProduce Pipe Fabrications/Assemblies (THREE)flanged pipestraight reduction pieceelbowequal tee piecereduction tee piecesegmented bendProduce Pipe Fabrications from Materials (ONE)ferrousnon-ferrousnon-metallicAssemble Components (TWO methods)boltedrivetedself-securedtemporary tack weldedadhesive bondingProduce Pipe Fabrications to Quality & Accuracy Standards (ALL)correctly assembleddimensions within tolerancesappropriate geometric tolerancespitch of flange holes to specificationleak & pressure testedsecure & clean


Candidate: Date:

Assessor: Date:

205

Unit 46 Producing Socket and Flange Fillet Welded Joints in Pipe using a Manual Welding Process

Unit Summary

This unit identifies the competencies you need to produce socket and flange fillet welded joints in pipe using a manual welding process such as manual metal arc (MMA), MIG, MAG, TIG, flux cored wire, plasma or gas welding equipment in accordance with instructions and/or approved welding procedures. You will be required to check that all the workholding equipment and manipulating devices required are available and in a usable condition. You will be expected to check the welding equipment to ensure that all the leads/cables, hoses and wire feed mechanisms are securely connected and free from damage.

In preparing to weld you will need to set and adjust the welding conditions in line with the instructions or welding procedure specification. You must operate the equipment safely and correctly and make any necessary adjustments to settings in line with your permitted authority in order to produce the welded joints to the required specification. You will be required to demonstrate you capability to produce the fillet welds to the required quality and this could be through tests according to BS 4872 or EN 287.

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

Your underpinning knowledge will be sufficient to provide a sound basis for your work, and provide an understanding of how the particular welding process works. You will know about the equipment, materials and consumables in adequate depth to provide a sound background for the welding operations to be performed, and for ensuring the work output is produced to the required specification. You will understand the safety precautions required when working with the welding equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

206







Manual Metal ArcMIG/MAGTIG

Cored wirePlasmaGas welding

2. Use consumables appropriate to the material and application to include either of the following:two types of electrode from:� rutile� basic� cellulosic � nickel alloy� stainless� other

two types of filler wire from different material groups

3. Produce socket and flange fillet welded joints in one of the following:small bore pipe (50mm outside diameter or less)large bore pipe (above 50mm outside diameter)

4. Weld joints according to approved welding procedures in good access situations in four of the following BS EN287 positions:

Flat (PA) rotatingHorizontal vertical (PB) fixedHorizontal vertical (PB) rotating

Vertical upwards (PF) fixedVertical down (PG) fixedHorizontal overhead (PD) fixed

5. Produce welded pipes which: achieve minimum weld quality requirements applicable to fillet welds equivalent to those given in the

relevant European / International Standards (e.g. EN 25817 / ISO 5187 and EN 30042 / ISO 10042) required by the application standard or specification


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You must have knowledge and understanding of: (as applicable to the process used)

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


3. The hazards associated with the selected welding process and how they can be minimised (live electrical components, poor earthing, arc radiation, fumes and gases, gas supply leaks, spatter, hot slag and metal, elevated working, grinding and mechanical metal/slag removal; enclosed spaces, slips, trips and falls)

4. The manual welding process selected, and an awareness of the different types of welding equipment (basic principles of fusion welding, AC and DC power sources, ancillary equipment, power ranges, care of equipment, terminology used in welding, flame setting).


6. The consumables associated with the chosen welding process (types of electrodes and or filler metal and application; types of shielding gas and their application; gas supply and control; correct storage and drying of electrodes and filler wire)

7. The types and features of welded joints in pipe (fillet and butt welds, single and multi-run welds, welding positions, weld quality)

8. Methods of setting up and restraining the joint to achieve correct location of components and control of distortion (edge preparation; use of jigs and fixtures; manipulators and positioners; tack welding size and spacing in relationship to material thickness and component size; use of temporary attachments; pre-setting)

9. Preparing the welding equipment and checks that need to be made to ensure that it is safe and ready to use (electrical connections, earthing arrangements; equipment calibration, setting welding parameters)

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


methods of control; effects of welding on materials and sources of weld defects; methods of prevention) 13. The organisational quality systems used and weld standards to be achieved, weld inspection and test procedures


208






(if required)Evidence TypeDateSet up, check, adjust and use equipment for welding processes (ONE of the following)Manual Metal ArcMIG/MAGTIGCored WirePlasmaGas WeldingUse appropriate Consumables to include EITHER TWO types of Electrode from: OR TWO types of Filler Wire from different Material Groupsrutilebasiccellulosicnickel alloystainlessotherFiller wire 1Filler wire 2Produce Socket & Flange Fillet Welded Joints (ONE)small bore pipe 50mmlarge bore pipe > 50mmWeld Joints to Approved Welding Procedures in BS EN287 Positions (FOUR)PA rotatingPB fixedPB rotatingPF fixedPG fixedPD fixedProduce Welded Pipes which meet requirements EN 25817 / ISO 5187 & EN 30042 / ISO 10042generalMeet Required Dimensional Accuracywithin specified tolerance


Candidate: Date:

Assessor: Date:

209

Unit 47 Producing Components by Fibre Reinforced Plastic (FRP) Moulding

Unit Summary

This unit identifies the competencies you need to produce components from fibre reinforced plastic in accordance with approved procedures. You will be required to use appropriate manufacturing drawings, specifications and documentation, together with other quality documentation to produce the various types of component. You will be expected to produce a range of components from a variety of materials such as glass fibre, aramid, teralyne, boron, nylon, carbide, jute and carbon mouldings using the specified techniques. The components to be produced may combine a range of techniques and shapes and will have features that include flat laminates, box/tray sections, double curvatures, convex or concave profile and stiffened mouldings.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying FRP moulding procedures. You will understand the moulding manufacturing requirements and procedures, and their application, and will know about the manufacturing tools and techniques used, materials and consumables in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the safety precautions required when carrying out the moulding operations. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

210



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the correct component drawing or any other related specifications for the component to be producedc. Determine what has to be done and how this will be achievedd. Obtain and prepare the appropriate tools, equipment and materialse. Carry out the moulding or laying-up activities using the correct methods and techniquesf. Produce components to the required specification g. Check that all the required operations have been completed to specificationh. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all the following activities during the installation:

● use the correct issue of drawings, specifications, material data sheets and planning documentation● use copies of relevant COSHH sheets and risk assessments ● obtain materials (in life batches, correctly protected)● obtain tools to be used and check they are fit for purpose (part marked, cleared inspection, undamaged)● return all tools and equipment to the correct location● leave the work area in a safe condition on completion of the activities

2. Apply moulding and laying-up methods and techniques to include five of the following: ● metal tooling● composite tooling● wooden tooling● tape laying

● vacuum bagging● pressure bagging● interference moulding● cutting methods

● mixing methods● autoclave moulding● hot wax process● matched metal

● oven moulding● press moulding● quick pressing

3. Carry out six of the following operations: ● tool/equipment preparation● curing temperature/pressure

● lay-up ● trimming

● mat orientation● number of plies

● room temperature control● de-moulding

4. Produce a range of components with all the following features: ● flat laminates● tray sections

● single curvature● double curvatures

● convex shapes● concave shapes

● stiffened mouldings

5. Produce a range of components using one type of resin from: ● polyester● thermoplastic

● elastomer ● phenolic ● silicon ● epoxy ● bismaliemide

6. Produce a range of components using one type of material from: ● glass fibre● aramid

● teralyne● boron

● nylon● carbide

● jute● carbon

7. Produce a range of components using one type of stiffener from: ● honeycomb ● foam ● syntactic core

8. Produce a range of components using three ancillary materials from:● bagging films

bleed plies● tapes● release agents

● solvents● foaming adhesives

● fillers● sealants

9. Components produced must comply with one or more of the following standards:● ISO 9000 series and procedures● customer standards and requirements● company standards and procedures

211




1. The specific safety practices and procedures that you need to observe when working with fibre reinforced plastics (FRP) including any specific legislation, regulations/codes of practice for the activities, equipment or materials

2. The health and safety requirements of the work area you are carrying out the activities and the responsibility it places on you

3. The protective equipment that you need to use for both personal protection and where appropriate, protection of others

4. The hazards associated with FRP moulding activities and how they can be minimised5. The procedure for the correct separation and safe disposal of waste materials6. The interpretation of drawings, standards, quality control procedures and specifications used for the moulding

activity and the currency/issue checks of the documents you are working with7. The conventions/terminology used in moulding/laying up (such as material tailoring, ‘B’ staging, vacuum bagging,

backing materials, peel piles, bleed felt, foaming adhesives, intensifiers, autoclave techniques, material wet lay up, dry fibre drying procedures)

8. The types of component trimming/cutting methods available and trimming methods on the tool9. The methods of achieving consolidation at foam/honeycomb/discontinuous laying-up points10. The reasons for part cure procedures and their effect11. The material types and their merits (such as material life, their construction, types of weave, resins, bulk problems

with liquid resins, thermoplastics, pre impregnated materials, foam, honeycomb, discontinuous materials)12. The procedures when temperature cure is used and the need for thermocouples on temperature control13. The procedures for remoulding, lost wax removal and first article inspection such as: test samples, non-destructive

testing (NDT) requirements14. The quality control procedures that need to followed during the lay-up moulding operations15. The procedures for ensuring you have the correct type of tools and equipment16. The methods and techniques for lifting, handling and supporting the components/equipment/materials during the lay-

up moulding activities17. Recognition of lay-up/moulding defects such as misalignment, distortion, foreign object damage, contamination and

surface defects18. The tools and equipment used in the lay-up moulding activities and their calibration, care, preparation and control

procedures19. Why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on

completion of the activities20. The sort of problems that can occur with the lay-up/moulding operations, and how these can be overcome21. The recording documentation that needs to be completed for the lay-up/moulding activities undertaken and, where

appropriate, marking and identifying specific pieces of work in relation to the documentation22. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

212






Evidence TypeDateCarry out during Installation (ALL)correct drawings etcrelevant COSHH sheetsobtain materialsobtain & check toolsreturn tools correctlyleave work area safeApply Moulding & Laying Up Methods and techniques (FIVE)metal toolingcomposite toolingwooden toolingtape layingvacuum baggingpressure bagginginference mouldingcutting methodsmixing methodsautoclave mouldinghot wax processmatched metaloven mouldingpress mouldingquick pressingsCarry out Operations (SIX)tool/equipment preparationcuring temp’/pressurelay uptrimmingmat orientationnumber of pliesroom temperature controlde-mouldingProduce a range of Components with features (ALL)flat laminatestray sectionssingle curvaturedouble curvaturesconvex shapesconcave shapesstiffened mouldingsProduce a range of Components using resin (ONE type)polyesterthermoplasticelastomerphenolicsiliconepoxybismaliemide

(continued on next page)

213


Produce a range of Components using material (ONE type)glass fibrearamidteralyneboronnyloncarbidejutecarbonProduce a range of Components using Stiffener (ONE type)honeycombfoamsyntactic coreProduce a range of Components using Ancillary Materials (THREE)bagging filmsbleed pliestapesrelease agentssolventsfoaming adhesivesfillerssealantsProduce a range of Components to Comply with Standards (ONE or more)ISO 9000 seriescustomer standards and requirementscompany standards and procedures


Candidate: Date:

Assessor: Date:

214


215

Unit 48 Producing Components by Acrylic Moulding

Unit Summary

This unit identifies the competencies you need to mould acrylics in accordance with approved procedures. You will be required to use appropriate manufacturing drawings, specifications and documentation to produce the various types of components. You will be expected to produce the acrylic components using the specified/appropriate moulding process and techniques. The equipment will include air circulating ovens, presses, trimming and automated cutting equipment. The products produced will include deep drawn, double curvature and convex/concave shapes.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying moulding procedures. You will understand the moulding procedures, and their application, and will know about the moulding equipment, materials, and consumables used in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the safety precautions required when carrying out the moulding operations. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

216




Scope of the unit:

The numbers of scope items specified (below) indicate the minimum requirements for this Occupational Standard.


● use the correct issue of drawings, specifications, material data sheets and planning documentation● use copies of relevant COSHH sheets and risk assessments ● obtain materials (batch number, colour, thickness, sheet size, surface texture, material protection)● obtain tools to be used and check they are fit for purpose (part marked, cleared inspection, undamaged)● return all tools and equipment to the correct location● leave the work area in a safe condition on completion of the activities

2. Carry out two of the following moulding methods and techniques:● vacuum moulding● deep drawing● shape clamping● positive pressure shaping ● stress relieving

3. Carry out all of the following operations during the moulding process: ● tool/equipment preparation● setting and controlling temperatures● sheet preparation● trimming

● stress relieving● sheet forming● de-moulding

4. Produce a range of components with four of the following features: ● box sections● cylindrical section● convex shapes

● concave shapes● single curvatures● double curvatures

5. Produce components which comply with one or more of the following standards: ● ISO 9000 series and procedures● customer standards and requirements● company standards and procedures

217




1. The specific safety practices and procedures that you need to observe when working with acrylics (including any specific legislation, regulations/codes of practice for the activities, equipment or materials)

2. The health and safety requirements of the work area where you are carrying out the activities and the responsibility they place on you

3. The protective equipment that you need to use for both personal protection and, where appropriate, protection of others

4. The hazards associated with moulding acrylic materials and how they can be minimised5. The procedure for the correct separation and safe disposal of waste materials6. The layout of the area to give maximum throughput7. The interpretation of drawings, standards, quality control procedures and specifications used for the moulding

activity and the currency/issue checks of the documents you are working with8. The principles of deep drawing, concave/convex moulding, positive pressure moulding and stress relieving principles9. The different methods of heating materials and the temperature control methods10. The sheet profiling procedures and material trimming methods/procedures11. The supply of acrylic sheet (such as colour, thickness, sheet size, surface texture, material protection)12. The use of forming aids13. The methods of sheet trimming and sheet cleaning prior to moulding14. The preparation methods and procedures applied to the moulding surface15. The material cleaning methods and procedures to be applied16. The procedures for de-moulding, and first article inspection (such as test samples, non-destructive testing (NDT)

requirements)17. The quality control procedures that need to followed during the moulding operations18. The procedures for ensuring you have the correct type of tools and equipment19. The methods and techniques for lifting, handling and supporting the components/equipment/materials during the

moulding activities20. Recognition of moulding defects such as misalignment, distortion, foreign object damage, contamination and surface

defects21. The tools and equipment used in the moulding activities and their calibration, care, preparation and control


completion of the activities23. The problems that can occur with the moulding operations and how these can be overcome24. The recording documentation that needs to be completed for the moulding activities undertaken and, where


218






(if required)Evidence TypeDateCarry out activities during installation (ALL)use correct drawingsrelevant COSHH sheetsobtain materialsobtains & check toolsreturn tools & equipmentleave work area safeCarry out moulding methods and techniques (TWO)vacuum mouldingdeep drawingshape clampingpositive pressure shapingstress relievingCarry out operations during the moulding process (ALL)tool/equipment preparationsetting/controlling temp’sheet preparationtrimmingstress relievingsheet formingde-mouldingProduce a range of Components with Features (FOUR)box sectionscylindrical sectionconvex shapesconcave shapessingle curvaturesdouble curvaturesComply with Standards (ONE or more)ISO 9000 Seriescustomer standards and requirementscompany standards procedures


Candidate: Date:

Assessor: Date:

219

Unit 49 Producing Components from Carbon Fibre

Unit Summary

This unit identifies the competencies you need to produce components from carbon fibre in accordance with approved procedures. You will be required to use appropriate manufacture drawings, specifications and documentation to produce the various types of components. You will be expected to produce the carbon fibre components using the specified/appropriate moulding/laying-up process and techniques. The equipment will include, air circulating ovens, autoclaves, presses, trimming and automated cutting equipment vacuum tables automated laying equipment. The components produced will include flat laminates, double curvatures, convex/concave shapes and stiffened mouldings.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying carbon fibre production techniques and procedures. You will understand the carbon fibre production techniques used, and will know about the manufacturing tools and techniques in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the production output meets the required specification. You will understand the safety precautions required when carrying out the moulding operations. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

220





You must: 1. Carry out all the following activities during the installation:

● use the correct issue of drawings, specifications, material data sheets and planning documentation● use copies of relevant COSHH sheets and risk assessments ● obtain materials (in life batches, correctly protected)● obtain tools to be used and check they are fit for purpose (part marked, cleared inspection, undamaged)● return all tools and equipment to the correct location on completion of the activities● leave the work area in a safe condition on completion of the activities

2. Apply moulding and laying up methods and techniques which include four of the following:● use of metal tooling● use of composite tooling● tape laying

● vacuum bagging● pressure bagging● interference moulding

● cutting methods● lost wax process

● rolling● matched metal

3. Carry out all of the following operations: ● room temperature control● curing (temperature/pressure cycle)

● lay-up ● tool preparation


● trimming● demoulding

4. Produce a range of components with features that include two from: ● flat laminates ● double curvatures ● convex/concave shapes ● stiffened mouldings

5. Produce a range of components using one type of resin from:● polyester ● thermoplastic ● phenolic ● epoxy ● bismaliemide

6. Produce a range of components using one type of material from:● carbon fibre woven ● carbon fibre unidirectional

7. Produce a range of components using one type of stiffener from: ● honeycomb ● foam

8. Produce a range of components using three ancillary materials from: ● bagging films● bleed plies

● tapes● release agents



9. Produce components which comply with one of the following standards:● ISO 9000 series and procedures● customer standards and requirements● company standards and procedures

221




1. The specific safety practices and procedures that you need to observe when working with carbon fibre (including any specific legislation, regulations/codes of practice for the activities, equipment or materials)



4. The hazards associated with carbon fibre and how they can be minimised5. The procedure for the correct separation and safe disposal of waste materials6. The layout of the area to give maximum throughput7. The interpretation of drawings, standards, quality control procedures and specifications used for the lay-up activity

and the currency/issue checks of the documents you are working with8. The conventions/terminology used in laying up (such as material tailoring, ‘B’ staging, vacuum bagging, backing

materials, bleed felt, foaming adhesives, intensifiers, autoclave techniques) 9. The types of component trimming/cutting methods available and trimming methods on the tool10. The methods of achieving consolidation at foam/honeycomb/discontinuous laying-up points11. The reasons for part cure procedures and their effect12. The material types and their merits (such as material life, their construction, types of weave, resins, bulk problems

with liquid resins, pre-impregnated materials, foam, honeycomb, discontinuous materials)13. The procedures when temperature cure is used and the need for thermocouples on temperature control14. The methods for preparing/handling tools and materials (such as material cutting, tool preparation techniques,

effects of poor bagging, lay-up aids, use of benches and trolleys)15. The procedures for de-moulding, lost wax removal and first article inspection (such as test samples, non-destructive

testing (NDT) requirements)16. The quality control procedures that need to followed during the lay-up operations17. The procedures for ensuring you have the correct type of tools and equipment18. The methods and techniques for lifting, handling and supporting the components/equipment/materials during the lay-

up activities19. Recognition of lay-up defects (such as misalignment, distortion, foreign object damage, contamination and surface

defects)20. The tools and equipment used in the lay-up activities and their calibration, care, preparation and control procedures21. Why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on

completion of the activities22. The problems that can occur with the lay-up operations and how these can be overcome23. The recording documentation that needs to be completed for the lay-up activities undertaken and, where


222






Evidence TypeDateInstallation Activities (ALL)use correct drawingsrelevant COSHH sheetsobtain materialsobtain & check toolsreturn tools correctlyleave work area safeApply moulding & laying up methods and techniques (FOUR)use of metal toolinguse of composite toolingtape layingvacuum baggingpressure bagginginterference mouldingcutting methodslost wax processrollingmatched methodCarry out Operations (ALL)room temperature controlcuringlay uptool preparationmat orientationnumber of pliestrimmingde-mouldingProduce a range of Components with Features (TWO)flat laminatesdouble curvaturesconvex/concave shapesstiffened mouldingsProduce a range of Components using Resin (ONE type)polyesterthermoplasticphenolicepoxybismaliemideProduce a range of Components using Material (ONE type)carbon fibre wovencarbon fibre unidirectionalProduce a range of Components using Stiffener (ONE type)honeycombfoamProduce a range of Components using Ancillary Materials (THREE)bagging filmsbleed pliestapesrelease agentssolventsfoaming adhesivesfillerssealantsProduce components which comply with Standards (ONE)ISO 9000 Seriescustomer standardscompany standards


Candidate: Date:

Assessor: Date:

223

Unit 50 Producing Components from Glass Fibre

Unit Summary

This unit identifies the competencies you need to produce components from Glass fibre in accordance with approved procedures. You will be required to use appropriate manufacturing drawings, specifications and documentation to produce the various types of components. You will be expected to produce the glass fibre components using the specified/appropriate moulding/laying-up process and techniques. The equipment will include, air circulating ovens, autoclaves, presses, trimming and automated cutting equipment, vacuum tables and automated laying equipment. The components produced will include flat laminates, double curvatures, convex/concave shapes and stiffened mouldings.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying glass fibre production techniques and procedures. You will understand the glass fibre production process used, and will know about the manufacturing tools and techniques in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification. You will understand the safety precautions required when carrying out the moulding operations. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

224






● use the correct issue of drawings, specifications, material data sheets and planning documentation● use copies of relevant COSHH sheets and risk assessments ● obtain materials (in life batches, correctly protected)● obtain tools to be used and check they are fit for purpose (part marked, cleared inspection, undamaged)● return all tools and equipment to the correct location● leave the work area in a safe condition on completion of the activities

2. Apply moulding and laying-up methods and techniques to include four of the following:● use of metal tooling● use of composite tooling● tape laying

● vacuum bagging● pressure bagging● interference moulding

● cutting methods● lost wax process

● rolling● matched metal

3. Carry out all of the following operations:● room temperature control● curing (temperature/pressure cycle)

● lay-up ● tool preparation


● trimming● de-moulding

4. Produce a range of components with features that include two from: ● flat laminates ● double curvatures ● convex/concave shapes ● stiffened mouldings

5. Produce a range of components using one type of resin from: ● polyester● thermoplastic

● elastomer, ● phenolic ● silicon ● epoxy ● bismaliemide

6. Produce a range of components using one type of mat from: ● glass fibre woven ● glass fibre unidirectional ● discontinous glass

7. Produce a range of components using one type of stiffener from: ● honeycomb ● foam ● syntactic core

8. Produce a range of components using three ncillary materials from: ● bagging films● bleed plies

● tapes● release agents




225




1. The specific safety practices and procedures that you need to observe when working with glass fibre (including any specific legislation, regulations/codes of practice for the activities, equipment or materials)


3. The protective equipment that you need to use for both personal protection and where appropriate, protection of others

4. The hazards associated with glass fibre and how they can be minimised5. The procedure for the correct separation and safe disposal of waste materials6. The layout of the area to give maximum throughput7. The interpretation of drawings, standards, quality control procedures and specifications used for the lay-up activity

and the currency/issue checks of the documents you are working with8. The use of and conventions/terminology used in laying-up (such as material tailoring, ‘B’ staging, vacuum bagging,

backing materials, bleed felt, foaming adhesives, intensifiers, autoclave techniques)9. The types of component trimming/cutting methods available and trimming methods on the tool10. The methods of achieving consolidation at foam/honeycomb/discontinuous laying-up points11. The reasons for part cure procedures, and their effect12. The material types and their merits (such as material life, their construction, types of weave, resins, bulk problems

with liquid resins, thermoplastics, pre-impregnated materials, foam, honeycomb, discontinuous materials)13. The procedures when temperature cure is used and the need for thermocouples on temperature control14. The methods for preparing/handling tools and materials (such as material cutting, tool preparation techniques,

effects of poor bagging, lay-up aids, use of benches and trolleys) 15. The procedures for de-moulding, lost wax removal and first article inspection (such as test samples, non-destructive

testing (NDT) requirements)16. The quality control procedures that need to followed during the lay-up operations17. The procedures for ensuring you have the correct type of tools, equipment18. The methods and techniques for lifting, handling and supporting the components/equipment/materials during the lay-

up activities19. Recognition of lay-up defects such as misalignment, distortion, foreign object damage, contamination and surface

defects20. The tools and equipment used in the lay-up activities and their calibration, care, preparation and control procedures21. Why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on

completion of the activities22. The problems that can occur with the lay-up operations and how these can be overcome23. The recording documentation that needs to be completed for the lay-up activities undertaken and where appropriate

marking and identifying specific pieces of work in relation to the documentation24. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

226






Evidence TypeDateInstallation Activities (ALL)use correct drawings etcrelevant COSHH sheetsobtain materialsobtain & check toolsreturn tools correctlyleave work area safeMoulding & Laying Up Methods (FOUR)use of metal toolinguse of composite toolingtape layingvacuum baggingpressure bagginginterference mouldingcutting methodslost wax processrollingmatched methodCarry Out Operations (ALL)room temperature controlcuringlay uptool preparationmat orientationnumber of pliestrimmingde-mouldingRange of Components with Features (TWO)flat laminatesdouble curvaturesconvex/concave shapesstiffened mouldingsProduce a range of components using Resin (ONE)polyesterthermoplasticelastomerphenolicsiliconepoxybismaliemideProduce a range of components using Mat (ONE)glass fibre wovenglass fibre unidirectionaldiscontinuous glassProduce a range of components using Stiffener (ONE)honeycombfoamsyntactic coreProduce a range of components using Ancillary Materials (THREE)bagging filmsbleed pliestapesrelease agentssolventsfoaming adhesivesfillerssealantsProduce components which comply with Standards (ONE)ISO 9000 Seriescustomer standardscompany standards


Candidate: Date:

Assessor: Date:

227

Unit 51 Producing Composite Assemblies

Unit Summary

This unit identifies the competencies you need to produce composite assemblies from composite components and non-composite components in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to produce composite assemblies using the correct techniques. You will produce a range of composite assemblies incorporating a variety of features and using a range of techniques and processes.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying composite assembly techniques and procedures. You will understand the composite assembly techniques used, and their application in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the finished assembly is to the required specification. You will understand the safety precautions required when carrying out the assembly activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

228



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant instructions, assembly drawings and any other specificationsc. Ensure that the specified components are available and that they are in a usable conditiond. Use the appropriate methods and techniques to assemble the components in their correct positionse. Secure the components using the specified connectors and securing devicesf. Check the completed assembly to ensure that all operations have been completed and the finished assembly meets

the required specificationg. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all of the following activities during the assembly activities:

• use the correct issue production documentation (drawings, manuals, specifications, job cards)• use relevant health and safety documentation (material data sheets, COSHH sheets, risk assessments)• use the correct tools and equipment for the activity and ensure they are safe to use and suitably stored• keep the work area in a safe condition

2. Carry out all the following activities when preparing for the assembly activity:• check mouldings are correct and complete• check for any defects in the mouldings• check components are correct and complete• check availability of ancillary materials required

• select correct equipment for the activity• check equipment is suitable for use• check for any defects in the components

• identify and protect the moulding and components in the work area

3. Produce two of the following types of composite assembly: • trial assemblies • one-off assemblies • batch assemblies • assembly line

4. Produce assemblies that incorporate four of the following features: • loose fit tolerances • close fit tolerances

• non permanent fixing• shape location

• joggle joins• permanent fixing

• return joins• overlap joins

5. Produce composite assemblies that require four of the following methods to be used:• fettling• pinning

• clamping• trial fitting

• aligning• assembly Jigs

• assembly sequences

6. Produce composite assemblies that use three of the following joining methods: • thread inserts• quick release fasteners

• mechnical fasteners • anchor nuts • rivets

7. Composite components must include three of the following features:• trim• closing panels

• body panels• tubes

• structural• aerodynamic

• core materials • sections

• inserts • housings

8. Non-composite components must include three of the following types:• brackets • fixtures • fittings • trim • tapes • memory foam • films

9. Produce a range of assemblies which comply with one of the following standards:• ISO 9000 Quality Assurance procedures• customer standards and requirements

• company standards and procedures

229




1. Health and safety precautions to be taken and procedures to be used when working with composite materials, consumables, tools and equipment in the specific work area

2. The hazards associated with composite materials, consumables, tools and equipment, and how to minimise these in the work area

3. Protective equipment that is needed for personal protection and, where required, the protection of others4. The application of COSHH regulations in relation to the storage, use and disposal of composite materials and

consumables5. How to use and extract information from engineering drawings and related specifications to include symbols and


points and system of tolerancing7. Quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting

specification etc.) and the completion of such documents8. Quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting

specification etc.) and the completion of such documents9. Conventions and terminology used for assembly activities (e.g. metric and imperial threads, rivet specifications,

clearances, types of fittings)10. The types of component trimming/cutting methods and preparation methods available11. The visual identification of cured composite materials12. Operations and their sequence when performing assembly activities13. Methods for handling composite assemblies throughout the assembly activities14. The identification and rectification of defects in composite assemblies15. Tools and equipment used in assembly activities and their care, preparation and control procedures16. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

230






Evidence TypeDateCarry out during assembly activities (ALL)use correct documentationuse health & safety docs’use suitable toolskeep work area safeCarry out when preparing for assembly activity (ALL)check mouldings correctcheck defects in mouldingscomponents correctavailability of ancillary materialsselect correct equipmentcheck equipment suitabledefects in componentsprotect moulding & components in work areaProduce composite assemblies (TWO)trial assembliesone-off assembliesbatch assembliesassembly lineProduce composite assemblies incorporating features (FOUR)loose fit tolerancesclose fit tolerancesnon-permanent fixingshape locationjoggle joinspermanent fixingreturn joinsoverlap joins Produce composite assemblies that require different assembly methods (FOUR)fettlingpinningclampingtrial fittingaligningassembly jigsassembly sequencesProduce composite assemblies using joining methods (THREE)thread insertsquick release fastenersmechanical fastenersanchor nutsrivetsComposite Components Featurestrimclosing panelsbody panelstubesstructuralaerodynamiccore materialssectionsinsertshousings


231


Non-Composite Components Types (THREE)bracketsfixturesfittingstrimtapesmemory foamfilmsComply with Standards (ONE)ISO 9000customer standardscompany standards


Candidate: Date:

Assessor: Date:

232


233

Unit 52 Producing Components by Vacuum Forming

Unit Summary

This unit identifies the competencies you need to vacuum form components in accordance with approved procedures. You will be required to use appropriate manufacturing drawings and specifications, together with other quality documentation to produce the various types of components from thermoplastic sheet, fibre reinforced sheet and structural foam, using air circulating ovens, vacuum forming machines, trimming equipment and various tooling. The components produced will have the following features: male shapes, female shapes, double curvatures and stiffened mouldings.

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

Your underpinning knowledge will provide a good understanding of your work, and provide an informed approach to applying vacuum forming procedures. You will understand the vacuum forming procedures used, and their application, and will know about the vacuum moulding techniques, materials, tooling and consumables used, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work output is to the required specification. You will understand the safety precautions required when carrying out the vacuum forming operations. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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You must: 1. Carry out all the following activities during the installation:

● use the correct issue of drawings, specifications, material data sheets and planning documentation● use copies of relevant COSHH sheets, risk assessment and standards ● obtain materials (colour, size, composition)● obtain tools to be used and check they are fit for purpose (part marked, cleared inspection, undamaged)● return all tools and equipment to the correct location● leave the work area in a safe condition on completion of the activities

2. Use three of the following types of equipment : ● air circulating ovens● vacuum forming machines● tufnol tooling

● metal tooling● wood tooling

● trimming equipment● composite tooling

3. Carry out four of the following operations:● bubble blowing to minimize webbing● positioning of robbers● tooling cleaning

● temperature control● trimming techniques● drying of sheet

● use of intensifiers● sheet cleaning

4. Produce a range of components with three of the following features:● double curvatures● male shapes

● female shapes● stiffened mouldings

5. Produce a range of components using all the following materials: ● thermoplastic sheet (such as polycarbonate, polysulphone, acrylic, polyvinyl chloride, abs)● fibre reinforced thermoplastic sheet● structural foams (Polyvinyl Chloride (PVC), polymethate (Rohacell) etc)


235




1. The specific safety practices and procedures that you need to observe when working with vacuum forming equipment including any specific legislation, regulations/codes of practice for the activities, equipment or materials



4. The hazards associated with vacuum forming, and how they can be minimised5. The procedure for the correct separation and safe disposal of waste materials6. The layout of the area to give maximum throughput7. The interpretation of drawings, standards, quality control procedures and specifications used for the vacuum

forming activity and the currency/issue checks of the documents you are working with8. The methods and techniques to be used during tool preparation9. The reasons for the use of intensifiers, and the robber system10. The equipment checks, and the stores and kitting functions11. The methods of sheet trimming and sheet cleaning prior to forming12. The principles of deep drawing, concave/convex moulding, positive pressure moulding and stress relieving.13. The sheet profiling procedures and material trimming methods/procedures14. The supply and storage of stock material (such as colour, thickness, sheet size, surface texture, material protection)15. The preparation methods and procedures applied to the moulding surface16. The merits of male/female moulding, de-moulding techniques and temperature control procedures17. The methods and techniques for carrying out the de-moulding procedures and first article inspection (such as test

samples, non-destructive testing (NDT) requirements)18. The methods and techniques for lifting, handling and supporting the components/equipment/materials during the

vacuum forming activities19. Recognition of vacuum forming defects (such as misalignment, distortion, foreign object damage, contamination and

surface defects)20. The quality control procedures that need to followed during the vacuum forming operations21. The procedures for ensuring you have the correct type of tools and equipment22. The tools and equipment used in the vacuum forming activities and their calibration, care, preparation and control


completion of the activities24. The sort of problems that can occur with the vacuum forming operations and how these can be overcome25. The recording documentation that needs to be completed for the vacuum forming activities undertaken and, where


236






(if required)Evidence TypeDateCarry out installation activities (ALL)use correct drawings etcrelevant COSHH sheetsobtain materialsobtain & check toolsreturn tools correctlyleave work area safeUse Equipment (THREE)air circulating ovensvacuum forming machinestufnol toolingmetal toolingwood toolingtrimming equipmentcomposite toolingCarry out Operations (FOUR)bubble blowingpositioning of robberstooling cleaningtemperature controltrimming techniquesdrying of sheetuse of intensifierssheet cleaningProduce a range of components Features (THREE)double curvaturesmale shapesfemale shapesstiffened mouldingsProduce a range of components using Materials (ALL)thermoplastic sheetfibre reinforced thermoplastic sheetstructural foamsProduce components which comply with standardsISO 9000 Seriescustomer standardscompany standards


Candidate: Date:

Assessor: Date:

237

Unit 53 Trimming Composite Mouldings using Hand Tools

Unit Summary

This unit identifies the competencies you need to trim composite mouldings (moulds, components, splashes, jigs) using hand tools in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to ensure you trim various mouldings using the correct trimming techniques.

You will be expected to select the correct tools and equipment for the trimming activity. You will trim a range of composite mouldings incorporating a variety of features and using cutting, sanding, drilling and polishing techniques and processes. Mouldings trimmed will include a range of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy and procedures for the trimming activities undertaken and to report any problems with the trimming activities, equipment or materials, that you cannot personally resolve, to the relevant people. You will be expected to work with minimum supervision, taking personal responsibility for your own actions and the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying composite moulding trimming techniques and procedures. You will understand the trimming techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the safety precautions required when carrying out the trimming activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

238



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow relevant specifications for the component to be produced c. Obtain the appropriate tools and equipment for the shaping operations and check they are in a safe and usable

conditiond. Shape the materials using appropriate methods and techniquese. Check that all the required shaping operations have been completed to the required specificationf. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all of the following activities during the trimming activities:


2. Carry out all the following activities when preparing for the trimming activity:• check moulding is correct and complete• check for any defects in the moulding• select correct equipment for the activity

• check equipment is suitable for use• identify and protect the moulding in the work area

3. Mark out mouldings using all of the following methods:• scriber • height gauge • moulded scribe lines • centre punch • trimming templates

4 Cut mouldings using two the following methods:• cutting wheels/discs • saws • routers • trim jigs

5. Sand mouldings using three of the following methods:• rubbing blocks • diamond files • pencil grinders • disc sanders • belt sanders

6. Use hand drill or pedestal drill to drill mouldings using three of the following methods:• drill jigs • hole saws • counter-bores • countersinks • drill bits

7. Polish mouldings using four of the following methods:• wet sanding• cutting compound

• polishing compound• rubbing block

• orbital sander • polisher

8. Trim mouldings using techniques for two of the following resin types: • polyester • vinyl ester • epoxy • phenolic • bismaleimide • cyanate ester

9. Trim mouldings using techniques for two of the following fibre types: • polyethylene • glass • aramid • carbon

10. Trim mouldings that require or incorporate eight of the following features:• straight edges• curved edges• flat surfaces• polished surfaces • shaped surfaces

• radius corners• returns• nett edges• joggle details• removal of join lines

• multiple holes• multiple hole sizes• countersinks• counterbores• further lay-up stages

• inserts to be drilled• inserts to be tapped• solid cores• honeycomb cores• edge filling

11. Trim a range of mouldings which comply with one of the following standards: • ISO 9000 Quality Assurance procedures• customer standards and requirements• company standards and procedures

239




1. Health and safety precautions to be taken and procedures used when working with composite materials, consumables, tools and equipment in the specific work area

2. The hazards associated with composite materials, consumables, tools and equipment and minimising these in the work area





specification etc.) and the completion of such documents8. Conventions and terminology used for trimming activities (scribe lines, sanding grades, types of cutting tools,

speeds)9. Different types of manual and power tools and their merits10. Different types of cutting tools and abrasives and their merits11. Different types of materials used in cutting tools and abrasives and their merits12. Different types of resins, fibres, reinforcement and their merits13. The visual identification of cured composite materials14. The identification and rectification of defects in composite mouldings15. The methods used in the trimming of composite mouldings16. Operations and their sequence when preparing for trimming activities17. Methods for handling composite mouldings throughout the trimming activities18. Tools and equipment used in trimming activities and their care, preparation and control procedures19. The care of and safe handling of composite mouldings throughout the trimming cycle20. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

240






(if required)Evidence TypeDateCarry out during trimming activities (ALL)use issue production docshealth & safety docscorrect tools for activitykeep work area safeCarry out when preparing for trimming activity (ALL)moulding correct/completecheck moulding for defectsselect correct equipmentcheck suitable equipmentprotect mouldingMark out Mouldings (ALL)scriberheight gaugemoulded scribe linescentre punchtrimming templatesCut Mouldings (TWO methods)cutting wheels/discssawsrouterstrim jigsSand Mouldings (THREE methods)rubbing blocksdiamond filespencil grindersdisc sandersbelt sandersUse Hand Drill or Pedestal Drill to Drill Mouldings (THREE methods)drill jigshole sawscounter-borescountersinksdrill bitsPolish Mouldings (FOUR)wet sandingcutting compoundpolishing compoundrubbing blockorbital sanderpolisherTrim Mouldings for different resin types (TWO)polyestervinyl esterepoxyphenolicbismaleimidecyanate ester


241

Unit 53 Trimming Composite Mouldings using Hand Tools (continued)

Trim Mouldings for different fibre types (TWO)polyethyleneglassaramidcarbonTrim Mouldings that Require or Incorporate Features (EIGHT)straight edgescurved edgesflat surfacespolished surfacesshaped surfacesradius cornersreturnsnett edgesjoggle detailsremoval of join linesmultiple holesmultiple hole sizescountersinkscounter-boresfurther lay up stagesinserts to be drilledinserts to be tappedsolid coreshoneycomb coresedge fillingComply with Standards (ONE)ISO 9000customer standardscompany standards


Candidate: Date:

Assessor: Date:

242


243

Unit 54 Joining Plastics using Manual Welding Processes

Unit Summary

This unit identifies the competencies you need to prepare and operate manual plastics welding equipment in accordance with instructions and/or approved welding procedures. You will be required to check that all the workholding equipment and manipulating devices required are available and in a usable condition. You will be expected to check the welding equipment to ensure that all gas supplies and electrical inputs are securely connected and free from damage. In preparing to weld you will need to set and adjust the welding conditions in line with the instructions or welding procedure specification. You must operate the equipment safely and correctly and make any necessary adjustments to settings in line with your permitted authority in order to produce the welded joints to the required specification.

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

Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will provide an understanding of how manual plastics welding processes work. You will know about the equipment, materials and consumables in adequate depth to provide a sound background for the welding operations to be performed, and for ensuring the work output is produced to the required specification. You will understand the safety precautions required when carrying out the welding activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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You must:1. Set up, check, adjust and use plastics welding and related equipment to include two of the following:

(one of the processes chosen must be hot gas or extrusion welding)hot gasextrusionsocket fusionheated wedge

2. Use materials and consumables as appropriate to the welding process used to include both of the following:two types of material from different material groupstwo sizes or types of consumables

3. Produce welded joints as appropriate to the process which incorporate either:• Fillet welds

or• Butt welds

or• Socket welds

or• Lap welds

5. Weld joints according to approved welding procedures in good access situations in two of the following BS EN287 positions or two other positions as appropriate to the process:

Flat (PA)Horizontal vertical (PB)Horizontal (PC)Vertical upwards (PF)

5. Produce welded components which:achieve a minimum weld quality in accordance with EN 13067 or as required by the application

standardmeet the required dimensional accuracy within specified tolerances

245




1. The safe working practices and procedures to be observed when working with manual plastics welding equipment (general workshop and site safety, appropriate personal protective equipment, fire prevention, protecting other workers, safety in enclosed/confined spaces; fume control; accident procedures; statutory regulations)

2. The hazards associated with plastics welding and how they can be minimised (live electrical components, fumes and gases, hot material, elevated working temperature, enclosed spaces)

3. The manual plastics welding processes (basic principles of hot gas, extrusion, socket fusion and geomembrane welding; ancillary equipment; care of equipment; consumables; power ranges)

4. Types of consumables and their correct storage5. The types of welded joints to be produced (fillet and butt welds, single and multi-run welds, joints in pipe plate and

sections, welding positions)6. Setting up and restraining the joint (the use of jigs and fixtures, restraining devices, tack welding size and spacing in

relationship to material thickness)7. Checks to be made prior to welding (confirming correct set-up of joint, cleanliness of materials, condition of gas and

electrical connections, earthing arrangements, operating parameters)8. The techniques of operating the welding equipment to produce a range of joints in the various joint positions (fine

tuning parameters, correct manipulation of consumables, safe closing down of the welding equipment)9. The importance of complying with the job instructions and the welding procedure specification10. Problems that can occur with the welding activities and how these can be overcome (causes of distortion and

methods of control; effects of welding on materials and sources of weld defects; methods of prevention)11. The organisational quality control systems used and weld standards to be achieved12. Weld inspection and test procedures used, including destructive and non-destructive methods13. Personal approval tests and their applicability to your work14. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

246






(if required)Evidence TypeDateSet up, Check, Adjust & Use Plastic Welding Equipment (TWO - one of the processes must be hot gas or extrusion)

hot gasextrusionsocket fusionheated wedgeUse Appropriate Materials & Consumables (BOTH)two types of material from different material groupstwo sizes or types of consumablesProduce Welded Joints as appropriate incorporating EITHERfillet weldsOR butt weldsOR socket weldsOR lap weldsWeld Joints to Approved Procedures in BS EN287 Positions or Other Appropriate Positions (TWO)PAPBPCPFProduce Welded Components to Quality Standard EN 13067 or as requiredgeneralMeet Dimensional Accuracywithin required tolerances


Candidate: Date:

Assessor: Date:

247

Unit 55 Bonding Composite Mouldings

Unit Summary

This unit identifies the competencies you need to bond composite mouldings (cured panels, moulds, components and jigs) in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to bond advanced composites materials using the correct techniques.

You will produce a range of bonded composite mouldings incorporating a variety of features and using a range of techniques and processes. Bonded mouldings produced will include a range of resin, fibre and adhesive materials.

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

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying composite bonding techniques and procedures. You will understand the bonding techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the work produced is to the required specification. You will understand the safety precautions required when carrying out the composite bonding activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

248



You must:a. Work safely at all times, complying with health and safety and other relevant regulations and guidelinesb. Follow the relevant bonding procedure specification and job instructionsc. Check that the materials to be bonded and bonding agents comply with the specificationd. Correctly prepare the parent materials and bonding agents in line with the bonding specificatione. Carry out the bonding operations using the specified processes and techniques to position and bond thef. materials in their correct locations g. Ensure that any equipment used to maintain surface contact during the bonding activities is set up and used correctlyh. Achieve bonds of the required quality and within the specified dimensional accuracy i. Deal promptly and effectively with problems within your control and report those that cannot be solved


You must:1. Carry out all of the following during the bonding activities:


2. Carry out all the following activities when preparing for the bonding activity: • check mouldings are correct and complete• check for any defects in the mouldings• check bonding materials are within life

• check availability of ancillary materials required• select correct equipment for the activity• check equipment is suitable for use

• identify and protect the moulding and bonding materials in the work area• check bonding materials are correct and complete

3. Bond composites mouldings using techniques for two of the following: • one part pastes • two part pastes • film adhesives • syntactic films

4. Prepare bonding surfaces using four of the following methods: • peel plies• templates

• abrading• bead blasting

• water cleaning• solvent cleaning

• dry fitting• acid etching

• priming• surface masks

5. When bonding composite mouldings, use three of the following methods:• dry fitting• bonding sequences• shimming materials

• mixing adhesives• wetting out by brush• applicator gun

• laying film adhesives• oven curing• heated press

6. During curing, retain the bond using two of the following: • weighting down• bonding jigs

• pinning joins • clamping • press • vacuum bagging

7. Bond composites mouldings using techniques for two of the following: • sandwich panels • butt joins • overlap joins • joggle joins • return joins

8. Bond composites mouldings using techniques for two of the following:• flat surfaces • shaped surfaces • internal surfaces • external surface

9. Use techniques for bonding three of the following materials to the composite moulding:• other composites • metals • ceramics • plastics • wood based materials

(continued over page)

249


10. Bond composite mouldings using adhesives suitable for two of the following resin types:• polyester • epoxy • phenolic • bismaleimide • cyanate ester • vinyl ester

11. Bond composite mouldings using adhesives suitable for two of the following fibre types:• polyethylene • glass • aramid • carbon • other specific types

12. Bond a range of mouldings which comply with one of the following standards:• ISO 9000 Quality Assurance procedures• customer standards and requirements• company standards and procedures



1. Health and safety precautions to be taken and procedures used when working with composite materials, consumables, tools and equipment in the specific work area

2. The hazards associated with composite materials, consumables, tools and equipment and minimising these in the work area





specification etc.) and the completion of such documents8. Conventions and terminology used for bonding (gel points, cure times, bond thickness, bond strength, peel strength)9. Different types of composite resin systems, fibres, reinforcements and their merits10. Different bonding agents and their merits11. Correct methods of storage and handling of bonding agents12. Methods of preparation for bonding different materials13. Mixing methods and ratios for two-part pastes, and the associated working times14. Methods of application for different bonding agents15. Methods of retaining the bond during curing, and their merits16. Tools and equipment used in bonding activities and their care, preparation and control procedures17. The identification and rectification of bond defects18. Problems that can occur during the bonding process, including defects such as contamination, distortion19. How defects can be overcome during the bonding activity20. The extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

250






(if required)Evidence TypeDateCarry out during Bonding Activities (ALL)use correct documentationuse health & safety docscorrect tools for activitykeep work area safeCarry out when preparing for Bonding Activities (ALL)check mouldings correctcheck mouldings for defectsbonding material within lifeancillary materials availableselect correct equipmentcheck equipment suitableprotect moulding & bonding materialscheck bonding materials correctBonding Composite Mouldings Techniques (TWO)one part pastestwo part pastesfilm adhesivessyntactic filmsPrepare Bonding Surfaces (FOUR methods)peel pliestemplatesabradingbead blastingsolvent cleaningwater cleaningdry fittingacid etchingprimingsurface masksBonding Composite Mouldings (THREE Methods)dry fittingbonding sequencesshimming materialsmixing adhesiveswetting out by brushapplicator gunlaying film adhesivesoven curingheated pressRetain Bond During Curing (TWO)weighting downbonding jigspinning joinsclampingpressvacuum bagging

(continued over page)

251

Unit 55 Bonding Composite Mouldings (continued)

Bonding Composites Moulding Techniques (TWO)sandwich panelsbutt joinsoverlap joinsjoggle joinsreturn joinsBond Composites Moulding Techniques (TWO)flat surfacesshaped surfacesinternal surfacesexternal surfaceUse Techniques for Bonding Materials to Composite Moulding (THREE)other compositesmetalsceramicsplasticswood based materialsBond Composite Mouldings Using Adhesives Suitable for Resins (TWO types)polyesterepoxyphenolicbismaleimidecyanate estervinyl esterBond Composite Mouldings Using Adhesive Suitable for Fibre (TWO types)polyethyleneglassaramidcarbonother specific typesBond a range of mouldings which comply with Standards (ONE)ISO 9000customer standardscompany standards


Candidate: Date:

Assessor: Date:

252

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253

Level 3 NVQ on Fabrication and Welding Level 3

Opportunities for generation of Key Skills evidence:

The Level 3 award in Fabrication and Welding has been contextualised by EMTA from the National Engineering Competency Standards (ECS). The following table lists the opportunities for generation of Key Skills evidence for each unit in the award and also gives reference to the ECS unit it has been derived from.

Key Skills ReferenceFabrication and Welding Unit ECS Unit Communication Application of

NumberProblem Solving

1 Complying with Statutory Regulations and Organisational Safety Requirements

N/A

2 Using and Interpreting Engineering Drawings and Documents

1.13 C2.1aC2.2

N2.1 PS1.1PS1.2PS1.3

3 Working Efficiently and Effectively in Engineering

N/A

4 Welding Materials by the Manual Metal Arc Process

3.09 C1.1C2.2

PS1.1PS1.2PS1.3

5 Welding Materials by the Manual MIG/MAG and other Continuous Wire Processes

3.09 C1.1C2.2

PS1.1PS1.2PS1.3

6 Welding Materials by the Manual TIC and Plasma Arc Welding Process

3.09 C1.1C2.2

PS1.1PS1.2PS1.3

7 Welding Materials by the Manual Gas Welding Process

3.09 C1.1C2.2

PS1.1PS1.2PS1.3

8 Welding Pipe/Tube using Multiple Manual Arc Welding Processes

3.09 C1.1C2.2

PS1.1PS1.2PS1.3

9 Welding Plate using Multiple Manual Arc Welding Processes

3.09 C1.1C2.2

PS1.1PS1.2PS1.3

10 Preparing Mechanised Arc Welding Equipment for Production

2.09 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

11 Preparing Resistance Spot, Seam and Projection Welding Machines for Production

2.09 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

12 Preparing Laser Welding Machines for Production

2.09 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

13 Preparing Electron Beam Welding Machines for Production

2.09 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

254

Key Skills ReferenceFabrication and Welding Unit ECS Unit Communication Application

of NumberProblem Solving

14 Preparing Friction Welding Machines for Production

2.09 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

15 Preparing Brazing Machines for Production

2.09 C2.1aC2.2C2.3

N2.1 PS1.1PS1.2PS1.3

16 Welding Materials with Mechanised Arc Welding Equipment

3.10 C1.1C2.2

PS1.1PS1.2PS1.3

17 Welding Materials using Resistance Spot, Seam and Projection Welding Machines

3.10 C1.1C2.2

PS1.1PS1.2PS1.3

18 Welding Materials using Laser Welding Machines

3.10 C1.1C2.2

PS1.1PS1.2PS1.3

19 Welding Materials using Electron Beam Welding Machines

3.10 C1.1C2.2

PS1.1PS1.2PS1.3

20 Welding Materials using Friction Welding Machines

3.10 C1.1C2.2

PS1.1PS1.2PS1.3

21 Joining Materials using Brazing Machines

3.10 C1.1C2.2

PS1.1PS1.2PS1.3

22 Marking Out Components for Metalwork

2.04 C2.1aC2.3

N2.1 PS1.2PS1.2PS1.3

23 Cutting Sheetmetal to Shape using Hand and Machine Tools

3.03 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

24 Forming Sheetmetal using Hand and Machine Tools

3.16 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

25 Producing Sheetmetal Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

26 Heat Treating Materials for Fabrication Activities

3.15 C1.1C2.2

PS1.1PS1.2PS1.3

27 Developing and Marking Out Templates for Metalwork

2.04 C2.1aC2.3

N2.1 PS1.1PS1.2PS1.3

28 Joining Fabricated Components using Mechanical Fasteners

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

255



29 Bonding Engineering Materials using Adhesives

3.11 C1.1C2.2

PS1.1PS1.2PS1.3

30 Joining Materials by Resistance Spot Welding

3.10 C1.1C2.2

PS1.1PS1.2PS1.3

31 Producing Fillet Welding Joints using a Manual Welding Process

3.09 C1.1C2.2

PS1.1PS1.2PS1.3

32 Cutting Plate and Sections using Shearing Machines

3.04 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

33 Cutting and Shaping Materials using Portable Thermal Cutting Equipment

3.04 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

34 Cutting Materials using Saws and Abrasive Discs

3.04 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

35 Bending and Forming Plate using Press Brakes or Bending Machines

3.06 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

36 Forming Platework using Power Rolling Machines

3.06 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

37 Producing and Finishing Holes using Drilling Machines

3.04 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

38 Producing Platework Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

39 Slinging, Lifting and Moving Materials and Components

4.08 PS2.1PS2.2PS2.3

40 Forming Structural Sections using Machines

3.06 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

41 Producing Structural Steel Ancillary Components

3.03 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

42 Producing Major Structural Components/Sub-assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

43 Erecting Structural Steelwork 4.05 C2.1aC2.3

PS2.1PS2.2PS2.3

256



44 Forming Pipework by Machine Bending

3.06 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

45 Producing Pipe Fabrications 3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

46 Producing Socket and Flange Fillet Welded Joints in Pipe using a Manual Welding Process

3.09 C1.1C2.2

PS1.1PS1.2PS1.3

47 Producing Components by Fibre Reinforced Plastic (FRP) Moulding

3.05 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

48 Producing Components by Acrylic Moulding

3.05 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

49 Producing Components from Carbon Fibre

3.05 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

50 Producing Components from Glass Fibre

3.05 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

51 Producing Composite Assemblies

3.12 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

52 Producing Components by Vacuum Forming

3.06 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

53 Trimming CompositeMouldings using Hand Tools

3.03 C1.1C2.2

N2.1 PS1.1PS1.2PS1.3

54 Joining Plastics using Manual Welding Processes

3.09 C1.1C2.2

PS1.1PS1.2PS1.3

55 Bonding Composite Mouldings

3.11 C1.1C2.2

PS1.1PS1.2PS1.3

257

Further information

Further information regarding centre/scheme approval or any aspect of assessment of the NVQs should be referred to the relevant City & Guilds regional/national office:

Region Telephone Facsimile

City & Guilds Scotland 0131 226 1556 0131 226 1558

City & Guilds North East 0191 402 5100 0191 402 5101

City & Guilds North West 01925 897900 01925 897925

City & Guilds Yorkshire 0113 380 8500 0113 380 8525

City & Guilds Wales 02920 748600 02920 748625

City & Guilds West Midlands 0121 359 6667 0121 359 7734

City & Guilds East Midlands 01773 842900 01773 833030

City & Guilds South West 01823 722200 01823 444231

City & Guilds London and South East

020 7294 2820 020 7294 2419

City & Guilds Southern 020 7294 2724 020 7294 2412

City & Guilds East 01480 308300 01480 308325

City & Guilds Northern Ireland/ Ireland

028 9032 5689 028 9031 2917

City & Guilds Head Office –Customer Service Enquiry Unit

020 7294 2800 020 7294 2400

Website http://www.city-and-guilds.co.uk

The National Occupational Standards have been produced by SEMTA who can provide advice on learning, apprenticeships and careers within the industry.

SEMTA

14 Upton Road Watford Hertfordshire WD17 0JT

Tel: 01923 238441Email: [email protected]: www.semta.org.uk

SP-03-1681