Summary Document of the New ABC Level 1, 2 and 3 Qualifications in Fabrication and Welding Practice

Transcription

1 Summary Document of the New ABC Level 1, 2 and 3 Qualifications in Fabrication and Welding Practice

2 Contents Contents... 2 Introduction... 3 Qualifications Codes... 4 Qualifications Structure Summaries... 5 ABC Level 1 Certificate in Fabrication and Welding Practice... 5 ABC Level 2 Award in Fabrication and Welding Practice... 6 ABC Level 2 Certificate in Fabrication and Welding Practice... 7 ABC Level 3 Certificate in Fabrication and Welding Practice... 8 ABC Level 3 Diploma in Fabrication and Welding Practice... 9 Qualifications Assessment Summaries ABC Level 1 Certificate in Fabrication and Welding Practice ABC Level 2 Award in Fabrication and Welding Practice ABC Level 2 Certificate in Fabrication and Welding Practice ABC Level 3 Certificate in Fabrication and Welding Practice ABC Level 3 Diploma in Fabrication and Welding Practice Summaries 2

3 Introduction ABC Awards have updated the current suite of Fabrication and Welding qualifications. The new suite of qualifications have been revised to include the latest fabrication and welding techniques, materials, processes and practices, and assessed in line with industry demands, which include updated rigorous practical assessments and online on-demand assessments. Qualification structures have been developed with the typical learner in mind, to ensure the units contained within them are relevant and facilitate progression, whether that is onto higher levels of learning, employment or specialist fabrication and welding procedures. The qualifications have been developed in conjunction with academia and industry experts and informed by the work of professional bodies in the fabrication and welding field. Summaries 3

4 Qualifications Codes ABC Level 1 Certificate in Fabrication and Welding Practice ABC Awards Code C Ofqual Code 603/2239/1 ABC Level 2 Award in Fabrication and Welding Practice ABC Awards Code A Ofqual Code 603/2242/1 ABC Level 2 Certificate in Fabrication and Welding Practice ABC Awards Code C Ofqual Code 603/2243/3 ABC Level 3 Certificate in Fabrication and Welding Practice ABC Awards Code C Ofqual Code 603/2258/5 ABC Level 3 Diploma in Fabrication and Welding Practice ABC Awards Code D Ofqual Code 603/2259/7 Summaries 4

5 Qualifications Structure Summaries ABC Level 1 Certificate in Fabrication and Welding Practice Learners must pass all 4 units to achieve the qualification. Units 1. Health and Safety in an Industrial Environment 2. Welding Processes (Manual Metal-Arc and Metal Active Gas) 3. Fabrication Processes (Sheet Metal and Plate) Unit Number Level Credit Value GLH K/616/ M/616/ T/616/ Engineering Drawing A/616/ GLH: 200 hours TQT: 200 hours Credit value: 20 Summaries 5

6 ABC Level 2 Award in Fabrication and Welding Practice Learners wishing to follow a Welding Pathway must pass a minimum of 2 units from Group B. Learners wishing to follow a Fabrication and Welding Pathway must pass a minimum of 1 unit from Group B and minimum of 1 unit from Group C. For this qualification, the Group A unit is not applicable and the Group D unit is optional. Units Group A Unit Number Level Credit Value 1. NA NA NA NA NA GLH Group B 2. Manual Metal-Arc Welding Low Carbon Steel or Stainless Steel 3. Metal Active Gas Welding Low Carbon Steel, Stainless Steel or Aluminium 4. Tungsten Inert Gas Shielded Welding Low Carbon Steel, Stainless Steel or Aluminium Group C J/616/ L/616/ R/616/ Fabrication Processes Plate J/616/ Fabrication Processes Sheet Metal Group D 7. Engineering Drawing Using Manual and CAD Techniques L/616/ R/616/ GLH: 100 hours TQT: 120 hours Credit value: 12 Summaries 6

7 ABC Level 2 Certificate in Fabrication and Welding Practice Learners wishing to follow a Welding Pathway must pass a minimum of 4 units. 1 unit must be from Group A and 3 units must be from Group B. Learners wishing to follow a Fabrication and Welding Pathway must pass a minimum of 4 units. 1 unit must be from Group A. 1 unit must be from Group B and 1 unit must be from Group C. A 4 th unit can come from Group B, C or D. Units Group A 1. Materials, Science and Calculations for Fabrication and Welding Practice Group B 2. Manual Metal-Arc Welding Low Carbon Steel or Stainless Steel 3. Metal Active Gas Welding Low Carbon Steel, Stainless Steel or Aluminium 4. Tungsten Inert Gas Shielded Welding Low Carbon Steel, Stainless Steel or Aluminium Group C Unit Number Level Credit Value GLH F/616/ J/616/ L/616/ R/616/ Fabrication Processes Plate J/616/ Fabrication Processes Sheet Metal Group D 7. Engineering Drawing Using Manual and CAD Techniques L/616/ R/616/ GLH: 230 hours TQT: 260 hours Credit value: 26 Summaries 7

8 ABC Level 3 Certificate in Fabrication and Welding Practice Learners wishing to follow a Welding Pathway must pass a minimum of 4 units. 1 unit must be from Group A and 3 units must be from Group B. Learners wishing to follow a Fabrication and Welding Pathway must pass a minimum of 4 units. 1 unit must be from Group A. 1 unit must be from Group B and 1 unit must be from Group C. A 4 th unit can come from Group B or C. Units Group A 1. Materials, Science and Calculations for Fabrication and Welding Practice Group B 2. Manual Metal-Arc Welding (Vertical) Low Carbon Steel or Stainless Steel. 3. Metal Active Gas Welding (Vertical) Low Carbon Steel, Stainless Steel or Aluminium 4. Tungsten Inert Gas Shielded Welding (Vertical) Low Carbon Steel, Stainless Steel or Aluminium Group C 5. Fabrication Processes Plate (3 mm and Above in Thickness) 6. Fabrication Processes Sheet Metal (below 3 mm in Thickness) Unit Number Level Credit Value GLH D/616/ H/616/ K/616/ M/616/ T/616/ A/616/ GLH: 230 hours TQT: 290 hours Credit value: 29 Summaries 8

9 ABC Level 3 Diploma in Fabrication and Welding Practice Learners wishing to follow a Welding Pathway must pass a minimum of 7 units. 4 units must come from the Level 3 Certificate Welding pathway. A further 3 units must come from Group D. Learners wishing to follow a Fabrication and Welding Pathway must pass a minimum of 7 units. 4 units must come from the Level 3 Certificate Fabrication and Welding pathway. 1 unit must come from Group D and 1 unit must be from Group E. A 7 th unit can come from Group D or E. In addition to both pathways, all learners must pass a further end-ofprogramme 40 question multiple-choice question (MCQ) examination on either Welding Practice and Procedures or Fabrication Practice and Procedures. Summaries 9

10 Units Group D 7. Manual Metal-Arc Welding (Overhead) Low Carbon Steel or Stainless Steel 8. Metal Active Gas Welding (Overhead) Low Carbon Steel, Stainless Steel or Aluminium 9. Tungsten Inert Gas Shielded Welding (Overhead) Low Carbon Steel, Stainless Steel or Aluminium 10. Thick Plate Welding using Flux Cored Metal Active Gas Welding 11. Pipe Welding using Manual Metal-Arc Welding, Metal Active Gas Welding or Tungsten Inert Gas Shielded Welding Group E 12. Advanced Fabrication Processes Plate (3 mm and Above in Thickness) 13. Advanced Fabrication Processes Sheet Metal (below 3 mm in Thickness) End of programme MCQ End-of-programme MCQ examination: Welding Practice and Procedures or Fabrication Practice and Procedures Unit Number Level Credit Value GLH F/616/ J/616/ L/616/ T/616/ A/616/ F/616/ J/616/ NA 3 NA NA GLH: 440 hours TQT: 500 hours Credit value: 50 Summaries 10

11 Qualifications Assessment Summaries ABC Level 1 Certificate in Fabrication and Welding Practice All learners must pass all four mandatory units to achieve the qualification. Assessment of this qualification will be covered by: 1. Unit 1 Health and Safety in an Industrial Environment o Completion of a risk assessment document 2. Unit 2 Welding Processes o Practical welding task 3. Unit 3 Fabrication Processes o Practical fabrication assembly 4. Unit 4 Engineering Drawing o Produce an orthographic drawing A mandatory multiple-choice external examination o 30 questions, 60% pass mark (18 / 30) o The time given for this exam is 1 hour. o Questions will cover the following range Unit No. of questions 1. Health and Safety in an Industrial Environment Welding Processes (Manual Metal-Arc and Metal 7 Active Gas) 3. Fabrication Processes (Sheet Metal and Plate) 7 4. Engineering Drawing 6 Total 30 Summaries 11

12 ABC Level 2 Award in Fabrication and Welding Practice All learners must pass a minimum of two units to achieve the qualification. 1. Unit 1 Not applicable to the Level 2 Award 2. Unit 2 Manual Metal-Arc Welding Low Carbon Steel or Stainless Steel o Complete a single vee butt weld welded in the PA (flat) position. o Complete a tee fillet weld welded in the PB (horizontal vertical) position. o On completion, both welds shall be subjected to visual and destructive testing. of the welding procedure for the single vee butt welded joint. 3. Unit 3 Metal Active Gas Welding Low Carbon Steel, Stainless Steel or Aluminium o Assessment requirements same as Unit 2 4. Unit 4 Tungsten Inert Gas Shielded Welding Low Carbon Steel, Stainless Steel or Aluminium o Assessment requirements same as Unit 2 5. Unit 5 Fabrication Processes Plate o Produce a fabricated assembly in materials greater than 3 mm in thickness that meets dimensional accuracy and within the stated tolerances. of the fabrication procedure for the fabricated assembly. 6. Unit 6 Fabrication Processes Sheet Metal o Produce a fabricated assembly in materials less than 3 mm in thickness that meets dimensional accuracy and within the stated tolerances. of the fabrication procedure for the fabricated assembly. 7. Unit 7 Engineering Drawing Using Manual and CAD Techniques o Produce an orthographic drawing in first or third angle projection of a fabricated assembly. The completed drawing should cover: full details of each elevation (front and end elevation, plan view) Summaries 12

13 show hidden detail fully dimensioned to current standards title box showing all relevant details use of appropriate symbols to current standards drawn to scale. ABC Level 2 Certificate in Fabrication and Welding Practice All learners must pass a minimum of four units to achieve the qualification 1. Unit 1 Materials, Science and Calculations for Fabrication and Welding Practice o A mandatory multiple-choice external examination o 30 questions, 60% pass mark (18 / 30) o The time given for this exam is 1 hour. o Questions will cover a minimum of 1 and maximum of 2 from each assessment criteria in the unit. Assessment requirements for Units 2 7 as per the ABC Level 2 Award in Fabrication and Welding Practice. Summaries 13

14 ABC Level 3 Certificate in Fabrication and Welding Practice All learners must pass a minimum of four units to achieve this qualification. 1. Unit 1 Materials, Science and Calculations for Fabrication and Welding Practice o A mandatory multiple-choice external examination o 40 questions, 60% pass mark (24 / 40) o The time given for this exam is 1½ hours. o Questions will cover the following range: Learning outcome 1. Identify a range of materials used in engineering 6 2. Know about the crystalline structure of weld deposits in steels 3. Know about heat treatments and the effects of heat on materials 4. Know about the mechanical testing of materials and the properties of materials 5. Understand the structure and state of matter 3 No. of questions Understand the units used in the SI system 1 7. Understand the electrical principles and conditions of welding processes 8. Be able to use calculations relating to fabrication and welding activities 9. Know about the problems associated with the manufacture of fabricated and welded assemblies 10. Know the importance of quality assurance in fabrication and welding activities Total Summaries 14

15 2. Unit 2 Manual Metal-Arc Welding (Vertical) Low Carbon Steel or Stainless Steel. o Complete a single vee butt weld welded in the PF (vertical up) position. o Complete a tee fillet weld welded in the PF (vertical up) position. o On completion, both welds shall be subjected to visual and destructive testing. of the welding procedure for the single vee butt welded joint. 3. Unit 3 Metal Active Gas Welding (Vertical) Low Carbon Steel, Stainless Steel or Aluminium o Assessment requirements same as Unit 2 4. Unit 4 Tungsten Inert Gas Shielded Welding (Vertical) Low Carbon Steel, Stainless Steel or Aluminium o Complete a butt weld welded in the PF (vertical up) position. o Complete a tee fillet weld welded in the PF (vertical up) position. o On completion, both welds shall be subjected to visual and destructive testing. of the welding procedure for the butt welded joint. 5. Unit 5 Fabrication Processes Plate (3 mm and Above in Thickness) o Produce a fabricated assembly that meet dimensional accuracy and within stated tolerances. of the fabrication procedure for the fabricated pipe end connection. 6. Unit 6 Fabrication Processes Sheet Metal (Below 3 mm in Thickness) o Produce a fabricated assembly that meet dimensional accuracy and within stated tolerances. of the fabrication procedure for the fabricated sheet metal guard. Summaries 15

16 ABC Level 3 Diploma in Fabrication and Welding Practice All learners must pass a minimum of seven units to achieve this qualification. In addition, learners must pass a further end-of-programme 40 question multiple-choice question (MCQ) examination on either Welding Practice and Procedures or Fabrication Practice and Procedures. Assessment requirements for Units 1 6 as per the ABC Level 3 Certificate in Fabrication and Welding Practice. 7. Unit 7 Manual Metal-Arc Welding (Overhead) Low Carbon Steel or Stainless Steel o Complete a single vee butt weld in the PE (overhead) position. o Complete a tee fillet weld in the PE (overhead) position. o On completion, both welds shall be subjected to visual and destructive testing. of the welding procedure for the single vee butt welded joint. 8. Unit 8 Metal Active Gas Welding (Overhead) Low Carbon Steel, Stainless Steel or Aluminium o Assessment requirements same as Unit 7 9. Unit 9 Tungsten Inert Gas Shielded Welding (Overhead) Low Carbon Steel, Stainless Steel or Aluminium o Complete a butt weld welded in the PE (overhead) position. o Complete a tee fillet weld welded in the PE (overhead) position. o On completion, both welds shall be subjected to visual and destructive testing. of the welding procedure for the butt welded joint. 10. Unit 10 Thick Plate Welding using the Flux Cored Welding Process o Complete a double vee butt weld in low carbon steel in a thickness of 10 mm or above welded in the PA (flat) position. o Complete a tee fillet weld in low carbon steel in a thickness of 10 mm or above welded in the PA (flat) or PC (horizontal) position. o On completion, all welds shall be subjected to visual and destructive testing. Summaries 16

17 of the welding procedure for the double vee butt welded joint. 11. Unit 11 Pipe Welding using Manual Metal-Arc Welding, Metal Active Gas or Tungsten Inert Gas Shielded Welding o Complete a single vee pipe butt weld in a choice of materials to be welded by ONE process (MMA, MIG/MAG or TIG) to be welded in the PA 1G (pipe rotating flat) position. o Complete a single vee pipe butt weld in a choice of materials to be welded by ONE process (MMA, MIG/MAG or TIG) to be welded in the PH 5G (fixed vertical up) position. o Complete a pipe to flange weld in a choice of materials to be welded by ONE process (MMA, MIG/MAG or TIG) to be welded in the PA 1FR (pipe rotating flat) position. o Complete a set-on branch weld in a choice of materials to be welded by ONE process (MMA, MIG/MAG or TIG) to be welded in the PA (flat) position. o On completion, all welds shall be subjected to visual and destructive testing. of the welding procedure for the single vee butt (rotated) welded joint. 12. Unit 12 Advanced Fabrication Processes Plate (3 mm and Above in Thickness) o Produce a fabricated assembly in materials greater than 3 mm in thickness that meets dimensional accuracy and within the stated tolerances. of the fabrication procedure for the fabricated box and cylinder assembly. 13. Unit 13 Advanced Fabrication Processes Sheet Metal (Below 3 mm in Thickness) o Produce a fabricated assembly in materials less than 3 mm in thickness that meets dimensional accuracy and within the stated tolerances. of the fabrication procedure for the fabricated rectangle to round assembly. End of programme Mandatory External MCQ Examination on either o Welding Practice and Procedures or Fabrication Practice and Procedures Summaries 17

18 o Each exam will have 40 multiple-choice questions, with a 60% pass mark (24 / 40). o The time given for each exam is 1½ hours. o Questions in each exam will cover the following range: Summaries 18

19 Welding Practice and Procedures No. of questions 1. Health and safety in welding practice 5 2. Power sources and electrical features in welding 5 3. Consumables used in welding 5 4. Welding parameters 5 5. Material preparation for welding 5 6. Defects in welding 5 7. Distortion in welding 5 8. Inspection, QC and QA in welding practice 5 Total 40 Fabrication Practice and Procedures No. of questions 1. Health and safety in fabrication practice 5 2. Safe handling and moving of materials 5 3. Techniques for marking out 5 4. Thermal cutting techniques 5 5. Mechanical cutting techniques 5 6. Forming operations 5 7. Methods used for joining assemblies 5 8. Assembly and inspection of completed assemblies 5 Total 40 Summaries 19