PROGRAM OUTLINE. Welder Level C

Transcription

1 PROGRAM OUTLINE Welder Level C

2 WELDER LEVEL C PROGRAM OUTLINE November 2007 Developed By Industry Training Authority Province of British Columbia

3 FOREWORD This Program Outline was developed to meet the needs of Employers and other Industry Stakeholders. It will be used primarily as a guide for instructors in the delivery of Welder Level C apprenticeship technical training classes sponsored by the Industry Training Authority. Practical demonstration and student participation should be integrated with classroom sessions. Safe working practices, though not always specified in each of the competencies and learning tasks, are an implied part of the program and should be stressed throughout the apprenticeship. This document contains an Occupational Analysis Chart for Welder level C for each general area of competency. Additional Information for Training Providers: This Welder Level C Apprenticeship Program is competency based with many options available for the delivery of technical training, for example; this program may be offered in as a: Full-time day school program (including block release and continuous entry) Continuous entry competency based model Part-time studies (night-school and/or weekend) Several modules may be combined for short courses Some theory may be offered as interactive synchronistic on-line delivery Time lines expressed on the Occupational Analysis Chart are considered as the maximum time allowed and based on consecutive delivery of modules This Program Outline also includes: A list of recommended curriculum and reference textbooks Requirements for Instructor Qualifications, Facilities (classroom and shop sizes), as well as the necessary Tools and Equipment Shop projects and weld destructive tests Welder Level C Program Outline Industry Training Authority i

4 ACKNOWLEDGEMENTS The Program Outline was prepared with the advice and direction from an industry Steering Committee convened by the Mechanical Contractors Association (MCA) with funding support from the Industry Training Authority. Industry Steering Committee Dana Taylor Chair- Mechanical Contractors Association of B.C. Stan Boehm President, S.S. Stainless Inc. Sheldon Frank Welding Articulation Chair, University College of the Fraser Valley Mike Longo Ideal Welders Brad MQuhae President, Accent Stainless Steel Mfg. Ltd. Brad Smith Catalyst Paper Brian Pichette Welding Supervisor, Empire Dynamic Structures Ltd. Paul Sourisseau Interior Forest Labour Relations Association, Co-Chair HITAC Ron Van Eyk President, Van Eyk Manufacturing Corp. John Van Muyen President, I & J Metal Fabrications Ltd. John Little Welding Industry Consultant Les Wiebe Welding Instructor, Thompson Rivers University The Industry Training Authority would like to acknowledge the dedication and hard work of the industry representatives appointed to identify the training requirements of the Welding trade. Industry Subject Matter Experts John Little Welding Industry Consultant Mervyn Kube Piping Industry Apprenticeship Board Jim Carson University College of the Fraser Valley Rod Walters British Columbia Institute of Technology Sheldon Frank University College of the Fraser Valley Les Wiebe Thompson Rivers University Stanley McArthur Catalyst Paper Stan Boehm President, S.S. Stainless Inc. Gerry Dillman Weyerhauser Barry Westgate Spectra Energy Facilitators Dick Vanier Training Consultant- Vanier Training Consultants Ltd. Rick Vanier Facilitator - Vanier Training Consultants Ltd. Jody Jankola Technical Writer - Vanier Training Consultants Ltd. Kathleen ONiel Technical Writer - Vanier Training Consultants Ltd. Michelle Probert Technical Writer - Vanier Training Consultants Ltd. Welder Level C Program Outline Industry Training Authority ii

5 TABLE OF CONTENTS FOREWORD... I ACKNOWLEDGEMENTS... II SECTION 1 OCCUPATION ANALYSIS CHART... 1 SECTION 2 PROGRAM OUTLINE... 6 Suggested Schedule Of Time Allotment For Level C... 7 Program Outline For Level C SECTION 3 TRAINING PROVIDER STANDARDS Welder C Training Provider Standards Welder C Training Provider Standards Facilities Guidelines For Practical Examinations APPENDIX ONE WELDER LEVEL C FINAL WELD TESTS APPENDIX TWO WELDER LEVEL C PROGRAM FINAL PRACTICAL EXAMINATION # APPENDIX THREE WELDER LEVEL C PROGRAM FINAL PRACTICAL EXAMINATION # APPENDIX FOUR WELDER LEVEL C PROGRAM FINAL WELD TEST - # APPENDIX FIVE WELDER LEVEL C PROGRAM FINAL WELD TEST - # APPENDIX SIX WELDER LEVEL C PROGRAM FINAL WELD TEST - # APPENDIX SEVEN WELDER LEVEL C PROGRAM ACHIEVEMENT CRITERIA FOR FINAL WELD TEST Welder Level C Program Outline Industry Training Authority iii

6 SECTION 1 OCCUPATION ANALYSIS CHART Welder Level C Program Outline Industry Training Authority 1

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11 SECTION 2 PROGRAM OUTLINE Welder Level C Program Outline Industry Training Authority 6

12 SUGGESTED SCHEDULE OF TIME ALLOTMENT FOR LEVEL C Theory Practical Line A Applies Occupational Skills % of Time 50% 50% A-1 Describe Scope of Trade and Apprenticeship in BC, and Other Options A-2 Describe Safe Working Practices A-3 Describe WHMIS Training Requirements A-4 Describe Training Requirements for Confined Space Entry A-5 Describe Requirements for H2S Training A-6 Perform Basic Trade Related Mathematical Calculations for Linear Measure A-7 Use Measuring and Layout Tools A-8 Use Hand Tools A-9 Use Power Tools (Electric and Pneumatic) A-10 Discuss Basic Welding Quality Control and Inspection Requirements Line B Performs Oxy-Fuel Cutting Processes (OFC) % of Time 20% 80% B-1 Describe the OFC Process and Its Application B-2 Describe OFC Equipment and Its Operation B-3 Perform Freehand and Guided Cuts on Low Carbon Steel Plate, Sheet, Round Stock, Structural Shapes and Pipe B-4 Perform Cuts with Cutting Machines, Automatic and Semi- Automatic Line C Performs Fusion and Braze Welding Using Oxy-Fuel Process (OFW) % of Time 20% 80% C-1 Describe Fusion Welding, Braze Welding and Brazing Processes and Their Applications C-2 Describe Fusion and Braze Welding Equipment and Their Operation C-3 Describe Filler Metals, Fluxes and Tips Used for Fusion and Braze Welding and Brazing C-4 Describe Joint Design and Weld Positions C-5 Describe Fusion Welding on Low Carbon Steel Sheet C-6 Fusion Weld Stringer Beads and Fillet Welds on Low Carbon Steel Sheet C-7 Fusion Weld Square Groove Welds on Low Carbon Steel Sheet C-8 Braze Weld Fillet Welds on Low Carbon Steel Sheet C-9 Braze Weld Groove Welds on Grey Cast Iron C-10 Silver Alloy Braze on Similar and Dissimilar Metals Welder Level C Program Outline Industry Training Authority 7

13 Theory Practical Line D Performs Shielded Metal Arc Welding (SMAW) % of Time 20% 80% D-1 Describe the SMAW Process and Its Application D-2 Describe SMAW Equipment and Its Operation D-3 Describe and Select Low Carbon Steel Electrodes for SMAW D-4 Describe Basic Joint Design and Weld Positions D-5 Describe Causes of Weld Faults and Distortions in Fabrications and Methods for Prevention and Control D-6 Use the SMAW Process to Weld Beads in the Flat Position D-7 Use the SMAW Process to Weld Fillet Welds on Low Carbon Steel Plate D-8 Use the SMAW Process to Weld Fillet Welds on Low Carbon Steel Sheet D-9 Describe and Demonstrate Surface Build Up and Hardface in the Flat Position on Low Carbon Steel Plate D-10 Use the SMAW process to Weld Groove Welds in the Flat G1 Position on Grey Cast Iron D-11 Describe and Demonstrate Use of SMAW Stainless Steel Electrodes on Low Carbon Steel Plate D-15 Use the SMAW Process to Weld Groove Welds on Low Carbon Steel Plate Line E E-1 E-2 E-3 Performs Electric Arc Cutting, Gouging and Related Processes (AAC) (PAC) (SMAC) % of Time Describe Electric Arc Cutting and Gouging Processes and Their Applications Describe and Demonstrate AAC Equipment Its Cutting and Gouging Operations Describe and Demonstrate PAC Equipment and Its Cutting and Gouging Operations 20% 80% Line F F-1 F-2 F-3 F-4 F-5 F-6 Perform Semi-Automatic Welding (GMAW) (GMAW-P) (FCAW) (GMAW/MC*) % of Time Describe the GMAW, GMAW-P, FCAW and GMAW/MC* Processes and Their Application Describe GMAW, GMAW-P, FCAW and GMAW/MC* Equipment and Their Operation Describe and Select Filler Metal and Shielding Gases for GMAW Use the GMAW Process to Weld Stringer Beads and Fillet Welds on Low Carbon Steel Plate Use the GMAW Process to Weld Fillet Welds on Low Carbon Steel Sheet Use the GMAW Process to Weld Square Groove Welds on Low Carbon Steel Sheet 25% 75% Welder Level C Program Outline Industry Training Authority 8

14 F-7 F-8 F-9 F-10 F-11 F-13 F-16 F-22 F-23 F-24 F-25 F-26 F-27 F-29 Use the GMAW Process to Weld Groove Welds on Low Carbon Steel Plate Use the GMAW-P Process to Weld Fillet Welds on Low Carbon Steel Plate Use the GMAW-P Process to Fillet Weld on Low Carbon Steel Sheet Use the GMAW-P Process to Weld Square Groove Welds on Low Carbon Steel Sheet Use the GMAW-P Process to Weld Groove Welds on Low Carbon Steel Plate Describe and Demonstrate GMAW-P Weld Fillet Welds Using Stainless Steel Filler Metal on Low Carbon Steel Plate and Sheet Describe and Demonstrate Procedures Specific to GMAW and GMAW-P on Aluminum Plate Describe and Select Filler Metals and Shielding Gases for FCAW and GMAW/MC* Use the FCAW Self-Shielding Process Weld to Fillet Welds on Low Carbon Steel Plate Use the FCAW Gas-Shielded Process to Weld to Fillet Welds on Low Carbon Steel Plate Use the FCAW Process to Weld Groove Welds on Low Carbon Steel Plate Use the GMAW/MC* Process to Weld Fillet Weld on Low Carbon Steel Plate Use the GMAW/MC* Process Weld to Groove Welds on Low Carbon Steel Plate Describe and Demonstrate FCAW Fillet Welds Using Stainless Steel Metal Wire on Low Carbon Steel Plate Theory Practical Line G Describe Basic Metallurgy Relating to Production, Properties and Weldability % of Time 90% 10% G-1 Describe Production Processes for Manufacturing Metals G-2 Describe Mechanical and Physical Properties of Metals G-3 Describe Metals G-5 Describe the Alloy Content and Heat Treatments on the Weldability of Steel Line I Describes and Performs Material Handling and Rigging Procedures % of Time 65% 35% I-1 Describe Safety Procedures for Rigging and Material Handling I-2 Perform Safe Working Load Calculations Involving Geometric Formulas, Volumes and Capacities I-3 Use Fibre Ropes to Tie Knots I-4 Describe Slings and Rigging Hardware Uses Welder Level C Program Outline Industry Training Authority 9

15 Theory Practical I-5 Describe Hoisting Equipment I-6 Use Hoisting Equipment to Perform a Lift Line J Reads Welding Drawings % of Time 50% 50% J-1 Perform Mathematical Calculations Involving Formulas, Angles, Triangles and Geometric Construction J-2 Sketch Basic Objects Using Orthographic Projection J-3 Sketch Isometric Drawings of Basic Objects J-4 Sketch a Dimensional Drawing J-5 Identify Common Welding Symbols and Bolted Connections J-6 Read Structural Drawings Line K Layout and Fabricate Components % of Time 15% 85% K-2 Source Required Information K-3 Prepare Work Area K-4 Layout Materials K-5 Prepare Materials K-6 Fabricate Weldments (Shop Projects) Line N Performs Submerged Arc Welding Process (SAW) % of Time 90% 10% N-1 Describe SAW Process and Equipment N-2 Describe Consumables and Fluxes N-3 Describe Operating Parameters N-4 Set Up SAW Equipment N-5 Use SAW Process to Weld Fillet Welds on Low Carbon Steel Plate Total Percentage for Level C 100% Welder Level C Program Outline Industry Training Authority 10

16 PROGRAM OUTLINE FOR LEVEL C Welder Level C Program Outline Industry Training Authority 11

17 LINE A: APPLIES OCCUPATIONAL SKILLS Competency: A-1 Describe Scope of Trade and Apprenticeship in BC, and Other Options Learning Objectives: The learner will be able to describe the scope of the Welder Level C, B and A trade and the apprenticeship in BC, and other options, using a variety of techniques for interpretation. LEARNING TASKS 1. Describe the three levels of training in the BC welder. CONTENT Historical description of apprenticeship training Current apprenticeship Foundation Level C Level B Level A 2. Describe the requirements and procedure for registration at each level. Skills and qualities of a welder Specific job knowledge Equipment knowledge Metal identification Personal qualities 3. Explain the general differences between P-lines and RK lines. 4. Describe employment opportunities for each level of the training program. 5. Describe the Log Book requirements. 6. Explain other more advanced training opportunities which lead to other jobs. The training program Training requirements High school, college or technical training institute Tacker Welding operator Welder Welder fabricator/fitter Identification of the welder Registration seals Training endorsements Qualifications tests, general section Employment record W.P.Q.R. College, technical institute or university: Welding inspector level 1, 2 and 3 Welding technician Welder technologist Mechanical engineer Welding engineer Welder Level C Program Outline Industry Training Authority 12

18 7. Identify industrial and Metal fabricating construction fields that provide Ship building employment opportunities for Pulp and paper mills welders. Wood products manufacture Machinery manufacture Equipment maintenance and repair Smelt and refining Motor vehicle, truck/trailer manufacture Mining Construction Iron and steel mills Special trades Mining services Coal mines Gas distribution and transmission Public administration and defence Machinery wholesalers Forestry and forest services Electric utilities Motor vehicle dealers and repairs Communications equipment and manufacture Pipeline Food and beverage industry 8. Communicate effectively. Resumes Cover letter Internet information sourcing Listening skills Effective verbal communication Non effective verbal communication Workplace culture NOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-1. Achievement Criteria: Given a 10 question test on the scope of the Welder Level C, B and A trade and apprenticeship in BC, and other options, the learner will be able to demonstrate knowledge of the trade by correctly answering 7 or more questions. Welder Level C Program Outline Industry Training Authority 13

19 LINE A: APPLIES OCCUPATIONAL SKILLS Competency: A-2 Describe Safe Working Practices Learning Objectives: The learner will be able to describe safe work practices according to WorkSafeBC standards for Welder Level C trade in BC. LEARNING TASKS 1. Describe applications of WorkSafeBC and OHS in the work place. CONTENT Responsibilities of WorkSafeBC in the workplace Responsibilities of employers in the workplace Responsibilities of employees in the workplace Contravention or regulations Workers who are covered by the WorkSafeBC Workers who are not covered Reporting injury or industrial disease Circumstances for compensation 2. Describe general safety precautions for welding. 3. Describe physical hazards and select PPE for welding. General procedures for shop safety Electrical safety Lock out procedures Worksite safety Safety requirements for welding processes Personal fall protection Safety requirements for ladders and scaffolds Safety requirements for handrails and guardrails Radiation Extreme temperatures Noise Bodily injury hazards Chemical hazards Protective clothing Skin protection (leathers) Head protection Hand protection Foot protection Hearing protection Welder Level C Program Outline Industry Training Authority 14

20 4. Identify fire hazards and describe methods of fire prevention. Eye protection Safety glasses and goggles Face shields Flash goggles Welding helmets Welding goggles Eye protection for electrical welding processes Auto darkening helmets Welding screens and curtains Goggles for oxyfuel welding and cutting Fire triangle Fire preventing and stopping fires The four classes of fires Types of fire extinguishers Fire hazards Fire prevention Clean area of combustible debris Fire/water hose/fire extinguisher set up before and after work Contain sparks by the use of fireretardant blankets Wet area down in high hazard area before starting hot work Cover wall/floor openings with fire retardant blanket Welding work general fire safety precautions WorkSafeBC requirements for fire watch 5. Describe respiratory equipment. Air-line respirator Self contained breathing apparatus (SCBA) Cartridge type respirator NOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-2. Achievement Criteria: Given an 80 question test on the safe working practices according to WorkSafeBC standards for Welder Level C trade in BC, the learner will answer 56 or more questions correctly. The learner will also be evaluated during shop activities and must achieve a grade of 70% or better based on a summative total of Instructor assessment. Welder Level C Program Outline Industry Training Authority 15

21 LINE A: APPLIES OCCUPATIONAL SKILLS Competency: A-3 Describe WHMIS Training Requirements Learning Objectives: The learner will be able to describe WHMIS training requirements. LEARNING TASKS 1. Explain the purpose and necessity of WHMIS in the workplace. CONTENT Canada-wide legislated system Provides information on workplace hazardous materials How to safely use, store and handle hazardous materials Although nation-wide, employer WHMIS compliance is regulated and enforced by the WorkSafeBC province s inspectors 2. Explain the need to identify hazardous materials in the workplace and the 3 main elements of WHMIS. 3. Identify the warning labels based on the six classes of hazardous materials, the symbols and classifications. Each workplace must have a system in place that tells workers what they need to know about the products they work with WHMIS information is provided in three ways: Container labels Materials Safety Data Sheets (MSDSs) Employee training A supplier label must appear on all controlled products received at workplaces in Canada and contain the following information: Product identifier (name of product) Supplier identifier (name of company that sold it) A statement that an MSDS is available Risk phrases (words that describe the main hazards of the product) Welder Level C Program Outline Industry Training Authority 16

22 4. Explain the general duties of employers to provide MSDS sheets and training. MSDSs describe the hazards of the materials used on the job Developed for each product by its manufacturer Supplier must provide specs Employer and Worker must be able to provided proof of training NOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-2. Achievement Criteria: Given a 30 question test on WHMIS training requirements, the learner will be required to answer a minimum of 21 questions correctly. Welder Level C Program Outline Industry Training Authority 17

23 LINE A: APPLIES OCCUPATIONAL SKILLS Competency: A-4 Describe Training Requirements for Confined Space Entry Learning Objectives: The learner will complete the confined space program and be able to describe the hazards associated with confined space hazards as per WorkSafeBC Part 9. LEARNING TASKS 1. Describe the precautions and procedures for confined space entry as per WorkSafeBC Part 9. CONTENT General requirements Responsibilities Hazard assessment and work procedures Identification and entry permits Lockout and isolation Verification and testing Cleaning, purging, venting, inserting Ventilation Standby persons Rescue Lifelines, harnesses and lifting equipment Personal protective equipment and other precautions 2. Describe the most common jobs related to Welder Cs facing confined space entry. Pressure vessels and tanks Excavations Ship hulls Containers Hoppers and chutes NOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-2. Achievement Criteria: Given a 20 question test on hazards associated with confined spaces as per WorkSafeBC Part 9, the learner will correctly answer 14 or more questions. Welder Level C Program Outline Industry Training Authority 18

24 LINE A: APPLIES OCCUPATIONAL SKILLS Competency: A-5 Describe Requirements for H2S Training Learning Objectives: The learner will be able to describe the requirements for H2S training. LEARNING TASKS 1. Describe H2S precautions and procedures. CONTENT Properties, characteristics and locations of H2S Health hazards MSDS requirements Work hazards Initial response strategy How to protect yourself (ventilation, controls and PPE) Respiratory protective equipment Self Contained Breathing Apparatus (SCBA) Supplied Air Breathing Apparatus (SABA) Detecting and monitoring for H2S Detector tube devices Electronic monitors Rescue techniques Rescue breathing Emergency response planning NOTE: Refer to video A Matter of Life and Death (video can be purchased on the following website: **This video has the following inaccuracies that need to be discussed upon viewing: 1. Fire Resistance coveralls are required in all gas and oil field operating areas. This is contrary to the video which showed workers in street clothing. 2. Some companies use a ceiling limit of 10 ppm for Hydrogen Sulphide. Any exposure of H S over 2 10 ppm is prohibited unless an SCBA is used. This is contrary to the video which indicated that the acceptable ceiling limit is 15 ppm. 3. Some companies allow the use of contact lenses inside a SCBA as long as the site First Aid Attendant is aware of their use. This is contrary to the video which indicated that contact lenses were prohibited when donning a SCBA. Achievement Criteria: Given a 10 question test on hazards associated H2S, the learner will correctly answer 7 or more questions. Welder Level C Program Outline Industry Training Authority 19

25 LINE A: APPLIES OCCUPATIONAL SKILLS Competency: A-6 Perform Basic Trade Related Mathematical Calculations for Linear Measure Learning Objectives: The learner will be able to perform basic Welder Level C trade related mathematical calculations for linear measure. LEARNING TASKS 1. Solve problems involving fractions. CONTENT Key terms and concepts used in working with fractions Add and subtract fractions Multiply and divide fractions Calculate averages Change fractions to common denominator Solve problems using whole numbers Solve problems using whole numbers and fractions in practical applications 2. Solve problems involving decimals. 3. Solve problems involving percentage. Read and write decimal fractions Round decimal fractions to specific place values Convert decimal inches to a fraction with a practical denominator Convert decimal feet to fee and inches with a practical denominator Convert fractions to decimals Add and subtract decimal fractions Multiply and divide decimal fractions Convert between fractions and percents Convert between decimals and percents Solve percent problems Welder Level C Program Outline Industry Training Authority 20

26 4. Solve problems involving metric and imperial measure. Identify commonly used metric units of measurement Convert between units of measurement Convert imperial units: feet to inches, square inches to square feet, and cubic measures to gallons NOTE: Refer To Current Welder Training Program Curriculum Module/Line RK2B. Achievement Criteria: Given a 40 question test on basic Welder Level C trade related mathematical calculations for linear measure, the learner will be able to demonstrate knowledge by correctly answering 28 questions or more. Welder Level C Program Outline Industry Training Authority 21

27 LINE A: APPLIES OCCUPATIONAL SKILLS Competency: A-7 Use Measuring and Layout Tools Learning Objectives: The learner will be able to describe and demonstrate the safe use and care of measuring and layout tools as related to the Welder Level C trade. LEARNING TASKS 1. Use layout and measuring tools and their uses. CONTENT Systems of measuring Metric Imperial Layout Measuring tools Pocket measuring tape Steel rule Torpedo level Spirit level Laser level Plumb bob Framing square Combination squares Square head Centre head Protractor head Marking tools Soapstone Scriber or awl Chalkline Divider and trammel points Centre punch Prick punch Spring loaded punch Transfer punch Number and letter stamps Gauges Fillet weld Pipe internal alignment Single purpose weld Bridge cam Automatic weld size Visual weld acceptance criteria NOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-3. Welder Level C Program Outline Industry Training Authority 22

28 Achievement Criteria: Given a 20 question test on the safe use and care of measuring and layout tools used in the Welder Level C trade, the learner will correctly answer 14 or more questions. The learner will also be evaluated on the use of measuring and layout tools as part of a practical shop projects as per the acceptance criteria in the current curriculum module/line P1-5. Welder Level C Program Outline Industry Training Authority 23

29 LINE A: APPLIES OCCUPATIONAL SKILLS Competency: A-8 Use Hand Tools Learning Objectives: The learner will be able to demonstrate the use and care of Welder Level C related hand tools. LEARNING TASKS 1. Use clamping tools, their uses, maintenance and care. CONTENT Safety Bench vise Machine vise Pipe vises Top screw bench chain vise Tri-stand yolk vise Clamps Welding specific line up tools and clamps Pliers Combination Interlocking slip-joint Needle-nose and round-nose MIG 2. Use cutting tools, their uses, maintenance and care. 3. Use other common hand tools, their uses, maintenance and care. Safety Hacksaws Files Manual sheers Cold chisels Bolt cutters Wire cutters Safety Wire brushes MIG pliers Hammers Ball-peen Soft-faced Chipping hammers Sledge hammers Dead blow hammers Cross-peen Drifts Pinch line up bars Pry bars Welder Level C Program Outline Industry Training Authority 24

30 Anvils Wrenches Open-end Box-end Combination Adjustable Cylinder Socket Pipe Hexagon key Screwdrivers Blade Phillips Robertson Torx 4. Use taps and dies and their uses. Safety Taps Tap wrenches Dies Tapping internal threads Common tapping problems Cutting external threads NOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-3 and P1-5. Achievement Criteria: Given a 40 question test on hand tools used in the Welder Level C trade, the learner will correctly answer 28 or more questions. The learner will also be evaluated on the use of hand tools as part of a practical shop project as per the acceptance criteria the current curriculum module/line P1-5. Welder Level C Program Outline Industry Training Authority 25

31 LINE A: APPLIES OCCUPATIONAL SKILLS Competency: A-9 Use Power Tools (Electric and Pneumatic) Learning Objectives: The learner will be able to demonstrate the use and care of Welder C related power tools. LEARNING TASKS CONTENT 1. Use power drilling tools. Safety Portable power drills Keyless chuck drills Hammer drills Magnetic base Drill presses Hollow bits Hole saws Carbide tipped masonry Rechargeable drills 2. Use power grinding tools. Safety Stationary grinders Portable grinders Stationary belt sanders Portable belt sanders Abrasives and disks Carbide burrs Mini belt sanders 3. Use power shearing tools. Safety Power squaring shears Rotary throatless shears Universal machines Iron worker Nibblers Pipe cutters 4. Use power sawing tools. Abrasive cut-off saw Power hacksaw Metal-cutting band saws Reciprocating saws Sabre Circular saws Blades for metal-cutting saws Welder Level C Program Outline Industry Training Authority 26

32 5. Use specialty tools. Scaler Needle scaler NOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-4 and P1-5. Achievement Criteria: Given a 60 question test on power tools used in the Welder Level C trade, the learner will correctly answer 42 or more questions. The learner will also be evaluated on the use of power tools as part of a practical shop project as per the acceptance criteria the current curriculum module/line P1-5. Welder Level C Program Outline Industry Training Authority 27

33 LINE A: Competency: APPLIES OCCUPATIONAL SKILLS A-10 Discuss Welding Quality Control and Inspection Requirements Learning Objectives: The learner will be able to discuss welding quality control and inspection requirements. LEARNING TASKS 1. Describe the different quality and control inspections requirements. CONTENT Examine components (fit-up and preparation) prior to assembly. Examine completed welds Measure final product for compliance to blueprints and drawings Types and uses of non-destructive testing methods Types and uses of destructive testing methods Standards, specifications and codes 2. Describe CWB jurisdiction. Accreditation covers welding certification programs for companies engaged in: Fusion welding Welding consumables Welding inspection organizations 3. Describe CWB certification programs. CSA W 47.1 Steel CSA W 47.2 Aluminum CSA W 55.3 Resistance Welding CSA A 660 Steel Building CSA W 186 Reinforcing Bar NOTE: Refer To Current Welder Training Program Curriculum Module/Line RK-4 and RK-5. Achievement Criteria: Given a 20 question test on welding quality control and inspection requirements, the learner will be able to demonstrate knowledge by correctly answering 14 questions or more. Welder Level C Program Outline Industry Training Authority 28

34 LINE B: PERFORMS OXY-FUEL CUTTING PROCESSES (OFC) Competency: B-1 Describe the OFC Process and Its Application Learning Objectives: The learner will able to describe the OFC process, its applications, techniques used for cutting difficult-to-cut ferrous alloys, the main components of an OFC station, thermal effects and safety precautions. LEARNING TASKS CONTENT 1. Describe the OFC process. Principles of OFC Components of basic OFC systems 2. Describe the applications of OFC. 3. Describe the cutting characteristics of ferrous and non-ferrous metals. 4. Describe the thermal effects of OFC. 5. Describe safety requirements for OFC. Cutting plate, pipe and structural shapes Washing bolts and rivets Gouging and scarfing Stack cutting Cutting machines Ferrous alloys Techniques for cutting ferrous alloys Preheating Waster plates Non-ferrous alloys Aluminum Copper Brass Bronze Magnesium Distortion Surface hardening PPE Fire and explosion prevention Refer to WorkSafeBC for fire watch regulations Toxic fumes/ventilation Cadmium Zinc Lead Beryllium Other alloys Synthetic materials Welder Level C Program Outline Industry Training Authority 29

35 NOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-2. Achievement Criteria: Given a 40 question test on the oxy-fuel process and application, the learner will demonstrate knowledge by correctly answering 28 questions or more. Welder Level C Program Outline Industry Training Authority 30

36 LINE B: PERFORMS OXY-FUEL CUTTING PROCESSES (OFC) Competency: B-2 Describe OFC Equipment and Its Operation Learning Objectives: The learner will be able to describe of the oxygen and fuel gases used in OFC, gas cylinders and regulators, cutting tips and attachments, and cutting machines, used in the OFC process. LEARNING TASKS 1. Describe the gases and their properties, used in OFC. CONTENT Oxygen Acetylene Other fuel gases Mapp gas (methylacetylenepropadiene) Natural gas Propane gas 2. Describe oxygen and fuel gas cylinders. 3. Describe pressure regulators and their functions. 4. Describe oxy-fuel hoses and fittings. Oxygen cylinders Oxygen cylinder valve Cylinder safety device Acetylene cylinders Acetylene cylinder valves Cylinder safety devices Liquid fuel cylinders Storage and handling of cylinders Storage Handling Safety precautions for using cylinders Oxygen and acetylene regulators Single and two-stage regulators Single-stage regulator Two-stage regulator Safe use of regulators Oxy-fuel hose Safe handling of hose Hose fitting Welder Level C Program Outline Industry Training Authority 31

37 5. Describe cutting torches, cutting tips and heating tips. Injector torch Equal pressure torch Torch types One-piece cutting torch Two-piece cutting torch Machine torch Torch line explosions causes and prevention Backfire Flashbacks Reverse flow check valves Cutting tips Cutting tip size Types of cutting tips Tips for special purposes Rivet-cutting tips Gouging tips Heating tips Cutting tip maintenance 6. Describe gas manifold systems. Oxygen manifold systems Acetylene manifold systems 7. Describe oxy-fuel gas cutting accessories and machines. Manual cutting guides Straight-line cutting guide Circle cutting guide templates Cutting machines Straight-line cutting machines Shape-cutting machines Electronic eye tracer Magnetic tracer Pipe-beveling machines Welder Level C Program Outline Industry Training Authority 32

38 8. Describe the correct procedures to assemble, ignite and shut down a portable oxyacetylene outfit. Assemble a portable oxyacetylene outfit Secure the cylinders Remove the caps Crack the valves Attach the regulators Install RFCV Connect the hoses Open the valves Purge the hoses Connect the cutting attachment Set working pressure Select and install the appropriate cutting tip Set working pressure Test for leaks Light and adjust flame Ignite the torch Add oxygen to the flame Shut down an oxyacetylene outfit Disassemble the oxyacetylene outfit NOTE: Refer To Current Welder Training Program Curriculum Module/Line P2-2 and P2-3. Achievement Criteria: Given a 90 question test on oxy-fuel cutting equipment and its operation, the learner will demonstrate knowledge by correctly answering 63 questions or more. Welder Level C Program Outline Industry Training Authority 33

39 LINE B: PERFORMS OXY-FUEL CUTTING PROCESSES (OFC) Competency: B-3 Perform Freehand and Guided Cuts on Low Carbon Steel Plate, Sheet, Round Stock, Structural Shapes and Pipe Learning Objectives: The learner will be able to assemble the appropriate oxy-fuel cutting equipment, set pressures, light and adjust the cutting torch, make freehand and guided cuts on low carbon steel plate, make freehand cuts on round stock, structural shape and pierce holes in low carbon steel plate. LEARNING TASKS 1. Describe the characteristics of an acceptable cut. CONTENT Characteristics of an acceptable cut Top edge square Vertical draglines Bottom edge sharp Factors that affect the quality of cut Speed of travel Surface condition of the metal Oxygen pressure Tip size Size of the preheat flames Thickness of the material Position of the cutting torch tip Position in relation to the work Starting cuts 2. Perform freehand cuts on low carbon steel plate and sheet. 3. Pierce holes in low carbon steel plate. 4. Perform freehand cuts on structural shapes and round stock. Freehand cuts on low carbon steel plate - refer to practical competency for procedure Freehand cuts on low carbon steel sheet - refer to practical competency for procedure Free hand bevel cuts on low carbon steel plate - refer to practical competency for procedure Refer to practical competency for procedure Freehand cuts on angle iron, channel, and S-beam - refer to practical competency for procedure Freehand cuts on round stock - refer to practical competency for procedure Welder Level C Program Outline Industry Training Authority 34

40 5. Perform guided cuts on low carbon steel plate and sheet. 6. Wash nuts off bolts and gouge weldments. Guided cuts on low carbon steel plate and sheet - refer to practical competency for procedure Guided circular cuts on low carbon steel plate - refer to practical competency for procedure Wash nuts off bolts - refer to practical competency for procedure Gouge weldments - refer to practical competency for procedure 7. Perform freehand cuts on mild steel pipe. Straight cuts on low carbon steel pipe - refer to practical competency for procedure Bevel cuts on low carbon steel pipe - refer to practical competency for procedure NOTE: Refer To Current Welder Training Program Curriculum Module/Line P2-4. Achievement Criteria: The learner will be evaluated on the ability to perform freehand and guided cuts on low carbon steel plate, sheet round stock, structural shapes and pipes as part of a practical shop project as per the acceptance criteria in the current curriculum module/line P2-4.. Welder Level C Program Outline Industry Training Authority 35

41 LINE B: PERFORMS OXY-FUEL CUTTING PROCESSES (OFC) Competency: B-4 Perform Cuts with Cutting Machines, Automatic and Semi-Automatic Learning Objectives: The learner will be able to set up and operate a variety of cutting machines and produce high quality straight and bevel cuts safely. LEARNING TASKS 1. Performs cuts with a straight-line cutting machine using oxy-fuel gas. 2. Perform cuts with a shape-cutting machine using oxy-fuel gas. CONTENT Refer to practical competency for procedure Refer to practical competency for procedure 3. Perform cuts with a pipe-beveling machine using oxy-fuel gas. Refer to practical competency for procedure NOTE: Refer To Current Welder Training Program Curriculum Module/Line P2-5. Achievement Criteria: The learner will be evaluated on the ability to perform cuts with cutting machines, automatic and semi-automatic as part of a practical shop project as per the acceptance criteria in current curriculum module/line P2-5. Welder Level C Program Outline Industry Training Authority 36

42 LINE C: PERFORMS FUSION AND BRAZE WELDING USING OXY-FUEL PROCESSES (OFW) Competency: C-1 Describe Fusion Welding, Braze Welding and Brazing Processes and Their Applications Learning Objectives: The learner will be able to describe fusion welding, braze welding, brazing processes, their applications and safety precautions. LEARNING TASKS 1. Describe the fusion welding process and its application. CONTENT Principles of fusion welding Filler rods Applications of fusion welding Maintenance or repair work Fabrication 2. Describe the braze welding process and its application. 3. Describe the brazing process and its applications. Principles of braze welding Filler rods Applications Maintenance or repair work Light gauge metals Dissimilar metals Grey cast iron Non-ferrous metals Principles of brazing Filler rods Applications 4. Describe safety requirements. PPE Fire and explosion prevention Refer to WorkSafeBC for fire watch regulations Toxic fumes/ventilation (refer to B-1,5) NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-1. Achievement Criteria: Given a 20 question test on fusion welding, braze welding, brazing processes and application, the learner will demonstrate knowledge by correctly answering 14 questions or more. Welder Level C Program Outline Industry Training Authority 37

43 LINE C: PERFORMS FUSION AND BRAZE WELDING USING OXY-FUEL PROCESSES (OFW) Competency: C-2 Describe Fusion and Braze Welding Equipment and Their Operation Learning Objectives: The learner will be able to describe fusion and braze welding equipment and their operation. LEARNING TASKS 1. Describe OFW equipment and application. CONTENT Fundamentals of OFW process Types of equipment Regulators Flashback arrestors Hoses Types of torch bodies Torch attachments Match equipment to application 2. Describe fuel gas precautions and procedures. 3. Describe tips and their application. 4. Describe consumables and requirements. Characteristics of fuel gases Fuel gas delivery systems Cylinder and gases handling procedures Cylinder and gases storage requirements Hazards associated with different fuel gases Match fuel gas to type of equipment Identify type of fuel gas from information on label Type of base metal Base metal thickness Tip functions Required weld Types of tips Match tip to base metal and required weld Differentiate between tips Fluxes Filler metals Welder Level C Program Outline Industry Training Authority 38

44 5. Describe operating parameters. Base metal thickness Welding tip sizes Gas regulators Manufacturers recommendations Other task specific guidelines Reference information 6. Describe setting up OFW equipment. 7. Describe operating OFW equipment. Set-up procedures OFW safe practices Equipment leak test procedures Follow safe procedures Reference manufacturers instructions Required task-specific PPE Safe operating practices Flashback conditions Backfire burnback conditions Welding techniques Metallurgy Types of flames Braze welding techniques Brazing fluxes Flame temperatures Metal fusion techniques Recognize flashback Recognize backfire burnback Prevent flashback conditions Prevent backfire burnback conditions Light and adjust torch Apply appropriate welding techniques Detect defects in weld 8. Shut down OFW equipment. Shutdown sequence Check regulators Perform complete shutdown NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-2. Achievement Criteria: Given a 40 question test on fusion and braze welding equipment and its operation, the learner will demonstrate knowledge by correctly answering 28 questions or more. Welder Level C Program Outline Industry Training Authority 39

45 LINE C: PERFORMS FUSION AND BRAZE WELDING USING OXY-FUEL PROCESSES (OFW) Competency: C-3 Describe Filler Metals, Fluxes and Tips Used for Fusion and Braze Welding and Brazing Learning Objectives: The learner will be able to identify filler metals, fluxes, torches and tips used for fusion and braze welding. LEARNING TASKS 1. Describe the filler rods for fusion welding, brazing and braze welding. CONTENT Filler rods for fusion welding Low carbon steel rods RG 45 RG 60 RG 65 Filler rod size Brazing and braze welding alloys Silver (BAg) Aluminum-silicon (BA 1Si) Precious-metals (BAu) Copper and copper-zinc (BCu and RBCuZn) brass Copper-phosphorous (BCuP) Magnesium (BMg) Nickel (BNi) Cobalt (BCo) Choosing a brazing filler rod Braze welding filler rods 2. Describe the flux for fusion welding, brazing and braze welding. Purpose of flux Welding flux Brazing flux High temperature Special purpose or low temperature General purpose flux Choosing the correct brazing flux Using flux Removing flux Welder Level C Program Outline Industry Training Authority 40

46 3. Describe the torches and tips for fusion welding, braze welding and brazing. Oxy-fuel welding torches How welding torches work Welding tips Selecting the correct welding tip Welding tip maintenance NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-2. Achievement Criteria: Given a 20 question test on identifying filler metals, fluxes, torches and tips used for fusion and braze welding, the learner will demonstrate knowledge by correctly answering 14 questions or more. Welder Level C Program Outline Industry Training Authority 41

47 LINE C: PERFORMS FUSION AND BRAZE WELDING USING OXY-FUEL PROCESSES (OFW) Competency: C-4 Describe Joint Design and Weld Positions Learning Objectives: The learner will be able to identify basic joint designs, weld positions and the abbreviations associated with them when doing fusion and braze welding using OFW processes. LEARNING TASKS CONTENT 1. Describe the five basic joints. Corner joint Lap joint Tee joint Butt joint Edge joint 2. Describe the four basic welding positions. Flat position Horizontal position Vertical position Overhead position 3. Identify abbreviations for weld position and weld type. Flat position (1) Horizontal position (2) Vertical position (3) Overhead position (4) NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-2. Achievement Criteria: Given a 20 question test on identifying basic joint designs, weld positions and the abbreviations associated with them when doing fusion and braze welding using OFW processes, the learner will demonstrate knowledge by correctly answering 14 questions or more. Welder Level C Program Outline Industry Training Authority 42

48 LINE C: PERFORMS FUSION AND BRAZE WELDING USING OXY-FUEL PROCESSES (OFW) Competency: C-5 Describe Fusion Welding on Low Carbon Steel Sheet Learning Objectives: The learner will describe fusion weld stringer beads in the flat position on low carbon steel sheet using OFW processes. LEARNING TASKS 1. Describe the main factors to consider in gas fusion welding. CONTENT Correct tip sizes Correct flame setting Distance between work and flame Types of welding technique Torch angle Speed and travel movement Operator comfort and position 2. Describe process related weld faults and discuss their causes. Weld defects Lack of penetration Lack of fusion undercut Reinforcement on groove welds Correct weld profile for fillet weld NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-3. Achievement Criteria: Given a 10 question test on describing fusion weld stringer beads in the flat position on low carbon steel sheet using OFW processes, the learner will demonstrate knowledge by correctly answering 7 questions or more Welder Level C Program Outline Industry Training Authority 43

49 LINE C: PERFORMS FUSION AND BRAZE WELDING USING OXY-FUEL PROCESSES (OFW) Competency: C-6 Fusion Weld Stringer Beads and Fillet Welds on Low Carbon Steel Sheet Learning Objectives: The learner will fusion weld stringer beads and fillet welds on low carbon steel sheet using OFW processes. LEARNING TASKS 1. Fusion weld stinger beads in the flat position. CONTENT Weld stinger beads without a filler rod in the flat position - refer to practical competency for Weld Procedure Specification (WPS) Weld stinger beads with a filler rod in the flat position - refer to practical competency for Weld Procedure Specification (WPS) 2. Fusion weld fillet welds in the flat (1F) position on lap and corner joint on low carbon steel sheet. 3. Fusion weld fillet welds in the horizontal (2F) position on lap joint on low carbon steel sheet. 4. Fusion weld fillet welds in the vertical (3F) position on lap joints on low carbon steel sheet. Fillet weld on lap joint in the 1F position - refer to practical competency for Weld Procedure Specification (WPS) Fillet weld on corner joint in the 1F position - refer to practical competency for Weld Procedure Specification (WPS) Fillet weld on lap joint in the 2F position - refer to practical competency for Weld Procedure Specification (WPS) Fillet weld on lap joint in the 3F position - refer to practical competency for Weld Procedure Specification (WPS) NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-4. Achievement Criteria: The learner will be evaluated on the ability to fusion weld fillet welds on low carbon steel sheet using OFW processes as part of a practical shop project as per the acceptance criteria in the current curriculum module/line P3-4; evaluation must meet CSA W59 standards for cyclically loaded structures. Welder Level C Program Outline Industry Training Authority 44

50 LINE C: PERFORMS FUSION AND BRAZE WELDING USING OXY-FUEL PROCESSES (OFW) Competency: C-7 Fusion Weld Square Groove Welds on Low Carbon Steel Sheet Learning Objectives: The learner will fusion weld groove welds on low carbon steel sheet using OFW processes. LEARNING TASKS 1. Fusion weld groove welds in the flat (1G) position on low carbon steel sheet. CONTENT Refer to practical competency for Weld Procedure Specification (WPS) NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-5. Achievement Criteria: The learner will be evaluated on the ability to fusion weld groove welds on low carbon steel sheet using OFW processes as part of a practical shop project as per the acceptance criteria in the current curriculum module/line P3-5; evaluation must meet CSA W59 standards for cyclically loaded structures. Welder Level C Program Outline Industry Training Authority 45

51 LINE C: PERFORMS FUSION AND BRAZE WELDING USING OXY-FUEL PROCESSES (OFW) Competency: C-8 Braze Weld Fillet Welds on Low Carbon Steel Sheet Learning Objectives: The learner will braze weld fillet welds on low carbon steel sheet using OFW processes. LEARNING TASKS 1. Describe the procedures for braze welding low carbon steel. CONTENT Pre-leaning and edge preparation Flame setting Filler rods and flux Number of passes Determining the quality of work 2. Braze weld fillet welds in the flat (1F) and horizontal (2F) positions on lap and tee joints on low carbon steel sheet. Braze weld on lap joint in the 2F position - refer to practical competency for Weld Procedure Specification (WPS) Braze weld on tee joint in the 1F position - refer to practical competency for Weld Procedure Specification (WPS) NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-7. Achievement Criteria: The learner will be evaluated on the ability to braze weld fillet welds on low carbon steel sheet using OFW processes as part of a practical shop project as per the acceptance criteria the current curriculum module/line P3-7; evaluation must meet CSA W59 standards for cyclically loaded structures. Welder Level C Program Outline Industry Training Authority 46

52 LINE C: PERFORMS FUSION AND BRAZE WELDING USING OXY-FUEL PROCESSES (OFW) Competency: C-9 Braze Weld Groove Welds on Grey Cast Iron Learning Objectives: The learner will braze weld and fusion weld groove welds on grey cast iron using OFW processes. LEARNING TASKS 1. Describe the procedures for braze welding and fusion welding grey cast iron. CONTENT Braze weld grey cast iron Pre-leaning Preheating Fusion welding grey cast iron Special factors in welding grey cast iron Cast iron filler rod Welding technique 2. Braze weld groove welds in the flat (1G) position. Refer to practical competency for Weld Procedure Specification (WPS) NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-9. Achievement Criteria: The learner will be evaluated on the ability to braze weld and fusion weld groove welds on grey cast iron using OFW processes as part of a practical shop project as per the acceptance criteria in the current curriculum module/line P3-9; evaluation must meet CSA W59 standards for cyclically loaded structures. Welder Level C Program Outline Industry Training Authority 47

53 LINE C: Competency: PERFORMS FUSION AND BRAZE WELDING USING OXY-FUEL PROCESSES (OFW) C-10 Silver Alloy Braze on Similar and Dissimilar Metals Learning Objectives: The learner will silver alloy braze on similar and dissimilar metals using OFW processes. LEARNING TASKS 1. Describe the materials, equipment and procedures for silver brazing. CONTENT Joint preparation and design Flux selection Filler alloys (rods) Flame for brazing Silver brazing procedure 2. Braze with silver alloys. Braze with silver phosphorous alloy on copper tube - refer to practical competency for Weld Procedure Specification (WPS) Braze with silver alloy filler metals on tee joints for copper to stainless steel in the horizontal position - refer to practical competency for Weld Procedure Specification (WPS) NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-10. Achievement Criteria: The learner will be evaluated on the ability to silver alloy braze on similar and dissimilar metals using OFW processes as part of a practical shop project as per the acceptance criteria in the current curriculum module/line P3-10; evaluation must meet CSA W59 standards for cyclically loaded structures. Welder Level C Program Outline Industry Training Authority 48