PROGRAM OUTLINE. Welder Level A

Transcription

1 PROGRAM OUTLINE Welder Level A

2 WELDER LEVEL A PROGRAM OUTLINE April 2008 Developed By Industry Training Authority Province of British Columbia

3 TABLE OF CONTENTS FOREWORD... II ACKNOWLEDGEMENTS... III SECTION 1 OCCUPATIONAL ANALYSIS CHART... 1 SECTION 2 PROGRAM OUTLINE... 3 Suggested Schedule of Time Allotment for Level A... 4 Program Outline for Level A... 6 SECTION 3 TRAINING PROVIDER STANDARDS Welder A Training Provider Standards Inspectors For Practical Examinations Welder A Training Provider Standards Facilities Minimum Shop Equipment For Level A Training Welder A Tools and Equipment Provincial Curriculum Materials Recommended Reference Materials Websites APPENDIX ONE RECOMMENDED WELDER LEVEL A FINAL WELD TESTS guidelines For Practical Examinations Recommended Welder Level A Final Weld Tests Welder Level A Program Outline Industry Training Authority i

4 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 A 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 level A outlines all of the competencies required for apprenticeship technical training to complete the practical and written tests for a Welder Level A Certificate of Qualification. Additional Information for Training Providers: This Welder Level A Apprenticeship Program is competency based with many options available for the delivery of technical training, for example; this program may be offered as a: Full-time day school program (including block release and continuous entry) Program is one level of training of 240 hours Continuous entry competency based model 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 the modules This Program Outline also includes: 1. Requirements for Instructor Qualifications, Facilities (classroom and shop sizes), as well as the necessary Tools and Equipment 2. Practical competencies as well as destructive and non-destructive testing 3. Fabrication competencies PLEASE NOTE: All provincial welder training program curriculum is currently under review and subject to amendments by the BC Welding Articulation Committee Welder Level A Program Outline Industry Training Authority ii

5 ACKNOWLEDGEMENTS The Program Outline was prepared with the advice and direction from a Project Review Committee convened by the Resource Training Organization (RTO) of British Columbia, with funding support from the Industry Training Authority (ITA) of British Columbia, including: Industry Steering Committee Lindsay Langill Industry Training Authority Brad Smith Catalyst Paper (Campbell River) Judy Kujundzic Victoria Shipyards Sheldon Frank University College of the Fraser Valley Al Phillips PIAB/UA Trade School Ken R. Bauder International Longshore & Warehouse Union Industry Subject Matter Experts Ian MacDonald Highland Valley Copper Stan Boehm SS Stainless Inc. Stan McArthur Catalyst Paper (Campbell River) Tim Cross FMF Cape Breton Greg Burkett Okanagan College Al Wood BCIT Mervyn Kube PIAB/UA Trade School Eric Parmar (Al Constable) ILWU Local 500 Dan Burroughs Sheet Metal Workers Local 280 Ron McKeown Kwantlen College Faculty Association Facilitators Dick Vanier Training Consultant- Vanier Training Consultants Ltd. Jody Jankola Technical Writer - Vanier Training Consultants Ltd. Resource Training Organization Curt Cain Director Program Standards Welder Level A Program Outline Industry Training Authority iii

6 SECTION 1 OCCUPATIONAL ANALYSIS CHART Welder Level A Program Outline Industry Training Authority 1

7 WELDER LEVEL A Occupational Analysis Chart PERFORMS SHIELDED METAL ARC WELDING (SMAW) Use the SMAW process to weld groove welds using low-alloy filler metal on low carbon steel plate. Describe and demonstrate use of SMAW stainless steel filler metal on low carbon steel plate. Use the SMAW/GTAW process to weld groove welds using low-alloy filler metal on low carbon steel pipe. Use the SMAW/GTAW process to weld groove welds using stainless steel filler metal on low carbon steel pipe. D D-11 D-12 D-13 A A A A D-15 DESCRIBES BASIC METALLURGY RELATING TO PRODUCTION, PROPERTIES AND WELDABILITY Describe the grain structure of metals. Describe common nonferrous metals and their weldability. Describe reactive metals and their weldability. Describe die castings and their weldability. G G-4 G-7 G-8 A A A A G-9 PERFORMS GAS TUNGSTEN ARC WELDING (GTAW) H Use the GTAW process to groove weld using low carbon steel filler metal on low carbon steel pipe. H-5 Use the GTAW process to groove weld using stainless steel filler metal on low carbon steel pipe. H-7 Use the GTAW process to groove weld using stainless steel filler metal on thin wall stainless steel pipe. H-8 Use the GTAW process to weld stainless steel sanitary tubing. H-9 Use GTAW process to weld groove welds on aluminum pipe. A A A A A H-11 READS AND UTILIZES INDUSTRY DRAWINGS Develop detail drawings on transition pieces. Interpret detail drawings of a rolling offset. Develop piping spool drawings from single line isometric drawings. Estimate job materials and labour costs for projects. J J-9 J-10 J-11 A A A A J-12 LAYOUT AND FABRICATE COMPONENTS Interpret and apply mechanical drawings. Identify materials and information required. Layout materials. Prepare materials. Fabricate project(s). K K-1 K-2 K-4 K-5 A A A A A K-6 *NOTE: FCAW/MC is metal cored filler metals under the CSA. GMAW/MC is metal cored filler metals under the AWS: A5.18 specification. Source: American Welding Society and Canadian Standards Association (03/2007) Welder Level A Program Outline Industry Training Authority 2

8 SECTION 2 PROGRAM OUTLINE Welder Level A Program Outline Industry Training Authority 3

9 SUGGESTED SCHEDULE OF TIME ALLOTMENT FOR LEVEL A Theory Practical Line D Performs Shielded Metal Arc Welding (SMAW) 15% 85% D-11 D-12 D-13 D-15 Use the SMAW Process to Weld Groove Welds Using Low- Alloy Filler Metal on Low Carbon Steel Plate Describe and Demonstrate Use of SMAW Stainless Steel Filler Metal on Low Carbon Steel Plate Use the SMAW/GTAW Process to Weld Groove Welds Using Low-Alloy Filler Metal on Low Carbon Steel Pipe Use the SMAW/GTAW Process to Weld Groove Welds Using Stainless Steel Filler Metal on Low Carbon Steel Pipe Line G Describes Basic Metallurgy Relating to Production, Properties and Weldability G-4 Describe the Grain Structure of Metals G-7 Describe Common Non-Ferrous Metals and Their Weldability G-8 Describe Reactive Metals and Their Weldability G-9 Describe Die Castings and Their Weldability 100% Line H Performs Gas Tungsten Arc Welding (GTAW) 15% 85% H-5 H-7 H-8 H-9 H-11 Use the GTAW Process to Groove Weld Using Low Carbon Steel Filler Metal on Low Carbon Steel Pipe Use the GTAW Process to Groove Weld Using Stainless Steel Filler Metal on Low Carbon Steel Pipe Use the GTAW Process to Groove Weld Using Stainless Steel Filler Metal on Thin Wall Stainless Steel Pipe Use the GTAW Process to Weld Stainless Steel Sanitary Tubing Use the GTAW Process to Weld Groove Welds on Aluminum Pipe Line J Reads and Utilizes Industry Drawings 50% 50% J-9 Develop Detail Drawings on Transition Pieces J-10 Interpret Detail Drawings of a Rolling Offset J-11 Develop Piping Spool Drawings from Single Line Isometric Drawings J-12 Estimate Job Materials and Labour Costs for Projects Welder Level A Program Outline Industry Training Authority 4

10 Theory Practical Line K Layout and Fabricate Components 10% 90% K-1 Interpret and Apply Mechanical Drawings K-2 Identify Materials and Information Required K-4 Layout Materials K-5 Prepare Materials K-6 Fabricate Shop Project(s) Total Percentage for Level A 100% Welder Level A Program Outline Industry Training Authority 5

11 PROGRAM OUTLINE FOR LEVEL A Welder Level A Program Outline Industry Training Authority 6

12 LINE D: Competency: PERFORMS SHIELDED METAL ARC WELDING (SMAW) D-11 Use the SMAW Process to Weld Groove Welds Using Low-Alloy Filler Metal on Low Carbon Steel Plate Learning Objectives: The learner will be able to weld groove welds in 2G, 3G and 4G positions using low-alloy filler metal on low carbon steel plate. LEARNING TASKS 1. Identify low-alloy filler metal for SMAW. 2. Weld groove welds in the horizontal (2G) position on low carbon steel plate. 3. Weld groove welds in the vertical (3G) position (uphill) on low carbon steel plate. 4. Weld groove welds in the overhead (4G) position on low carbon steel plate. CONTENT Low alloy electrodes composition and designation: o Carbon-molybdenum o Chromium-molybdenum o Nickel o Manganese-molybdenum o Special military grades Multi-pass groove weld on vee butt joint in the 2G position - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure Multi-pass groove weld on vee butt joint in the 3G position - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure Multi-pass groove weld on vee butt joint in the 4G position - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure NOTE: Refer to Current Welder Training Program Curriculum Module/Line P11-1, and Amendments by the BC Welding Articulation Committee Achievement Criteria: The learner will be evaluated on their ability to weld groove welds in the 2G, 3G and 4G positions using low-alloy filler metal on low carbon steel plate. This is part of a practical shop project as per the practical components in the current curriculum module/line P11-1. This evaluation must meet CSA W59 standards for cyclically loaded structures and/or Section IX ASME code. Welder Level A Program Outline Industry Training Authority 7

13 LINE D: Competency: PERFORMS SHIELDED METAL ARC WELDING (SMAW) D-12 Describe and Demonstrate Use of SMAW Stainless Steel Filler Metal on Low Carbon Steel Plate Learning Objectives: The learner will be able to weld fillet and groove welds using stainless steel filler metal on low carbon steel plate. LEARNING TASKS 1. Review the safety requirements and main factors for SMAW. 2. Identify stainless steel electrodes for SMAW. 3. Welds fillet welds in the horizontal (2F) position. CONTENT Safe working practices: o Electric shock o Arc flash o Arc burn o Electrode stubs o Slag o PPE o Ventilation o Fire prevention Main factors: o Machine setting o Correct position o Arc length o Electrode angle o Speed of travel Stainless steel electrodes classification Standard AISI stainless steels: o Austenitic o Ferritic o Martensitic Common stainless steel electrodes: o E307 o E308, E3087L, E308Mo o E309, E309Cb, E309Mo o E318 o E320 o E330, E330HC o E347 o E349 o E410 o E430 o E442 o E446 o E502 o E505 o E7Cr Multi-pass fillet weld in the 2F position on low carbon steel plate - refer to practical competency for Weld Procedure Specification (WPS) Welder Level A Program Outline Industry Training Authority 8

14 4. Welds fillet welds in the vertical (3F) position. 5. Weld groove welds in the vertical (3G) position (uphill) on low carbon steel plate. Multi-pass fillet weld in the 3F position on low carbon steel plate - refer to practical competency for Weld Procedure Specification (WPS) Multi-pass groove weld on vee butt joint in the 3G position (uphill) on low carbon steel plate - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure NOTE: Refer to Current Welder Training Program Curriculum Module/Line P11-1 and P11-2, and Amendments by the BC Welding Articulation Committee Achievement Criteria: The learner will be evaluated on their ability to weld fillet and groove welds using stainless steel filler metal on low carbon steel plate. This is part of a practical shop project as per the practical components in the current curriculum module/line P11-1 and P11-2. This evaluation must meet CSA W59 standards for cyclically loaded structures and/or Section IX ASME code. Welder Level A Program Outline Industry Training Authority 9

15 LINE D: Competency: PERFORMS SHIELDED METAL ARC WELDING (SMAW) D-13 Use the SMAW/GTAW Process to Weld Groove Welds Using Low-Alloy Filler Metal on Low Carbon Steel Pipe Learning Objectives: The learner will be able to weld groove welds in the 6G position using SMAW/GTAW and lowalloy filler metal on low carbon steel pipe. LEARNING TASKS 1. Identify low-alloy filler metal for SMAW. 2. Weld groove welds in the inclined fixed 45º (6G) position (uphill) on low carbon steel pipe. CONTENT Low alloy electrode composition and designation: o Carbon-molybdenum o Chromium-molybdenum o Nickel o Manganese-molybdenum o Special military grades Multi-pass groove weld using GTAW and SMAW processes in the 6G position - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure NOTE: Refer to Current Welder Training Program Curriculum Module/Line P11-1, and Amendments by the BC Welding Articulation Committee Achievement Criteria: The learner will be evaluated on their ability to weld groove welds in the 6G position using SMAW/GTAW and low-alloy electrodes on low carbon steel pipe. This is part of a practical shop project as per the practical components in the current curriculum module/line P11-1. This evaluation must meet CSA W59 standards for cyclically loaded structures and/or section IX ASME code. Welder Level A Program Outline Industry Training Authority 10

16 LINE D: Competency: PERFORMS SHIELDED METAL ARC WELDING (SMAW) D-15 Use the SMAW/GTAW Process to Weld Groove Welds Using Stainless Steel Filler Metal on Low Carbon Steel Pipe Learning Objectives: The learner will be able to weld groove welds in the 2G, 5G and 6G positions using stainless steel filler metal on low carbon steel pipe. LEARNING TASKS 1. Weld groove welds in the vertically fixed (2G) position on low carbon steel pipe. 2. Weld groove welds in the horizontally fixed (5G) position (uphill) on low carbon steel pipe. 3. Weld groove welds in the inclined fixed 45º (6G) position (uphill) on low carbon steel pipe. CONTENT Multi-pass groove weld on single vee butt joint in the 2G position using the GTAW and SMAW processes - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure Multi-pass groove weld on single vee butt joint in the 5G position (uphill) using the GTAW and SMAW processes - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure Multi-pass groove weld on single vee butt joint in the 6G position (uphill) using the GTAW and SMAW processes - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure NOTE: Refer to Current Welder Training Program Curriculum Module/Line P11-2, and Amendments by the BC Welding Articulation Committee Achievement Criteria: The learner will be evaluated on their ability to weld groove welds in the 2G, 5G and 6G positions using stainless steel filler metal on low carbon steel pipe. This is part of a practical shop project as per the acceptance criteria in the current curriculum module/line P11-2. This evaluation must meet section IX ASME code. Welder Level A Program Outline Industry Training Authority 11

17 LINE G: DESCRIBES BASIC METALLURGY RELATING TO PRODUCTION, PROPERTIES AND WELDABILITY Competency: G-4 Describe the Grain Structure of Metals Learning Objectives: The learner will be able to describe the grain structure in metals, dendritic growth, space-latticed types in metals and changes in grain structure that result from welding. LEARNING TASKS 1. Review the microstructure of metals. CONTENT Crystalline or grain structure Grain size in metal Grain structure in pure iron Grain structure of carbon steels 2. Review the changes in grain structure that result from welding. Heat zones in welds Grain characteristics in welds Preheating NOTE: Refer to Current Welder Training Program Curriculum Module/Line RK7-1, and Amendments by the BC Welding Articulation Committee Achievement Criteria: Given a 10 question test on the grain structure in metals, dendritic growth, space-latticed types in metals and changes in grain structure that result from welding, the learner will demonstrate their knowledge by correctly answering 7 questions or more. Welder Level A Program Outline Industry Training Authority 12

18 LINE G: DESCRIBES BASIC METALLURGY RELATING TO PRODUCTION, PROPERTIES AND WELDABILITY Competency: G-7 Describe Common Non-Ferrous Metals and Their Weldability Learning Objectives: The learner will be able to describe non-ferrous alloys, the uses of non-ferrous alloys and the methods for welding. LEARNING TASKS 1. Identify nickel and nickel alloys, and their weldability. CONTENT Nickel alloys: o Monel o Inconel o Nichrome o Nimonic alloys o Hastelloys Basic considerations in welding Thermal conductivity Electrical resistance and heat input Porosity Filler metals Hot cracking Iron dilution 2. Identify copper and copper alloys and their weldability. 3. Identify magnesium and magnesium alloys, and their weldability. Copper alloys: o Brass o Bronze o Copper-silicon alloys (silicon bronze) Copper-aluminum (aluminum bronze) Copper-beryllium Copper-nickel alloys Welding copper and copper alloys: o Preheating o Shielding o Joint geometry o Deoxidization o Filler metals o Post-weld heat treatment o Vaporization o Hot cracking Pure magnesium Magnesium alloys Welding magnesium and its alloys: o Joint preparation o Cleaning o Shielding o Cracking o Filler metals Welder Level A Program Outline Industry Training Authority 13

19 4. Identify lead and lead alloys, and their weldability. Lead alloys Welding NOTE: Refer to Current Welder Training Program Curriculum Module/Line RK8-1, and Amendments by the BC Welding Articulation Committee Achievement Criteria: Given a 10 question test on non-ferrous alloys, the uses of non-ferrous alloys and the methods for welding, the learner will demonstrate their knowledge by correctly answering 7 questions or more. Welder Level A Program Outline Industry Training Authority 14

20 LINE G: DESCRIBES BASIC METALLURGY RELATING TO PRODUCTION, PROPERTIES AND WELDABILITY Competency: G-8 Describe Reactive Metals and Their Weldability Learning Objectives: The learner will be able to describe the properties and weldability of reactive metals. LEARNING TASKS 1. Identify titanium and titanium alloys and their weldability. CONTENT Characteristics of reactive metals Titanium: o Grain structure: Alpha alloys Beta alloys Alpha-beta alloys Welding titanium: o Shielding o Porosity o Heat affected zone (HAZ) o Filler metals 2. Identify zirconium and zirconium alloys and their weldability. 3. Identify tantalum and tantalum alloys and their weldability. 4. Identify columbium and columbium alloys and their weldability. Zirconium alloys: o Alpha alloys o Beta alloys o Commercial zirconium alloys Weldability: o Zirconium filler metals Tantalum: o Weldability Columbium alloys: o Weldability NOTE: Refer to Current Welder Training Program Curriculum Module/Line RK8-2, and Amendments by the BC Welding Articulation Committee Achievement Criteria: Given a 10 question test on the properties and weldability of reactive metals, the learner will demonstrate their knowledge by correctly answering 7 questions or more. Welder Level A Program Outline Industry Training Authority 15

21 LINE G: DESCRIBES BASIC METALLURGY RELATING TO PRODUCTION, PROPERTIES AND WELDABILITY Competency: G-9 Describe Die Castings and Their Weldability Learning Objectives: The learner will be able to describe aluminum, magnesium and zinc die castings and the processes for welding each type. LEARNING TASKS 1. Identify die castings and their weldability. CONTENT Magnesium Aluminum Zinc NOTE: Refer to Current Welder Training Program Curriculum Module/Line RK8-3, and Amendments by the BC Welding Articulation Committee Achievement Criteria: Given a 10 question test on aluminum, magnesium and zinc die castings and the processes for welding each type, the learner will demonstrate their knowledge by correctly answering 7 questions or more. Welder Level A Program Outline Industry Training Authority 16

22 LINE H: PERFORMS GAS TUNGSTEN ARC WELDING (GTAW) Competency: H-5 Use the GTAW Process to Groove Weld Using Low Carbon Steel Filler Metal on Low Carbon Steel Pipe Learning Objectives: The learner will be able to weld groove welds in the 1G, 2G, 5G and 6G positions on low carbon steel pipe using low carbon steel filler metal. LEARNING TASKS 1. Review the safety requirements and the main factors for GTAW. CONTENT Safety: o PPE o Electrical hazards o Arc flash and arc burn o Ventilation o Fire prevention Using GTAW: o Machine setting o Arc length o Nozzle size o Torch angle o Electrode stickout o Speed of travel o Shielding gas flow rate o Operator comfort and position 2. Describe the preparation of pipe for GTAW. Edge preparation Pipe alignment Tacking Consumable inserts EB weld insert Type Y insert The Grinnel insert 3. Weld groove welds in the flat (rolled) (1G) position on low carbon steel pipe. 4. Weld groove welds in the vertical fixed (2G) position on low carbon steel pipe. Multi-pass groove weld on single vee butt joint in the 1G position using the GTAW and SMAW processes - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure Multi-pass groove weld on single vee butt joint in the 2G position using the GTAW and SMAW processes - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure Welder Level A Program Outline Industry Training Authority 17

23 5. Weld groove welds in the horizontal fixed (5G) position (uphill) on low carbon steel pipe. 6. Weld groove welds in the inclined fixed 45º (6G) position (uphill) on low carbon steel pipe. Multi-pass groove weld on single vee butt joint in the 5G position (uphill) using the GTAW and SMAW processes - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure Multi-pass groove weld on single vee butt joint in the 6G position (uphill) using the GTAW and SMAW processes - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure NOTE: Refer to Current Welder Training Program Curriculum Module/Line P12-1, and Amendments by the BC Welding Articulation Committee Achievement Criteria: The learner will be evaluated on their ability to weld groove welds in 1G, 2G, 5G and 6G positions on low carbon steel pipe using low carbon steel filler metal. This is part of a practical shop project as per the acceptance criteria in the current curriculum module/line P12-1. This evaluation must meet section IX ASME code. Welder Level A Program Outline Industry Training Authority 18

24 LINE H: PERFORMS GAS TUNGSTEN ARC WELDING (GTAW) Competency: H-7 Use the GTAW Process to Groove Weld Using Stainless Steel Filler Metal on Low Carbon Steel Pipe Learning Objectives: The learner will be able to weld groove welds using stainless steel filler metal on low carbon steel pipe. LEARNING TASKS 1. Review and assemble purging equipment. 2. Weld groove welds in the vertical fixed (2G) position on steel pipe. CONTENT Purge pipe to appropriate cfm prior to welding Multi-pass groove weld on single vee butt joint in the 2G position using the GTAW and SMAW processes - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure 3. Weld groove welds in the horizontal fixed (5G) position (uphill) on steel pipe. 4. Weld groove welds in the inclined fixed 45º (6G) position (uphill) on steel pipe. Multi-pass groove weld on single vee butt joint in the 5G position (uphill) using the GTAW and SMAW processes - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure Multi-pass groove weld on single vee butt joint in the 6G position (uphill) using the GTAW and SMAW processes - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure NOTE: Refer to Current Welder Training Program Curriculum Module/Line P12-2, and Amendments by the BC Welding Articulation Committee Achievement Criteria: The learner will be evaluated on their ability to weld groove welds using stainless steel filler metal on low carbon steel pipe. This is part of a practical shop project as per the acceptance criteria in the current curriculum module/line P12-2. This evaluation must meet section IX ASME code. Welder Level A Program Outline Industry Training Authority 19

25 LINE H: PERFORMS GAS TUNGSTEN ARC WELDING (GTAW) Competency: H-8 Use the GTAW Process to Groove Weld Using Stainless Steel Filler Metal on Thin Wall Stainless Steel Pipe Learning Objectives: The learner will be able to weld groove welds using stainless steel filler metal on thin wall stainless steel pipe using both solar flux type B backing and argon purging gas. LEARNING TASKS 1. Weld groove welds in the vertical fixed (2G) position on steel pipe using solar flux type B backing. 2. Weld groove welds in the horizontal fixed (5G) position (uphill) on steel pipe using solar flux type B backing. 3. Weld groove welds in the vertical fixed (2G) position on steel pipe using argon purging gas. 4. Weld groove welds in the horizontal fixed (5G) position (uphill) on steel pipe using argon purging gas. CONTENT Multi-pass groove weld on butt joint in the 2G position - refer to practical competency for Weld Procedure Specification (WPS) Multi-pass groove weld on butt joint in the 5G position (uphill) - refer to practical competency for Weld Procedure Specification (WPS) Multi-pass groove weld on butt joint in the 2G position - refer to practical competency for Weld Procedure Specification (WPS) Multi-pass groove weld on butt joint in the 5G position (uphill) - refer to practical competency for Weld Procedure Specification (WPS) NOTE: Refer to Current Welder Training Program Curriculum Module/Line P12-3, and Amendments by the BC Welding Articulation Committee Achievement Criteria: The learner will be evaluated on their ability to weld groove welds using stainless steel filler metal on thin wall stainless steel pipe. This is part of a practical shop project as per the acceptance criteria in the current curriculum module/line P12-3. This evaluation must meet section IX ASME code. Welder Level A Program Outline Industry Training Authority 20

26 LINE H: PERFORMS GAS TUNGSTEN ARC WELDING (GTAW) Competency: H-9 Use the GTAW Process to Weld Stainless Steel Sanitary Tubing Learning Objectives: The learner will be able to use the GTAW process to weld stainless steel sanitary tubing. LEARNING TASKS 1. Describe the requirements and applications involved in the welding of sanitary sheet and tubing. 2. Weld groove welds in the vertical fixed (2G) position on stainless steel tubing using argon purging gas. 3. Weld groove welds in the horizontal fixed (5G) position (uphill) on stainless steel tubing using argon purging gas. 4. Optional procedure: Weld groove welds in the flat (1G) position on stainless steel sheet using argon purging gas. CONTENT Industry uses and applications: o Breweries o Food processing o Hospitals Material preparation: o Cleaning o Joint preparation Tacking procedure: o Tack sequencing Distortion control methods: o Backing bars Welding techniques: o Back stepping Purge techniques: o Purge caps o Purge dams o Purging bars Single-pass groove weld on butt joint in the 2G position - refer to practical competency for Weld Procedure Specification (WPS) Single-pass groove weld on butt joint in the 5G position (uphill) - refer to practical competency for Weld Procedure Specification (WPS) Single pass groove weld on butt joint in the 1G position - refer to practical competency for Weld Procedure Specification (WPS) Achievement Criteria: The learner will be evaluated on their ability to use the GTAW process to weld stainless steel sanitary tubing. This evaluation must meet ASME B 31-3 process piping code. Welder Level A Program Outline Industry Training Authority 21

27 LINE H: Competency: PERFORMS GAS TUNGSTEN ARC WELDING (GTAW) H-11 Use the GTAW Process to Weld Groove Welds on Aluminum Pipe Learning Objectives: The learner will be able to weld groove welds on aluminum pipe. LEARNING TASKS 1. Weld groove welds in the vertical fixed (2G) position on aluminum pipe. 2. Weld groove welds in the horizontal fixed (5G) position (uphill) on aluminum pipe. CONTENT Multi-pass groove weld on single vee butt joint in the 2G position - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure Multi-pass groove weld on single vee butt joint in the 5G position (uphill) - refer to practical competency for Weld Procedure Specification (WPS) Face and root bends tests - refer to practical competency for procedure NOTE: Refer to Current Welder Training Program Curriculum Module/Line P12-4, and Amendments by the BC Welding Articulation Committee Achievement Criteria: The learner will be evaluated on their ability to weld groove welds on aluminum pipe. This is part of a practical shop project as per the acceptance criteria in the current curriculum module/line P12-4. This evaluation must meet section IX ASME code. Welder Level A Program Outline Industry Training Authority 22

28 LINE J: READS AND UTILIZES INDUSTRY DRAWINGS Competency: J-9 Develop Detail Drawings on Transition Pieces Learning Objectives: The learner will be able to develop template drawings of transition pieces. LEARNING TASKS 1. Develop template drawings of transition pieces. CONTENT Methods of developing templates True length elements Radial-line development Triangulation Principles of triangulation Refer to practical competency for procedure NOTE: Refer to Current Welder Training Program Curriculum Module/Line RK9-1, and Amendments by the BC Welding Articulation Committee Achievement Criteria: The learner will be evaluated on their ability to develop template drawings of transition pieces, as part of a practical shop project as per the acceptance criteria in the current curriculum module/line RK9-1. Welder Level A Program Outline Industry Training Authority 23

29 LINE J: Competency: READS AND UTILIZES INDUSTRY DRAWINGS J-10 Interpret Detail Drawings of a Rolling Offset Learning Objectives: The learner will be able to interpret detail drawings of a rolling offset. LEARNING TASKS 1. Read a detail drawing of a rolling offset. 2. Calculate simple and rolling offset dimensions. CONTENT Offset terminology: o Piping offset o Travel o Advance o Angle fit Types of offset Offset piping problems Trigonometric terms and functions Triangles Triangle part labels Trigonometric functions Calculating trigonometric functions Table of trigonometric functions Using a scientific calculator to find trigonometric functions Apply trigonometry to simple offsets Apply the Pythagorean theorem to simple piping offsets Apply trigonometry and the Pythagorean theorem to rolling offsets NOTE: Refer to Current Welder Training Program Curriculum Module/Line RK9-2, and Amendments by the BC Welding Articulation Committee Achievement Criteria: Given a 20 question test on detail drawings of a rolling offset, the learner will demonstrate their knowledge by correctly answering 14 questions or more. Welder Level A Program Outline Industry Training Authority 24

30 LINE J: Competency: READS AND UTILIZES INDUSTRY DRAWINGS J-11 Develop Piping Spool Drawings from Single Line Isometric Drawings Learning Objectives: The learner will be able to develop piping spool drawings from single line isometric drawings. LEARNING TASKS 1. Review interpreting basic piping drawings. CONTENT Types of piping drawings Process flow P and ID Plan views Elevations Sections Single line isometric Spool drawings Drawing views 2. Develop a spool drawing from a single line isometric. Sketch and dimension spool drawing Identify fittings: o Type and size Develop material lists Calculate cut lengths NOTE: Refer to Current Welder Training Program Curriculum Module/Line RK6, and Amendments by the BC Welding Articulation Committee Achievement Criteria: The learner will be evaluated on their ability to develop piping spool drawings from single line isometric drawings, to conventional design practices. Welder Level A Program Outline Industry Training Authority 25

31 LINE J: Competency: READS AND UTILIZES INDUSTRY DRAWINGS J-12 Estimate Job Materials and Labour Costs for Projects Learning Objectives: The learner will be able to estimate job materials and labour costs for projects. LEARNING TASKS 1. Determine materials required and their costs. 2. Determine labour costs to assemble and weld materials. CONTENT Material quantity Calculate costs based on quantity Allowances for material loss Finishing (e.g. painting) requirements if applicable Estimate time required to prepare, assemble and weld materials Calculate costs based on time and hourly rate Material handling and storage requirements 3. Determine installation costs. 4. Estimate total costs for projects. Field welds applications Shipping and assembly Materials Labour Equipment Shipping Rigging Inspection Insurance Profit margin Achievement Criteria: Given a 10 question test on estimating job materials and labour costs for projects, the learner will demonstrate their knowledge by correctly answering 7 questions or more. Welder Level A Program Outline Industry Training Authority 26

32 LINE K: LAYOUT AND FABRICATE COMPONENTS Competency: K-1 Interpret and Apply Mechanical Drawings Learning Objectives: The learner will be able to interpret and apply mechanical drawings. LEARNING TASKS 1. Review types of mechanical drawings. CONTENT Orthographic Isometric Oblique Detail drawings Spool sheets 2. Review mechanical drawings applications. 3. Review applicable standards and codes when interpreting mechanical drawings. 4. Review the use of drawing notes and their applications. Industrial Commercial Oil and gas Marine CSA standards ASME standards: o B31.3 o B31.1 API standards Reference points Details Tolerances Specifications Working from centerlines 5. Review the use of drawing scales. 6. Review how multiple views of a part or assembly relate to each other on a drawing. 7. Review the relationship between drawing numbers, part numbers and drawing revision. Interpreting dimensions Metric or imperial Use of autocad (e.g. computer space scaled to paper space) Multiple views Detail views Assembly views Detail/assembly views Procedures Drawing numbers identifies specific project Part numbers identifies assembly components (includes spooling numbers) Latest revised drawing must be used for construction or assembly Welder Level A Program Outline Industry Training Authority 27

33 NOTE: Refer to Current Welder Training Program Curriculum Module/Line RK6-1, and Amendments by the BC Welding Articulation Committee Achievement Criteria: Given a 10 question test on interpreting and applying mechanical drawings, the learner will demonstrate their knowledge by correctly answering 7 questions or more. Welder Level A Program Outline Industry Training Authority 28

34 LINE K: LAYOUT AND FABRICATE COMPONENTS Competency: K-2 Identify Materials and Information Required Learning Objectives: The learner will be able to identify applicable standards, codes and specifications and interpret information to select materials and equipment. LEARNING TASKS 1. Review interpreting information and selecting materials. CONTENT Material information sources Type of materials Location of information Identify unique or special information Select materials 2. Review identifying applicable standards, codes and specifications. 3. Review documentation and markings. 4. Review interpreting information and selecting equipment. Standards Codes Specifications Mill test reports Traceability methods Traceability requirements Equipment information sources Select equipment Achievement Criteria: Given a 10 question test on identifying applicable standards, codes and specifications and interpreting information to select materials and equipment, the learner will demonstrate their knowledge by correctly answering 7 questions or more. Welder Level A Program Outline Industry Training Authority 29

35 LINE K: LAYOUT AND FABRICATE COMPONENTS Competency: K-4 Layout Materials Learning Objectives: The learner will be able to layout and prepare templates for piping assembly. LEARNING TASKS 1. Review and expand template development. CONTENT Construct template (e.g. square-to-round transition piece): o Template materials o Measuring tools o Conform to dimensional tolerances 2. Interpret and transfer dimensions from drawings to materials. Transfer methods: o Measuring tools o Layout tools o Conform to dimensional tolerances Achievement Criteria: Given a 10 question test on laying out and preparing templates for piping assembly, the learner will demonstrate their knowledge by correctly answering 7 questions or more. Welder Level A Program Outline Industry Training Authority 30

36 LINE K: LAYOUT AND FABRICATE COMPONENTS Competency: K-5 Prepare Materials Learning Objectives: The learner will be able to prepare materials for a square-to-round transition. LEARNING TASKS 1. Layout materials. 2. Cut materials to dimensions. CONTENT Check templates to verify accuracy Mark accordingly Safe work practices specific to cutting refer to WorkSafeBC requirements Cutting sequence Tolerances and bevel Select cutting equipment Achievement Criteria: Given a practical project to prepare material for a square-to-round transition, the learner will be assessed using 70% as the passing criteria. Welder Level A Program Outline Industry Training Authority 31

37 LINE K: LAYOUT AND FABRICATE COMPONENTS Competency: K-6 Fabricate Project(s) Learning Objectives: The learner will be able to layout, assemble and weld a square-to-square transition, a square-toround transition, and a rolling offset. LEARNING TASKS 1. Layout square-to-square transition. CONTENT Fitting techniques: o Use of fitting equipment o Tack techniques o Distortion control Follow specifications 2. Assemble and weld a square-tosquare transition. 3. Layout square-to-round transition. 4. Assemble and weld a square-toround transition. 5. Layout rolling offset. 6. Assemble and weld components for a rolling offset. Refer to practical competency for procedure Layout and break components Fitting techniques: o Use of fitting equipment o Tack techniques o Distortion control Follow specifications Refer to practical competency for procedure Select required fitting equipment: o Wedges o Clamps o Hand tools o Pipe stands Welding process and consumables Organize work in sequential order Fitting techniques: o Use of fitting equipment o Tack techniques o Distortion control Follow specifications Refer to practical competency for procedure Welder Level A Program Outline Industry Training Authority 32

38 NOTE: Refer to Current Welder Training Program Curriculum Module/Line RK9-1 and RK9-2, and Amendments by the BC Welding Articulation Committee Achievement Criteria: Given a practical project to layout, assemble and weld a square-to-square transition, a squareto-round transition, and a rolling offset, the learner will be assessed using criterion reference standard (pass/fail), as per the following guidelines for practical examinations (pg.47). Apprentices should consult with their Instructor when they feel that they are ready to attempt a Final Practical Examination or a Final Weld Test Applicants who are unsuccessful on their attempt of the enclosed Final Practical Examination will be required to upgrade in the applicable area(s) of error Welder Level A Program Outline Industry Training Authority 33

39 SECTION 3 TRAINING PROVIDER STANDARDS Welder Level A Program Outline Industry Training Authority 34

40 INSTRUCTORS TRADE QUALIFICATION WELDER A TRAINING PROVIDER STANDARDS Level A Welder with an Inter-Provincial Red-Seal endorsement WORK EXPERIENCE Must have a minimum of 5 years experience as a journeyperson Must have diverse industry experience including code work such as shop fabrication, heavy construction, and maintenance/repair (ASME or CSA W59) TRAINING QUALIFICATIONS Instructors Certificate (minimum 30 hr course) Instructors must have or be registered in an Instructor s Diploma Program, to be completed within a five year period Or, hold a Bachelors or Masters degree in Education INSPECTORS FOR PRACTICAL EXAMINATIONS All final practical fabrication and welding tests as listed in the appendices to be assessed by a Certified Welding Inspector Welder Level A Program Outline Industry Training Authority 35

41 WELDER A TRAINING PROVIDER STANDARDS FACILITIES CLASSROOM AREA Comfortable seating and tables suitable for training, teaching, lecturing Compliance with all local and national fire code and occupational safety requirements Lighting controls to allow easy visibility of projection screen while also allowing students to take notes Windows must have shades or blinds to adjust sunlight Heating / Air conditioning for comfort all year round In-room temperature regulation to ensure comfortable room temperature In-room ventilation sufficient to control training room temperature Acoustics in the room must allow audibility of the Instructor White marking board with pens and eraser (optional: flipchart in similar size) Projection screen or projection area at front of classroom Overhead projector and/or multi-media projector SHOP AREA (fixed properties) One welding booth per student (minimum booth size must be 6 x 6 ) fully equipped with: o Industrial grade multi-process welding power source or equipment suitable for all Level A required welding processes o Welding table (minimum recommended size 18 x 20 ) o One height adjustable positioning arm for pipe o One 115 volt receptacle or pneumatic air supply for grinders o Ventilation as per WorkSafeBC standards o Task lighting Suitable demonstration area of approximately 7 x 14 Aisles size must be a minimum of 6 wide The grinding and test coupon preparation area must be a minimum 300 square feet Material storage area (including a separate, secured cylinder storage area) Ceiling shall be a minimum height of 16 or as varied by good engineering practices and code STUDENT FACILITIES Adequate lunch room as per WorkSafeBC requirements Adequate washroom facilities as per WorkSafeBC requirements Personal storage lockers Welder Level A Program Outline Industry Training Authority 36

42 MINIMUM SHOP EQUIPMENT FOR LEVEL A TRAINING one floor model drill press, ½ hp minimum, ½ x 8 one 3 x 6 work bench with two vices one pedestal grinder, 12 x 2 stone one pedestal belt sander with a minimum 3 belt one floor model vertical band saw one horizontal band saw one abrasive chop saw one guided bend test jig as per ASME Section IX dimensional specifications two track cutters two 5 grinders per student (one grinding, one bead brush) four 7 grinders (electric or pneumatic) for general shop use electrode stabilizing oven (minimum 250 lbs) one semi-automatic or automatic submerged arc welder six pipe stands two pipe positioners two pipe beveling machines pipe layout hand tools (one set for every two students) purging equipment (plugs, backing bars, caps, flow meters, hose) one sheet metal hand brake Note: See booth equipment as outlined in Shop Area OPTIONAL EQUIPMENT one ¼ x 4 hydraulic shear one iron worker HOISTING AND RIGGING EQUIPMENT one ton overhead jib crane or overhead crane rigging hardware -- shackles, cable clamps, swivels, eyebolts, turn buckles, snatch blocks, etc. plate clamps chain, wire rope and synthetic slings come-alongs (chain and cable) connectors tirfor jacks chain fall Welder Level A Program Outline Industry Training Authority 37

43 WELDER A TOOLS AND EQUIPMENT Basic Tools and Equipment Adjustable wrenches (various sizes) Allen wrenches (metric and imperial) Ammeter Bench vise Broom Brushes (various bristle brushes for cleaning and scrubbing) C clamps Center head Centering pins Chain hoists Chalk line Chokers Cold chisels (various sizes) Combination wrenches (metric and imperial) Come-alongs Contour marker Cylinder carts Cylinder cradles Dollies Electric cords Files (flat, half-round, rat-tail, bastard) Flange pins Flashlight Friction lighter Funnels Hack saw Hammers (chipping, ball peen, claw, sledge, various sizes) Hand shears Jacks Knives Ladders Magnets Metal markers Mop Oil can Pails (plastic and metal) Paint brushes Pipe cutters Pipe stands Pipe wrenches Pliers (needle nose, slip joint) Positioners Pry bars Punches Rollers Scaffolding (safety) Scrapers (various sizes) Screwdrivers (flat, Phillips, Robertson, various sizes) Shovels (flat mouthed) Slings Snips (heavy duty sheet metal cutting) Soapstone markers Socket sets (metric and imperial) Soldering iron Stamping tools Temperature sticks Tip cleaners Tool boxes Vice grips Vices (chain vice, pipe vice) Water hose Wire brush Wire cutter Wrap arounds Wrench sets (open and closed ends, both metric and imperial) Measuring Tools Calculator Calipers Depth gauge Feeler gauges Fillet gauges Laser level Torpedo level Micrometer Plumb bob Protractor Scribers Spirit level Squares Stop watch Straight edges Tape measure Welder Level A Program Outline Industry Training Authority 38

44 Tri squares Vernier calipers Welding gauges Testing Equipment Adapter fittings Ammeter Calibrating gauges Infrared pyrometer Pressure difference gauges Pressure gauge kit Temperature gauges Temperature sticks Power Tools and Equipment Air hose and nozzle Air monitoring device Arc welder Oxy-fuel cutting equipment Band saw Buffers Chop saw (cut-off saw) Circular saw Coil heating equipment Compressors Cranes (overhead, gantry-type, monorail, boom) Drills (portable, magnetic base, drill press) Electric drills Electronic measuring device (hand-held electronic tape measure type) Feeders-wire Fork lifts Gas detector Grinders (wire brush, angle grinders) Guns-welding Hammer drill Hand-held and stationary radios Headphones Heated hoppers Heaters (electric, natural gas, oil, propane) Heating torch Hydraulic press brake Hydraulic shear Hydrostatic equipment Impact wrenches (electric or pneumatic) Nibblers Ovens Oxyacetylene brazing torch Oxyacetylene cutting torch Pipe-bevelling machine Pipe cutters Plasma console Pneumatic equipment Power hack saw Power vice Propane torch Reamer (hand held or mounted on power threader) Reciprocating saw Routers Sand-blast equipment Sanders Scissor lift Testing pump Torches Vacuum (wet/dry) Winches Wire wheel (body grinder or angle grinder with wire brush) Hoisting and Lifting Equipment Cable clamps Chain block hoist Chains Chokers Come-alongs (chain or cable) Connectors Forklift Overhead hoist Portable boom Rope Slings Spreader bars Stands Supports Tuggers Welder Level A Program Outline Industry Training Authority 39

45 Safety Equipment Air hoods Aprons Body harness Boots Coveralls Ear-plugs and muffs Eye wash station Face shields Fire blankets Fire extinguishers Fire hoses Gloves Goggles Masks (particle, vapour) Respirators Safety glasses Safety helmet Welding shield Code books Drawings Engineering specifications Job schedules Manufacturers specifications, manuals, and charts Material Safety Data Sheets Packing slips Pamphlets Prints Regulatory information Safety manuals Service bulletins Shop manuals Specifications Waybills Written informational or instructional material Resource Material Welder Level A Program Outline Industry Training Authority 40

46 PROVINCIAL CURRICULUM MATERIALS WELDER LEVEL A TRAINING PROGRAM MODULES: WELDER TRAINING PROGRAM LEVEL A MODULE/LINE P11 SHIELDED METAL ARC WELDING (SMAW III) Goal/Competency P11-01 To 02 (MN1923) ( )..... ISBN WELDER TRAINING PROGRAM LEVEL A MODULE/LINE P12 GAS TUNGSTEN ARC WELDING (GTAW II) Goal/Competency P12-01 To 04 (MN1924) ( )...ISBN WELDER TRAINING PROGRAM LEVEL A MODULE/LINE RK08 WELDING METALLURGY III Goal/Competency RK08-01 to 04 (MN1925) ( )..ISBN X WELDER TRAINING PROGRAM LEVEL A MODULE/LINE RK09 BLUEPRINT READING III Goal/Competency Rk09-01 To 02 (MN1926) ( )..ISBN WELDER TRAINING PROGRAM LEVEL B MODULE/LINE P10 GAS TUNGSTEN ARC WELDING (GTAW I) Goal/Competency P10-01 to 08 (MN1930) ( )..ISBN WELDER TRAINING PROGRAM LEVEL B MODULE/LINE RK04 WELDING QUALITY CONTROL AND INSPECTION PROCEDURES Goal/Competency RK04 (MN1931) ( )... ISBN WELDER TRAINING PROGRAM LEVEL B MODULE/LINE RK05 WELDING QUALITY CODES, STANDARDS AND SPECIFICATIONS Goal/Competency RK (MN1932) ( )....ISBN WELDER TRAINING PROGRAM LEVEL C MODULE/LINE P04 SHIELDED METAL ARC WELDING (SMAW I) (MN1810) ( ) ISBN WELDER TRAINING PROGRAM LEVEL C MODULE/LINE P06 GAS METAL ARC WELDING (FMAW I) & FLUX CORED ARC WELDING (FCAW I) (MN1812) ( )...ISBN Welder Level A Program Outline Industry Training Authority 41