cblm smaw

COMPETENCY-BASED LEARNING MATERIAL

Sector: Metals and Engineering

Qualification Title: Shielded Metal Arc Welding NC II

Unit of Competency: Weld Carbon Steel Plates

Module Title: Performing Groove Welding on Carbon Steel Plates

Kabankalan Training Center (KTC)Kabankalan Training Center/Provincial Training Center – Kabankalan

FZO Subd., Brgy 1‚ Kabankalan City‚ Negros Occidental

KABANKALAN TRAINING CENTER

KTC

QASYSTEM

MODULE IN SHIELDED METAL ARC WELDING

SMAW NCII

Weld Carbon Steel Plates using SMAW

Date Developed:August 2012

Document No.

Issued by: of 55Developed by:

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Plan Training Session


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How to Use This Competency Based Learning Materials

Welcome to the module in Performing Groove Welding on Carbon Steel Plates. This module contains training materials and activities for you to comply.

The unit of competency “Weld Carbon Steel Plates” contains knowledge, skills and attitudes essential for Shielded Metal Arc Welding NC II.

You are required to go through a series of learning activities in order to complete each learning outcome in the module. In each learning outcome are information sheets, self-checks, operation sheets and job sheets. Follow these activities on your own. If you have questions, don’t hesitate to ask your facilitator for assistance.

This module was prepared to help achieve the required competency in Shielded Metal Arc Welding NC II.

When you have completed this module and feel confident that you have had sufficient practice, tell your trainer that you are ready for assessment. He will arrange an appointment with a registered assessor to assess you. The results of your assessment will be recorded in your competency Achievement Record.


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Data Gathering Instrument for Trainee's Characteristics

Name of Trainee:ANDAN, CLYDE ANTHONY

Qualification Title: SHIELDED METAL ARC WELDING NC II

Instructions: Please answer the following instrument according to the characteristics described below. Encircle the letter of your choice that best describes you as a learner. Blank spaces are provided for some data that need your response.

Characteristics of Learners

Language, literacy and numeracy (LL&N)

Average grade in:

English Math

a. 95 and above a. 95 and above

b. 90 to 94 b. 90 to 94 c. 85 to 89 c. 85 to 89 d. 80 to 84 d. 80 to 84 e. 75 to 79 e. 75 to 79

Cultural and language background

Ethnicity/culture: a. Ifugao b. Igorot c. Ibanag d. Gaddang e. Muslim f. Ibaloy g. Others( please specify)____Hiligaynon_________

Education & Highest Educational Attainment:


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general knowledge

h. High School Level i. High School Graduate j. College Level k. College Graduate l. with units in Master's degree m. Masteral Graduate n. With units in Doctoral Levelo. Doctoral Graduate

Sex a. Male

b. Female Age Your age: _19

Physical ability

1. Disabilities(if any)_____________________ 2. Existing Health Conditions (Existing illness if any) a. None b. Asthma c. Heart disease d. Anemia e. Hypertension f. Diabetes g. Others(please specify) ___________________

Previous experience with the topic

Certificates Shielded Metal Arc Welding SMAW NCI ______

Previous learning experience

List down trainings related to Shielded Metal Arc Welding

Training Level Shielded Metal Arc Welding SMAW NCI

Special courses Other courses related to Shielded Metal Arc Welding

Learning style a. Visual - The visual learner takes mental pictures of information given,


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so in order for this kind of learner to retain information, oral or written, presentations of new information must contain diagrams and drawings, preferably in color. The visual learner can't concentrate with a lot of activity around him and will focus better and learn faster in a quiet study environment. b. Kinesthetic - described as the students in the classroom, who have problems sitting still and who often bounce their legs while tapping their fingers on the desks. They are often referred to as hyperactive students with concentration issues.

c. Auditory- a learner who has the ability to remember speeches and lectures in detail but has a hard time with written text. Having to read long texts is pointless and will not be retained by the auditory learner unless it is read aloud.

Other needs

a. Financially challenged b. Working student c. Solo parent d. Others(please specify) ________________________


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FORM 1.1 SELF-ASSESSMENT CHECK

INSTRUCTIONS: This Self-Check Instrument will give the trainer necessary data or information which is essential in planning training sessions. Please check the appropriate box of your answer to the questions below.

Name of Trainee : _____________________________ Date : __________________Training Duration : _____________________________ CAN I ?...

YES NOCORE COMPETENCIES

1. Weld carbon steel plates using SMAW

Can I deposit weld beads on plate? Can I weld plates in single pass fillet joints in all positions? Can I weld plates in multiple pass fillet joints in all positions?

Can I weld plates in single pass groove joints in flat, horizontal and vertical positions?

Can I weld plates in multiple pass groove joints in flat, horizontal and vertical positions?

2. Weld carbon steel plates and pipes using SMAW Can I weld plates in single pass groove joints in overhead position?

Can I weld plates in multiple pass groove joints in overhead position?

Can I weld pipe in 1G, 2G, 5G and 6G positions?

Prepared By : ERIC D. EINOSAS, C.E.


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Evidences/Proof of Current Competencies

Form 1.2: Evidence of Current Competencies acquired related to Job/Occupation Name of Trainee:

ANDAN, CLYDE ANTHONY

Qualification Title:

SHIELDED METAL ARC WELDING NC II

Current Competenci

esProof/Evidence Means of Validating

Weld Carbon Steel Plates Using SMAW

certificate of achievement

Check authenticity of certificate of achievement

Performed tasks correctly according to standard operating procedure through Institutional evaluation

Weld Carbon Steel Pipes

Using SMAW


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Identifying Training Gaps

From the accomplished Self-Assessment Check (Form 1.1) and the evidences of current competencies (Form 1.2), the Trainer will be able to identify what the training needs of the prospective trainee are.

Form 1.3 Summary of Current Competencies Versus Required Competencies (Sample)

Name of Trainee: ANDAN, CLYDE ANTHONY

Qualification Title: SHIELDED METAL ARC WELDING NC II

Required Units of Competency /

Learning Outcomes based

on CBC

Current Competencie

sTraining Gaps/ Requirements

1. Weld Carbon Steel Plates Using SMAW

1. Welding Carbon Steel Plates Using SMAW

1.1 Perform Root pass 1.1 Perform Root pass

1.2. Clean Root Pass 1.2. Clean Root Pass

1.3 Weld Subsequent/Filling passes

1.3. Weld Subsequent/Filling passes

1.4 Perform capping 1.4. Perform capping

2. Weld Carbon Steel Pipes Using SMAW

2. Weld Carbon Steel Pipes Using SMAW

2.1 Perform Root pass 2.1 Perform Root pass

2.2. Clean root pass 2.2. Clean root pass

2.3 Weld subsequent/Filling passes

2.3 Weld subsequent/Filling passes


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2.4. Perform capping 2.4. Perform capping

Name of Trainee: Andan, Clyde Anthony

Qualification Title: Shielded Metal Arc Welding NCII

Training Needs ( Learning Outcomes)

Module Title / Module of Instruction

L.O.1 Weld carbon steel plates in flat position (1G)

2. Weld Carbon Steel Pipes Using SMAWL.O.2 Weld carbon steel plates in

horizontal position (2G)L.O.3 Weld carbon steel plates in vertical position (3G)L.O.4 Weld carbon steel plates in overhead position (4G)L.O.1 Weld Carbon Steel Pipes In Horizontal Position (2G)

2. Weld Carbon Steel Pipes Using SMAWL.O.2 Weld Carbon Steel Pipe In Fixed

Pipe, Horizontal Position (5G)

L.O.3 Weld carbon steel pipes in fixed pipe, inclined at 45º position (6G)


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LIST OF COMPETENCY

No.

Unit of Competency

Module Title Code

1 Weld Carbon Steel Plates

Performing groove welding on carbon steel plates

MEE721306

2 Weld Carbon Steel Pipes

Performing groove welding on carbon steel plates

MEE721306


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MODULE CONTENT

QUALIFICATION : Shielded Metal Arc Welding NC II

UNIT OF COMPETENCY : Weld Carbon Steel Plates

MODULE TITLE : Preparing Groove Welding on Carbon Steel Plates

NOMINAL DURATION:

INTRODUCTION:This module covers the skills, knowledge and attitude

required in welding carbon steel plates in different positions such as 1G, 2G, 3G, & 4G using SMAW process.

LEARNING OUTCOMES: 1. Weld carbon steel plates in flat position (1G)2. Weld carbon steel plates in horizontal position (2G)3. Weld carbon steel plates in vertical position (3G)4. Weld carbon steel pates in overhead position (4G)

ASSESSMENT CRITERIA:1. Instructions for the preparation of the work activity are

communicated and confirmed to ensure clear understanding.2. Tools, and equipments needed to perform SMAW process are

identified, checked to ensure they work correctly as intended and are safe to use in accordance with established procedures

3. Materials needed for work are obtained in accordance with established procedures

4. Protective gears and body coverings should be used to avoid accidents and injuries. Safety should always be observed.

5. SMAW process is performed in accordance to the latest edition of Training Regulations (TR), Competency Based Curriculum and other related articles obtained from the Technical Education and Skills Development Authority.


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Learning Outcome # 1: WELD CARBON STEEL PLATES IN FLAT POSITION (1G)

CONTENTS:1. Preparation of base plate2. Welding carbon steel plate in Flat position

ASSESSMENT CRITERIA:1.Root penetration not exceeding allowable tolerances specified by

welding codes/standards on; concavity, convexity, undercut, excess penetration, lack of fusion, burn-through and cracks.

2.Weld capping/final pass not exceeding allowable tolerances specified by welding codes/standards on; height of reinforcement, under fill, porosities, undercut, cracks and cold laps.

3.Uniformity of bead ripples must be in accordance with welding standards.

4.Stringer or layered beads deposited in accordance with welding standards.

5.Finish weldment visually acceptable in accordance with welding standards on; spatters, arc strikes; slag; uniformity of beads.

CONDITIONS:

Students/trainees must be provided with the following:1. WORKPLACE2. TOOLS, ACCESSORIES AND SUPPLIES

Welding mask, electrodes, steel brush, clear and dark glass, chipping hammer, mechanical pliers.

3. EQUIPMENTWelding machine (AC or AC/DC), welding table, portable grinder,Welding booth, portable oven

4. TRAINING MATERIALSCompetency Based Learning Material on SMAW NCII

ASSESSMENT METHODS:Direct observation Visual examination of plates

Learning Experiences


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Learning Activities Specific Instruction

1. READ INFORMATION SHEET NO. 1.1-1 on AWS Code

After reading INFORMATION SHEET NO. 1.1-1 proceed to Task Sheet 1.1-1

2. Perform Task Sheet 1.1-1 Weld Carbon Steel Plates In Flat Position

After performing Weld Carbon Steel Plates In Flat Position, Let the trainer evaluate your work.

After the trainer’s evaluation and approval of the plate, you can proceed to the next LO.

Information Sheet No. 1.1-1


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Weld Carbon Steel Plates In Flat Position (1G)

Preparation of Base PlateThe bevels are to be flame cut on the edges of the plate before

the parts are assembled. The bevel face must be smooth and free of notches.

The groove face and inside and outside plate surface with in 1” (25mm) of the joint must be mechanically cleaned of slag, rust and mill scale. Cleaning must be done with a wire brush or grinder down to bright metal.

Flat Position (1G)

1G is a plate in the flat position that is beveled. This position is the most basic and only covers the welder in that position


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TASK SHEET 1.1-1Title: Weld Carbon Steel Plates In Flat Position (1G)

Performance Objective: Should be able to perform penetration, filling and capping to plates in flat position

Supplies/Materials: Electrode, welding mask, clear and dark glass, chipping hammer, steel brush, mechanical pliersEquipment: Welding machine (AC or AC/DC), welding table, portable grinder, welding booth, portable oven Steps/Procedure:1. Wear PPE2. Prepare the base metal. 3. Place the base metal in a flat position4. Turn on the welding machine5. Perform welding of carbon steel plates in flat position6. turn off the welding machine

Assessment Method: 1. Observation2. Examination of plates

Performance Criteria Checklist 1.1-1


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CRITERIA YES

NO

1. Deposit weld beads on plate?2. weld plates in single pass groove joints in flat

positions3. weld plates in multiple pass groove joints in

flat position

SELF-CHECK NO. 1.1-1


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Is your response is satisfactory?

Direction: Answer the following questions briefly. Compare your response to the model answer provided. Tick on the box to indicate whether your response is satisfactory or not satisfactory based on your own judgment.

Satisfactory

Not Satisfactory

1. Performed lecture and demonstration

2. Trainees comprehension on the subject

3. Trainees performance on Weld carbon steel plates in flat position

As an overall result, is your response satisfactory?

Satisfactory Not Satisfactory

Learning Outcome # 2: WELD CARBON STEEL PLATES IN HORIZONTAL


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POSITION (2G)

CONTENTS:1. Preparation of base plate2. Welding carbon steel plate in Horizontal position

ASSESSMENT CRITERIA:1. Root penetration not exceeding allowable tolerances specified by


2. Weld capping/final pass not exceeding allowable tolerances specified by welding codes/standards on; height of reinforcement, under fill, porosities, undercut, cracks and cold laps.3. Uniformity of bead ripples must be in accordance with welding standards.

4. Stringer or layered beads deposited in accordance with welding standards.

5. Finish weldment visually acceptable in accordance with welding standards on; spatters, arc strikes; slag; uniformity of beads.

CONDITIONS:Students/trainees must be provided with the following:

1. WORKPLACE2. TOOLS, ACCESSORIES AND SUPPLIES




ASSESSMENT METHODS:Direct observationVisual examination of plates

LEARNING ACTIVITIES



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1. READ INFORMATION SHEET NO. 1.2-1 on WELD CARBON STEEL PLATES IN HORIZONTAL POSITION (2G)


2. Perform Weld Carbon Steel Plates In Horizontal Position

After performing Weld Carbon Steel Plates In Horizontal Position, Let the trainer evaluate your work.


INFORMATION SHEET NO. 1.2-1


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Horizontal Welding

When welding in the 2G or 2F position it is necessary to control the weld puddle and travel speed to produce a strong weld. The horizontal position is used widely in agricultural sectors to make repairs.

The steps necessary to perform welds in the 2G or 2F position are:-Secure the plate in a position for running beads in a straight line

from left to right. Use adjustable locking piers or C-clamps to secure the metal firmly.

-When performing this type of weld, the electrode and the plate sides should form a 90º angle. Lean the electrode slightly in the direction of the weld area.

-Adjust the amperage, travel speed, and arc length to prevent the weld puddle from running or sagging.

-Metal that is over 1/8 inch thick should be beveled prior to welding in the horizontal position. If welding thicker metal, or metal that has been beveled, it is necessary to make more than one weld pass to enhance the strength of the weld.

-A root, filler, and cap pass will be necessary.

TASK SHEET 1.2-1


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Title: Weld Carbon Steel Plates In Horizontal Position (2G)


Supplies/Materials: Electrode, welding mask, clear and dark glass, chipping hammer, steel brush, mechanical pliersEquipment: Welding machine (AC or AC/DC), welding table, portable grinder, welding booth, portable oven Steps/Procedure:1. Wear PPE2. Prepare the base metal. 3. Place the base metal in a flat position4. Turn on the welding machine5. Perform welding of carbon steel plates in flat position6. turn off the welding machine

Assessment Method: 1. demonstration2. observation



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CRITERIA YES

NO

1. deposit weld beads on plate?2. weld plates in single pass groove joints in

horizontal positions3. weld plates in multiple pass groove joints in

horizontal position



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Satisfactory

Not Satisfactory






Learning Outcome # 3: WELD CARBON STEEL PLATES IN VERTICAL POSITION (3G)


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CONTENTS:1. Preparation of base plate2. Welding carbon steel plate in Vertical position



2. Weld capping/final pass not exceeding allowable tolerances specified by welding codes/standards on; height of reinforcement, under fill, porosities, undercut, cracks and cold laps.

3. Uniformity of bead ripples must be in accordance with welding standards.





Welding mask, electrodes, steel brush, clear and dark glass, chipping hammer, mechanical pliers.EQUIPMENTWelding machine (AC or AC/DC), welding table, portable grinder,Welding booth, portable oven

4. 4. TRAINING MATERIALSCompetency Based Learning Material on SMAW NCII


LEARNING ACTIVITIESLearning Activities Specific Instruction


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1. READ INFORMATION SHEET NO. 1.3-1 on WELD CARBON STEEL PLATES IN VERTICAL POSITION (3G)


2. Perform Weld Carbon Steel Plates In Vertical Position

After performing Weld Carbon Steel Plates In Vertical Position, Let the trainer evaluate your work.


INFORMATION SHEET NO. 1.3-1


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Vertical Welding

There are two basic techniques for performing welds in the vertical position. These two techniques are commonly referred to as “vertical up” and “vertical down.” These two techniques can be used to perform welds in the 3G and 3F positions.

The following is a set of instructions for performing “vertical up” and “vertical down” welds. For most welders, light metal is easier to weld than heavy metal because it requires less penetration.

Be certain that the metal plate is secured in a vertical position. The use of adjustable locking pliers or C-clamps is recommended to aid in securing the metal in position.

Position the electrode at an angle of 60º to the plate and in the path of the weld. The electrode should be perpendicular to the sides of the plate.

For “vertical down” welding, begin at the top of the plate with a short arc. If the electrode sticks, stop and increase the amperage. If the electrode burns through the metal, lower the amperage. If the electrode continues to burn through the metal, increase the speed of the electrode movement downward.

When welding “vertical up”, position the electrode 85º to the plate in the path of the weld. Begin at the bottom of the plate and work up. Use the same procedures if the electrode sticks or burns through the metal.


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As you become better at welding in the 3G and 3F positions, begin work on thicker metals. Experiment and increase the amperage accordingly. When welding thick plate, use one or more side-to-side electrode movements.

As with fillet welds, “vertical up” and “vertical down” welds will need more than one pass. A root pass should be made, along with a filler and cap pass.

TASK SHEET 1.3-1


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Title: Weld Carbon Steel Plates In Vertical Position (3G)


Supplies/Materials :Electrode, welding mask, clear and dark glass, chipping hammer, steel brush, mechanical pliersWelding machine (AC or AC/DC), welding table, portable grinder, welding booth, portable oven Steps/Procedure:1. Wear PPE2. Prepare the base metal. 3. Place the base metal in a flat position4. Turn on the welding machine5. Perform welding of carbon steel plates in flat position6. turn off the welding machine




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CRITERIA YES

NO


vertical positions3. weld plates in multiple pass groove joints in

vertical position



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Satisfactory

Not Satisfactory






Learning Outcome # 4: WELD CARBON STEEL PLATES IN OVERHEAD POSITION (4G)


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CONTENTS:1. Preparation of base plate2. Welding carbon steel plate in Vertical position



2. Weld capping/final pass not exceeding allowable tolerances specified by welding codes/standards on; height of reinforcement, under fill, porosities, undercut, cracks and cold laps.3. Uniformity of bead ripples must be in accordance with welding standards.






3. 3. EQUIPMENTWelding machine (AC or AC/DC), welding table, portable grinder,Welding booth, portable oven

4. 4. TRAINING MATERIALSCompetency Based Learning Material on SMAW NCII


LEARNING ACTIVITIES



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1. READ INFORMATION SHEET NO. 1.4-1 on WELD CARBON STEEL PLATES IN OVERHEAD POSITION (4G)


2. Perform Weld Carbon Steel Plates In Overhead Position

After performing Weld Carbon Steel Plates In Overhead Position, Let the trainer evaluate your work.


INFORMATION SHEET NO. 1.4


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Overhead Welding

Welding in the 4G or 4F position is the most difficult of the out-of-position welds. The major challenge in this type of welding is controlling the weld puddle. The procedures for performing overhead welds are very similar to the flat position, except that they are far more difficult. It is necessary to pay special attention to the weld puddle and travel speed. You must maintain a short arc as well. The steps in overhead welding are:

Secure the metal overhead with the use of an adjustable locking pliers or C-clamps.

Find a position that is comfortable for you before starting to weld. Welding in the 4G or 4F position is much more difficult if the welder is uncomfortable from the start.

Adjust the amperage setting and travel speed. The amperage should be set at approximately the same setting as needed during vertical welding (3). Be certain to maintain a very short arc length throughout the entire process.

Weld with a short arc and use a moderately fast rate of travel to prevent sagging and undercutting.

A weaving pattern is recommended for use on heavier metals. This motion must be faster than weaves used for other position welds. Three passes will be needed to complete this weld properly.

TASK SHEET 1.4-1


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Title: Weld Carbon Steel Plates In Overhead Position (4G)


Supplies/Materials: Electrode, welding mask, clear and dark glass, chipping hammer, steel brush, mechanical pliersWelding machine (AC or AC/DC), welding table, portable grinder, welding booth, portable oven Steps/Procedure:1. Wear PPE2. Prepare the base metal. 3. Place the base metal in a flat position4. Turn on the welding machine5. Perform welding of carbon steel plates in flat position6. turn off the welding machine




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CRITERIA YES

NO


overhead positions3. weld plates in multiple pass groove joints in

overhead position



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Satisfactory

Not Satisfactory






Learning Outcome # 5: WELD CARBON STEEL PIPES IN HORIZONTAL


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POSITION (2G)

CONTENTS:1. Preparation of base plate2. Welding carbon steel pipe in horizontal position



2. Weld capping/final pass not exceeding allowable tolerances specified by welding codes/standards on; height of reinforcement, under fill, porosities, undercut, cracks and cold laps.

3. Uniformity of bead ripples must be in accordance with welding standards.









LEARNING ACTIVITIES


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1. READ INFORMATION SHEET NO. 1.5-1 on WELD CARBON STEEL PIPES IN HORIZONTAL POSITION (2G)


2. Perform Weld Carbon Steel Pipes in Horizontal Position

After performing Weld Carbon Steel Pipes in Horizontal Position, Let the trainer evaluate your work.


INFORMATION SHEET NO. 1.5


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Horizontal Position

The 1G pipe welding position is a pipe in the horizontal position and the pipe is rolled when welding. This is basically welding in the flat position. The 1G pipe welding certification is rarely used.

TASK SHEET 1.5-1


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Title: Weld Carbon Steel pipes In Horizontal Position (2G)

Performance Objective: Should be able to perform penetration, filling and capping to plates in flat positionSupplies/Materials:Electrode, welding mask, clear and dark glass, chipping hammer, steel brush, mechanical pliersEquipment:Welding machine (AC or AC/DC), welding table, portable grinder, welding booth, portable oven Steps/Procedure:1. Wear PPE2. Prepare the base metal. 3. Place the base metal in a flat position4. Turn on the welding machine5. Perform welding of carbon steel plates in flat position6. turn off the welding machine




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CRITERIA YES

NO

1. deposit weld beads on pipe?2. weld plates in single pass groove joints in

horizontal position3. weld plates in multiple pass groove joints

horizontal position



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Satisfactory

Not Satisfactory







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cblm smaw

Documents

shielded metal arc welding

groove welding

training materials

required competency

learning outcome

college graduate

series of learning activities

high school graduate