level 3 welding project

ASSESSMENT: MMA, TAGS AND WELDING

ASSESSMENT NO: 6088-06 I/C MMA1

TITLE: Installation of LCS LPHW Heating mains and header

LINK: MMA Welding Industrial/commercial 6088 NVQ Level 3

MODULE ORGANISATION PEOPLE WELDING TESTING SAFETY SYSTEMS

CODE LETTER

(A) (B) (C) (E) (F) (H)

BOXNUMBER

1,2,3,5,6,7,8,9,10,11,12,13,14,15,16

1,2,4 1,2,3,4,5,6 1,2,3 1,2,3,5,6,7,8,9,10,

11,12,13

1

MODULE QUALITY ENVIRONMENT ELECTRICS RECORDS & INFORMATION

SITES

CODE LETTER

(I) (J) (K) (L) (M)

BOXNUMBER

1,2,3 1,2 1 1,2,3,4,5,6,7,8,9,10 1,2,3,4,5

INTRODUCTION:

This assessment covers the installation of LPHW heating, distribution header and branch connections. The main purpose of this assessment is to test the candidates competence in working without supervision in the areas of planning, preparation, installation and testing of LCS pipework with MMA welded joints.

This assessment should be carried out in a realistic working environment with all the restraints that site work involves.

SPECIFICATION:

100 mm distribution header and 65 mm branch connections are to be installed in LCS BS 1387 heavy weight pipe. The system has a high level flow and return to a low level distribution header. Jointing of pipework will be:

Manual Metal Are (MMA) welding with general purpose fittings to BS 1965 and welding flanges to BS 459.

All welds to be in accordance with NJIC test specifications.The preparation and testing of MMA and TAGS welded joints should be in accordance with HVAC publication TR 5/6 Welding of carbon steel pipework.All work carried out should have due regard to the HSWA 1974.

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INSTRUCTION:

Candidates are advised to study all the assessment details and drawings for the specified task before starting. Reference sources will need to be consulted for certain aspects of the tasks, the references used should be noted next to your answers. The assessor will be your customer/client or main contractor for the purpose of this assessment.

SECTIONS:

1.1 The following hazards have been identified in the immediate working area:

a. Fire risk from welding processb. Ultra violet light from MMA/TAGS welding processc. Portable; electric hand tools (grinder)d. Personal protection of operatives (PPE)

Under current regulations you the employee have a responsibility to your employer and fellow operatives to state the safety requirements and equipment need to limit the risk level of the four hazards above.

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1. PLANNING Organising, Records

1.2 As TAGS is not yet a common welding process on most sites you will need to hire the additional equipment:

a. Make a list of the equipment necessary to complete the weld ready to pass to your employer.

Answer______________________________________________________________

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b. State the procedure for setting-up this equipment ready for use.

Answer______________________________________________________________

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1.3 The fumes from the MMA/GAGS welding process creates specialhazards to the welder if they rely on general ventilation systems. What advice and recommendations would you suggest to overcome this problem.

Answer______________________________________________________________

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1. PLANNING Organising, Records

2.1 Slip on bossed flanges are to be welded to the 100 mm diameter LCS distribution header having a wall thickness of 6 mm. to enable other welder to complete the headers the following information is required by your employer:

a. Sketch the joint setup, showing all dimensions and detail prior to welding.

Answer

b. List a selection of electrode diameters used for this weld and their approximate current values.

Answer______________________________________________________________

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2. PREPARATION: Sites, Records

2.1 Clarification of manual metal arc electrodes BS 639 is important especially on sites were different types of electrodes are used. The client requires a brief explanation of the following:

a. The letters and numbers given to electrodes.

Answer______________________________________________________________

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b. The composition, characteristics and uses of different types of flux coatings.

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Reference: Welding Schedule 5.3 may be used as the answers for the above questions, so long as the standards of competency have been reached in the schedule.


2. PREPARATION: Sites, Records

3.1 This assessment must be installed in position from the fixed heights shown in the working drawing.

b. The installation of MMA welded 100 mm header with slip on bossed flange, fixed butt, horizontal vertical on 65 mm branch with welding elbow, terminating on the flow with a screwed flange. A horizontal vertical on the branch pipe must be welded in position using the MMA welding process. Please note the 100 mm slip-on boss flange may be welded off-site.


3. DOING: Installation, Records

4.1 On completion of the installation all mechanical and welded joints must be tested in accordance with HVCA publications TR 5/6 , Welding of Carbon

Steel and Site Pressure Testing of Pipework.

This to include hydraulic pressure test, bend tests, macro etching and visual examination

For future reference you are required to record the results of your testing on the form provided drawing.


4. FINISHING: Testing, Commissioning


16 2

3

4

5

1195

1040

450

Weld No

1

2

3,4

5

6

Description

100mm fixed but

65 mm ONTO 100mmm vertical branch

65mm Horizontal Vertical

65mm Fixed Butt

Slip on boss flange onto 100mm pipe

Detail drawing of pipework Pipe installation all measurements are approximate.

Drawing not to scale

TEST CERTIFICATE

OPERATIVE’S NAME:

CLIENT’S NAME:

DATE OF 1ST TEST: DATE OF 2nd TEST

SYSTEM WORKING PRESSURE: Bar TEST PRESSURE: Bar1½ times maximum working pressure

TEST DURATION: Minutes

WELD NUMBER COMPETENT

ACTIONS/OBSERVATIONS

1. Fixed ButtBend Tests

a) Top b) Side c) BottomVisual

a) Penetration b) Appearance2. Branch

Macro Etcha) Crotch

b) FlankVisual

a) Penetration b) Appearance3. Horizontal/Vertical Bend Test

a) Stop & Start b) Directly OppositeVisual

a) Penetration b) Appearance4. & 5. Weld-on Elbow Subject to visual Examination6. Slip-on Boss FlangeSubject to visual Examination


KNOWLEDGE ASSESSMENT

Answer all the questions in the assessment. Please circle the appropriate answer after carefully reading each question.

1. Which ONE of the listed articles of legislation applies to all places of work?

a) Electricity at Work Regulations 1988b) Gas safety (Installation & Use) Regulations 1998 c) Part P of the Building Regulations 2000d) Electricity Supply Regulations 1988

PC: 9.1 (All)

2. What MINIMUM period of time must elapse after an acetylene cylinder has been up righted from the horizontal position before being used?

a) 120 minutesb) 90 minutesc) 60 minutesd) 30 minutes

PC: 9.2.1; 9.2.2; 9.2.3; 9.2.6

3. What Grade of BS 1387 LCS tube is best suited to jointing by the welding process?

a) Heavy – red bandb) Medium – blue bandc) Heavy – blue bandd) Medium – red band

PC: 9.1.5

4. What preparation technique is necessary after flame cutting LCS tube before carrying out welding?

a) Painting with oxide paintb) Application of a fluxc) Removal of oxide coatingd) None required

PC: 9.1.1 to 9.1.6


NVQ LEVEL 3 6088-06 IC MMA

5.1 Supplementary Assessment questions, objective type:

5. What component must be installed between cylinder regulators and the gas hose?

a) None requiredb) Flashback arresterc) Flexible jointd) Non-return

PC: 9.1 (all)

6. When welding in confined spaces which item of safety plant listed MUST be used?

a) Mechanical extractionb) Natural ventilation systemc) Fire blanketd) Bucket of water

PC: 9.1 (all)

7. Before MMA welding work commences, WHICH of the following must be carried out?

a) General tidying upb) Take a breakc) Install screensd) Risk assessment

PC: 9.1.1 to 9.1.6

8. Before work starts the welding area must be shielded to prevent?

a) The SSR watchingb) Other people getting arc eyec) The welder getting arc eyed) Welding fumes escaping

PC: 9.2.3

9. Information on the Company’s safety procedures for the welding process can be found in the

a) Site induction videob) Local libraryc) Site diaryd) Safety guidance sheets

PC: 9.2 (all)



10. Before using angle grinders which of the following are essential checks?

a) Fire extinguisher typeb) Tightness of vicec) Abrasive wheel and cabled) Type of pipe and fittings

PC: 9.2.2; 9.2.3

11. To whom would you report defects in welding equipment?

a) Foremanb) Branch Managerc) Site Agentd) Contracts Manager

PC: 9.2 (all)

12. For general purpose cutting using compressed gas cylinders which of the following blowtorch would be used?

a) Propane/airb) High pressurec) Low pressured) Single gas

PC: 9.2 .2; 9.2.3

13. Which document is used to acknowledge the competence of a pipe welder on site?

a) Driving licenceb) HASAWA 1974c) ADVANCED Craft Certificated) Engineering Services SKILLcard

PC: 10.1 (all)

14. The recognised industry standard for the welding of LCS pipe is:

a) JTC specificationb) BS6644: Part 1c) HVCA TR 5d) BS5440: Part 2

PC: 10.1.1 to 10.1.3



15. A certificate of Competency for Manual Arc Welding permits an operative to weld on systems with maximum temperatures and pressures of:

a) 100oC and 10 barb) 100oC and 17 barc) 220oC and 10 bard) 220oC and 17 bar

PC: 10.1.1 to 10.1.3

16. Slag inclusions can be caused by?

a) Amperage too lowb) Correct type of electrodec) Correct techniqued) Welding in flat position only

PC: 10.1.1; 10.1.4 to 10.1.7

17. Undercut can be caused by?

a) Correct currentb) Correct techniquec) Amperage too lowd) Amperage too high

PC: 10.1.1; 10.1.4 to 10.1.7

18. During positional welding the electrode angles are important because...................................... tends to work against the welder.

a) The base metalb) The electrode holderc) The force gravityd) The current amperage

PC: 10.1.1; 10.1.4 to 10.1.7

19. Root penetration must not enter the pipe bore more than?

a) 1 mmb) 2 mmc) 3 mmd) 4 mm

PC: 10.1.1; 10.1.4 to 10.1.7



20. For the protection of the welder the electrode holder must be

a) blackb) crackedc) insulatedd) hot

PC: 10.1.1; 10.1.4 to 10.1.7



No Question Ref PC Comp N.Y.C. Inv Ev

1.1 Planning 9.1.1,9.1.2,9.1.5,9.1.6,9.1.7,9.1.8

1.2 Planning 9.2.1 – 9.2.61.3 Planning 9.1.1,9.1.2,

9.1.3,9.1.4,9.1.5,9.1.6,9.1.82.1 Preparation 9.1.2,9.1.7,1.1.82.2 Preparation 9.1.2,9.1.7,1.1.83.1 Doing 10.1.1 -10.1.94.1 Finishing 10.2.1 – 10.2.6

Supplementary Assessment Questions

5.1 Objective Questions 1 - 20

9.1.1 – 9.1.89.2.1 – 9.2.610.1.1 – 10.1.910.2.1 – 10.2.6

KEY SKILLSCommunicationApplication of numberInformation Technology


Confirmation of Completion of Assessment

Competent: ........................................... Not Yet Competent: ..............................

Candidate: ............................................. Signature: .............................................

Assessor: ............................................. Signature: ............................................

Internal Verifier: .................................... Signature: ...........................................

Date of Assessment: ........................... Date of Verification: ...........................

Feed back to candidate:

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level 3 welding project

Documents

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assessment details

testing of mma

lcs bs

mma welded joints