COMPETENCY - BASED LEARNING MATERIALS

Sector:
METALS AND ENGINEERING

Qualification:
Shielded Metal Arc Welding (SMAW) NCI

Unit of Competency:
Weld Carbon Steel Plate using SMAW

Module Title:
Welding Carbon Steel Plate using SMAW
 HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome

The unit of competency Weld carbon steel plate using SMAW is one of the
competencies of SHIELDED METAL ARC WELDING NC I. This module covers
the knowledge, skills and attitudes required for TVET trainee to possess.

The module on, Welding carbon steel plate using SMAW contains
training materials and activities related to identifying learner’s requirement.

In this module you are required to go through a series of learning

activities in order to complete each learning outcome such as Information-
Sheets, Self-checks, Operation Sheets and Task/Job Sheets. Follow and
perform the activities on your own. If you have questions do not hesitate to
ask for assistance from your trainer.

Remember to:
 Work through all the information and complete the activities in each
section.

Read information sheets and complete the self-check. Suggested references

are included to supplement the materials provided in this module.

 Most probably, your trainer will also your supervisor or manage. he is

there to support you and show you the correct way to do things.

 You will be given plenty of opportunities to ask questions and practice

on the job make sure you practice your new skills during regular work
shifts. This way you will improve your speed, memory and your
confidence.

 Use the self-check, Operation Sheets and Task/job Sheets at the end of
each section to test your own progress. Use the Performance Criteria
Checklist or Procedural Checklist located after the sheet to check your
own performance.

 When you feel confident that you have sufficient practice, ask your
trainer to evaluate you. The result of your assessment will be recorded
in your Progress Chart and Accomplishment Chart.

 You need to complete this module before you can perform the next module
 LIST OF COMPETENCIES

No. Unit of Competency Module Title Code

Weld Carbon Steel Welding Carbon Steel

1. MEE721301
Plates Using SMAW Plates Using SMAW
 SUMMARY OF LEARNING OUTCOMES

QUALIFICATION: Shielded Metal Arc Welding NCI

UNIT OF COMPETENCY: Weld Carbon Steel Plates Using SMAW

MODULE TITLE: Welding Carbon Steel Plate Using SMAW

MODULE DESCRIPTION: This module covers the knowledge, skills and

attitude in performing fillet welding on carbon
steel plates in different positions such as 1F, 2F,
3F & 4F.

This module covers the knowledge, skills and

attitude in performing groove welding on carbon
steel plates in different positions such as 1G, 2G
& 3G.

NOMINAL DURATION: 184 Hrs.

LEARNING OUTCOMES:
LO1. Perform single pass fillet weld in different positions (1F-4F)
LO2. Perform multiple pass fillet weld in different positions (1F-4F)
LO3. Perform multiple pass groove weld in different positions (1G-3G)
 DETAILS OF LEARNING OUTCOME

Perform single pass fillet weld in

LEARNING OUTCOME 1:
flat position (1F)
CONTENTS:
 Essentials of welding
 International welding codes and standards
 Acceptable weld profiles
 Weld defects, causes and remedies
 Welding Procedure Specifications (WPS)
 Welding techniques and procedures
 Safe welding practices
ASSESSMENT CRITERIA:
1. Specify weld capping/ final pass not exceeding allowable tolerances by
welding codes/ standards on
 Height of reinforcement
 Under-fill
 Porosities
 Undercut
 Cracks
 Cold laps
2. Observe uniformity of bead ripples must be in accordance with welding
standards
3. Deposit stringer or layered beads in accordance with welding standards
4. Visually accept finish weldment in accordance with welding standards
for:
 Spatters
 Arc strikes
 Slag
 Uniformity of beads
CONDITIONS:(Tools, equipment, s/m, references/materials)
 Equipment
- SMAW Welding machine (AC/DC)
- Welding table or jig
- Portable grinder
- Welding booth
 Tools/Accessories
- Welding mask
- Steel brush
- Clear glass
- Chipping hammer
- Dark glass
 Supplies/ Materials
- Welding electrode 6011/6010 and 6013/7018
- Carbon steel plates
- Cutting grinding disk
  Personal protective equipment
- Safety shoes
- Apron
- Leggings
- Safety goggles
- Gloves
 Training Materials
- SMAW welding manuals
- Welding procedures specifications (WPS)
- Welding standards

METHODOLOGIES:
 Lecture/demonstration
 Self-paced learning
 Guided demonstration
ASSESSMENT METHODS:
 Written test
 Demonstration with oral questioning
 LEARNING EXPERIENCE

LEARNING OUTCOME 1: Perform single pass fillet weld in flat position (1F)

Learning Activities Special Instructions

1. Read Information sheet 1.1.1 about welding
techniques and procedures (1F)

2. Answer Self-Check 1.1.1 Compare your answers to

3. Watch video presentation about perform
single pass fillet weld in flat position (1F)
4. Perform Task sheet 1.1
Answer Key 1.1.1
Take notes from a video to
perform single pass fillet
weld in flat position (1F).
Your performance will be
evaluated by your trainer
using Performance Criteria
Checklist 1.1
 INFORMATION SHEET 1.1.1
WELDING TECHNIQUES AND PROCEDURES
SINGLE PASS FILLET WELD IN FLAT POSITIONS (1F)

LEARNING OBJECTIVE/S:
After reading this INFORMATION SHEET you will able to:
1. Perform single pass fillet weld in flat position (1F)
2. Review unit of competency cluster:
 1- Apply Safety Practices
 2- Interpret Working Drawings And Sketches
 3- Perform Industry Calculations
 4- Contribute To Quality System
 5- Use Hand Tools
 6- Prepare Weld Materials
 7- Setup Welding Equipment
 8- Fit Up Weld Materials
 9- Repair Welds
 TASK SHEET 1.1.1
Title of Task:
Cut and prepare edge of materials using Oxy-Acetylene (Manual)
Performance Objective:
Given necessary materials, tools, and equipment the student/trainee must be
able to cut & prepare edge using Oxy-Acetylene (Manual)
Supplies / Materials:
 Carbon steel plate - 10mm x 150mm x 200
 Cutting/Grinding disc - 100mm
Equipment / Accessories :
 Oxygen/acetylene & cutting outfit
 Personal Protective Equipment (PPE)
 Cutting table
 Angle grinder 4”
Steps / Procedure:
1. Identify hazardous area
2. Use personal protective clothing and devices
3. Perform safe handling of tools, equipment and materials
4. Interpret standard drawing symbols, dimensional tolerances and notations
5. Inspect work done
6. Apply quality standards to work
7. Select hand tools
8. Set up cutting equipment
9. Cut and prepare edge of materials
10. Clean surfaces and edges

Assessment method : Demonstration

 TASK SHEET 1.1.1
Title of Task:
Set up welding machine
Performance Objective:
Given necessary materials, tools, and equipment the student/trainee must be
able to set up welding machine
Supplies / Materials:
 Carbon steel plate - 10mm x 150mm x 200
 Cutting/Grinding disc - 100mm
Equipment / Accessories :
 Welding machine w/ complete accessories
 Personal Protective Equipment (PPE)
 Welding table
 Angle grinder 4”
Steps / Procedure:
1. Identify hazardous area
2. Use personal protective clothing and devices
3. Inspect work done
4. Apply quality standards to work
5. Select hand tools
6. Attach Primary cable to welding machine primary cable terminal
7. Attach Primary cable to power source.
8. Check Welding machine for functionality.
9. Set Polarity switch, if any, to DC reverse.
10. Check Cable terminals for tightness.
11. Connect Electrode cable to positive of welding machine.
12. Connect Ground cable to negative terminal of welding machine.
13. Attach Ground clamp to workpiece/material.
14. Check Welding cable for crack, burns and cuts.
15. Attach Primary cable to welding machine primary cable terminal

Assessment method : Demonstration

 TASK SHEET 1.1.1
Title of Task:
Tack welding (Plate)
Performance Objective:
Given necessary materials, tools, and equipment the student/trainee must be
able to tack welding of the plate
Supplies / Materials:
 Mild steel plate - 10mm x 150mm x 200
 Cutting/Grinding disc - 100mm
Equipment / Accessories :
 Welding machine w/ complete accessories
 Personal Protective Equipment (PPE)
 Welding table/welding booth (positioner, jigs & fixture)
 Oven
 Tools – steel brush, chipping hammer
 Angle grinder 4”
Steps / Procedure:
1. Identify hazardous area
2. Use personal protective clothing and devices
3. Perform safe handling of tools, equipment and materials
4. Interpret standard drawing symbols, dimensional tolerances and notations
5. Inspect work done
6. Apply quality standards to work
7. Select hand tools
8. Perform Tack welding in accordance with the welding procedure requirements
9. Free Joints from rust, paints, grease and other foreign materials prior to fit
up or tacking.
10. Check Alignment of work piece in accordance with welding standard
11. Check Included angle in accordance with WPS

Assessment method : Demonstration

 TASK SHEET 1.1.1
Title of Task:
Welding techniques and procedures (weld plates in single pass fillet joints in flat
position (1F)
Performance Objective:
Given necessary materials, tools, and equipment the student/trainee must be
able to weld plates in single pass fillet joints in flat positions (1F)
Supplies / Materials:
 Mild steel plate - 10mm x 150mm x 200mm
 Cutting/Grinding disc - 100mm
Equipment / Accessories :
 Welding machine w/ complete accessories
 Personal Protective Equipment (PPE)
 Welding table/welding booth (positioner, jigs & fixture)
 Oven
 Tools – steel brush, chipping hammer
 Angle grinder 4”
Steps / Procedure:
1. Identify hazardous area
2. Use personal protective clothing and devices
3. Perform safe handling of tools, equipment and materials
4. Interpret standard drawing symbols, dimensional tolerances and notations
5. Inspect work done
6. Apply quality standards to work
7. Select hand tools
8. Weld plates in single pass fillet joints in flat position (1F)
9. Mark/locate weld defects, remove defects & perform re-welding
Assessment method : Demonstration
 TASK SHEET
WELDING TECHNIQUES AND PROCEDURES 1.1.1
WELD PLATES IN SINGLE PASS FILLET JOINTS IN FLAT POSITION (1F)

Trainee’s Name: __________________________________ Date: ________________

CRITERIA YES NO
1. Specify weld capping/ final pass not exceeding
allowable tolerances by welding codes/ standards on
 Height of reinforcement
 Under-fill
 Porosities
 Undercut
 Cracks
 Cold laps
2. Observe uniformity of bead ripples must be in
accordance with welding standards
3. Deposit Stringer or layered beads in accordance with
welding standards
4. Visually accept finish weldment in accordance with
welding standards for:
 Spatters
 Arc strikes
 Slag
 Uniformity of beads