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WELDING: SHIELDED METAL ARC WELDER (SMAW) OD24301 Flipbook PDF
OD24301: Shielded Metal Arc Welder 1 SHIELDED METAL ARC WELDER (SMAW) SKILLS STANDARDS Frequency and Criticality Ratings
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Skills Standards
WELDING: SHIELDED METAL ARC WELDER (SMAW)
OD24301
ALIGNED WITH AMERICAN WELDING SOCIETY (AWS) ENDORSED BY AWS
COMPETENCY-BASED EDUCATION: OKLAHOMA’S RECIPE FOR SUCCESS BY THE INDUSTRY FOR THE INDUSTRY Oklahoma’s CareerTech system of competency-based education uses industry professionals and certification standards to identify the knowledge and abilities needed to master an occupation. This industry input provides the foundation for development of instructional materials that help prepare the comprehensively trained, highly skilled employees demanded by our workplace partners.
TOOLS FOR SUCCESS CareerTech relies on three basic instructional components to deliver competency-based instruction: skills standards, curriculum materials, and competency assessments. Skills standards provide the foundation for competency-based instruction in Oklahoma’s CareerTech system. The skills standards outline the knowledge, skills, and abilities needed to perform related jobs within an industry. Skills standards are aligned with national skills standards; therefore, a student trained to the skills standards possesses technical skills that make him/her employable in both state and national job markets. Curriculum materials contain information and activities that teach students the knowledge and skills outlined in the skills standards. In addition to complementing classroom instruction, curriculum resources provide supplemental activities to enhance learning and provide hands-on training experiences. Competency Assessments test the student over material outlined in the skills standards and taught using the curriculum materials. When used with classroom performance evaluations, written competency assessments provide a means of measuring occupational readiness. Although each of these components satisfy a unique purpose in competency-based education, they work together to reinforce the skills and abilities students need to gain employment and succeed on the job.
MEASURING SUCCESS Written competency assessments are used to evaluate student performance. Results reports communicate competency assessment scores to students and provide a breakdown of assessment results by duty area. The results breakdown shows how well the student has mastered skills needed to perform major job functions and identifies areas of job responsibility that may require additional instruction and/or training. Group analysis of student results also provides feedback to instructors seeking to improve the effectiveness of career and technology training. Performance patterns in individual duties indicate opportunities to evaluate training methods and customize instruction.
TRUE TO OUR PURPOSE “Helping Oklahomans succeed in the workplace” defines the mission of Oklahoma CareerTech and its competency-based system of instruction. Skills standards, curriculum, and assessments that identify and reinforce industry expectations provide accountability for programs and assure CareerTech’s continued role in preparing skilled workers for a global job market Copyright 2005 Oklahoma Department of Career and Technology Education All rights reserved Printed in the United States of America by the Oklahoma Department of Career and Technology Education Stillwater, Oklahoma The Oklahoma Department of Career and Technology Education does not discriminate on the basis of race, creed, color, national origin, sex, age, veteran status, or qualified handicap.
SHIELDED METAL ARC WELDER (SMAW) SKILLS STANDARDS Frequency and Criticality Ratings Duty A: Demonstrate Safety Skills Duty B: Interpret and Fabricate Parts from Drawings and Welding Symbols Duty C: Demonstrate Knowledge of Shielded Metal Arc Welding (SMAW) Principles and Practices Duty K: Demonstrate Knowledge of Welding Inspection and Testing Principles and Practices Duty L: Demonstrate Knowledge of Electrical Fundamentals Duty M: Perform Basic Mathematical Operations -------------------------------------------------------------------------------------------Frequency: represents how often the task is performed on the job. Frequency rating scales vary for different occupations. The rating scale used in this publication is presented below: 1 = less than once a week 2 = at least once a week 3 = once or more a day
Criticality:
denotes the level of consequence associated with performing a task incorrectly. The rating scale used in this publication is presented below:
1 = slight 2 = moderate 3 = extreme --------------------------------------------------------------------------------------------------------Duty A: CODE A.01 A.02
Demonstrate Safety Skills TASK Understand and explain the purpose of safety policies Explain the proper steps in reporting an accident or emergency
F/C 3/3 3/3
A.03
Describe and discuss established first aid procedures
3/3
A.04
Describe and discuss the role of the Occupational Safety and Health Act (OSHA) and the EPA (Environmental Protection Agency)
3/3
A.05
Demonstrate knowledge of OSHA requirements
3/3
•
Lock Out/Tag out procedures
•
Personal protective equipment
•
Precautionary labeling
•
Working in confined spaces
•
Hot work permits
•
HAZCOM
•
MSDS
•
Blood borne Pathogens
A.06 A.07
Demonstrate safe behavior on and around ladders and scaffolds Explain the hazards associated with specific welding process, material, equipment and tools
3/3 3/3
A.08
Demonstrate safety techniques for storing and handling cylinders
3/3
A.09
Describe workplace fire hazards and how to properly extinguish fires
3/3
A.10
Discuss electrical hazards and how to avoid electric shock
3/3
A.12
Demonstrate proper use and inspection of equipment used for ventilation and how to avoid welding fumes
3/3
A.13
Demonstrate safe material handling techniques
3/3
OD24301: Shielded Metal Arc Welder 1
•
Lifting
•
Transporting
•
Storing
A.14
Practice tool safety
3/3
A.15
Practice good housekeeping and work area operation
3/3
A.16
Perform safety inspection of equipment and accessories • Protective clothing and equipment • Hand and power tools • Work area • Communicate hazard warnings • Welding equipment and accessories
3/3
DUTY B: Interpret and Fabricate Parts From Drawings and Welding Symbols CODE B.01
B.02
B.03
B.04
TASK Interpret basic elements of a drawing or sketch • Terms • Components • Revisions • Symbols • Structural members • Inspection/test requirements • Sequence of assembly • Dimensions and tolerances • Revisions • Scale • View interpretation • List of materials Interpret welding symbol information • Type of weld required • Filler metal • Special details • Non-destructive testing requirements Interpret written welding procedures • Procedure ID number cross-referencing to drawing • Appropriate welding process/base materials/filler materials • Appropriate machine settings Fabricate parts from a drawing or sketch • Prepare, assemble, and tack weld parts according to drawing or sketch specifications
F/C 3/3
1/3
3/3
3/3
DUTY C: Demonstrate Knowledge of Shielded Metal Arc Welding (SMAW) Principles and Practices CODE C.01
TASK Set up • • • • • • • •
for shielded metal arc welding on carbon steel plate and pipe E7024, E6010, or E6011 and E7018 electrodes Base/filler metal selection/identification/preparation Review appropriate weld procedures Filler metal selection Proper hand tool selection Adjust amperage and polarity Base metal preparation Parts fit up and preheated as necessary
OD24301: Shielded Metal Arc Welder 2
F/C 3/3
C.02 C.03 C.04
Operate shielded metal arc welding equipment • Flat single pass surfacing welds • Flat multiple pass, multi-directional, surfacing welds Make fillet welds in all positions, on carbon steel plate, and on pipe in the 2F position • Multi-pass start/stop points staggered • Different techniques for different electrodes Make groove welds in all positions, on carbon steel plate with and without backing • Multi-pass start/stop points staggered • Different techniques for different electrodes
3/3
3/3
3/3
DUTY K: Demonstrate Knowledge of Welding Inspection and Testing Principles and Practices CODE K.01
K.02
TASK Examine cut surfaces and edges of prepared base metal parts • Appearance • Uniformity • Proper fit-up • Base metal preparation • Cleanliness of weld area Examine tack, intermediate layers, and completed welds • Visual check for weld discontinuity and defects to an acceptable criteria • Destructive or non-destructive examination • Check for proper weld size • Understand types of destructive and nondestructive exams
Duty L: Demonstrate Knowledge of Electrical Fundamentals CODE TASK L.01 Demonstrate the fundamental use of polarity with respect to equipment set up for process used L.02 Perform routine electrical equipment inspections and operation system troubleshooting L.03 Demonstrate compliance with electrical safety postings and personal shock prevention practices L.04 Make minor external repairs to equipment and accessories • Manufacturer’s recommendations • Company’s and/or institution’s repair policies • Equipment troubleshooting • Regulators Duty M: Perform Basic Mathematical Operations CODE TASK M.01 Demonstrate conversion between the US customer and SI metric systems M.02 Add, subtract, multiply, divide, and convert between whole numbers, fractions, mixed numbers, and decimals M.03 Demonstrate the proper use of and interpretation of measuring devices to determine size, length, angle, and distance M.04 Use a calculator and demonstrate rounding of basic arithmetic operations M.05 Prepare parts using the principles of geometry, functions of angles and parts of a circle
OD24301: Shielded Metal Arc Welder 3
F/C 3/3
3/3
F/C 3/3 3/3 3/3 1/3
F/C 3/3 3/3 3/3 3/3 3/3
WELDING SKILLS STANDARDS CROSSWALKED TO AMERICAN WELDING SOCIETY (AWS) ENTRY LEVEL WELDER (LEVEL I) AND MAVCC CURRICULUM MAVCC Curriculum 1) Fundamental of Welding 2) Shielded Metal Arc Welding & Carbon Arc Cutting-Air 3) Gas Tungsten Arc Welding & Plasma Arc Cutting 4) Gas Metal Arc Welding & Flux-Cored Arc Welding 5) Oxyacetylene Welding and Oxyfuel Cutting 6) Shielded Metal Arc Pipe Welding Duty A: CODE A.01 A.02
Demonstrate Safety Skills TASK Understand and explain the purpose of safety policies Explain the proper steps in reporting an accident or emergency
A.03
Describe and discuss established first aid procedures
1) Unit 3 all
A.04
Describe and discuss the role of the Occupational Safety and Health Act (OSHA) and the EPA (Environmental Protection Agency)
1) Unit 2.1
A.05
Demonstrate knowledge of OSHA requirements
1) Unit 2.1
A.06
Demonstrate safe behavior on and around ladders and scaffolds
A.07
Explain the hazards associated with specific welding process, material, equipment and tools
1) Unit 2.18, 2.20, 2.30 1) Unit 2.3
A.08
Demonstrate safety techniques for storing and handling cylinders
A.09
Describe workplace fire hazards and how to properly extinguish fires
A.10
Discuss electrical hazards and how to avoid electric shock
A.12
Demonstrate proper use and inspection of equipment used for ventilation and how to avoid welding fumes
A.13
Demonstrate safe material handling techniques
A.14
Practice tool safety
AWS
MAVCC 1) Unit 3.2 & 3 1) Unit 3.18
1) Unit 3.14, 3.14 1) Unit 2.10-14 1) Unit 2.3f 1) Unit 3.19 4) Unit 1.7
A.15
Practice good housekeeping and work area operation
1) Unit 2.3d, Unit 3.9, Unit 4.20-22 4) All job sheets
A.16
Perform safety inspection of equipment and accessories
1) Unit 2
DUTY B: Interpret and Fabricate Parts From Drawings and Welding Symbols CODE B.01 B.02
TASK Interpret basic elements of a drawing or sketch Interpret welding symbol information
AWS Module 3
MAVCC 1) Unit 7.4
Module 3
1) Unit 7 1) Unit 8.2; 10-14
B.03 B.04
Interpret written welding procedures Fabricate parts from a drawing or sketch
Module 3 Module 3
OD24301: Shielded Metal Arc Welder Crosswalk 4
DUTY C: Demonstrate Knowledge of Shielded Metal Arc Welding (SMAW) Principles and Practices CODE C.01 C.02 C.03 C.04
TASK Set up for shielded metal arc welding on carbon steel plate and pipe Operate shielded metal arc welding equipment Make fillet welds in all positions, on carbon steel plate, and on pipe in the 2F position Make groove welds in all positions, on carbon steel plate with and without backing
AWS Module 4
MAVCC 3) Unit 1 & 2
Module 4 Module 4
3) Unit 1 & 2 3) Unit 1 & 2
Module 4
3) Unit 1 & 2
DUTY D: Demonstrate Knowledge of Gas Metal Arc Welding (GMAW) Principles and Practices CODE D.01 D.02 D.03 D.04
D.05 D.06
TASK Set up for gas metal arc welding operations on carbon steel plate Operate gas metal arc welding Short Circuit Transfer Make fillet welds, all positions, on carbon steel plate and pipe in 2F position-flat, multiple pass, surfacing welds Make groove welds, all positions, on carbon steel plate with backing and pipe in 1G Spray Transfer Make 1F and 2F welds on carbon steel plate Make 1G welds on carbon steel plate
AWS Module 5 Module 5
MAVCC 4) Unit 2 4) Unit 2
Module 5 Module 5
4) Unit 2 4) Unit 2
Module 5
4) Unit 2
Module 5
4) Unit 2
Module 5 Module 5
4) Unit 2 4) Unit 2
DUTY E: Demonstrate Knowledge of Flux-Cored Arc Welding (FCAW, FCAW-G/GM) Principles and Practices CODE E.01 E.02 E.03 E.04
TASK Set up for flux cored arc welding operations on carbon steel plate and pipe Operate flux cored arc welding equipment Make fillet welds in all positions on carbon steel plate Make groove welds in all positions on carbon steel plate
AWS Module 6
MAVCC 4) Unit 3
Module 6
4) Unit 3
Module 6 Module 6
4) Unit 3 4) Unit 3
DUTY F: Demonstrate Knowledge of Gas Tungsten Arc Welding (GTAW) Principles and Practices CODE F.01 F.02 F.03 F.04 F.05 F.06 F.07 F.08
TASK Set up for gas tungsten arc welding operations on carbon steel plate, aluminum, and stainless steel plate Operate gas tungsten arc welding equipment Make fillet welds, 2F and 3Fpositions, on carbon steel plate Make groove welds, 3G position without backing, on carbon steel plate Make 1F-2F welds on aluminum plate Make 1G with backing welds on aluminum plate Make 1F-2F-3F welds on stainless steel plate Make 1G-2G-3G welds on stainless steel plate
AWS Module 7
MAVCC 4) Unit 2
Module 7
4) Unit 2
Module 7 Module 7
4) Unit 2 4) Unit 2
Module 7 Module 7
4) Unit 2 4) Unit 2
Module 7 Module 7
4) Unit 2 4) Unit 2
DUTY G: Demonstrate Knowledge of Manual Oxyfuel Cutting (OFC) Principles and Practices CODE G.01
TASK Set up for manual oxyfuel gas cutting operations on carbon steel plate
G.02
Operate manual oxyfuel cutting equipment
OD24301: Shielded Metal Arc Welder Crosswalk
5
AWS Module 8 Unit1 Module 8 Unit1
MAVCC 5) Unit 2 5) Unit 2
G.03
Perform straight cutting operations on carbon steel plate and pipe
G.04
Perform shape cutting operations on carbon steel plate and pipe
G.05
Perform bevel cutting operations on carbon steel plate and pipe
Module 8 Unit1 Module 8 Unit1 Module 8 Unit1
5) Unit 2 5) Unit 2 5) Unit 2
DUTY H: Demonstrate Knowledge of Mechanized Oxyfuel Cutting (OFC) Principles and Practices CODE H.01 H.02
TASK Set up for oxyfuel gas cutting (track burner) operations on carbon steel plate machine Operate machine oxyfuel gas cutting (track burner) equipment
AWS Module 8 Unit 2
MAVCC 5) Unit 2
Module 8 Unit 2
5) Unit 2
DUTY I: Demonstrate Knowledge of Air Carbon Arc Cutting (CAC-A) Principles and Practices CODE TASK AWS MAVCC Module 8 3) Unit 4 I.01 Set up for manual air carbon arc gouging and cutting operations on Unit 4 carbon steel plate Module 8 3) Unit 4 I.02 Operate manual air carbon arc cutting equipment I.03
Perform metal removal operations on carbon steel plate
Unit 4 Module 8 Unit 4
3) Unit 4
DUTY J: Demonstrate Knowledge of Plasma Arc Cutting (PAC) Principles and Practices CODE J.01 J.02 J.03
TASK Set up for manual plasma arc cutting operations on carbon steel plate, aluminum, and stainless steel plate Operate manual plasma arc cutting equipment Perform shape cutting operations on carbon steel plate, aluminum, and stainless steel plate
AWS Module 8 Unit 3
MAVCC 4) Unit 3
Module 8 Unit 3 Module 8 Unit 3
4) Unit 3 4) Unit 3
DUTY K: Demonstrate Knowledge of Welding Inspection and Testing Principles and Practices CODE K.01 K.02
TASK Examine cut surfaces and edges of prepared base metal parts Examine tack, intermediate layers, and completed welds
Duty L: Demonstrate Knowledge of Electrical Fundamentals CODE TASK L.01 Demonstrate the fundamental use of polarity with respect to equipment set up for process used L.02 Perform routine electrical equipment inspections and operation system troubleshooting L.03 Demonstrate compliance with electrical safety postings and personal shock prevention practices L.04 Make minor external repairs to equipment and accessories Duty M: Perform Basic Mathematical Operations CODE TASK M.01 Demonstrate conversion between the US customer and SI metric systems OD24301: Shielded Metal Arc Welder Crosswalk
6
AWS Module 9 Module 9
MAVCC 4) Unit 2 4) Unit 2
AWS
MAVCC
AWS
MAVCC 1) Unit 6.13
M.02 M.03 M.04 M.05
Add, subtract, multiply, divide, and convert between whole numbers, fractions, mixed numbers, and decimals Demonstrate the proper use of and interpretation of measuring devices to determine size, length, angle, and distance Use a calculator and demonstrate rounding of basic arithmetic operations Prepare parts using the principles of geometry, functions of angles and parts of a circle
OD24301: Shielded Metal Arc Welder Crosswalk
7
Unit 6 all Unit 6 all
Unit 6 all