Welding materials by the manual metal arc process

Welding materials by the manual metal arc process
SEMFWE3-04
Welding materials by the manual metal arc process
Overview
This standard identifies the competencies you need to prepare and operate
manual metal arc (MMA) welding equipment in accordance with approved
welding procedures. You will be required to set up and check the welding
equipment and associated workholding and manipulating devices required. In
setting up the equipment you will need to connect all the required leads/cables,
electrode holder and workpiece earthing arrangements ready for use, and set
and adjust the welding conditions in line with the welding procedure
specification. You must operate the equipment safely and correctly and make
any necessary adjustments to settings in order to produce the welded joints to
the required specification.
Your responsibilities will require you to comply with organisational policy and
procedures for the welding activities undertaken and to report any problems
with the welding equipment or welding activities that you cannot resolve, or are
outside your permitted authority, to the relevant person. You will be expected to
work with minimum supervision, taking personal responsibility for you’re own
actions and for the quality and accuracy of the work that you produce.
Your underpinning knowledge will provide a good understanding of your work,
and provide an informed approach to applying welding procedures and
instructions. You will understand the manual metal-arc welding process, and its
application, and will know about the equipment, materials and consumables in
adequate depth to provide a sound basis for setting up and operating the
equipment, recognising and correcting faults and ensuring the work output is
produced to the required specification. Non-destructive testing of your
completed work is implied. You will understand the safety precautions required
when working with the welding equipment. You will be required to demonstrate
safe working practices throughout, and will understand the responsibility you
owe to yourself and others in the workplace.
SEMFWE3-04 Welding materials by the manual metal arc process
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SEMFWE3-04
Welding materials by the manual metal arc process
Performance
criteria
You must be able to:
P1
P2
P3
P4
P5
P6
P7
P8
P9
work safely at all times, complying with health and safety and other
relevant regulations and guidelines
follow the relevant joining procedure and job instructions
check that the joint preparation complies with the specification
check that joining and related equipment and consumables are as
specified and fit for purpose
make the joints as specified using the appropriate thermal joining
technique
produce joints of the required quality and of specified dimensional
accuracy
shut down the equipment to a safe condition on completion of joining
activities
deal promptly with excess and waste materials and temporary
attachments, in line with approved and agreed procedures
deal promptly and effectively with problems within your control and
report those that cannot be solved
SEMFWE3-04 Welding materials by the manual metal arc process
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SEMFWE3-04
Welding materials by the manual metal arc process
Knowledge and
understanding
You need to know and
understand:
K1
the safe working practices and procedures to be observed when working
with MMA welding equipment (general workshop and site safety;
appropriate personal protective equipment (PPE); fire prevention;
protecting other workers from effects of the arc; safety in
enclosed/confined spaces; fume control; accident procedure; statutory
requirements, risk assessment procedures and relevant requirements of
HASAWA, COSHH and Work Equipment Regulations; safe disposal of
waste materials)
K2
the hazards associated with MMA welding and how they can be
minimised (live electrical components; poor earthing; the electric arc;
fumes and gases; spatter; hot slag and metal; grinding and mechanical
metal/slag removal; elevated working; enclosed spaces)
K3
principles of MMA welding, the equipment and its operation (fusion
welding principles, characteristics of the metal arc, AC and DC power
sources, typical equipment and power ranges, care of equipment,
terminology used in welding)
K4
extracting information required from drawings and welding procedure
specifications (interpretation of welding symbols; scope, content and
application of the welding procedure specification) to include symbols
and conventions to appropriate British, European or relevant
International standards in relation to work undertaken
K5
types and classification of electrodes (flux coverings, correct control,
storage and drying of electrodes)
K6
types and features of welded joints in plate, tube and sections (fillet and
butt welds, single and multi-run welds, welding positions, weld quality)
K7
problems that can occur with the welding activities and how these can
be overcome (causes of distortion and methods of control, effects of
welding on materials and sources of weld defects; methods of
prevention)
K8
methods of setting up the joint to achieve correct location of components
and control of distortion (edge preparation, use of jigs/fixtures;
manipulators and positioners, tack welding, size and spacing in
relationship to material thickness and component size, use of temporary
attachments, pre-setting)
K9
setting up the welding equipment and checks that need to be made to
ensure that it is safe and ready to use (electrical connections, power
return and earthing arrangements; equipment calibration, setting welding
parameters, care and maintenance of equipment)
K10 the techniques of operating the welding equipment to produce a range of
joints in the various joint positions (fine tuning parameters, correct
manipulation of electrode, safe closing down of the welding equipment)
SEMFWE3-04 Welding materials by the manual metal arc process
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SEMFWE3-04
Welding materials by the manual metal arc process
K11 the organisational quality systems used and weld standards to be
achieved
K12 weld inspection and test procedures used including destructive and nondestructive methods
K13 personal approval tests and their applicability to your work
K14 the extent of your own responsibility and whom you should report to if
you have problems that you cannot resolve
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SEMFWE3-04
Welding materials by the manual metal arc process
Additional Information
Scope/range
related to
performance
criteria
You must be able to:
1. set up, check, adjust and use manual metal-arc welding and related
equipment to include either:
1.1.
alternating current equipment (AC)
1.2.
direct current equipment (DC)
2. use two types and two sizes of electrode from the following:
2.1.
rutile
2.2.
basic
2.3.
nickel alloy
2.4.
cellulosic
2.5.
stainless steel
2.6.
other electrodes
3. produce welded joints which incorporate both:
3.1.
butt welds
3.2.
fillet welds
4. produce joints in two forms of specified materials from different material
groups to include the following:
4.1.
plate
4.2.
section
4.3.
pipe/tube
4.4.
other forms
5. weld joints according to approved welding procedures in good access
situations in the following BS EN ISO 6947positions:
5.1.
Vertical upwards (PF) butt weld
and four other positions chosen from:
5.2
flat (PA)
5.3
horizontal (PC)
5.4
overhead (PE)
5.5
horizontal vertical (PB)
5.6
vertical downwards (PG)
5.7
inclined tube/pipe (H-LO45 or J-LO45)
SEMFWE3-04 Welding materials by the manual metal arc process
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SEMFWE3-04
Welding materials by the manual metal arc process
6. produce welded components which:
6.2
achieve a weld quality equivalent to Suite B of BS EN ISO 5817
except for excess weld metal, excessive convexity, excess
throat thickness and excessive penetration for which Suite C
shall apply (for aluminium, EN30042/ISO10042 applies)
6.2
meet the required dimensional accuracy within specified
tolerances
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SEMFWE3-04
Welding materials by the manual metal arc process
Developed by
SEMTA
Version number
2
Date approved
December 2011
Indicative review
date
December 2016
Validity
Current
Status
Original
Originating
organisation
SEMTA
Original URN
4
Relevant
occupations
Engineering and manufacturing technologies; engineering; Metal Forming,
Welding and Related Trades
Suite
Fabrication and Welding Engineering Suite 3
Key words
Engineering, welding, fabrication, manual welding, metal arc, MMA,
electrodes, butt joint, fillet joint, welding process
SEMFWE3-04 Welding materials by the manual metal arc process
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