validated CS of fabricator and welder

Competency Standards
for
Fabricator & Welder

2
Table of Contents
Sr. No: Content Page No:
1. A: FollowSafetyRulesat Workplace 3
2. B: PerformCutting ofMaterial 6
3. C: Perform AssemblingofJob 10
4. D: PerformSolderingof Job 13
5. E: PerformBrazing of Job 15
6. F : Perform Oxy-Acetylene Welding 17
7. G: PerformWelding[SMAW (MMA) /GTAW (TIG) /GMAW (MIG/MAG)/SAW] 19
8. H: Repair Weldingdefects 27
9. I: DevelopProfessionalism 29
10. List of Tools, Equipment& Consumables 31

3
Title A: Follow Safety Rules at Workplace
Overview: ThisCompetencyStandardidentifiesthe competencies required to follow safety rules at workplace by Fabricator & Welder in accordance
withthe organization’sapprovedguidelinesandprocedures.Youwillbe expectedto applypersonal, workplace, tools & equipment and job/work piece
safety measures at all times. Your underpinning knowledge regarding safety rules will be sufficient enough to provide you the basis for your work.
Unit of Competency Performance Criteria Knowledge Tools & Equipment
A1. Applypersonal
safetymeasures
You will be able to:
P1. Selectpersonal protective equipmentin
termsof type andquantity accordingto
workpermit.
P2. Wear and adjustpersonal protective
equipmenttoensure correctfitand
optimumprotectionincompliance with
companyprocedures.
P3. Ensure personal protective equipmentis
cleanedandstoredinproperplace.
K1. ExplainImportance of usingPersonal
Protective Equipment(PPE)
K2. Define Typesof PPE.
K3. IdentifyProtective clothingand
equipment(PPE) tobe wornand from
where itcan be obtained.
K4. Explainthe Safe maintenanceof PPE.
Leatherapron,safety
gloves,safetygoggles,
weldinghelmet,safety
shoes,earplug,safetybelt,
fume mask,dungaree
A2. Applyworkplace
safetymeasures
P1. Applysafetymeasurestothe followingsat
workplace
 Ensure Ventilation
 No Inflammable material nearby
 Secure gas cylinders
 Availabilityof Fire extinguishers
 Secure Electrical connections
 Ensure Earthling
 No lightreflection
 Ensure availabilityof weldingbooths
K1. ExplainImportance of safetyatworkplace
and itsimplications.
K2. Describe Workplace safety guidelines.
K3. ExplainSpecificcompanyprocedures
regardingworkplace safety.
K4. Explainprocedure forcleaningand
storingof toolsand equipmentat
workplace.
Fire extinguisher,fire
blankets,face shield,gas
detectors,Tool box/bins,
Safetycovers,Firstaidbox,
worktable,fume extractor,
lightingsystem,PPE

4
(where necessary)
 Emergencyexit
P2. Exhibithousekeepingatworkplace according
to organizational guidelines
P3. Ensure the availabilityof firstaidbox at the
workplace
P4. Displaya listof emergencycontactnumbers
at workplace
A3. Applytools &
equipmentsafety
measures
P1. Applysafetymeasurestothe followingtools
and equipment
 Arc Weldingmachine/plantand
equipment
 Gas welding andcuttingequipment
 Mechanical cuttingand beveling
equipment
 Grindingmachines
 Hand tools(e.g:scrappers,files,
measuringtape,hammers,stacks,
Hatches,Anvils etc)
P2. Clean toolsand equipmentbefore andafter
the job
P3. Ensure safe placementof measuringand
cuttingtools
P4. Followtoolsandequipmentsafety
instructionmanuals
K1. ExplainImportance of toolsand
equipmentsafety anditsimplications.
K2. Describe use of cleaningtoolsand
equipment
K3. Describe the importance of safe handling
and placementof measuringandcuttingtools
K4. Readand applythe safetymanual
instructions
K5. ExplainSpecificcompany procedures
regardingtoolsandequipmentsafety.
K6. Explainprocedure forcleaningandstoring
of toolsandequipmentatworkplace.
Safetymanuals,safety
instructionsheets,cleaning
toolsand equipment

5
A4. Applyjob/work
piece safety
measures
P1. Followthe workpermitforthe job/work
piece safety
P2. Applythe followingsafetymeasuresforthe
job/workpiece safety
 Job/Workpiece isfree fromdust,oil,
grease,paintandmoisture
 Safelycoverthe job/workpiece afterthe
duty
 Safelyplace the job/workpiece afterthe
duty
P3. Applysafe handlingof job/workpiece
during
I. Fabrication
II. Welding
III. Loading/unloading
IV. Transportation
P4. Followspecific job/workpiece safety
instructions
K1. Readand implementworkpermit
accordingto the nature of job
K2. Describe the importance of job/workpiece
safety
K3. Explainthe importance of safe handling
and transportationof job/workpiece
K4. Explainspecificjob/workpiece safety
instructions
Work permit,safety
instructions,cleaningtools
and equipment,cranes,
lifters,handtrolleys

6
Title B: Perform Cutting of Material
Overview: This Competency Standard identifies the competencies required to perform cutting of material at workplace by Fabricator & Welder in
accordance withthe organization’sapprovedguidelinesandprocedures. You will be expected to arrange the required material for cutting, perform gas
cuttingmethod,performdisccuttingmethod, performSawcutting method and perform shear cutting method on job, at workplace. Your underpinning
knowledge regarding cutting of material will be sufficient enough to provide you the basis for your work.
B1. Arrange the
requiredmaterial
for cutting
P1. Interpretthe followingtypesof drawings
 2D drawing
 3D drawing
 Isometric
 Diametric
 Oblique
 Pipingandinstrumentdiagram(P&ID)
P2. Take measurementsandcalculationsasper
drawing
P3. Identifyrequiredmaterial asper
specificationsof drawing
P4. Followthe standardoperatingprocedures
(SOPs) forthe arrangementof required
material
P5. Arrange the markingtoolsrequired,asperjob
P6. Cleanthe material surface formarkingarea
P7. Mark the jobarea as per requirement
K1. Define typesof lines
K2. Readand Interpretsymbolsand
abbreviations of drawings
K3. Explaindifferenttypesof drawingviews
K4. Explaintypesof conversionmethods(e.g:
imperial andmetricsystem)
K5. Explainthe typesof measuringtools
K6. Solve basicarithmeticproblems
K7.-Solve basicgeometricrelations
K8. Solve basictrigonometricrelations
K9. Explainthe international standardsfor
material selection
K10. Explaintypesof fittings
K11. Explainthe importance of standard
Drawinginstruments,
measuringtools,symbol
and abbreviationsheets,
calculator,stationaryitems,
Standardoperating
procedures(SOPs),
Measuringtape,divider,
grinderwithpowerbrush,
line scriber,hammer,
centerpunch,prickpunch,
combinationset,set
square,inside andoutside
caliper,filesandscrappers,
wire brush,cottonwaste,
tong,emerypaper,marking
stone,straightbar,surface
plate/markingtable,anvil,
V block,wraparound,
benchand pipe vices,
chemicalsforcleaning,
Personal Protective
Equipment(PPE)

7
P8. Punchthe cuttingareaas per requirement
P9. Applyspecificsafetyprecautionsassociated
withthe material handling
operatingprocedures(SOPs)
K12. Explaintypesandusage of markingtools
K13. Describe variouscleaningmethodsfor
base metal specifications
K14. Explaindifferenttypesof tolerancesand
allowances
K15. Identifydifferentcoloursusedfor
highlightingthe markingsurface
K16. Describe specificsafetyprecautions
associatedwithmaterial handling
B2. Performgas
cutting methodon
job
P1. Arrange gas cuttingsetas per requirement
P2. Inspectthe equipmentandconnectionsas
perSOPs
P3. Place the jobfor cuttingas per requirement
P4. Performgascuttingoperationasper
specifications
P5. Followsafetyprecautionsatworkplace
K1. Explain- differenttype of gasesusedfor
cutting
K2. Describe usage of gas cuttingtorch and
nozzles
K3. Explainusage of the following:
 Hose pipes
 Regulators
 Nozzles
 Flashback arrester
 Gas cylinders
K4. Explainthe startupand shutdown
procedure of gas cutter
Gas cylinders(oxygen,fuel
gases),gascutter,hose
pipes,nozzles,regulator,
flashback arresters,spark
lighter,tipcleaner,
cylinder/spindlekey,
cylindertrolleywithchain,
adjustable spannerset,gas
workingtable,hose
protector,SOPs,gas
pressure settingchartas
pernozzle,PPE

8
K5. Describe pressure settingaspermaterial
thicknessandnozzle sizes(e.g.nozzle
selectionchart)
K6. Explainthe safetyhazardsrelatedtogas
cuttingprocess(e.g:flashback,backfire etc)
B3. Performdisc
cutting methodon
job
P1. Selecttoolsrequiredfordisccuttingmethod
P2. Prepare workplace fordisccuttingas per
requirement
P3. Performdisccuttingoperationsasper
specifications
P4. Performfinishing(remove burr/sharpedges
etc.) as perSOPs
P5. Inspectthe job,as perspecifications,after
completionof cutting
K1. Explainthe usage of disccuttingtools
K2. Describe the typesof grinders&cutting
discsand theirsizes
K3. Explainthe disccuttingprocess
K4. Explainthe usage of finishingtools
K5. Explainspecificsafetyprecautionsrelated
to disccuttingmethod
Grinder,cuttingdiscs,
grindingdiscs,files,emery
paper,conical- stone,
straightstone,emery
flower,grinderkey,power
supply,extensionboard,
PPE
B4. PerformSaw
cutting methodon
job
P1. Selecttoolsrequiredforsawcuttingmethod
as per material
P2. Prepare workplace forsawcuttingas per
requirement
P3. Performclampingof jobforsaw cutting
P4. Performsawcuttingoperationsasper
K1. Explainthe usage of sawcutting tools
K2. Describe the typesof sawbladesaccording
to material andteeth
K3. Explainthe sawcuttingprocess
Hacksaw,powerhacksaw,
blades,vices,coolants,
measuringtape, right
angle,PPE

9
specifications
etc) as per SOPs
P6. Inspectthe job,as perspecifications,after
completionof sawcutting
to saw cuttingmethod
B5. Performshear
cutting methodon
job
P1. Selectmachine andtoolsrequiredforshear
cuttingmethod
P2. Prepare workplace forshearcuttingasper
requirement
P3. Performholdingof jobforshearcutting
P4. Performshearcuttingoperationsasper
specifications
etc) as per SOPs
P6. Inspectthe job aftercompletionof shear
cuttingas per specification
K1. Explainthe usage of shearcuttingmachine
and tools
K2. Explainthe shearcuttingprocess
to shearcuttingmethods
Shearingmachines,lever
shear,handshear,
measuringtape,right
angle,files,emerypaper,
waste cotton,lubricants,
PPE

10
Title C: Perform Assembling of Job
Overview: This Competency Standard identifies the competencies required to perform Assembling of Job at workplace by Fabricator & Welder in
accordance withthe organization’sapprovedguidelinesandprocedures. You will be expected to perform grinding/ filing of job , take measurement of
jobparts for assembling,performalignmentof jobpieces,perform tacking of job, at workplace. Your underpinning knowledge regarding assembling of
job will be sufficient enough to provide you the basis for your work.
C1. Perform
grinding/ filingofjob
P1. Selectgrinding/filingprocessasper
material/requirement
P2. Arrange grindingmachinesanddifferent
typesof filesasper requirement
P3. Selectmachinesrequiredforgrinding/filing
method
P4. Prepare workplace forgrinding/filingasper
requirement
P5. Performgrinding/filing operationsasper
SOPs
etc) as per SOPs
P7. Inspectthe job aftercompletionof
grinding/filingasperspecifications
K1. Explaindifferenttypesof grinding and
filingprocesses
K2. Explainthe usage of grindingmachinesand
files
K2. Describe the typesof bevels
K3. Explainthe grinding/filing process
to grinding/filingprocess
Angle grinder,pedestal
grinder,pencil grinder,
grindingdiscs,grinding
stones, grinderkey, power
cable, flatfile,roundfile,
half roundfile,square file,
triangle file,knifefile,
smoothcut file,needle file
set,PPE
C2. Take
measurementofjob
You will be able to: You will be able to: Measuringtape,steel rule,
tri square,verniercaliper,

11
parts for assembling P1. Arrange measuringtoolsrequiredfor
assembling
P2. Checkmeasurementsof partsasper drawing
K1. Explainthe usage of differentmeasuring
toolsforassembling
K2. Explaindifferentconversionsystemsused
for measurement
K3. Explainspecificsafetymeasuresassociated
withthe workplace
outside insidecaliper,
vernierheightgauge,radius
gauge,fillergauge,bevel
gauge,PPE
C3. Perform
alignmentof job
pieces
P1. Arrange alignmenttoolsrequiredfor
alignmentof job
P2. Arrange workplace accordingtothe job
requirement(temporarysupport)
P3. Checkalignmentof partsas perdrawing
K1. Explainthe usage of differenttoolsfor
alignment
K2. Explainthe usage of differenttoolsfor
measurement
K3. Readand interpretdrawingforalignment
K4 Solve basicarithmeticproblemsand
trigonometricrelations
K4. Explainspecificsafety measuresassociated
withthe workplace
Measuringtape,steel rule,
tri square,verniercaliper,
outside insidecaliper,
vernierheightgauge,radius
gauge,fillergauge,bevel
gauge,combinationset,
waterlevel,spiritlevel,
plumbob,fishingline,
hammer,straightbar,PPE
C4. Perform tacking
of job
P1. Arrange tackingtoolsand equipment
requiredfortackingof job
P2. verifyalignmentof partsbefore tacking,as
perdrawing
P3. Checkthe gaps betweentwoparts as per
weldingprocedurespecifications(WPS)
P4. Performtackingof jobas per requirement
K1. Explainusage of toolsandequipmentfor
tacking
K2. Readand interpretdrawing/WPSfor
tacking
K3. Describe the effectsof temperature on
tackingof jobi.e.expansionandcontraction
K4. Explainthe processof tackingas perWPS
Welding equipment,
hammer,tri square,filler
gauge,chippinghammer,
tapergauge,high-low
gauge,tackingcleeds,gap
rod, temporary support,
tackingclamp,jigsand
fixtures,chainblock,
hydraulicjack,come along,
liftingandshifting
equipment,C- clamp,
adjustable wrench,screw

12
P5. Verifyalignmentof partsaftertackingas per
drawing
P6. Coverthe job,as per requirement,after
tacking
K5. Explainthe methodsof protectionof job
K6. Explainspecificsafetyprecautions
associatedwithtackingof job
driver,pre heatingtorch,
grinder,cuttingdisc,PPE

13
Title D: Perform Soldering of job
Overview: ThisCompetencyStandardidentifiesthe competenciesrequiredtoperformsoldering of Jobat workplace by Fabricator& Welderin
accordance withthe organization’sapprovedguidelinesandprocedures.Youwill be expectedto prepare jobforsoldering , Performsolderingoperation
on job, Performpostsolderinginspection,atworkplace.Yourunderpinningknowledge regarding solderingof jobwill be sufficientenoughtoprovide you
the basisfor yourwork.
D1. Prepare job for
soldering
P1. Selectthe solderingmethodasperjob
requirementi.e.electronicandgas
P2. Arrange the workplace accordingthe
solderingrequirement
P3. Arrange toolsrequiredforsolderingmethod
P4. Arrange fillermaterial andfluxasper
requirement
P5. Cleanthe solderingareaasperrequirement
i.e. chemicallyandmechanically
K1. Explaindifferentsolderingmethods
K2. Explainthe propertiesof metals
K3. Explainthe usage of solderingtools
K4. Explainthe usage of fillermaterialandflux
K5. Explaindifferenttypesof cleaning
materialsandtechniques
K6. Explainthe hazardsrelatedtosoldering
e.g.heatand fumesetc
Differentsolderingirons,
sucker,wire brush,gas
weldingset,solderingtips,
fillermaterials,flux,holding
clamp, tip cleaner,emery
paper,cottonwaste,
cleaningagents,PPE
D2. Perform
solderingon job
P1. Prepare solderingby:
 Connectingsolderingironwithelectric
supply
 Lit up the gas torch and make flame as
perrequirement
K1. Explainthe usage of toolsforsoldering
K2. Explainthe usage of consumables for
soldering
K3. Describe the postcleaningmethodsof
Differentsolderingirons,
sucker,wire brush,gas
weldingset,solderingtips,
fillermaterials,flux,holding
clamp, tipcleaner, emery
paper,cottonwaste,
cleaningagents,PPE

14
P2. Applyflux tojobsurface as perSOPs
P3. Performsolderingof jobas perSOPs
P4. Performpostcleaningof solderedareaas
perrequirement
soldered area
K4. Explainthe specificsafetyprecautions
associatedwithsoldering
D3. Performpost
solderinginspection
P1. Performvisual inspectionforlocating
solderingdefects
P2. PerformPneumaticandHydropressure tests
for inspectionof quality
P3. Remove defectsof solderingasper
requirement
K1. Explaindifferenttype of solderingdefects
K2. Describe differenttypesof testingapplied
on solderedjob
K3. Describe the methodof removal of
solderingdefects
withworkplace e.g.hazardsrelatedto
removal of fluxshutdownof heatingsource
Magnifyingglass, different
solderingirons,sucker,
wire brush,gas weldingset,
solderingtips,filler
materials,flux,holding
clamp,coppertube,emery
paper,cottonwaste,
cleaningagents, soap
testingmaterial, PPE

15
Title E: Perform Brazing of Job
Overview: ThisCompetencyStandardidentifiesthe competenciesrequiredtoperform brazingof Jobat workplace by Fabricator&Welderin
accordance withthe organization’sapprovedguidelinesandprocedures.Youwill be expectedto prepare jobforbrazing, Performbrazingoperationon
job, Performpostbrazinginspection,atworkplace.Yourunderpinningknowledge regarding brazingof jobwill be sufficientenoughtoprovideyouthe
basisfor yourwork.
E1. Prepare job for
Brazing
P1. Selectthe brazingtechnique asperjob
requirement
P2. Arrange the workplace accordingthe brazing
requirement
P3. Arrange toolsrequiredforbrazing method
P4. Arrange fillermaterial andfluxasper
requirement
P5. Cleanthe brazingchemicallyand
mechanically areaasperrequirement
K1. Explaindifferentbrazingtechniques
K3. Explainthe usage of brazingtools
K4. Explainthe usage of fillermaterialandflux
K5. Explaindifferenttypesof cleaning
materialsandtechniques
K6. Explainthe hazardsrelatedtobrazing
Steel wire brush,gas
weldingset,weldingtips,
fillermaterials,holding
clamp, flux, emerypaper,
cotton waste,cleaning
agents,sparklighter,tip
cleaner,spanners,cylinder
keys,SOPs,PPE
E2. Performbrazing
operationon job P1. Lit up the gas torch and make flame asper
requirement
P2. Applyflux tojobsurface as perSOPs
P3. Performbrazingof jobas per SOPs
P4. Performpostcleaningof brazedareaas per
K1. Explainusage of toolsforbrazing
K2. Explainusage of consumables forbrazing
K3. Describe the postcleaningmethods of
brazedarea
clamp,emerypaper,flux,
cotton waste,cleaning
agents, sparklighter,tip
cleaner,spanners,cylinder
keys,SOPs,PPE

16
requirement
associatedwith brazing
E3. Performpost
brazing inspection
P1. Performvisual inspectionforlocating brazing
defects
P2. PerformPneumaticandhydropressure tests
for inspectionof quality
P3. Remove defectsof brazingasper
requirement
K1. Explaindifferenttype of brazing defects
on brazingjob
K3. Describe the methodof removal of brazing
defects
withworkplace (e.g.hazardsrelatedto
removal of flux,shutdownof gasweldingset)
Magnifyingglass, Steel wire
brush,gas weldingset,
weldingtips,flux,filler
materials,holdingclamp,
emerypaper,cottonwaste,
cleaningagents,spark
lighter,tipcleaner,
spanners,cylinderkeys,
SOPs,PPE

17
Title F: Perform Oxy-Acetylene Welding
Overview: ThisCompetencyStandardidentifiesthe competenciesrequiredtoperform Oxy-Acetylene Welding, at workplace by Fabricator & Welder
in accordance with the organization’s approved guidelines and procedures. You will be expected to prepare job for oxy-acetylene welding , perform
operationsrelatedto oxy-acetylene welding,performpostoxy-acetylene weldinginspection ,at workplace.Yourunderpinningknowledge regarding oxy-
acetylene welding will be sufficient enough to provide you the basis for your work.
F1. Prepare job for
oxy-acetylene
welding
P1. Selectthe oxy-acetylene weldingtechnique
as per jobrequirement
P2. Arrange the workplace accordingthe oxy-
acetylene weldingrequirement
P3. Arrange toolsrequiredforoxy-acetylene
weldingmethod
P4. Arrange fillermaterial asperrequirement
P5. Cleanthe oxy-acetyleneweldingarea,
chemicallyandmechanically asperrequirement
K1. Explainoxy-acetylenegaswelding
techniques
K3. Explainthe usage of toolsforoxy-
acetylene welding
K4. Explainthe usage of fillermaterial
K5. Explaindifferenttypesof cleaningagents
and techniques
K6. Explainthe hazardsrelatedto oxy-
acetylene welding
clamp,emerypaper,cotton
waste,cleaningagents,
spark lighter,tipcleaner,
SOPs, PPE
F2. Perform
operationsrelatedto
oxy-acetylene
welding
P1. Lit up the gas torch and make flame asper
requirement
P2. Performcleaningof jobsurface before
weldingasperrequirement
K1. Explainthe usage of toolsforoxy-
acetylene welding
K2. Explainthe usage of consumables foroxy-
acetylene welding
clamp,emerypaper,cotton
waste,cleaningagents,
spark lighter,tipcleaner,

18
P3. Performoxy-acetylene weldingonjobasper
SOPs
P4. Performcleaningof weldedareaafter
welding, asperrequirement
K3. Describe the postcleaningmethods of oxy-
acetylene welded area
associatedwith oxy-acetylenewelding
SOPs,PPE
F3. Perform post
oxy-acetylene
weldinginspection
P1. Performvisual inspectionforlocating oxy-
acetylene weldingdefects
P2. Remove defectsof oxy-acetylene weldingas
perrequirement
P3. PerformPneumaticandhydropressure tests
on jobfor inspection
K1. Explaindifferenttype of oxy-acetylene
weldingdefects
on oxy-acetylene welded job
K3. Describe the methodof removal of oxy-
acetylene defects
withworkplace (e.g.hazardsrelatedto
removal of flux,shutdownof gasweldingset)
Magnifyingglass,wire
brush,gas weldingset,
weldingtips,filler
materials,flux,holding
clamp, jigsand fixtures,
emerypaper,cottonwaste,
cleaningagents,
instructionsmanuals,SOPs,
PPE

19
Title G: Perform Welding [SMAW (MMA) /GTAW (TIG) /GMAW (MIG/MAG)/SAW]
Overview: ThisCompetencyStandardidentifiesthe competenciesrequiredtoperform Welding, atworkplace by Fabricator& Welderinaccordance
withthe organization’sapprovedguidelinesandprocedures.Youwillbe expectedto prepare workplace forSMAWMMA/GTAW (TIG) /GMAW
(MIG/MAG) /SAWwelding,PerformoperationsrelatedtoSMAW(MMA)/GTAW(TIG) /GMAW (MIG/MAG) /SAWwelding andPerformpostwelding
operations,atworkplace.Yourunderpinningknowledgeweldingwillbe sufficientenoughtoprovide youthe basisforyourwork.
G1. Prepare
workplace for
SMAW(MMA)
welding
P1. Arrange the workplace accordingtothe
requirementof the job
• Weldingbooth/fire blanket
• WeldingPlant/machineandaccessories
• Powersupply
• Scaffolding
• Jigsand fixtures
• Lighting
P2. applythe safetymeasures atworkplace as
perwork permite.g.
• Ventilation
• Fire extinguishers
• FirstAidbox
• Emergencyalarm/light
• List of EmergencyNumbers
• Personal protectiveequipment
P3. Prepare the requiredwelding plant/machine
• Type of current(AC/DC)
• Currentpolarity
K1. Describe the requirementsof aworkplace
for weldingspecificjob
K2. Describe the organizational safetyrules
and guidelines
K3. Describe the preparationof welding
machine including
• Type of current(AC/DC)
• Currentpolarity
K4. Explainusesof LowerExplosiveLimits(LEL)
Tester,OxygenAnalyzer
Weldingmachine,grinder,
chippinghammer,wire
brush,electrode oven,
desiccators,jigsand
fixtures,lights,exhaust
fans,fire blankets,fire
extinguishers,firstaidbox,
PPE
G2. Prepare
workplace for GTAW
(TIG) welding
for weldingthe specificjob
Weldingmachine andgas
cylinders(Argon) with
accessories,tungsten
electrode,fillerrod/wire,

20
 Weldingbooth/fire blanket
 Weldingmachine andaccessories
 Gas cylinders( Argon) withaccessories
 Powersupply
 Scaffolding
 Jigsand fixtures
 Lighting
P2. applythe safetymeasuresasperwork
permit
 Ventilation
 Fire extinguishers
 FirstAidbox
 Emergencyalarm/light
 List of EmergencyNumbers Personal
protective equipment
P3. Prepare the requiredweldingmachine asper
jobrequirement
 Type of current(AC/DC)
 Currentpolarity
 Gas flowrate
and guidelines
plant/machine including
 Currentpolarity
 Gas flowrate
grinder,wire brush, jigs
and fixtures,lights,exhaust
weldinghelmet, PPE
G3. Prepare
workplace for
GMAW (MIG/MAG)
welding
 Weldingbooth/fire blanket
 Weldingplant/machineandaccessories
 Gas cylinders(CO2,Argon) with
accessories
 Powersupply
 Scaffolding
and guidelines
machine including
Weldingmachine andgas
cylinders(CO2,Argon) with
accessories,grinder,
chippinghammer,wire
brush,wire cutter,anti
spatterspray, consumable
wire,jigsandfixtures,
lights,exhaustfans,fire
blankets,fire extinguishers,
firstaidbox,PPE

21
 Lighting
permit
 Ventilation
 FirstAidbox
 List of EmergencyNumbers
 Personal protectiveequipment
P3. Prepare the requiredwelding plant/machine
 Currentpolarity
 Gas flowrate
 Type of current
 Currentpolarity
 Gas flowrate
G4. Prepare
workplace for
SubmergedArc
Welding(SAW)
welding
 Weldingmachine andaccessories
 Powersupply
 Lighting
permit
 Ventilation
 FirstAidbox
 List of EmergencyNumbers
 Personal protectiveequipment
and guidelines
machine including
 Currentpolarity
 Travel speed
Weldingmachine with
accessories,flux drying
oven,grinder,chipping
hammer,wire brush,jigs
and fixtures,lights,exhaust
fans,fire extinguishers,first
aidbox,PPE

22
P3. Prepare the requiredweldingmachine asper
jobrequirement
 Currentpolarity
 Travel speed
G5. Prepare job for
welding
P1. Arrange toolsand cleaningchemicals
requiredforthe job
P2. Prepare jointasper drawing
P3. Cleanjointasper requirement
P3. Followthe weldingprocedurespecification
(WPS) / instructionsheet forwelding
P4. Followspecificsafetyprecautionsassociated
withweldingjob
K1. Describe the usage of toolsrequiredfor
the job
K2. Describe the importance of joint
preparation,cleaningandtacking
K3. Define weldingprocedure specification
(WPS) / instructionsheet
K4. Applyspecificsafetyprecautions
associatedwithweldingjob
Grinders,cutters,beveling
machine,file,measuring
tools,WPS/instruction
sheet,PPE
G6. Perform
operationsrelatedto
SMAW(MMA)
welding
P1. Arrange the electrode as perwelding
procedure specification(WPS) /instruction
sheet
P2. Arrange pre-heatingequipmentasper
weldingprocedurespecification(WPS)/
instructionsheet
P3. Adjustelectrical parametersasperwelding
sheet
K1. Determine the specifications/
classificationof electroderequiredforthe job
K2. Readand interpretinstructionsof WPS
K3. State the importance of pre heating
K4. Describe howtoadjustweldingcurrent
parametersandtheireffectson weldedjoint
K5. Explainthe processof SMAW (MMA)
welding
Weldingplant/machine,
electrodes,pre-heating
equipment,grinders,wire
brush,chippinghammer,
temperature gun, temple
sticks,desiccators,PPE,
WPS/instructionsheet

23
P4. PerformfollowingasperWPS / instruction
sheet:
 Pre heat the job,if required
 Performweldingoperation
 Inter-passcleaning
 Inter-passinspection
 Maintaininter-passtemperature
withweldingjob/process
associatedwithweldingjob/process
G7. Perform
operationsrelatedto
GTAW (TIG) welding
P1. Arrange the fillerwire/rod asperwelding
sheet
instructionsheet
P3. Adjustfollowingweldingparametersasper
instructionsheet
 Amperes
 Gas flowrate
 Back purging,if required
P4. PerformfollowingasperWPS / instruction
sheet
K1. Describe the specifications/classification
of fillerwire/rodrequiredforthe job
K2. Readand interpretinstructionsof WPS/
instructionsheet
K4. Describe howtoadjustwelding
K5. Explainthe processof GTAW (TIG) welding
Weldingplant/machineand
gas cylinders(Argon) with
accessories,tungsten
electrode,grinder,wire
brush,fillerwire/rod,jigs
and fixtures,temperature
gun,dissolvingpaper(as
required),templestick,
maskingtape (as
required),lights,exhaust
weldinghelmet, PPE,WPS/
instructionsheet

24
G8. Perform
operationsrelatedto
GMAW (MIG/MAG)
welding
P1. Arrange the consumable wire spool asper
instructionsheet
instructionsheet
instructionsheet
 Voltage
 Amperes
 Wire feedspeed
 Gas flowrate
 Stickout
P4. PerformfollowingasperWPS/ instruction
sheet
of consumable wire requiredforthe job
instructionsheets
K5. Explainthe processof GMAW (MIG/MAG)
welding
Weldingplant/machineand
gas cylinders(CO2,Argon)
withaccessories,grinder,
chippinghammer,wire
brush,wire cutter,anti
spatterspray, consumable
wire spool,jigsandfixtures,
lights,exhaustfans,fire
blankets,fire extinguishers,
firstaidbox, PPE,WPS/
instructionsheet

25
G9. Perform
operationsrelatedto
SubmergedArc
Welding(SAW)
welding
P1. Arrange consumable wire spool andflux as
perweldingprocedure specification(WPS) /
instructionsheet
P2. Arrange pre-heatingequipment,if required,
as per weldingprocedure specification(WPS) /
instructionsheet
instructionsheet
 Voltage
 Amperes
 Travel speed
 Type of Polarity
 Stickout
 Wire speed
P4. Performfollowing asperweldingprocedure
specification(WPS) /instructionsheet
of wire andflux combinationrequiredforthe
job
instructionsheet
K5. Explainthe processof SAWwelding
operation
Weldingequipmentwith
accessories,wire spool,
flux,pre-heating
equipment,grinders,wire
brush,wire cutter,
chippinghammer,temple
sticks,flux dryingoven,
PPE,WPS/ instructionsheet
G10. Perform post
weldingoperations
P1. Applypostweldcleaningof the job with
followingprocess
K1. State the importance of postweldcleaning
of the job
post-heatingequipment,
weldingmachine,
consumables asperWPS,
grinders,wire brush,

26
 Removal/collection of un-fusedflux (for
SAW process)
 Removal of slag
 Removal of jigsandfixtures
P2. Performvisual inspectionof weldedarea
and rectify defectsasperrequirement
P3. Performpost-heatingof the jobasper WPS/
instructionsheet,if required
K2. Identify,imperfectionsof weldedarea
visually
K3. Describe the purpose of post-heating
chippinghammer,PPE,
WPS/instructionsheet
G11. Repair defected
areas of job/work
piece
P1. Followthe instructionsof supervisorand
inspector’sreporttoidentifydefectedpoint(s)
P2. Arrange the toolsand equipmentrequired
for repairingdefectedarea(s)
P3. Applythe followingrepairprocedure asper
inspectionreport
 Grinding
 Cutting
 Gouging
P4. Applyrepairweldingtospecificdefected
area(s) as perWPS/instructionsheet
P5. Applyspecificsafetyprecautions associated
withweldingequipment
K1.Readand interpretinspectionreport
regardingdefects
K2. Enlistthe nondestructive tests(NDT) for
weldinginspection
 Visual testing(VT)
 Magneticparticle test(MT)
 Radiographictest(RT)
 Ultrasonictest(UT)
 Dye penetrationtest(PT)
 Positive Material Identification(PMI)
K3. Describe the usage of toolsand equipment
requiredforthe job
K4. Describe the processandselectionof
defectremoval methods
Grinder,cutter,gouging
equipment,welding
equipmentwith
accessories,
electrodes/fillerwires,gas
cylinder,desiccators,
electrode dryingoven,
(argon),WPS/ instruction
sheet,PPE

27
K5. State the needforrepairwelding
K6. Describe specificsafetyprecautions
associatedwithweldingequipmentusage

28
TITLE H . Develop Professionalism
Overview: ThisCompetencyStandardidentifiesthe competenciesrequiredtoDevelopProfessionalism by Fabricator & Welder in accordance
withthe organization’sapprovedguidelinesandprocedures. Youwillbe expectedtoperformcommunicationwithothers,upgrade professional
skillsandworkina team.Your underpinningknowledgeregardingdevelopmentof professionalismwill be sufficient to provide you the basis for
your work.
H1. Perform
Communicationwith
others
P1. Communicate withsupervisorfollowing
communicationprocedure
P2. Communicate withcolleaguesfollowing
communicationprocedure
P3. Use mediato communicate effectively(e.g:
email,telephone,laptopetc)
K1. Identifyfactorsrequiredtocommunicate
effectivelyandpreciselywithin
organisation.
K2. Justifythe appropriate use of electronic
and relative mediaas perneed
K3. Knowledge of technical English
Computer/laptop,internet,
telephone
H2. Upgrade
professional skills
P1. Participate inSkill testforprofessional
development
P2. Attendseminars/trainingworkshopsfor
professionaldevelopment
P3. Adoptupcomingmarkettrendsinwelding
field
P4. followorganizational policies(SOPs) for
professionaldevelopment
K1. Describe the benefits of latestwelding
techniquesanddevelopments
K2. Identifythe needof skillsetsbygetting
involvedinseminars,workshopsand
competitions.
Computer,internetfacility,
magazines,books,codes
and standards

29
H3. Work ina team You will be able to:
P1. Demonstrate goodteamskillsincluding
 Cooperation/coordination
 Work ethics
 Etiquettes/manners
P2. Adoptdresscode as per SOPs.
P3. Showcomfortand tolerance.
K1. Describe the importance of beingagood
teamplayer.including
 Cooperation/coordination
 Work ethics
 Etiquettes/manners
Computer,internetfacility,
lectures

30
List of Tools, Equipment and Consumables
Tools and Equipment Consumables
 Calculator
 Bevel Machine
 Pedestal Grinder
 Angle grinder
 Pencil Grinder
 Bench vice
 Electric Hand drill machine
 Sprit level metallic
 Pipe vice
 Pipe cutter
 Tin cutter
 Hammer ball pien
 Hammer Straight
 Hammer Cross pien
 Prick Punch
 Center Punch
 Ms. Chisel Flat
 Pipe Wrench
 Adjustable Wrench
 Hack Saw Frame
 Hack saw Blade
 Tri-square
 Micrometer
 Vernier Calipers
 Tap and Die
 File (e.g: round, half round, flat, triangle)
 Jigs and fixtures
 Combination set
 Spanners
 Socket set
 Screw driver
 Steel scale
 Inside calipers
 Outside calipers
 Stationary items
 Marking Stone
 Wrap around
 Emery Paper
 C02 cylinder
 Acetylene cylinder
 Power brush
 Wire brush
 Safety goggles
 Safety gloves
 Overall
 Face Shield
 Dust Mask
 Ear Plugs
 Ear Muffs
 Welding Helmet
 Safety Helmet
 Safety shoes
 Black Glass for Welding Helmet (shade
10,11,12)
 Clear Glass for Welding Helmet
 Cutting Disc (4”, 5”, 7” 9” & 14”)
 Grinding Disc
 Fire Extinguisher (DCP, CO2, Foam, Water)
 Gases (O2, D/A, Argon, LPG, CO2 )
 Sand Buckets
 Lubricants
 Soldering Wire
 Filler Wire for Brazing
 Filler wire bras
 Copper Coated Mild Steel (CCMS) for gas
welding
 Electrode for SMAW (MMA) Welding (AWS
7018)
 Electrode for SMAW (MMA) Welding (E6013)

31
 Divider
 Tool Box
 Anvil steel
 Clamp
 Letter punch
 Number punch
 Chipping hammer
 Gas cutting torch set
 Argon cylinders
 Welding rectifier for electric welding
 Welding machine for Argon welding
 Welding machine for CO2 welding
 Welding Machine for SAW
 Electrode holder
 Welding cable
 Hose pipe
 Welding torch for GTAW
 Welding torch for Brazing
 Torch Head
 Baking oven
 Power cutter
 flash back Arrestor
 Welding booth
 Exhaust fans
 Welding Procedure Specification (WPS)
 Standard Operating Procedures (SOPs)
 Consumable Wire Spool for GMAW/MIG MAG
Process (AWS 70S-6)
 Consumable Wire for GTAW/TIG Process
 AWS ER 70S -3
 Consumable Wire Spool for SAW process
 Wire [AWS EM 12K/ Flux EH14]
 Consumable Flux for SAW process
 Masking Tape
 Hacksaw Blade
 Conical Stone
 Milling Cutter


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