welder level c program outline - Industry Training Authority

ACKNOWLEDGEMENTSThe Program Outline was prepared with the advice and direction from an industry SteeringCommittee convened by the Mechanical Contractors Association (MCA) with funding supportfrom the Industry Training Authority.Industry Steering CommitteeDana Taylor – Chair- Mechanical Contractors Association of B.C.Stan Boehm – President, S.S. Stainless Inc.Sheldon Frank – Welding Articulation Chair, University College of the Fraser ValleyMike Longo – Ideal WeldersBrad MQuhae – President, Accent Stainless Steel Mfg. Ltd.Brad Smith – Catalyst PaperBrian Pichette – Welding Supervisor, Empire Dynamic Structures Ltd.Paul Sourisseau – Interior Forest Labour Relations Association, Co-Chair HITACRon Van Eyk – President, Van Eyk Manufacturing Corp.John Van Muyen – President, I & J Metal Fabrications Ltd.John Little – Welding Industry ConsultantLes Wiebe – Welding Instructor, Thompson Rivers UniversityThe Industry Training Authority would like to acknowledge the dedication and hard work of theindustry representatives appointed to identify the training requirements of the Welding trade.Industry Subject Matter ExpertsJohn Little – Welding Industry ConsultantMervyn Kube – Piping Industry Apprenticeship BoardJim Carson – University College of the Fraser ValleyRod Walters – British Columbia Institute of TechnologySheldon Frank—University College of the Fraser ValleyLes Wiebe – Thompson Rivers UniversityStanley McArthur – Catalyst PaperStan Boehm – President, S.S. Stainless Inc.Gerry Dillman – WeyerhauserBarry Westgate – Spectra EnergyFacilitatorsDick Vanier – Training Consultant- Vanier Training Consultants Ltd.Rick Vanier – Facilitator - Vanier Training Consultants Ltd.Jody Jankola – Technical Writer - Vanier Training Consultants Ltd.Kathleen ONiel – Technical Writer - Vanier Training Consultants Ltd.Michelle Probert – Technical Writer - Vanier Training Consultants Ltd.Welder Level C Program Outline • Industry Training Authorityii

TABLE OF CONTENTSFOREWORD .................................................................................................................................. IACKNOWLEDGEMENTS ............................................................................................................ IISECTION 1 OCCUPATION ANALYSIS CHART ........................................................................ 1SECTION 2 PROGRAM OUTLINE ............................................................................................. 6Suggested Schedule Of Time Allotment For Level C ........................................................ 7Program Outline For Level C .......................................................................................... 11SECTION 3 TRAINING PROVIDER STANDARDS ................................................................ 139Welder C Training Provider Standards ......................................................................... 140Welder C Training Provider Standards – Facilities ....................................................... 141Guidelines For Practical Examinations ......................................................................... 147APPENDIX ONE WELDER LEVEL C FINAL WELD TESTS .................................................. 148APPENDIX TWO WELDER LEVEL C PROGRAM FINAL PRACTICALEXAMINATION #2 ............................................................................................... 154APPENDIX THREE WELDER LEVEL C PROGRAM FINAL PRACTICALEXAMINATION #3 ............................................................................................... 161APPENDIX FOUR WELDER LEVEL C PROGRAM FINAL WELD TEST - #1 .................... 167APPENDIX FIVE WELDER LEVEL C PROGRAM FINAL WELD TEST - #2........................ 169APPENDIX SIX WELDER LEVEL C PROGRAM FINAL WELD TEST - #3.......................... 171APPENDIX SEVEN WELDER LEVEL C PROGRAM ACHIEVEMENT CRITERIA FORFINAL WELD TEST ............................................................................................. 173Welder Level C Program Outline • Industry Training Authorityiii

SECTION 1OCCUPATION ANALYSIS CHARTWelder Level C Program Outline • Industry Training Authority 1

SECTION 2PROGRAM OUTLINEWelder Level C Program Outline • Industry Training Authority 6

TheoryPracticalLine DPerforms Shielded Metal Arc Welding (SMAW)% of Time20% 80%D-1 Describe the SMAW Process and Its Application D-2 Describe SMAW Equipment and Its Operation D-3Describe and Select Low Carbon Steel Electrodes forSMAWD-4 Describe Basic Joint Design and Weld Positions D-5Describe Causes of Weld Faults and Distortions inFabrications and Methods for Prevention and ControlD-6 Use the SMAW Process to Weld Beads in the Flat Position D-7Use the SMAW Process to Weld Fillet Welds on LowCarbon Steel Plate D-8Use the SMAW Process to Weld Fillet Welds on LowCarbon Steel Sheet D-9Describe and Demonstrate Surface Build Up and Hardfacein the Flat Position on Low Carbon Steel Plate D-10Use the SMAW process to Weld Groove Welds in the FlatG1 Position on Grey Cast Iron D-11Describe and Demonstrate Use of SMAW Stainless SteelElectrodes on Low Carbon Steel Plate D-15Use the SMAW Process to Weld Groove Welds on LowCarbon Steel Plate Line EE-1E-2E-3Performs Electric Arc Cutting, Gouging and RelatedProcesses (AAC) (PAC) (SMAC) % of TimeDescribe Electric Arc Cutting and Gouging Processes andTheir ApplicationsDescribe and Demonstrate AAC Equipment Its Cutting andGouging OperationsDescribe and Demonstrate PAC Equipment and Its Cuttingand Gouging Operations20% 80% Line FF-1F-2F-3F-4F-5F-6Perform Semi-Automatic Welding (GMAW) (GMAW-P)(FCAW) (GMAW/MC*) % of TimeDescribe the GMAW, GMAW-P, FCAW and GMAW/MC*Processes and Their ApplicationDescribe GMAW, GMAW-P, FCAW and GMAW/MC*Equipment and Their OperationDescribe and Select Filler Metal and Shielding Gases forGMAWUse the GMAW Process to Weld Stringer Beads and FilletWelds on Low Carbon Steel PlateUse the GMAW Process to Weld Fillet Welds on LowCarbon Steel SheetUse the GMAW Process to Weld Square Groove Welds onLow Carbon Steel Sheet25% 75% Welder Level C Program Outline • Industry Training Authority 8

F-7F-8F-9F-10F-11F-13F-16F-22F-23F-24F-25F-26F-27F-29Use the GMAW Process to Weld Groove Welds on LowCarbon Steel PlateUse the GMAW-P Process to Weld Fillet Welds on LowCarbon Steel PlateUse the GMAW-P Process to Fillet Weld on Low CarbonSteel SheetUse the GMAW-P Process to Weld Square Groove Weldson Low Carbon Steel SheetUse the GMAW-P Process to Weld Groove Welds on LowCarbon Steel PlateDescribe and Demonstrate GMAW-P Weld Fillet WeldsUsing Stainless Steel Filler Metal on Low Carbon SteelPlate and SheetDescribe and Demonstrate Procedures Specific to GMAWand GMAW-P on Aluminum PlateDescribe and Select Filler Metals and Shielding Gases forFCAW and GMAW/MC*Use the FCAW Self-Shielding Process Weld to Fillet Weldson Low Carbon Steel PlateUse the FCAW Gas-Shielded Process to Weld to FilletWelds on Low Carbon Steel PlateUse the FCAW Process to Weld Groove Welds on LowCarbon Steel PlateUse the GMAW/MC* Process to Weld Fillet Weld on LowCarbon Steel PlateUse the GMAW/MC* Process Weld to Groove Welds onLow Carbon Steel PlateDescribe and Demonstrate FCAW Fillet Welds UsingStainless Steel Metal Wire on Low Carbon Steel PlateTheoryPracticalLine GDescribe Basic Metallurgy Relating to Production,Properties and Weldability % of Time90% 10%G-1 Describe Production Processes for Manufacturing Metals G-2 Describe Mechanical and Physical Properties of Metals G-3 Describe Metals G-5Describe the Alloy Content and Heat Treatments on theWeldability of SteelLine IDescribes and Performs Material Handling and RiggingProcedures % of Time65% 35%I-1Describe Safety Procedures for Rigging and MaterialHandlingI-2Perform Safe Working Load Calculations InvolvingGeometric Formulas, Volumes and Capacities I-3 Use Fibre Ropes to Tie Knots I-4 Describe Slings and Rigging Hardware Uses Welder Level C Program Outline • Industry Training Authority 9

Theory PracticalI-5 Describe Hoisting Equipment I-6 Use Hoisting Equipment to Perform a Lift Line J Reads Welding Drawings % of Time 50% 50%J-1Perform Mathematical Calculations Involving Formulas,Angles, Triangles and Geometric Construction J-2 Sketch Basic Objects Using Orthographic Projection J-3 Sketch Isometric Drawings of Basic Objects J-4 Sketch a Dimensional Drawing J-5 Identify Common Welding Symbols and Bolted Connections J-6 Read Structural Drawings Line K Layout and Fabricate Components % of Time 15% 85%K-2 Source Required Information K-3 Prepare Work Area K-4 Layout Materials K-5 Prepare Materials K-6 Fabricate Weldments (Shop Projects) Line NPerforms Submerged Arc Welding Process (SAW)% of Time90% 10%N-1 Describe SAW Process and Equipment N-2 Describe Consumables and Fluxes N-3 Describe Operating Parameters N-4 Set Up SAW Equipment N-5Use SAW Process to Weld Fillet Welds on Low CarbonSteel Plate Total Percentage for Level C 100%Welder Level C Program Outline • Industry Training Authority 10

PROGRAM OUTLINEFORLEVEL CWelder Level C Program Outline • Industry Training Authority 11

LINE A:APPLIES OCCUPATIONAL SKILLSCompetency: A-1 Describe Scope of Trade and Apprenticeship in BC, andOther OptionsLearning Objectives:The learner will be able to describe the scope of the Welder Level C, B and A trade andthe apprenticeship in BC, and other options, using a variety of techniques forinterpretation.LEARNING TASKS1. Describe the three levels oftraining in the BC welder.CONTENT Historical description of apprenticeshiptraining Current apprenticeship Foundation Level C Level B Level A2. Describe the requirements andprocedure for registration ateach level.Skills and qualities of a welderSpecific job knowledgeEquipment knowledgeMetal identificationPersonal qualities3. Explain the general differencesbetween P-lines and RK lines.4. Describe employmentopportunities for each level ofthe training program.5. Describe the Log Bookrequirements.6. Explain other more advancedtraining opportunities which leadto other jobs. The training program Training requirements High school, college or technicaltraining institute Tacker Welding operator Welder Welder fabricator/fitter Identification of the welder Registration seals Training endorsements Qualifications tests, general section Employment record W.P.Q.R. College, technical institute or university: Welding inspector level 1, 2 and 3 Welding technician Welder technologist Mechanical engineer Welding engineerWelder Level C Program Outline • Industry Training Authority 12

7. Identify industrial and Metal fabricatingconstruction fields that provide Ship buildingemployment opportunities for Pulp and paper millswelders. Wood products manufacture Machinery manufacture Equipment maintenance and repair Smelt and refining Motor vehicle, truck/trailer manufacture Mining Construction Iron and steel mills Special trades Mining services Coal mines Gas distribution and transmission Public administration and defence Machinery wholesalers Forestry and forest services Electric utilities Motor vehicle dealers and repairs Communications equipment andmanufacture Pipeline Food and beverage industry8. Communicate effectively. Resumes Cover letter Internet information sourcing Listening skills Effective verbal communication Non effective verbal communication Workplace cultureNOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-1.Achievement Criteria:Given a 10 question test on the scope of the Welder Level “C,” B and A trade andapprenticeship in BC, and other options, the learner will be able to demonstrate knowledge ofthe trade by correctly answering 7 or more questions.Welder Level C Program Outline • Industry Training Authority 13

LINE A:APPLIES OCCUPATIONAL SKILLSCompetency: A-2 Describe Safe Working PracticesLearning Objectives:The learner will be able to describe safe work practices according to WorkSafeBCstandards for Welder Level C trade in BC.LEARNING TASKS1. Describe applications ofWorkSafeBC and OHS in thework place.CONTENT Responsibilities of WorkSafeBC in theworkplace Responsibilities of employers in theworkplace Responsibilities of employees in theworkplace Contravention or regulations Workers who are covered by theWorkSafeBC Workers who are not covered Reporting injury or industrial disease Circumstances for compensation2. Describe general safetyprecautions for welding.3. Describe physical hazards andselect PPE for welding.General procedures for shop safetyElectrical safetyLock out proceduresWorksite safetySafety requirements for weldingprocessesPersonal fall protectionSafety requirements for ladders andscaffoldsSafety requirements for handrails andguardrailsRadiationExtreme temperaturesNoiseBodily injury hazardsChemical hazardsProtective clothingSkin protection (leathers)Head protectionHand protectionFoot protectionHearing protectionWelder Level C Program Outline • Industry Training Authority 14

4. Identify fire hazards and describemethods of fire prevention.Eye protectionSafety glasses and gogglesFace shieldsFlash gogglesWelding helmetsWelding gogglesEye protection for electrical weldingprocessesAuto darkening helmetsWelding screens and curtainsGoggles for oxyfuel welding and cuttingFire triangleFire preventing and stopping firesThe four classes of firesTypes of fire extinguishersFire hazardsFire preventionClean area of combustible debrisFire/water hose/fire extinguisher set upbefore and after workContain sparks by the use of fireretardantblanketsWet area down in high hazard areabefore starting hot workCover wall/floor openings with fireretardant blanketWelding work general fire safetyprecautionsWorkSafeBC requirements for firewatch5. Describe respiratory equipment. Air-line respirator Self contained breathing apparatus(SCBA) Cartridge type respiratorNOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-2.Achievement Criteria:Given an 80 question test on the safe working practices according to WorkSafeBCstandards for Welder Level C trade in BC, the learner will answer 56 or more questionscorrectly. The learner will also be evaluated during shop activities and must achieve agrade of 70% or better based on a summative total of Instructor assessment.Welder Level C Program Outline • Industry Training Authority 15

LINE A:APPLIES OCCUPATIONAL SKILLSCompetency: A-3 Describe WHMIS Training RequirementsLearning Objectives:The learner will be able to describe WHMIS training requirements.LEARNING TASKS1. Explain the purpose andnecessity of WHMIS in theworkplace.CONTENT Canada-wide legislated system Provides information on workplacehazardous materials How to safely use, store and handlehazardous materials Although nation-wide, employer WHMIScompliance is regulated and enforcedby the WorkSafeBC province’sinspectors2. Explain the need to identifyhazardous materials in theworkplace and the 3 mainelements of WHMIS.3. Identify the warning labels basedon the six classes of hazardousmaterials, the symbols andclassifications.Each workplace must have a system inplace that tells workers what they needto know about the products they workwithWHMIS information is provided in threeways:Container labelsMaterials Safety Data Sheets (MSDSs)Employee trainingA supplier label must appear on allcontrolled products received atworkplaces in Canada and contain thefollowing information:Product identifier (name of product)Supplier identifier (name of companythat sold it)A statement that an MSDS is availableRisk phrases (words that describe themain hazards of the product)Welder Level C Program Outline • Industry Training Authority 16

4. Explain the general duties ofemployers to provide MSDSsheets and training.MSDSs describe the hazards of thematerials used on the jobDeveloped for each product by itsmanufacturerSupplier must provide specsEmployer and Worker must be able toprovided proof of trainingNOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-2.Achievement Criteria:Given a 30 question test on WHMIS training requirements, the learner will be requiredto answer a minimum of 21 questions correctly.Welder Level C Program Outline • Industry Training Authority 17

LINE A:APPLIES OCCUPATIONAL SKILLSCompetency: A-4 Describe Training Requirements for Confined SpaceEntryLearning Objectives:The learner will complete the confined space program and be able to describe thehazards associated with confined space hazards as per WorkSafeBC Part 9.LEARNING TASKS1. Describe the precautions andprocedures for confined spaceentry as per WorkSafeBC Part 9.CONTENT General requirements Responsibilities Hazard assessment and workprocedures Identification and entry permits Lockout and isolation Verification and testing Cleaning, purging, venting, inserting Ventilation Standby persons Rescue Lifelines, harnesses and liftingequipment Personal protective equipment andother precautions2. Describe the most common jobsrelated to Welder Cs facingconfined space entry.Pressure vessels and tanksExcavationsShip hullsContainersHoppers and chutesNOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-2.Achievement Criteria:Given a 20 question test on hazards associated with confined spaces as perWorkSafeBC Part 9, the learner will correctly answer 14 or more questions.Welder Level C Program Outline • Industry Training Authority 18

LINE A:APPLIES OCCUPATIONAL SKILLSCompetency: A-5 Describe Requirements for H2S TrainingLearning Objectives:The learner will be able to describe the requirements for H2S training.LEARNING TASKS1. Describe H2S precautions andprocedures.CONTENT Properties, characteristics and locationsof H2S Health hazards MSDS requirements Work hazards Initial response strategy How to protect yourself (ventilation,controls and PPE) Respiratory protective equipment Self Contained Breathing Apparatus(SCBA) Supplied Air Breathing Apparatus(SABA) Detecting and monitoring for H2S Detector tube devices Electronic monitors Rescue techniques Rescue breathing Emergency response planningNOTE: Refer to video “A Matter of Life and Death” (video can be purchased on thefollowing website: http://www.coastal.com/coastalACB/showdetl.cfm?&Product_ID=13813&DID=7)**This video has the following inaccuracies that need to be discussed upon viewing:1. Fire Resistance coveralls are required in all gas and oil field operating areas. This is contrary to thevideo which showed workers in “street” clothing.2. Some companies use a ceiling limit of 10 ppm for Hydrogen Sulphide. Any exposure of H S over210 ppm is prohibited unless an SCBA is used. This is contrary to the video which indicated thatthe acceptable ceiling limit is 15 ppm.3. Some companies allow the use of contact lenses inside a SCBA as long as the site First AidAttendant is aware of their use. This is contrary to the video which indicated that contact lenseswere prohibited when donning a SCBA.Achievement Criteria:Given a 10 question test on hazards associated H2S, the learner will correctly answer 7or more questions.Welder Level C Program Outline • Industry Training Authority 19

LINE A:APPLIES OCCUPATIONAL SKILLSCompetency: A-6 Perform Basic Trade Related Mathematical Calculationsfor Linear MeasureLearning Objectives:The learner will be able to perform basic Welder Level C trade related mathematicalcalculations for linear measure.LEARNING TASKS1. Solve problems involvingfractions.CONTENT Key terms and concepts used inworking with fractions Add and subtract fractions Multiply and divide fractions Calculate averages Change fractions to commondenominator Solve problems using whole numbers Solve problems using whole numbersand fractions in practical applications2. Solve problems involvingdecimals.3. Solve problems involvingpercentage.Read and write decimal fractionsRound decimal fractions to specificplace valuesConvert decimal inches to a fractionwith a practical denominatorConvert decimal feet to fee and incheswith a practical denominatorConvert fractions to decimalsAdd and subtract decimal fractionsMultiply and divide decimal fractionsConvert between fractions and percentsConvert between decimals andpercentsSolve percent problemsWelder Level C Program Outline • Industry Training Authority 20

4. Solve problems involving metricand imperial measure.Identify commonly used metric units ofmeasurementConvert between units of measurementConvert imperial units: feet to inches,square inches to square feet, and cubicmeasures to gallonsNOTE: Refer To Current Welder Training Program Curriculum Module/Line RK2B.Achievement Criteria:Given a 40 question test on basic Welder Level C trade related mathematicalcalculations for linear measure, the learner will be able to demonstrate knowledge bycorrectly answering 28 questions or more.Welder Level C Program Outline • Industry Training Authority 21

LINE A:APPLIES OCCUPATIONAL SKILLSCompetency: A-7 Use Measuring and Layout ToolsLearning Objectives:The learner will be able to describe and demonstrate the safe use and care ofmeasuring and layout tools as related to the Welder Level C trade.LEARNING TASKS1. Use layout and measuring toolsand their uses.CONTENT Systems of measuring Metric Imperial Layout Measuring tools Pocket measuring tape Steel rule Torpedo level Spirit level Laser level Plumb bob Framing square Combination squares Square head Centre head Protractor head Marking tools Soapstone Scriber or awl Chalkline Divider and trammel points Centre punch Prick punch Spring loaded punch Transfer punch Number and letter stamps Gauges Fillet weld Pipe internal alignment Single purpose weld Bridge cam Automatic weld size Visual weld acceptance criteriaNOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-3.Welder Level C Program Outline • Industry Training Authority 22

Achievement Criteria:Given a 20 question test on the safe use and care of measuring and layout tools used inthe Welder Level C trade, the learner will correctly answer 14 or more questions. Thelearner will also be evaluated on the use of measuring and layout tools as part of apractical shop projects as per the acceptance criteria in the current curriculummodule/line P1-5.Welder Level C Program Outline • Industry Training Authority 23

LINE A:APPLIES OCCUPATIONAL SKILLSCompetency: A-8 Use Hand ToolsLearning Objectives:The learner will be able to demonstrate the use and care of Welder Level C relatedhand tools.LEARNING TASKS1. Use clamping tools, their uses,maintenance and care.CONTENT Safety Bench vise Machine vise Pipe vises Top screw bench chain vise Tri-stand yolk vise Clamps Welding specific line up tools andclamps Pliers Combination Interlocking slip-joint Needle-nose and round-nose MIG2. Use cutting tools, their uses,maintenance and care.3. Use other common hand tools,their uses, maintenance andcare.SafetyHacksawsFilesManual sheersCold chiselsBolt cuttersWire cuttersSafetyWire brushesMIG pliersHammersBall-peenSoft-facedChipping hammersSledge hammersDead blow hammersCross-peenDriftsPinch line up barsPry barsWelder Level C Program Outline • Industry Training Authority 24

AnvilsWrenchesOpen-endBox-endCombinationAdjustableCylinderSocketPipeHexagon keyScrewdriversBladePhillipsRobertsonTorx4. Use taps and dies and their uses. Safety Taps Tap wrenches Dies Tapping internal threads Common tapping problems Cutting external threadsNOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-3and P1-5.Achievement Criteria:Given a 40 question test on hand tools used in the Welder Level C trade, the learner willcorrectly answer 28 or more questions. The learner will also be evaluated on the use ofhand tools as part of a practical shop project as per the acceptance criteria the currentcurriculum module/line P1-5.Welder Level C Program Outline • Industry Training Authority 25

LINE A:APPLIES OCCUPATIONAL SKILLSCompetency: A-9 Use Power Tools (Electric and Pneumatic)Learning Objectives:The learner will be able to demonstrate the use and care of Welder C related powertools.LEARNING TASKSCONTENT1. Use power drilling tools. Safety Portable power drills Keyless chuck drills Hammer drills Magnetic base Drill presses Hollow bits Hole saws Carbide tipped masonry Rechargeable drills2. Use power grinding tools. Safety Stationary grinders Portable grinders Stationary belt sanders Portable belt sanders Abrasives and disks Carbide burrs Mini belt sanders3. Use power shearing tools. Safety Power squaring shears Rotary throatless shears Universal machines Iron worker Nibblers Pipe cutters4. Use power sawing tools. Abrasive cut-off saw Power hacksaw Metal-cutting band saws Reciprocating saws Sabre Circular saws Blades for metal-cutting sawsWelder Level C Program Outline • Industry Training Authority 26

5. Use specialty tools. Scaler Needle scalerNOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-4and P1-5.Achievement Criteria:Given a 60 question test on power tools used in the Welder Level C trade, the learnerwill correctly answer 42 or more questions. The learner will also be evaluated on theuse of power tools as part of a practical shop project as per the acceptance criteria thecurrent curriculum module/line P1-5.Welder Level C Program Outline • Industry Training Authority 27

LINE A:Competency:APPLIES OCCUPATIONAL SKILLSA-10 Discuss Welding Quality Control and InspectionRequirementsLearning Objectives:The learner will be able to discuss welding quality control and inspection requirements.LEARNING TASKS1. Describe the different quality andcontrol inspections requirements.CONTENT Examine components (fit-up andpreparation) prior to assembly. Examine completed welds Measure final product for compliance toblueprints and drawings Types and uses of non-destructivetesting methods Types and uses of destructive testingmethods Standards, specifications and codes2. Describe CWB jurisdiction. Accreditation covers weldingcertification programs for companiesengaged in: Fusion welding Welding consumables Welding inspection organizations3. Describe CWB certificationprograms.CSA W 47.1 SteelCSA W 47.2 AluminumCSA W 55.3 Resistance WeldingCSA A 660 Steel BuildingCSA W 186 Reinforcing BarNOTE: Refer To Current Welder Training Program Curriculum Module/Line RK-4and RK-5.Achievement Criteria:Given a 20 question test on welding quality control and inspection requirements, thelearner will be able to demonstrate knowledge by correctly answering 14 questions ormore.Welder Level C Program Outline • Industry Training Authority 28

LINE B:PERFORMS OXY-FUEL CUTTING PROCESSES (OFC)Competency: B-1 Describe the OFC Process and Its ApplicationLearning Objectives:The learner will able to describe the OFC process, its applications, techniques used forcutting difficult-to-cut ferrous alloys, the main components of an OFC station, thermaleffects and safety precautions.LEARNING TASKSCONTENT1. Describe the OFC process. Principles of OFC Components of basic OFC systems2. Describe the applications ofOFC.3. Describe the cuttingcharacteristics of ferrous andnon-ferrous metals.4. Describe the thermal effects ofOFC.5. Describe safety requirements forOFC.Cutting plate, pipe and structuralshapesWashing bolts and rivetsGouging and scarfingStack cuttingCutting machinesFerrous alloysTechniques for cutting ferrous alloysPreheatingWaster platesNon-ferrous alloysAluminumCopperBrassBronzeMagnesiumDistortionSurface hardeningPPEFire and explosion preventionRefer to WorkSafeBC for fire watchregulationsToxic fumes/ventilationCadmiumZincLeadBerylliumOther alloysSynthetic materialsWelder Level C Program Outline • Industry Training Authority 29

NOTE: Refer To Current Welder Training Program Curriculum Module/Line P1-2.Achievement Criteria:Given a 40 question test on the oxy-fuel process and application, the learner willdemonstrate knowledge by correctly answering 28 questions or more.Welder Level C Program Outline • Industry Training Authority 30

LINE B:PERFORMS OXY-FUEL CUTTING PROCESSES (OFC)Competency: B-2 Describe OFC Equipment and Its OperationLearning Objectives:The learner will be able to describe of the oxygen and fuel gases used in OFC, gascylinders and regulators, cutting tips and attachments, and cutting machines, used inthe OFC process.LEARNING TASKS1. Describe the gases and theirproperties, used in OFC.CONTENT Oxygen Acetylene Other fuel gases Mapp® gas (methylacetylenepropadiene) Natural gas Propane gas2. Describe oxygen and fuel gascylinders.3. Describe pressure regulators andtheir functions.4. Describe oxy-fuel hoses andfittings.Oxygen cylindersOxygen cylinder valveCylinder safety deviceAcetylene cylindersAcetylene cylinder valvesCylinder safety devicesLiquid fuel cylindersStorage and handling of cylindersStorageHandlingSafety precautions for using cylindersOxygen and acetylene regulatorsSingle and two-stage regulatorsSingle-stage regulatorTwo-stage regulatorSafe use of regulatorsOxy-fuel hoseSafe handling of hoseHose fittingWelder Level C Program Outline • Industry Training Authority 31

5. Describe cutting torches, cuttingtips and heating tips.Injector torchEqual pressure torchTorch typesOne-piece cutting torchTwo-piece cutting torchMachine torchTorch line explosions – causes andpreventionBackfireFlashbacksReverse flow check valvesCutting tipsCutting tip sizeTypes of cutting tipsTips for special purposesRivet-cutting tipsGouging tipsHeating tipsCutting tip maintenance6. Describe gas manifold systems. Oxygen manifold systems Acetylene manifold systems7. Describe oxy-fuel gas cuttingaccessories and machines.Manual cutting guidesStraight-line cutting guideCircle cutting guidetemplatesCutting machinesStraight-line cutting machinesShape-cutting machinesElectronic eye tracerMagnetic tracerPipe-beveling machinesWelder Level C Program Outline • Industry Training Authority 32

8. Describe the correct proceduresto assemble, ignite and shutdown a portable oxyacetyleneoutfit.Assemble a portable oxyacetylene outfitSecure the cylindersRemove the capsCrack the valvesAttach the regulatorsInstall RFCVConnect the hosesOpen the valvesPurge the hosesConnect the cutting attachmentSet working pressureSelect and install the appropriatecutting tipSet working pressureTest for leaksLight and adjust flameIgnite the torchAdd oxygen to the flameShut down an oxyacetylene outfitDisassemble the oxyacetylene outfitNOTE: Refer To Current Welder Training Program Curriculum Module/Line P2-2and P2-3.Achievement Criteria:Given a 90 question test on oxy-fuel cutting equipment and its operation, the learner willdemonstrate knowledge by correctly answering 63 questions or more.Welder Level C Program Outline • Industry Training Authority 33

LINE B:PERFORMS OXY-FUEL CUTTING PROCESSES (OFC)Competency: B-3 Perform Freehand and Guided Cuts on Low CarbonSteel Plate, Sheet, Round Stock, Structural Shapes andPipeLearning Objectives:The learner will be able to assemble the appropriate oxy-fuel cutting equipment, setpressures, light and adjust the cutting torch, make freehand and guided cuts on lowcarbon steel plate, make freehand cuts on round stock, structural shape and pierceholes in low carbon steel plate.LEARNING TASKS1. Describe the characteristics of anacceptable cut.CONTENT Characteristics of an acceptable cut Top edge square Vertical draglines Bottom edge sharp Factors that affect the quality of cut Speed of travel Surface condition of the metal Oxygen pressure Tip size Size of the preheat flames Thickness of the material Position of the cutting torch tip Position in relation to the work Starting cuts2. Perform freehand cuts on lowcarbon steel plate and sheet.3. Pierce holes in low carbon steelplate.4. Perform freehand cuts onstructural shapes and roundstock.Freehand cuts on low carbon steel plate- refer to practical competency forprocedureFreehand cuts on low carbon steelsheet - refer to practical competency forprocedureFree hand bevel cuts on low carbonsteel plate - refer to practicalcompetency for procedureRefer to practical competency forprocedureFreehand cuts on angle iron, channel,and S-beam - refer to practicalcompetency for procedureFreehand cuts on round stock - refer topractical competency for procedureWelder Level C Program Outline • Industry Training Authority 34

5. Perform guided cuts on lowcarbon steel plate and sheet.6. Wash nuts off bolts and gougeweldments.Guided cuts on low carbon steel plateand sheet - refer to practicalcompetency for procedureGuided circular cuts on low carbon steelplate - refer to practical competency forprocedureWash nuts off bolts - refer to practicalcompetency for procedureGouge weldments - refer to practicalcompetency for procedure7. Perform freehand cuts on mildsteel pipe. Straight cuts on low carbon steel pipe -refer to practical competency forprocedure Bevel cuts on low carbon steel pipe -refer to practical competency forprocedureNOTE: Refer To Current Welder Training Program Curriculum Module/Line P2-4.Achievement Criteria:The learner will be evaluated on the ability to perform freehand and guided cuts on lowcarbon steel plate, sheet round stock, structural shapes and pipes as part of a practicalshop project as per the acceptance criteria in the current curriculum module/line P2-4..Welder Level C Program Outline • Industry Training Authority 35

LINE B:PERFORMS OXY-FUEL CUTTING PROCESSES (OFC)Competency: B-4 Perform Cuts with Cutting Machines, Automatic andSemi-AutomaticLearning Objectives:The learner will be able to set up and operate a variety of cutting machines and producehigh quality straight and bevel cuts safely.LEARNING TASKS1. Performs cuts with a straight-linecutting machine using oxy-fuelgas.2. Perform cuts with a shape-cuttingmachine using oxy-fuel gas.CONTENT Refer to practical competency forprocedureRefer to practical competency forprocedure3. Perform cuts with a pipe-bevelingmachine using oxy-fuel gas.Refer to practical competency forprocedureNOTE: Refer To Current Welder Training Program Curriculum Module/Line P2-5.Achievement Criteria:The learner will be evaluated on the ability to perform cuts with cutting machines,automatic and semi-automatic as part of a practical shop project as per the acceptancecriteria in current curriculum module/line P2-5.Welder Level C Program Outline • Industry Training Authority 36

LINE C:PERFORMS FUSION AND BRAZE WELDING USING OXY-FUELPROCESSES (OFW)Competency: C-1 Describe Fusion Welding, Braze Welding and BrazingProcesses and Their ApplicationsLearning Objectives:The learner will be able to describe fusion welding, braze welding, brazing processes,their applications and safety precautions.LEARNING TASKS1. Describe the fusion weldingprocess and its application.CONTENT Principles of fusion welding Filler rods Applications of fusion welding Maintenance or repair work Fabrication2. Describe the braze weldingprocess and its application.3. Describe the brazing processand its applications.Principles of braze weldingFiller rodsApplicationsMaintenance or repair workLight gauge metalsDissimilar metalsGrey cast ironNon-ferrous metalsPrinciples of brazingFiller rodsApplications4. Describe safety requirements. PPE Fire and explosion prevention Refer to WorkSafeBC for fire watchregulations Toxic fumes/ventilation (refer to B-1,5)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-1.Achievement Criteria:Given a 20 question test on fusion welding, braze welding, brazing processes andapplication, the learner will demonstrate knowledge by correctly answering 14 questionsor more.Welder Level C Program Outline • Industry Training Authority 37

LINE C:PERFORMS FUSION AND BRAZE WELDING USINGOXY-FUEL PROCESSES (OFW)Competency: C-2 Describe Fusion and Braze Welding Equipment andTheir OperationLearning Objectives:The learner will be able to describe fusion and braze welding equipment and theiroperation.LEARNING TASKS1. Describe OFW equipment andapplication.CONTENT Fundamentals of OFW process Types of equipment Regulators Flashback arrestors Hoses Types of torch bodies Torch attachments Match equipment to application2. Describe fuel gas precautionsand procedures.3. Describe tips and theirapplication.4. Describe consumables andrequirements.Characteristics of fuel gasesFuel gas delivery systemsCylinder and gases handlingproceduresCylinder and gases storagerequirementsHazards associated with different fuelgasesMatch fuel gas to type of equipmentIdentify type of fuel gas frominformation on labelType of base metalBase metal thicknessTip functionsRequired weldTypes of tipsMatch tip to base metal and requiredweldDifferentiate between tipsFluxesFiller metalsWelder Level C Program Outline • Industry Training Authority 38

5. Describe operating parameters. Base metal thickness Welding tip sizes Gas regulators Manufacturers’ recommendations Other task specific guidelines Reference information6. Describe setting up OFWequipment.7. Describe operating OFWequipment.Set-up proceduresOFW safe practicesEquipment leak test proceduresFollow safe proceduresReference manufacturers’ instructionsRequired task-specific PPESafe operating practicesFlashback conditionsBackfire burnback conditionsWelding techniquesMetallurgyTypes of flamesBraze welding techniquesBrazing fluxesFlame temperaturesMetal fusion techniquesRecognize flashbackRecognize backfire burnbackPrevent flashback conditionsPrevent backfire burnback conditionsLight and adjust torchApply appropriate welding techniquesDetect defects in weld8. Shut down OFW equipment. Shutdown sequence Check regulators Perform complete shutdownNOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-2.Achievement Criteria:Given a 40 question test on fusion and braze welding equipment and its operation, thelearner will demonstrate knowledge by correctly answering 28 questions or more.Welder Level C Program Outline • Industry Training Authority 39

LINE C:PERFORMS FUSION AND BRAZE WELDING USINGOXY-FUEL PROCESSES (OFW)Competency: C-3 Describe Filler Metals, Fluxes and Tips Used for Fusionand Braze Welding and BrazingLearning Objectives:The learner will be able to identify filler metals, fluxes, torches and tips used for fusionand braze welding.LEARNING TASKS1. Describe the filler rods for fusionwelding, brazing and brazewelding.CONTENT Filler rods for fusion welding Low carbon steel rods RG 45 RG 60 RG 65 Filler rod size Brazing and braze welding alloys Silver (BAg) Aluminum-silicon (BA 1Si) Precious-metals (BAu) Copper and copper-zinc (BCu andRBCuZn) brass Copper-phosphorous (BCuP) Magnesium (BMg) Nickel (BNi) Cobalt (BCo) Choosing a brazing filler rod Braze welding filler rods2. Describe the flux for fusionwelding, brazing and brazewelding.Purpose of fluxWelding fluxBrazing fluxHigh temperatureSpecial purpose or low temperatureGeneral purpose fluxChoosing the correct brazing fluxUsing fluxRemoving fluxWelder Level C Program Outline • Industry Training Authority 40

3. Describe the torches and tips forfusion welding, braze weldingand brazing.Oxy-fuel welding torchesHow welding torches workWelding tipsSelecting the correct welding tipWelding tip maintenanceNOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-2.Achievement Criteria:Given a 20 question test on identifying filler metals, fluxes, torches and tips used forfusion and braze welding, the learner will demonstrate knowledge by correctlyanswering 14 questions or more.Welder Level C Program Outline • Industry Training Authority 41

LINE C:PERFORMS FUSION AND BRAZE WELDING USINGOXY-FUEL PROCESSES (OFW)Competency: C-4 Describe Joint Design and Weld PositionsLearning Objectives:The learner will be able to identify basic joint designs, weld positions and theabbreviations associated with them when doing fusion and braze welding using OFWprocesses.LEARNING TASKSCONTENT1. Describe the five basic joints. Corner joint Lap joint Tee joint Butt joint Edge joint2. Describe the four basic weldingpositions.Flat positionHorizontal positionVertical positionOverhead position3. Identify abbreviations for weldposition and weld type. Flat position (1) Horizontal position (2) Vertical position (3) Overhead position (4)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-2.Achievement Criteria:Given a 20 question test on identifying basic joint designs, weld positions and theabbreviations associated with them when doing fusion and braze welding using OFWprocesses, the learner will demonstrate knowledge by correctly answering 14 questionsor more.Welder Level C Program Outline • Industry Training Authority 42

LINE C:PERFORMS FUSION AND BRAZE WELDING USINGOXY-FUEL PROCESSES (OFW)Competency: C-5 Describe Fusion Welding on Low Carbon Steel SheetLearning Objectives:The learner will describe fusion weld stringer beads in the flat position on low carbonsteel sheet using OFW processes.LEARNING TASKS1. Describe the main factors toconsider in gas fusion welding.CONTENT Correct tip sizes Correct flame setting Distance between work and flame Types of welding technique Torch angle Speed and travel movement Operator comfort and position2. Describe process related weldfaults and discuss their causes.Weld defectsLack of penetrationLack of fusionundercutReinforcement on groove weldsCorrect weld profile for fillet weldNOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-3.Achievement Criteria:Given a 10 question test on describing fusion weld stringer beads in the flat position onlow carbon steel sheet using OFW processes, the learner will demonstrate knowledgeby correctly answering 7 questions or moreWelder Level C Program Outline • Industry Training Authority 43

LINE C:PERFORMS FUSION AND BRAZE WELDING USINGOXY-FUEL PROCESSES (OFW)Competency: C-6 Fusion Weld Stringer Beads and Fillet Welds on LowCarbon Steel SheetLearning Objectives:The learner will fusion weld stringer beads and fillet welds on low carbon steel sheetusing OFW processes.LEARNING TASKS1. Fusion weld stinger beads in theflat position.CONTENT Weld stinger beads without a filler rod inthe flat position - refer to practicalcompetency for Weld ProcedureSpecification (WPS) Weld stinger beads with a filler rod inthe flat position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)2. Fusion weld fillet welds in the flat(1F) position on lap and cornerjoint on low carbon steel sheet.3. Fusion weld fillet welds in thehorizontal (2F) position on lapjoint on low carbon steel sheet.4. Fusion weld fillet welds in thevertical (3F) position on lap jointson low carbon steel sheet.Fillet weld on lap joint in the 1F position- refer to practical competency for WeldProcedure Specification (WPS)Fillet weld on corner joint in the 1Fposition - refer to practical competencyfor Weld Procedure Specification(WPS)Fillet weld on lap joint in the 2F position- refer to practical competency for WeldProcedure Specification (WPS)Fillet weld on lap joint in the 3F position- refer to practical competency for WeldProcedure Specification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-4.Achievement Criteria:The learner will be evaluated on the ability to fusion weld fillet welds on low carbon steelsheet using OFW processes as part of a practical shop project as per the acceptancecriteria in the current curriculum module/line P3-4; evaluation must meet CSA W59standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 44

LINE C:PERFORMS FUSION AND BRAZE WELDING USINGOXY-FUEL PROCESSES (OFW)Competency: C-7 Fusion Weld Square Groove Welds on Low Carbon SteelSheetLearning Objectives:The learner will fusion weld groove welds on low carbon steel sheet using OFWprocesses.LEARNING TASKS1. Fusion weld groove welds in theflat (1G) position on low carbonsteel sheet.CONTENT Refer to practical competency for WeldProcedure Specification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-5.Achievement Criteria:The learner will be evaluated on the ability to fusion weld groove welds on low carbonsteel sheet using OFW processes as part of a practical shop project as per theacceptance criteria in the current curriculum module/line P3-5; evaluation must meetCSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 45

LINE C:PERFORMS FUSION AND BRAZE WELDING USINGOXY-FUEL PROCESSES (OFW)Competency: C-8 Braze Weld Fillet Welds on Low Carbon Steel SheetLearning Objectives:The learner will braze weld fillet welds on low carbon steel sheet using OFW processes.LEARNING TASKS1. Describe the procedures forbraze welding low carbon steel.CONTENT Pre-leaning and edge preparation Flame setting Filler rods and flux Number of passes Determining the quality of work2. Braze weld fillet welds in the flat(1F) and horizontal (2F) positionson lap and tee joints on lowcarbon steel sheet.Braze weld on lap joint in the 2Fposition - refer to practical competencyfor Weld Procedure Specification(WPS)Braze weld on tee joint in the 1Fposition - refer to practical competencyfor Weld Procedure Specification(WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-7.Achievement Criteria:The learner will be evaluated on the ability to braze weld fillet welds on low carbon steelsheet using OFW processes as part of a practical shop project as per the acceptancecriteria the current curriculum module/line P3-7; evaluation must meet CSA W59standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 46

LINE C:PERFORMS FUSION AND BRAZE WELDING USINGOXY-FUEL PROCESSES (OFW)Competency: C-9 Braze Weld Groove Welds on Grey Cast IronLearning Objectives:The learner will braze weld and fusion weld groove welds on grey cast iron using OFWprocesses.LEARNING TASKS1. Describe the procedures forbraze welding and fusion weldinggrey cast iron.CONTENT Braze weld grey cast iron Pre-leaning Preheating Fusion welding grey cast iron Special factors in welding grey cast iron Cast iron filler rod Welding technique2. Braze weld groove welds in theflat (1G) position.Refer to practical competency for WeldProcedure Specification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-9.Achievement Criteria:The learner will be evaluated on the ability to braze weld and fusion weld groove weldson grey cast iron using OFW processes as part of a practical shop project as per theacceptance criteria in the current curriculum module/line P3-9; evaluation must meetCSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 47

LINE C:Competency:PERFORMS FUSION AND BRAZE WELDING USINGOXY-FUEL PROCESSES (OFW)C-10 Silver Alloy Braze on Similar and Dissimilar MetalsLearning Objectives:The learner will silver alloy braze on similar and dissimilar metals using OFWprocesses.LEARNING TASKS1. Describe the materials,equipment and procedures forsilver brazing.CONTENT Joint preparation and design Flux selection Filler alloys (rods) Flame for brazing Silver brazing procedure2. Braze with silver alloys. Braze with silver phosphorous alloy oncopper tube - refer to practicalcompetency for Weld ProcedureSpecification (WPS) Braze with silver alloy filler metals ontee joints for copper to stainless steel inthe horizontal position - refer topractical competency for WeldProcedure Specification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P3-10.Achievement Criteria:The learner will be evaluated on the ability to silver alloy braze on similar and dissimilarmetals using OFW processes as part of a practical shop project as per the acceptancecriteria in the current curriculum module/line P3-10; evaluation must meet CSA W59standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 48

LINE D:PERFORMS SHIELDED METAL ARC WELDING (SMAW)Competency: D-1 Describe the SMAW Process and Its ApplicationLearning Objectives:The learner will be able to describe the SMAW process and its applications, includingsafety precautions, power sources and the procedures used with SMAW.LEARNING TASKS1. Describe the SMAW process andits applications.CONTENT Principles of SMAW The arc welding circuit Power source Ground cable and clamp Electrode cable Welding electrode and electrode holder Workpiece The SMAW process Electrodes Power source Applications of SMAW Shipbuilding Commercial transport Boiler making Structural work Engineering applications Building Maintenance and repair of industrialand farm equipment Light gauge welding Assembly of automobiles Pipe welding The arc welding station Arc welding machine Work bench Electrode cable and terminals Electrode holder Electrode stub holder Booth or screens Work cable and terminals Ventilation system Ground clamp Welding station inspectionWelder Level C Program Outline • Industry Training Authority 49

2. Describe safety requirements,precautions and procedures forSMAW.PPEEye protection for the electrical weldingprocessesWelding helmetsRadiation protectionElectric shockDamp conditionsTreatment of electric shock victimsFire and explosion preventionRefer to WorkSafeBC for fire watchregulationsSafety requirements for operatingelectric welding equipmentMaintenance of equipmentWelding cables and connectionsElectrode holderGround clampElectrode stub disposalSlagToxic fumes/ventilationNOTE: Refer To Current Welder Training Program Curriculum Module/Line P4-1.Achievement Criteria:Given a 20 question test on the SMAW process and its applications, the learner willdemonstrate knowledge by correctly answering 14 questions or more.Welder Level C Program Outline • Industry Training Authority 50

LINE D:PERFORMS SHIELDED METAL ARC WELDING (SMAW)Competency: D-2 Describe SMAW Equipment and Its OperationLearning Objectives:The learner will be able to describe SMAW equipment and its operation including theprinciples of electricity, types of current, AC and DC welding machines and electrodeholders, ground clamps and welding cables.LEARNING TASKS1. Explain basic principles ofelectricity.CONTENT Resistance Effects of resistance Electromagnetism Transformers Reactor2. Describe types of current andtheir applications.3. Describe the effects of a voltamperecurve on the welding arc.4. Describe AC and DC weldingmachines.Alternating currentDirect currentPolarityArc blowDealing with arc blowVolt-ampere curveInterpreting the volt-ampere curveConstant current welding machinesConstant potential welding machinesAdjusting the voltageAdjusting the amperageTransformer type welding machinesAC transformersAC transformer controlTransformer/rectifiersTransformer/rectifier controlAC/DC transformers/rectifiersAdvantages of transformer type weldingmachinesDisadvantages of transformer typewelding machinesGenerator/alternator type weldingmachinesElectric motor drive DC machinesFuel engine driven AC, DC and AC/DCwelding machinesControlsWelder Level C Program Outline • Industry Training Authority 51

5. Describe and select electrodeholders, ground clamps andwelding cables.Advantages of generator/alternator typewelding machinesDisadvantages of generator/alternatortype welding machinesMulti-operator setsInvertersAdvantages of inverter type weldingmachinesRemote control devicesRatings for welding machinesPower requirementsDuty cycleChoosing between AC and DCmachinesGeneral maintenance of weldingmachinesElectrode holderJawTwist headGround clampsSpring-loadedC-clampRotaryMagneticWelding cablesSizeConnectionsNOTE: Refer To Current Welder Training Program Curriculum Module/Line P4-2.Achievement Criteria:Given a 50 question test on shielded metal arc welding equipment and its operation, thelearner will demonstrate knowledge by correctly answering 35 questions or more.Welder Level C Program Outline • Industry Training Authority 52

LINE D:PERFORMS SHIELDED METAL ARC WELDING (SMAW)Competency: D-3 Describe and Select Low Carbon Steel Electrodes forSMAWLearning Objectives:The learner will be able to describe and select low carbon steel electrodes for SMAWand their applications and the basic care, handling and storage procedures for theseelectrodes.LEARNING TASKS1. Describe the operation ofcommon electrodes for SMAW.CONTENT Functions of electrode coatings Types of electrodes F1 (fast-fill) F2 (fast-freeze) F3 (fill-freeze) F4 (low hydrogen/basic electrode) Electrode coating composition Cellulose Rutile China clay, silica and mica Potassium Ferro-magnanese Iron oxide (magnetite, hematite) Iron powder Sodium silicate Metal transfer with SMAW electrodes Gravity Gas expansion Electro-magnetic force Electromotive force Surface tension2. Describe the classifications oflow carbon steel electrodes.3. Select common electrodes forSMAW.Standards of coated electrodemanufactureCSA and AWS designationsElectrode lengthElectrode diameterPrinciples of electrode selectionProperties of the base metalJoint design and fit upWelding position and thickness of welddepositWelding currentWelder Level C Program Outline • Industry Training Authority 53

4. Describe correct handling andstorage of common electrodes.Service conditionsProduction factorsCommon low carbon steel electrodesE4310 (E6010)E4311 (E6011)E4312 (E6012)E4313 (E6013)E4914 (E7014)E4924 (E7024)E4918 (E7018)E4928 (E7028)E309Handling of electrodes before and afteruseStorage of electrodesElectrode ovensHandling of electrodes in useNOTE: Refer To Current Welder Training Program Curriculum Module/Line P4-3.Achievement Criteria:Given a 40 question test on identifying low carbon steel electrodes for SMAW and theirapplications and the basic care, handling and storage procedures for these electrodes,the learner will demonstrate knowledge by correctly answering 28 questions or more.Welder Level C Program Outline • Industry Training Authority 54

LINE D:PERFORMS SHIELDED METAL ARC WELDING (SMAW)Competency: D-4 Describe Basic Joint Design and Weld PositionsLearning Objectives:The learner will be able to identify basic joint design and weld positions for fillet weldsand groove welds when using the SMAW process.LEARNING TASKS1. Describe the five basic jointdesigns.CONTENT Lap Tee Corner Edge Butt Square Single vee and double vee Single bevel and double bevel Single U and double U Single J and double J Plate thickness transitions on butt joints2. Describe weld types, their sizesand profiles.3. Identify the common weldingpositions for plate.Bead weldsTack weldsFillet weldsProfiles and sizesGroove weldsProfiles and sizesPlug and slot weldsContinuous and intermittent weldingFlat positionHorizontal positionVertical positionOverhead positionAbbreviations for weld position andweld typeNOTE: Refer To Current Welder Training Program Curriculum Module/Line P4-4.Achievement Criteria:Given a 40 question test on basic joint design and weld positions for fillet welds andgroove welds when using the SMAW process, the learner will demonstrate knowledgeby correctly answering 28 questions or more.Welder Level C Program Outline • Industry Training Authority 55

LINE D:PERFORMS SHIELDED METAL ARC WELDING (SMAW)Competency: D-5 Describe Causes of Weld Faults and Distortions inFabrications and Methods for Prevention and ControlLearning Objectives:The learner will be able to describe weld faults, their causes and methods to avoid themwhen using the SMAW process.LEARNING TASKS1. Describe the process relatedweld faults and their causes.CONTENT Dimensional defects Incorrect weld size overlap Structural discontinuities in the weld Under cut Incomplete penetration Lack of fusion Porosity Slag inclusion Cracking (internal/external) Insufficient throat/underfill2. Identify distortions and determinemethods of prevention andcontrol.Types of distortionLongitudinal distortionTransverse distortionAngular distortionDistortion controlUse mechanical methodsDesign methodsProcedural methodsRate of heat input/joulesDistribute the heat input as uniformly aspossiblePre-heat and post-heat when necessaryNOTE: Refer To Current Welder Training Program Curriculum Module/Line P4-5.Achievement Criteria:Given a 30 question test on weld faults, their causes and methods to avoid them whenusing the SMAW process, the learner will demonstrate knowledge by correctlyanswering 21 questions or more.Welder Level C Program Outline • Industry Training Authority 56

LINE D:PERFORMS SHIELDED METAL ARC WELDING (SMAW)Competency: D-6 Use the SMAW Process to Weld Beads in the FlatPositionLearning Objectives:The learner will be able to identify the main factors of the SMAW process and theirimportance while striking an arc using the tap and scratch methods, weld stringer beadsin the flat position and weld beads in the flat position using the weave technique.LEARNING TASKS1. Describe main factors of theSMAW process.2. Weld beads in the flat (1S)position.CONTENT Operator comfort and position Machine setting Arc length Electrode angle Speed travel Electrode oscillation Strike an arc using scratch and tapmethod - refer to practical competencyfor Weld Procedure Specification(WPS) Weld stringer beads in the flat position -refer to practical competency for WeldProcedure Specification (WPS) Weld beads in the flat position using theweave method - refer to practicalcompetency for Weld ProcedureSpecification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P4-6and 7.Achievement Criteria:The learner will be evaluated on the ability to identify the main factors of the SMAWprocess and their importance while striking an arc using the tap and scratch methods,weld stringer beads in the flat position and weld beads in the flat position using theweave technique, as part of a practical shop project as per the acceptance criteria in thecurrent curriculum module/line P4-6; evaluation must meet CSA W59 standards forcyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 57

LINE D:PERFORMS SHIELDED METAL ARC WELDING (SMAW)Competency: D-7 Use the SMAW Process to Weld Fillet Welds on LowCarbon Steel PlateLearning Objectives:The learner will be able to weld fillet welds on low carbon steel plate in all positionsusing the SMAW process.LEARNING TASKS1. Weld fillet welds in the flat (1F)position on lap, tee and cornerjoints on low carbon steel plate.CONTENT Multi-pass fillet weld on lap joint in the1F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS) Multi-pass fillet weld on tee joint in the1F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS) Multi-pass fillet weld on corner joint inthe 1F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)2. Weld fillet welds in the horizontal(2F) position on lap, tee andcorner joints on low carbon steelplate.Multi-pass fillet weld on lap joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on corner joint inthe 2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Welder Level C Program Outline • Industry Training Authority 58

3. Weld fillet welds in the vertical(3F) position on lap, tee andcorner joints on low carbon steelplate.4. Weld fillet welds in the overhead(4F) position on lap tee andcorner joints on low carbon steelplate.5. Weld fillet welds in the horizontal(2F) position on structural shapeto plate.6. Weld fillet welds pipe to plate inthe fixed vertical (5F) position.Multi-pass fillet weld on lap joint in the3F position (uphill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the3F position (uphill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on corner joint inthe 3F position (downhill) - refer topractical competency for WeldProcedure Specification (WPS)Multi-pass fillet weld on lap joint in the4F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the4F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on corner joint inthe 4F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on structural shapeto plate in the 2F position - refer topractical competency for WeldProcedure Specification (WPS)Multi-pass fillet weld pipe to plate in the5F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P4-7.Achievement Criteria:The learner will be evaluated on the ability to weld fillet welds on low carbon steel platein all positions using the SMAW process, as part of a practical shop project as per theacceptance criteria in the current curriculum module/line P4-7; evaluation must meetCSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 59

LINE D:PERFORMS SHIELDED METAL ARC WELDING (SMAW)Competency: D-8 Use the SMAW Process to Weld Fillet Welds on LowCarbon Steel SheetLearning Objectives:The learner will be able to weld fillet welds on low carbon steel sheet in horizontal andvertical positions while using the SMAW process.LEARNING TASKS1. Weld fillet welds in the horizontal(2F) position on lap and tee jointson low carbon steel sheet.CONTENT Single pass fillet weld on lap joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS) Single pass fillet weld on tee joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)2. Weld fillet welds in the vertical(3F) position on laps and teejoints on low carbon steel sheet.Single pass fillet weld on lap joint in the3F position (downhill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Single pass fillet weld on tee joint in the3F position (downhill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P4-8.Achievement Criteria:The learner will be evaluated on the ability to weld fillet welds on low carbon steel platein the horizontal and vertical positions using the SMAW process, as part of a practicalshop project as per the acceptance criteria in the current curriculum module/line P4-8;evaluation must meet CSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 60

LINE D:PERFORMS SHIELDED METAL ARC WELDING (SMAW)Competency: D-9 Describe and Demonstrate Surface Build Up andHardface in the Flat Position on Low Carbon Steel PlateLearning Objectives:The learner will be knowledgeable of all aspects and uses of the hardsurfacing processand its application. The learner will also build up low carbon steel plate in the flatposition and hardsurface low carbon steel plate in the flat position using the SMAWprocess.LEARNING TASKS1. Describe hardsurfacingprocedures.CONTENT Welding polarity Types of wear Abrasion Impact Erosion Corrosion Oxidation Compression Thermal shock Electrodes High-speed steels Austenitic manganese steels Chromium carbides Tungsten carbides Copper alloys Nickel chromium alloys Depositing filler metal Surface preparations Buildup Preheating Cooling rate Types of patterns Waffle pattern Stringer beads Dot pattern Problems in hardsurfacing Dilution Spalling Underbead cracking Stress failure Weld cracking Transverse or cross cracking Longitudinal or centre-line crackingWelder Level C Program Outline • Industry Training Authority 61

2. Demonstrate the build-up andhardsurfacing of low carbon steelplate in the flat (1S) position.DistortionBuild up low carbon steel plate in theflat position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Hardsurface in the flat position on lowcarbon steel plate - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Hardsurface buttons in flat position onlow carbon steel plate - refer topractical competency for WeldProcedure Specification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P4-10.Achievement Criteria:The learner will be evaluated on ability to build up low carbon steel plate in the flatposition and hardsurface low carbon steel plate in the flat position using the SMAWprocess, as part of a practical shop project as per the acceptance criteria in the currentcurriculum module/line P4-10.Welder Level C Program Outline • Industry Training Authority 62

LINE D:Competency:PERFORMS SHIELDED METAL ARC WELDING (SMAW)D-10 Use the SMAW Process to Weld Groove Welds in theFlat 1G Position on Grey Cast IronLearning Objectives:The learner will be knowledgeable of the procedures for SMAW on grey cast iron andbe able to weld groove welds in the flat position on single-vee butt joints on grey castiron.LEARNING TASKS1. Describe procedure for SMAWon grey cast iron.CONTENT Welding techniques Hot welding Cold welding Peening to control bead shrinkage Patching with low carbon steel Electrodes ECI Group ESt group ENI group Joint preparation Problems welding grey cast iron Contamination Porosity Cracking Lack of fusion2. Weld groove welds in the flat(1G) position on grey cast iron.Multi-pass groove weld in the 1Gposition on grey cast iron - Refer topractical competency for WeldProcedure Specification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P4-11.Achievement Criteria:The learner will be evaluated on ability to weld groove welds in the flat position onsingle-vee butt joints in grey cast iron, as part of a practical shop project as per theacceptance criteria in the current curriculum module/line P4-11.Welder Level C Program Outline • Industry Training Authority 63

LINE D:Competency:PERFORMS SHIELDED METAL ARC WELDING (SMAW)D-11 Describe and Demonstrate the Use of SMAW StainlessSteel Electrodes on Low Carbon Steel PlateLearning Objectives:The learner will be able to SMAW using stainless steel electrodes on steel plate.LEARNING TASKS1. Describe specific safetyprecautions when weldingstainless steel.CONTENT PPE Toxic fumes/ventilation Chromium Nickel Electrode coatings Reflective radiation Chemical cleaners2. Describe proper handling andpreparation procedures formaterials and consumables.3. Describe the principalconsiderations in the SMAWwelding of stainless steel.4. Weld fillet welds in the horizontal(2F) position using stainless steelelectrodes on low carbon steelplate.ContaminationAbrasives and hand brushesRigging and toolingWork areaWork environmentConsumablesSet welding variablesHeat inputWeld contaminationSurface oxidation of weld areaDistortionWeld multi-pass fillet weld on lap andtee joints in the 2F position - refer topractical competency for WeldProcedure Specification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P11-1.Achievement Criteria:The learner will be evaluated on ability to SMAW using stainless steel electrodes onsteel plate, as part of a practical shop project as per the acceptance criteria in thecurrent curriculum module/line P11-1; evaluation must meet CSA W59 standards forcyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 64

LINE D:Competency:PERFORMS SHIELDED METAL ARC WELDING (SMAW)D-15 Use the SMAW Process to Weld Groove Welds on LowCarbon Steel PlateLearning Objectives:The learner will be knowledgeable of guided bend test methods and the equipmentused to perform them. The learner will also be required to weld groove welds on buttjoints in all positions.LEARNING TASKSCONTENT1. Describe guided bend tests. Guided bend test equipment Types of guided bend tests Face bend tests Root bend tests Side bend tests Causes of failure2. Weld groove fillets with backingin the (1GF) flat, (2GF)horizontal, (3GF) vertical, (4GF)overhead on butt joints on lowcarbon steel plate.Multi-pass groove fillet weld on singlebevel butt joint (with backing) in the1GF position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass groove fillet weld on singlebevel butt joint (with backing) in the2GF position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass groove fillet weld on singlebevel butt joint (with backing) in the3GF position (uphill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass groove fillet weld on singlebevel butt joint (with backing) in the4GF position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Welder Level C Program Outline • Industry Training Authority 65

3. Weld groove welds in the flat(1G) position without backing onbutt joints on low carbon steelplate.Multi-pass groove weld on single veebutt joint in the 1G position - refer topractical competency for WeldProcedure Specification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P4-9.Achievement Criteria:The learner will be evaluated on ability to perform groove welds on butt joints in allpositions, as part of a practical shop project as per the acceptance criteria in the currentcurriculum module/line P4-9; evaluation must meet CSA W59 standards for cyclicallyloaded structures.Welder Level C Program Outline • Industry Training Authority 66

LINE E:PERFORMS ELECTRIC ARC CUTTING, GOUGING AND RELATEDPROCESSES (AAC) (PAC) (SMAC)Competency: E-1 Describe Electric Arc Cutting and Gouging Processesand Their ApplicationsLearning Objectives:The learner will be able to describe the AAC and PAC cutting process, the componentsof a basic system and safety precautions.LEARNING TASKSCONTENT1. Describe the AAC process. Principles of AAC Components of a basic AAC system Quality of AAC cut surfaces Effects of AAC on the base metal2. Describe the applications ofAAC.Manual cuttingMachine cuttingApplication of AACWeld joint preparationWeld defectsDisassembly and repair3. Describe the PAC process. PAC process PAC cutting system Quality of cut Metallurgical effects Water-table cutting4. Describe the applications ofPAC.AdvantagesMachine cuttingManual cuttingApplications of PACCutting hard-to-cut metalsCutting carbon steelPlasma gouging5. Describe the SMAC process. Fundamentals Power sources Electrodes VentilationWelder Level C Program Outline • Industry Training Authority 67

6. Describe safety requirements. PPE Fire and explosion prevention Refer to WorkSafeBC for fire watchregulations Toxic fumes/ventilation Cadmium Zinc Lead Beryllium Other alloys Synthetic materialsNOTE: Refer To Current Welder Training Program Curriculum Module/Line P5-1.Achievement Criteria:Given a 20 question test on the AAC and PAC cutting process, the components of abasic system, and its safe use, the learner will demonstrate knowledge by correctlyanswering 14 questions or more.Welder Level C Program Outline • Industry Training Authority 68

LINE E:PERFORMS ELECTRIC ARC CUTTING, GOUGING ANDRELATED PROCESSES (AAC) (PAC) (SMAC)Competency: E-2 Describe AAC Equipment and Demonstrate Its Cuttingand Gouging OperationsLearning Objectives:The learner will be able to describe and demonstrate the power source and air supplyfor AAC, the AAC electrode holder, AAC electrodes and their uses, correct operatingprocedures, and correct technique for cutting, gouging and joint preparation.LEARNING TASKSCONTENT1. Describe AAC cutting equipment. AAC power sources Power rating DC power sources for AAC Connecting two DC power sources inparallel Power cables for AAC Electrode holder AAC air supply2. Describe and select electrodes Types of AAC electrodesfor AAC cutting. DC copper-coated electrodes DC uncoated electrodes AC copper-coated electrodes Electrode shapes Electrode size3. Describe the main factors of PolarityAAC. Torch angle Travel speed Correct positioning of electrode Electrode stickout Operator comfort Operating sequence forAAC Gouging in other positions Vertical Horizontal Overhead Other techniques for using AAC Cutting Beveling WashingWelder Level C Program Outline • Industry Training Authority 69

4. Describe procedures for gougingcast iron.5. Prepare joints on low carbonsteel.6. Remove weld faults on lowcarbon steel welds.PolarityPre and post heatGouge low carbon steel in all positions- refer to practical competencyBevel low carbon steel plate in the flatposition - refer to practical competencyRemove back-up strip/backing materialwith AAC - refer to practicalcompetencyRemove discontinuities and faults ongroove and fillet welds - Refer topractical competencyNOTE: Refer To Current Welder Training Program Curriculum Module/Line P5-2and P5-3.Achievement Criteria:Given a 10 question test on air carbon arc cutting equipment and its cutting and gougingoperations, the learner will demonstrate knowledge by correctly answering 7 questionsor more. Learner will also be evaluated on the use of on air carbon arc cuttingequipment and its cutting and gouging and its operation as part of a practical shopproject as per the acceptance criteria in the current curriculum module/line P5-3.Welder Level C Program Outline • Industry Training Authority 70

LINE E:PERFORMS ELECTRIC ARC CUTTING, GOUGING ANDRELATED PROCESSES (AAC) (PAC) (SMAC)Competency: E-3 Describe and Demonstrate PAC Equipment and ItsCutting and Gouging OperationsLearning Objectives:The learner will be able to describe and demonstrate PAC process, the components ofa PAC system, PAC equipment including PAC torches, the gases used and theirfunction.LEARNING TASKS1. Describe the plasma arc cuttingprocess.CONTENT Plasma arc cutting process Plasma cutting systems Quality of cut Metallurgical effects Safe work practices Electric shock Ventilation Arc radiation Noise Water-table cutting2. Describe the applications ofplasma arc cutting.3. Describe plasma arc cuttingequipment.AdvantagesMachine cuttingManual cuttingApplications of PACCutting alloy steels and non ferrousmetalsCutting low carbon steelPlasma gougingStack cuttingPower sourcesControl unitTorchesConsumablesTip stand-offAir-cooledWater-cooledAir quality controlOilMoistureContaminantsPlasma gasesWelder Level C Program Outline • Industry Training Authority 71

4. Describe the main factors ofPAC.Secondary gasesMaterials being cutEquipment set-upOperating variablesAir pressureTravel speedDouble arcingTip-to-work distanceTravel directionTorch maintenanceOperating procedure for PAC5. Assemble PAC equipment. Refer to practical competency forprocedure6. Perform square cuts using PACequipment.Ferrous and nonferrous - Refer topractical competency for procedure7. Perform bevel cuts using PAC. Refer to practical competency forprocedure8. Perform circular cuts using PAC. Refer to practical competency forprocedureNOTE: Refer To Current Welder Training Program Curriculum Module/Line P5-4,P5-5 and P5-6.Achievement Criteria:Given a 10 question test on plasma arc cutting equipment and its cutting and gougingoperations, the learner will demonstrate knowledge by correctly answering 7 questionsor more. Learner will also be evaluated on the use of plasma arc cutting equipment andits cutting and gouging operations as part of a practical shop project as per theacceptance criteria in the current curriculum module/line P5-6.Welder Level C Program Outline • Industry Training Authority 72

LINE F:PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-P)(FCAW)(GMAW/MC*)Competency: F-1 Describe GMAW, GMAW-P, FCAW, and GMAW/MC*Processes and Their ApplicationsLearning Objectives:The learner will be able to describe semi-automatic process, the set-up, equipment,modes of metal transfer, and safety precautions.LEARNING TASKSCONTENT1. Describe GMAW and GMAW-P. Principles of operation Advantages and disadvantages ofGMAW and GMAW-P2. Describe FCAW andGMAW/MC*.3. Describe modes of metal transferin GMAW and GMAW-P.4. Describe modes of metal transferin FCAW and GMAW/MC*.5. Describe safety requirements forsemi-automatic processes.Principles of operationAdvantages and disadvantages ofFCAWPinch effectShort-circuit transferGlobular transferSpray transferPulsed spray transferTransition currentsGlobular transferSpray transferPPEEye protection for the electrical weldingprocessesWelding helmetsRadiation protectionElectric shockDamp conditionsTreatment of electric shock victimsFire and explosion preventionRefer to WorkSafeBC for fire watchregulationsSafety requirements for operatingelectric welding equipmentMaintenance of equipmentWelding cables and connectionsGround clampWelder Level C Program Outline • Industry Training Authority 73

Welding gunToxic fumes/ventilationOzoneNitrogen dioxideCarbon monoxideMetal fumesShielding gasesNOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Achievement Criteria:Given a 50 question test on semi-automatic processes, set-up, equipment, modes ofmetal transfer and the safety precautions, the learner will demonstrate knowledge bycorrectly answering 35 questions or more.*Note: GMAW/MC is metal cored filler metals under the AWS: A5.18 specification.It is a FCAW/MC under CSA and/or CWB.Source: American Welding Society and Canadian Standards Association (03/2007)Welder Level C Program Outline • Industry Training Authority 74

LINE F:PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-P)(FCAW) (GMAW/MC*)Competency: F-2 Describe GMAW, GMAW-P, FCAW and GMAW/MC*Equipment and Their OperationLearning Objectives:The learner will be able to describe semi-automatic equipment and their operation,including power sources, wire-feed systems, shielding gases, and welding gunassembly.LEARNING TASKS1. Identify power sources for semiautomatic.CONTENT Constant voltage/current power sources Arc voltage Slope Inductance Types of controls on CV power sources Voltage controls Slope controls Inductance controls Current controls Voltmeters and ammeters Remote controls and dual schedules Pulsed power sources2. Identify the equipment for semiautomaticwire-feed systems.3. Describe welding gun assembliesfor semi-automatic processes.Push type systemsPull-type feed systemsPush-pull systemsFeed rollsWire-feed controlsConstant and variable speed wirefeedersWelding gun typesAmperage ratingWater cooledGas cooledSpoolWelding gun consumablesCable assemblySizeAdaptersLinersPreventive maintenanceWelder Level C Program Outline • Industry Training Authority 75

4. Describe equipment for semiautomaticprocesses.5. Describe primary processvariables for semi-automaticequipment.6. Describe secondary variables forsemi-automatic processes.7. Identify process related weldfaults and their causes.8. Diagnose and demonstratecorrective measures (eg. troubleshooting) for malfunctioningsemi-automatic equipment.Conventional power sourcesInverter power sourcesPulse controlsWelding cablesWelding gunsFiller metalShielding gasesVoltageWire feed speedWelding currentTrim or arc length (GMAW-P)InductanceElectrode extension (stickout)Arc lengthContact tip to work distancePush/pull techniqueGun to work anglesNozzle to work distanceDimensional defectsIncorrect weld sizeInsufficient throat/underfillStructural discontinuities in the weldUnder cutIncomplete penetrationLack of fusionCold lapPorosityCracking (internal/external)Slag inclusionsMechanicalDrive feed mechanismLinerElectricalCable sizesGroundingContact tipContactor (gun trigger)GasesLeaks in systemFlow ratesNozzleWelder Level C Program Outline • Industry Training Authority 76

NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6and Gmaw-P: Pulsed Spray Transfer, Miller Training Manual.Achievement Criteria:Given a 60 question test on semi-automatic equipment and their operation, the learnerwill demonstrate knowledge by correctly answering 42 questions or more.Welder Level C Program Outline • Industry Training Authority 77

LINE F:PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-P)(FCAW) (GMAW/MC*)Competency: F-3 Describe and Select Filler Metal and Shielding Gases forGMAWLearning Objectives:The learner will be able to select filler metal and shielding gases for GMAW based ontheir knowledge of the construction and operation of GMAW, the CSA and AWSclassification systems and specifications for GMAW low carbon steel filler metal, theapplication for commonly used GMAW low carbon steel filler metal and the basic care,handling and storage procedures for GMAW filler metal.LEARNING TASKS1. Identify low carbon steel fillermetal for GMAW.CONTENT Low carbon steel filler metalclassifications GMAW or solid filler metal Deoxidizers in GMAW wires ER49S-1 to 7 (ER70S-1 to 7) ER49S-G (ER70S-G)2. Identify the shielding gases forGMAW.Carbon dioxideInert shielding gases – argon andheliumDensityThermal conductivityIonization potentialGas mixturesArgon-oxygen mixturesHelium-argon mixturesSpecific gas mixtures to suitapplicationsShielding gas cylindersCarbon dioxide cylindersRegulatorsFlowmetersManifold systemsGas mixersFlowrates for shielding gasesSolutions for regulator “freeze-up”Safe handling of shielding gas cylindersand regulatorsNOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Welder Level C Program Outline • Industry Training Authority 78

Achievement Criteria:Given a 20 question test on selecting filler metal and shielding gases for GMAW basedon their knowledge of the construction and operation of GMAW filler metal, the CSA andAWS classification systems and specifications for GMAW low carbon steel filler metal,the application for commonly used GMAW low carbon steel filler metal and the basiccare, handling and storage procedures for GMAW filler metal, the learner willdemonstrate knowledge by correctly answering 14 questions or more.Welder Level C Program Outline • Industry Training Authority 79

LINE F:P)(FCAW)PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)Competency: F-4 Use the GMAW Process to Weld Stringer Beads andFillet Welds on Low Carbon Steel PlateLearning Objectives:The learner will be knowledgeable of the welding variables for GMAW on low carbonsteel and will be required to set up GMAW equipment using a DC constant voltagepower source, weld stringer beads in the flat position and fillet welds in the flat (1F),horizontal (2F) and vertical (3F) positions on low carbon steel plate.LEARNING TASKS1. Set up GMAW equipment using aDC constant voltage powersource.CONTENT Equipment Filler metal Shielding gas Assemble GMAW equipment Shut down GMAW equipment2. Weld stinger beads in the flatposition on low carbon steelplate.3. Weld fillet welds in the flat (1F)position on lap, tee and cornerjoints low carbon steel plate.4. Weld fillet welds in the horizontal(2F) position on lap, tee andcorner joints low carbon steelplate.Refer to practical competency for WeldProcedure Specification (WPS)Fillet weld on lap joint in the 1F position- refer to practical competency for WeldProcedure Specification (WPS)Fillet weld on tee joint in the 1F position- refer to practical competency for WeldProcedure Specification (WPS)Fillet weld on corner joint in the 1Fposition - refer to practical competencyfor Weld Procedure Specification(WPS)Fillet weld on lap joint in the 2F position- refer to practical competency for WeldProcedure Specification (WPS)Fillet weld on tee joint in the 2F position- refer to practical competency for WeldProcedure Specification (WPS)Fillet weld on corner joint in the 2Fposition - refer to practical competencyfor Weld Procedure Specification(WPS)Welder Level C Program Outline • Industry Training Authority 80

5. Weld fillet welds in the vertical(3F) position on lap and tee jointson low carbon steel plate.6. Weld fillet welds in the flat (1F)and horizontal (2F) position onlap and tee joints low carbonsteel plate using spray transfer.Fillet weld on lap joint in the 3F position(uphill) - refer to practical competencyfor Weld Procedure Specification(WPS)Fillet weld on lap joint in the 3F position(downhill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the3F position (uphill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the3F position (downhill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on lap joint in the1F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the1F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on lap joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Achievement Criteria:The learner will be evaluated on ability to set up GMAW equipment using a DC constantvoltage power source, weld stinger beads in the flat position and fillet welds in the flat(1F), horizontal (2F) and vertical (3F) positions on low carbon steel plate, as part of apractical shop project as per the practical components in the current curriculummodule/line P4; evaluation must meet CSA W59 standards for cyclically loadedstructures.Welder Level C Program Outline • Industry Training Authority 81

LINE F:P)(FCAW)PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)Competency: F-5 Use the GMAW Process to Weld Fillet Welds on LowCarbon Steel SheetLearning Objectives:The learner will be able to weld fillet welds in horizontal and vertical positions on lowcarbon steel sheet using the GMAW process.LEARNING TASKS1. Weld fillet welds in the horizontal(2F) position on lap and tee jointson low carbon steel sheet.CONTENT Single-pass fillet weld on lap joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS) Single-pass fillet weld on tee joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)2. Weld fillet welds in the vertical(3F) position (downhill) on lapand tee joints on low carbon steelsheet.Single-pass fillet weld on lap joint in the3F position (downhill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Single-pass fillet weld on tee joint in the3F position (downhill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Achievement Criteria:The learner will be evaluated on ability to weld fillet welds in horizontal and verticalpositions on low carbon steel sheet using the GMAW process, as part of a practicalshop project as per the practical components in the current curriculum module/line P4;evaluation must meet CSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 82

LINE F:P)(FCAW)PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)Competency: F-6 Use the GMAW Process to Weld Square Groove Weldson Low Carbon Steel SheetLearning Objectives:The learner will be able to weld square groove welds on butt joints on low carbon steelsheet using the GMAW process.LEARNING TASKS1. Weld square groove welds in theflat (1G) position and the vertical(3G) position on butt joints on lowcarbon steel sheet.CONTENT Single-pass fillet weld in the 1G position- refer to practical competency for WeldProcedure Specification (WPS) Single-pass groove weld in the 3Gposition (downhill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Achievement Criteria:The learner will be evaluated on ability to weld square groove welds on butt joints onlow carbon steel sheet using the GMAW process, as part of a practical shop project asper the practical components in the current curriculum module/line P4; evaluation mustmeet CSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 83

LINE F:P)(FCAW)PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)Competency: F-7 Use the GMAW Process to Weld Groove Welds on LowCarbon Steel PlateLearning Objectives:The learner will be able to weld groove welds on single-bevel butt joints with backingand single-vee butt joints without backing.LEARNING TASKS1. Weld groove welds in the flat(1GF) position on butt joints onlow carbon steel plate usingspray transfer.CONTENT Multi-pass groove weld on single-bevelbutt joint in the 1GF position (withbacking) - refer to practical competencyfor Weld Procedure Specification(WPS)2. Weld groove welds in the flatposition (1G) on butt joints on lowcarbon steel plate.3. Weld groove welds on butt jointsin the horizontal (2G) position.4. Weld groove welds on butt jointsin the vertical (3G) position.Multi-pass groove weld on single-veebutt joint in the 1G position - refer topractical competency for WeldProcedure Specification (WPS)Multi-pass groove weld on open root,single-vee butt joint in the 2G position -refer to practical competency for WeldProcedure Specification (WPS)Multi-pass groove weld on open root,single-vee butt joint in the 3G position(downhill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Face and root bends tests - refer topractical competency for procedureNOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Achievement Criteria:The learner will be evaluated on ability to weld groove welds on single-bevel butt jointswith backing and single-vee butt joints without backing, as part of a practical shopproject as per the practical components in the current curriculum module/line P4;evaluation must meet CSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 84

LINE F:P)(FCAW)PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)Competency: F-8 Use the GMAW-P Process to Weld Fillet Welds on LowCarbon Steel PlateLearning Objectives:The learner will be knowledgeable of the welding variables for GMAW-P on low carbonsteel and will be required to set up GMAW-P equipment, weld fillet welds in horizontal(2F), vertical (3F) and overhead (4F) positions on low carbon steel plate.LEARNING TASKS1. Identify welding variables forGMAW-P on low carbon plate.CONTENT Pre-selected variables Equipment selection Filler metal selection Mode of metal transfer and shieldinggas Primary adjustable variables Welding current Trim Secondary adjustable variables Pushing and pulling techniques Travel speed Stickout Gun angle2. Identify trouble shootingprocedures for GMAW-P.Dimensional defectsIncorrect weld sizeOverlapExcessive reinforcementStructural discontinuities in the weldUnder cutIncomplete penetrationLack of fusionPorosityCracking (internal/external)Insufficient throat/underfill3. Set up GMAW-P equipment. Equipment Filler wire Shielding gas Assemble GMAW-P equipment Shut down GMAW-P equipmentWelder Level C Program Outline • Industry Training Authority 85

4. Weld fillet welds in the horizontal(2F) position on lap joint.5. Weld fillet welds in the vertical(3F) position on lap and teejoints.6. Weld fillet welds in the overhead(4F) position on lap joint.Multi-pass fillet weld on lap joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on lap joint in the3F position (uphill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the3F position (uphill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on lap joint in the4F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6(Addendum).Achievement Criteria:The learner will be evaluated on their knowledge of the welding variables for GMAW-Pon low carbon steel and will be required to set up GMAW-P equipment fillet welds in allpositions on a on low carbon steel plate, as part of a practical shop project as per thepractical components in the current curriculum module/line P4 (addendum); evaluationmust meet CSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 86

LINE F:P)(FCAW)PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)Competency: F-9 Use the GMAW-P Process to Weld Fillet Welds on LowCarbon Steel SheetLearning Objectives:The learner will be able to weld fillet welds in horizontal and vertical positions on lap andtee- joints on low carbon steel sheet using the GMAW-P process.LEARNING TASKS1. Weld fillet welds in the horizontal(2F) position on lap and tee jointson low carbon steel sheet.CONTENT Single-pass fillet weld on lap joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS) Single-pass fillet weld on tee joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)2. Weld fillet welds in the vertical(3F) position (downhill) on lapand tee jointsSingle-pass fillet weld on lap joint in the3F position (downhill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Single-pass fillet weld on tee joint in the3F position (downhill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6(Addendum).Achievement Criteria:The learner will be evaluated on ability to weld fillet welds in horizontal and verticalpositions on lap and tee joints on low carbon steel sheet using the GMAW-P process,as part of a practical shop project as per the practical components in the currentcurriculum module/line P4 (addendum); evaluation must meet CSA W59 standards forcyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 87

LINE F:P)(FCAW)Competency:PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)F-10 Use the GMAW-P Process to Weld Square Groove Weldson Low Carbon Steel SheetLearning Objectives:The learner will be able to weld square groove butt joint on low carbon steel sheet usingthe GMAW-P process.LEARNING TASKS1. Weld square groove welds in thehorizontal (2G) position on buttjoints on low carbon steel sheet.CONTENT Single-pass groove weld in the 2Gposition - refer to practical competencyfor Weld Procedure Specification(WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6(Addendum).Achievement Criteria:The learner will be evaluated on ability to weld square groove butt joint on low carbonsteel sheet using the GMAW-P process, as part of a practical shop project as per thepractical components in the current curriculum module/line P4 (addendum); evaluationmust meet CSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 88

LINE F:P)(FCAW)Competency:PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)F-11 Use the GMAW-P Process to Weld Groove Welds onLow Carbon Steel PlateLearning Objectives:The learner will be able to weld single-bevel butt joints with backing in horizontal andvertical positions.LEARNING TASKS1. Weld groove fillet welds inhorizontal (2GF) and vertical(3GF) positions.CONTENT Multi-pass groove fillet weld in 2GF and3GF positions on single-bevel buttjoints with backing - refer to practicalcompetency for Weld ProcedureSpecification (WPS) Face and root bend tests – refer topractical competency for procedureNOTE: Refer To Current Welder Training Program Curriculum Module/Line P6(Addendum).Achievement Criteria:The learner will be evaluated on ability to weld single-bevel butt joints with backing inhorizontal and vertical positions, as part of a practical shop project as per the practicalcomponents in the current curriculum module/line P4 (addendum); evaluation mustmeet CSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 89

LINE F:P)(FCAW)Competency:PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)F-13 Describe and Demonstrate GMAW-P Weld Fillet WeldsUsing Stainless Steel Filler Metal on Low Carbon SteelPlate and SheetLearning Objectives:The learner will be able to describe and demonstrate GMAW-P fillet welds usingstainless steel filler metal on low carbon steel plate.LEARNING TASKS1. Identify specific safetyprecautions when weldingstainless steel.CONTENT PPE Toxic fumes/ventilation Chromium Nickel Reflective radiation Chemical cleaners2. Describe proper handling andpreparation procedures formaterials and consumables.3. Describe the principalconsiderations in the GMAW-Pwelding of stainless steel.4. Weld fillet weld in the horizontal(2F) position on tee joint on lowcarbon steel plate.5. Weld fillet weld in the horizontal(2F) position on lap joints on lowcarbon steel sheet.ContaminationAbrasives and hand brushesRigging and toolingWork areaWork environmentConsumablesSet welding variablesHeat inputShielding gasesWeld contaminationSurface oxidation of weld areaDistortionMulti-pass fillet weld on tee joint in the2F position – refer to practicalcompetency for Weld ProcedureSpecification (WPS)Single-pass fillet weld on lap joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Welder Level C Program Outline • Industry Training Authority 90

Achievement Criteria:The learner will be evaluated on ability to describe and demonstrate GMAW-P filletwelds using stainless steel filler metal on low carbon steel plate, as part of a practicalshop project as per the practical components in the current curriculum module/line P4(addendum); evaluation must meet CSA W59 standards for cyclically loaded.Welder Level C Program Outline • Industry Training Authority 91

LINE F:Competency:PERFORMS SEMI-AUTOMATIC WELDING(GMAW)(GMAW-P)(FCAW)(GMAW/MC*)F-16 Describe and Demonstrate Procedures Specific toGMAW and GMAW-P on Aluminum PlateLearning Objectives:The learner will be able to describe and demonstrate the precautions and proceduresspecific to GMAW and GMAW-P on aluminum plate.LEARNING TASKS1. Identify specific safetyprecautions when weldingaluminum.CONTENT PPE Toxic fumes/ventilation ozone Reflective radiation Chemical cleaners2. Describe proper handling andpreparation procedures formaterials and consumables.3. Describe the principalconsiderations in the GMAW andGMAW-P welding of aluminum.4. GMAW fillet welds in thehorizontal (2F) position lap andtee joint on aluminum plate.5. GMAW-P fillet welds in thevertical (3F) and overhead (4F)position tee joint on aluminumplate.ContaminationAbrasives and hand brushesRigging and toolingWork areaWork environmentConsumablesSet welding variablesHeat inputShielding gasesWeld contaminationSurface oxidation of weld areaDistortionSingle-pass fillet weld lap joint in the 2Fposition – refer to practical competencyfor Weld Procedure Specification(WPS)Multi-pass fillet weld tee joint in the 2Fposition – refer to practical competencyfor Weld Procedure Specification(WPS)Multi-pass fillet weld tee joint in the 3Fand 4F position– refer to practicalcompetency for Weld ProcedureSpecification (WPS)Welder Level C Program Outline • Industry Training Authority 92

Achievement Criteria:The learner will be evaluated on ability to describe and demonstrate the precautionsand procedures specific to GMAW and GMAW-P on aluminum plate, as part of apractical shop project as per the practical components in the current curriculummodule/line P4 (addendum); evaluation must meet CSA W59 standards for cyclicallyloaded.Welder Level C Program Outline • Industry Training Authority 93

LINE F:P)(FCAW)Competency:PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)F-22 Describe and Select Filler Metals and Shielding Gasesfor FCAW and GMAW/MC*Learning Objectives:The learner will be able to select filler metals and shielding gases for FCAW andGMAW/MC base on their knowledge of the construction and operation of FCAW andGMAW/MC filler metals, the CSA and AWS classification systems and specifications forFCAW and GMAW/MC low carbon steel filler metals, the application for commonly usedFCAW and GMAW/MC low carbon steel filler metals and the basic care, handling andstorage procedures for FCAW and GMAW/MC filler metals.LEARNING TASKS1. Describe and select low carbonsteel filler metals for FCAW andGMAW/MC.CONTENT Major classifications of FCAW lowcarbon filler metals T-1 to T-11 Classification T-G Classification Major classifications of GMAW/MC lowcarbon filler metals Metal cored filler metal Shielding/self-shielding filler metals Characteristics of shielding gases Filler metal handling procedures Filler metal storage requirements Detect damage or defects inconsumables Follow manufacturers’recommendationsWelder Level C Program Outline • Industry Training Authority 94

2. Describe and select the shieldinggases for FCAW andGMAW/MC.Carbon dioxideCathode jetInert shielding gases – argon andheliumDensityThermal conductivityIonization potentialGas mixturesArgon-oxygen mixturesHelium-argon mixturesQuaternary mixturesShielding gas cylindersCarbon dioxide cylindersRegulator “freeze-up”RegulatorsFlowmetersGas mixersFlowrates for shielding gasesSafe handling of shielding gasequipmentNOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Achievement Criteria:Given a 20 question test on selecting filler metals and shielding gases for FCAW andGMAW/MC base on their knowledge of the construction and operation of FCAW andGMAW/MC filler metals, the CSA and AWS classification systems and specifications forFCAW and GMAW/MC low carbon steel filler metals, the application for commonly usedFCAW and GMAW/MC low carbon steel filler metal and the basic care, handling andstorage procedures for FCAW and GMAW/MC filler metals, the learner will demonstrateknowledge by correctly answering 14 questions or more.Welder Level C Program Outline • Industry Training Authority 95

LINE F:Competency:PERFORMS SEMI-AUTOMATIC WELDING(GMAW)(GMAW-P)(FCAW)(GMAW/MC*)F-23 Use the FCAW Self-Shielding Process to Weld FilletsWelds on Low Carbon Steel PlateLearning Objectives:The learner will be able to weld stringer beads in the flat position on low carbon steelplate and weld fillet welds on lap and tee joints in the flat (1F), horizontal (2F) andvertical (3F) positions using the FCAW process with self-shielding filler metals.LEARNING TASKS1. Identify welding variables forFCAW on low carbon plate.CONTENT Pre-selected variables Equipment selection Filler metal selection Mode of metal transfer Primary adjustable variables Welding current Arc voltage Secondary adjustable variables Pushing and pulling techniques Travel speed Stickout Gun angle2. Weld stinger beads on lowcarbon steel plate using selfshieldingfiller metal.3. Weld fillet weld in the flat (1F)position on lap joint using selfshieldingfiller metal.4. Weld fillet welds in the horizontal(2F) position on tee joint in usingself-shielding filler metal.5. Weld fillet welds in the vertical(3F) position (uphill) on tee jointusing self-shielding filler metal.Refer to practical competency for WeldProcedure Specification (WPS)Multi-pass fillet weld on lap joint in the1F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the3F position (uphill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Welder Level C Program Outline • Industry Training Authority 96

6. Weld fillet weld in the overhead(4F) position on structural shapeto plate using self-shielding fillermetal.Multi-pass fillet weld on structural shapeto plate in the 4Fposition - refer topractical competency for WeldProcedure Specification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Achievement Criteria:The learner will be evaluated on ability to weld stringer beads in the flat position on lowcarbon steel plate, weld fillet welds on lap and tee joints in a variety of positions usingthe FCAW process with self-shielding filler metal as part of a practical shop project asper the acceptance criteria in the current curriculum module/line P4; evaluation mustmeet CSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 97

LINE F:Competency:PERFORMS SEMI-AUTOMATIC WELDING(GMAW)(GMAW-P)(FCAW)(GMAW/MC*)F-24 Use the FCAW Gas-Shielded Process to Weld FilletWelds on Low Carbon Steel PlateLearning Objectives:The learner will be able to weld stringer beads in the flat position on low carbon steelplate and weld fillet welds on lap and tee joints in the flat (1F), horizontal (2F), vertical(3F) and overhead (4F) positions using the FCAW process with gas- shielded fillermetals.LEARNING TASKS1. Identify welding variables forFCAW on low carbon plate.CONTENT Pre-selected variables Equipment selection Filler metal selection Mode of metal transfer and shieldinggas Primary adjustable variables Welding current Arc voltage Secondary adjustable variables Pushing and pulling techniques Travel speed Stickout Gun angle2. Weld stinger beads on lowcarbon steel plate using gasshieldedfiller metal.3. Weld fillet weld in the flat (1F)position on tee joint using gasshieldedfiller metal.4. Weld fillet welds in the horizontal(2F) position on lap and tee jointsin using gas-shielding filler metal.Refer to practical competency for WeldProcedure Specification (WPS)Multi-pass fillet weld on tee joint in the1F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on lap joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Welder Level C Program Outline • Industry Training Authority 98

5. Weld fillet welds in the vertical(3F) position (uphill) on lap andtee joints using gas-shielded fillermetal.6. Weld fillet weld in the overhead(4F) position on tee joint usinggas-shielded filler metal.7. Weld fillet weld in the horizontal(2F) position on structural shapeto plate using gas-shielded fillermetal.Multi-pass fillet weld on lap joint in the3F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joints in the3F position (uphill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the4Fposition - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on structural shapeto plate in the 2F position - refer topractical competency for WeldProcedure Specification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Achievement Criteria:The learner will be evaluated on ability to weld groove welds using FCAW, in a varietyof positions using gas-shielded filler metal, as part of a practical shop project as per theacceptance criteria in the current curriculum module/line P4; evaluation must meet CSAW59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 99

LINE F:P)(FCAW)Competency:PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)F-25 Use the FCAW Process to Weld Groove Welds on LowCarbon Steel PlateLearning Objectives:The learner will be able to weld groove welds in all positions on low carbon steel plateusing the FCAW process with gas-shielded filler metals.LEARNING TASKS1. Weld square groove welds in theflat (1G) position on butt joints onlow carbon steel plate. Gouge toSound Metal (GTSM).CONTENT Multi-pass square groove weld on buttjoint (both sides) in the 1G position -refer to practical competency for WeldProcedure Specification (WPS)2. Weld groove fillets with backingin the flat (1GF), horizontal(2GF), vertical (3GF), andoverhead (4GF) positions on buttjoints on low carbon steel plate.Multi-pass groove welds on single bevelbutt joint (with backing) in the 1GFposition - refer to practical competencyfor Weld Procedure Specification(WPS)Multi-pass groove weld on single bevelbutt joint (with backing) in the 2GFposition - refer to practical competencyfor Weld Procedure Specification(WPS)Multi-pass groove weld on single bevelbutt joint (with backing) in the 3GFposition (uphill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass groove weld on single bevelbutt joint (with backing) in the 4GFposition (uphill) - refer to practicalcompetency for Weld ProcedureSpecification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Achievement Criteria:The learner will be evaluated on ability to weld groove welds in all positions, using theFCAW process with gas-shielded filler metals, as part of a practical shop project as perthe acceptance criteria in the current curriculum module/line P4; evaluation must meetCSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 100

LINE F:P)(FCAW)Competency:PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)F-26 Use the GMAW/MC* Process to Weld Fillets Welds onLow Carbon Steel PlateLearning Objectives:The learner will be able to weld fillet welds in the flat and horizontal position on lowcarbon steel using the GMAW/MC* process.LEARNING TASKS1. Identify welding variables forGMAW/MC* on low carbon plate.CONTENT Pre-selected variables Equipment selection Filler metal selection Mode of metal transfer and shieldinggas Primary adjustable variables Welding current Arc voltage Secondary adjustable variables Pushing and pulling techniques Travel speed Stickout Gun angle2. Weld fillet welds in the flat (1F)position on lap and tee joints.3. Weld fillet welds in the horizontal(2F) position on lap and teejoints.Multi-pass fillet weld on lap joint in the1F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the1F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on lap joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Welder Level C Program Outline • Industry Training Authority 101

Achievement Criteria:The learner will be evaluated on ability to weld fillet welds in the flat and horizontalposition on low carbon steel using the GMAW/MC* process as part of a practical shopproject as per the acceptance criteria in the current curriculum module/line P4;evaluation must meet CSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 102

LINE F:P)(FCAW)Competency:PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)F-27 Use the GMAW/MC* Process to Weld Groove Welds onLow Carbon Steel PlateLearning Objectives:The learner will be able to weld groove welds using the GMAW/MC* process.LEARNING TASKS1. Weld square groove welds in theflat (1G) position on butt joints onlow carbon steel plate. Gouge toSound Metal (GTSM).CONTENT Multi-pass square groove weld on buttjoint (both sides) in the 1G position -refer to practical competency for WeldProcedure Specification (WPS)NOTE: Refer To Current Welder Training Program Curriculum Module/Line P6.Achievement Criteria:The learner will be evaluated on ability to weld groove welds using the GMAW/MC*process as per the acceptance criteria in the current curriculum module/line P4;evaluation must meet CSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 103

LINE F:P)(FCAW)Competency:PERFORMS SEMI-AUTOMATIC WELDING (GMAW)(GMAW-(GMAW/MC*)F-29 Describe and Demonstrate FCAW Fillet Welds UsingStainless Steel Filler on Low Carbon Steel PlateLearning Objectives:The learner will be able to describe and demonstrate FCAW fillet welds using stainlesssteel filler metal on low carbon steel plate.LEARNING TASKS1. Identify specific safetyprecautions when weldingstainless steel.CONTENT PPE Toxic fumes/ventilation Chromium Nickel Reflective radiation Chemical cleaners2. Describe proper handling andpreparation procedures formaterials and consumables.3. Describe the principalconsiderations in the FCAWwelding of stainless steel.4. Weld fillet welds in the horizontal(2F) position on lap joints on lowcarbon steel sheet.5. Weld fillet welds in the horizontal(2F) position on tee joint on lowcarbon steel plate.ContaminationAbrasives and hand brushesRigging and toolingWork areaWork environmentConsumablesSet welding variablesHeat inputShielding gasesWeld contaminationSurface oxidation of weld areaDistortionSingle-pass fillet weld on lap joint in the2F position - refer to practicalcompetency for Weld ProcedureSpecification (WPS)Multi-pass fillet weld on tee joint in the2F position – refer to practicalcompetency for Weld ProcedureSpecification (WPS)Welder Level C Program Outline • Industry Training Authority 104

Achievement Criteria:The learner will be evaluated on ability to describe and demonstrate FCAW fillet weldusing stainless steel filler metal on low carbon steel plate, as part of a practical shopproject as per the acceptance criteria in the current curriculum module/line P4;evaluation must meet CSA W59 standards for cyclically loaded structures.Welder Level C Program Outline • Industry Training Authority 105

LINE G:DESCRIBE BASIC METALLURGY RELATING TOPRODUCTION, PROPERTIES AND WELDABILITYCompetency: G-1 Describe Production Processes for ManufacturingMetalsLearning Objectives:The learner will be able to describe the production processes for manufacturing metals.LEARNING TASKS1. Describe types of iron andcurrent production methods.CONTENT Blast furnace – pig iron Cast irons Grey cast iron White cast iron Malleable cast iron Nodular iron (ductile iron)2. Describe current steel productionand forming methods.Open hearth furnaceBasic oxygen furnaceElectric furnaceBessemer converterIngotsRimmed, killed and semi-killed steelContinuous casting processBlooms, billets and slabsHot and cold-rolled sheet productsGalvanized sheet steel productsTin mill productsStructural shapes and barsSteel plate and large diameter pipePipe and tubingERWSeamlessForging processOpen-die forgingClosed-die forgingCasting processSand castingCentrifugal castingDie castingWelder Level C Program Outline • Industry Training Authority 106

3. Describe types of steel and steelclassifications.Main elements of carbon steelssix elementsTypes of steelLow carbonMedium carbonHigh carbon (tool)Alloying elementsChromiumCobaltCopperMagnesiumNickelTitaniumTungstenVandiumSteel classificationCSA standardsUNS numbering systemSAE and AISI systemsFirst digitSecond digitThird and fourth digitsASTM classificationManufacturer’s certification andidentification markingsColour codingNumbering systemsHeat numbersMill certificationAchievement Criteria:Given a 20 question test on the production processes for manufacturing metals, thelearner will demonstrate knowledge by correctly answering 14 questions or more.Welder Level C Program Outline • Industry Training Authority 107

LINE G:DESCRIBE BASIC METALLURGY RELATING TOPRODUCTION, PROPERTIES AND WELDABILITYCompetency: G-2 Describe Mechanical and Physical Properties of MetalsLearning Objectives:The learner will be able to identify the mechanical and physical properties of metals.LEARNING TASKS1. Define the terms relating tomechanical and physicalproperties of metals.CONTENT Metallurgy Alloys Ferrous metals Wrought iron Cast iron Carbon steels Low alloy steels Alloy steels Nonferrous metals Aluminum Copper Lead Magnesium Nickel Silver Tin Zinc2. Describe the mechanicalproperties of metals.Tensile strengthElasticity, yield point, ultimate tensilestrengthElongationImpact strengthCompressive strengthFatigue strengthToughnessHardnessDuctilityMalleabilityBrittlenessWelder Level C Program Outline • Industry Training Authority 108

3. Describe the physical propertiesof metals.DensityResistance to corrosionElectrical conductivityThermal conductivityThermal expansionMelting pointNOTE: Refer To Current Welder Training Program Curriculum Module/LineRK3-1.Achievement Criteria:Given a 20 question test on identifying the mechanical and physical properties ofmetals, the learner will demonstrate knowledge by correctly answering 14 questions ormore.Welder Level C Program Outline • Industry Training Authority 109

LINE G:DESCRIBE BASIC METALLURGY RELATING TOPRODUCTION, PROPERTIES AND WELDABILITYCompetency: G-3 Describe MetalsLearning Objectives:The learner will identify metals by their visual appearance, relative weight, typical shapeand texture, and will perform chip tests, spark tests, hardness tests and flame tests.LEARNING TASKS1. Describe identifying types ofmetals by their physicalcharacteristics such as visualappearance, colour, relativeweight, typical shape and texture.CONTENT Steel Cast steel Cast irons Copper Brass and bronze Aluminum Stainless steel Lead Magnesium Zinc Titanium2. Describe identifying types ofmetals by mechanical andthermal tests.ChipSparkHardnessFilesCenter punchChiselFlameMagneticNon-magneticMagneticSlightly magneticMelting point3. Identify metals. Refer to practical competency forprocedureNOTE: Refer To Current Welder Training Program Curriculum Module/LineRK3-3.Welder Level C Program Outline • Industry Training Authority 110

Achievement Criteria:Given a 10 question test the learner will demonstrate knowledge of identifying metals bytheir visual appearance, relative weight, typical shape and texture, chip tests, sparktests, hardness tests and flame tests by correctly answering 7 questions or more. Thelearner will be evaluated on ability to inspect metals for identification as part of apractical shop project as per the acceptance criteria in the current curriculummodule/line RK3-3.Welder Level C Program Outline • Industry Training Authority 111

LINE G:DESCRIBE BASIC METALLURGY RELATING TOPRODUCTION, PROPERTIES AND WELDABILITYCompetency: G-5 Describe the Alloy Content and Heat Treatments on theWeldability of SteelLearning Objectives:The learner will be able to describe how welding affects the mechanical properties oflow carbon steel.LEARNING TASKS1. Describe the precautions andweldability of low carbon steel.CONTENT Factors affecting the weldability of lowcarbon steels Contamination Thickness Temperature Moisture2. Describe the effects of weldingon low carbon steel.Heat affected zones in weldsHeat transferEffects of expansion and contractionThe purpose and effects of:PreheatingPost heatingQuenchingTemperature indicating devices:Temperature sticks/crayonPyrometerAchievement Criteria:Given a 10 question test on how welding affects the mechanical properties of lowcarbon steel, the learner will demonstrate knowledge by correctly answering 7 questionsor more.Welder Level C Program Outline • Industry Training Authority 112

LINE I:DESCRIBES AND PERFORMS MATEIAL HANDLING ANDRIGGING PROCEDURESCompetency: I-1 Describe Safety Procedures for Rigging and MaterialHandlingLearning Objectives:The learner will be able to describe safety procedures for rigging and material handling.LEARNING TASKS1. Describe rigging and generalsafety precautions.CONTENT Introduction to rigging WorkSafeBC rigging regulations Rejection criteria PPE Common hazards SWL not known Defective equipment and hardware Unrated lifting lugs Electrical contact Weather conditionsNOTE: Refer To Current Welder Training Program Curriculum Module/Line RK1-1and RK-2.Achievement Criteria:Given a 40 question test on describing safety procedures for rigging and materialhandling, the learner will demonstrate knowledge by correctly answering 28 questionsor more.Welder Level C Program Outline • Industry Training Authority 113

LINE I:DESCRIBES AND PERFORMS MATEIAL HANDLING ANDRIGGING PROCEDURESCompetency: I-2 Performs Safe Working Load Calculations InvolvingGeometric Formulas, Volumes and CapacitiesLearning Objectives:The learner will be able to perform safe working load calculations involving geometricformulas, volumes and capacities.LEARNING TASKS1. Solve problems involvinggeometric formulas.CONTENT Key terms and concepts used inworking with formulas Identify common formulas and solveproblems for perimeter Identify common formulas and solveproblems for area Identify common formulas and solveproblems for volume, calculate theweight of a solid Calculate the capacity of a container inlitres and gallons2. Determine weight and centre ofgravity.Calculating the weight of loadPlateStructural steel shapePipeCentre of gravity3. Explain safe working load ratios. WorkSafeBC regulations (part 15) Material and personnelNOTE: Refer To Current Welder Training Program Curriculum Module/Line RK1-2and RK2B-6.Achievement Criteria:Given a 10 question test on safe working load calculations involving geometric formulas,volumes and capacities, the learner will demonstrate knowledge by correctly answering7 questions or more.Welder Level C Program Outline • Industry Training Authority 114

LINE I:DESCRIBES AND PERFORMS MATERIAL HANDLING ANDRIGGING PROCEDURESCompetency: I-3 Use Fibre Ropes to Tie KnotsLearning Objectives:The learner will be able to use fibre ropes to tie knots, bends and hitches.LEARNING TASKS1. Describe fibre ropecharacteristics and theirapplications.CONTENT Natural fibres Manila Synthetic fibres Nylon Polyester Polypropylene2. Determine the safe working loadof fibre rope.3. Describe proper care andinspection of rope.SWL for:ManilaNylonPolyesterPolypropyleneDe-rated capacity using knots, bends orhitchesStorageVisual inspectionCutsAbrasionsDirtRotFatigueHeat damageDry-testingCleanlinessKinksChemical damageWelder Level C Program Outline • Industry Training Authority 115

4. Recognize and name commonknots, bends and hitches usedwith ropes.5. Describe and demonstrateapplications of knots, bends andhitches. Parts of a rope Basic knots Figure 8 Square (reef) knot Clove hitch Sheetbend Round turn and two half hitches Bowline Half hitch Single Dutchman (chain knot) Tag lines (rigging) Load lines (tie-down) Hoisting lines (materials) Safety harness Joining ropes Stopper knotNOTE: Refer To Current Welder Training Program Curriculum Module/Line RK1-1.Achievement Criteria:Given a 10 question test on the use of fibre ropes to tie knots, bends and hitches thelearner will demonstrate knowledge by correctly answering 7 questions or more. Thelearner will be evaluated on ability to use fibre ropes to tie knots, bends and hitches, aspart of a practical shop project as per the acceptance criteria in the current curriculummodule/line RK1-1.Welder Level C Program Outline • Industry Training Authority 116

LINE I:DESCRIBES AND PERFORMS MATERIAL HANDLING ANDRIGGING PROCEDURESCompetency: I-4 Describe Slings and Rigging Hardware UsesLearning Objectives:The learner will be able to describe slings and rigging hardware uses.LEARNING TASKS1. Identify safe working loads forwire rope slings.CONTENT Wire rope classification Diameter SWL calculations Rejection criteria2. Describe common types of slingsand safe working loads.3. Describe common type of slingconfigurations, safe workingloads and their application.Synthetic web slingsWire rope slingsAlloy steel chain slingsMetal mesh slingsMandatory rating tags on all slingsRejection criteriaSingle vertical hitchBridle hitchSingle basket hitchDouble basket hitchDouble-wrap basket hitchesSingle choker hitchDouble choker hitchDouble-wrap chocker hitchAdjust rated capacity for slingconfigurationsSling anglesSling configurationWelder Level C Program Outline • Industry Training Authority 117

4. Identify common rigginghardware.Below-the-hook lifting devicesHoisting hooksChoker hooksWire rope clipsNumberSpacingCable clipsSwivelsShacklesEye boltsSnatch blocksTurnbucklesSpreader and equalizer beamsPlate clampsNOTE: Refer To Current Welder Training Program Curriculum Module/Line RK1-1.Achievement Criteria:Given a 20 question test on the use of slings and rigging hardware, the learner willdemonstrate knowledge by correctly answering 14 questions or more.Welder Level C Program Outline • Industry Training Authority 118

LINE I:DESCRIBES AND PERFORMS MATERIAL HANDLING ANDRIGGING PROCEDURESCompetency: I-5 Describe Hoisting EquipmentLearning Objectives:The learner will be able to describe hoisting and lifting equipment.LEARNING TASKS1. Describe common types ofhoisting equipment and describetheir application.CONTENT Jacks (ratchet, hydraulic) Jack stands Rollers Block and tackle Lever-operated hoists or come-a-longs Chain blocks Chain hoists Grip action hoists (Tirfors) Electric hoists and pendant cranes Floor hoists Winches Gantry cranes Remote pendant control Overhead runways Jib crane Overhead traveling cranes Mobile cranes Tower cranes ForkliftsNOTE: Refer To Current Welder Training Program Curriculum Module/LineRK1-1.Achievement Criteria:Given a 20 question test on hoisting and lifting equipment, the learner will demonstrateknowledge by correctly answering 14 questions or more.Welder Level C Program Outline • Industry Training Authority 119

LINE I:DESCRIBES AND PERFORMS MATERIAL HANDLING ANDRIGGING PROCEDURESCompetency: I-6 Use Hoisting Equipment to Perform LiftLearning Objectives:The learner will be able to use common types of hoisting equipment and operate basiclifting devices to perform a lift.LEARNING TASKSCONTENT1. Operate hoisting equipment. WorkSafeBC regulations Identify hand signals for craneoperations Hoisting equipment Manufacturers’ specifications Plan a lift Estimate weight of load Factors that reduce capacity Select proper rigging Attach proper rigging Apply safe operating practices2. Describe and demonstratecorrect procedures for handlingand storing structural shapes.Rigging structural shapesRotating structural shapesBlocking and stacking3. Lift, hoist and move loads. Use a hoist (chain fall) Use come-alongs Use a tirfor jackNOTE: Refer To Current Welder Training Program Curriculum Module/LineRK1-3.Achievement Criteria:The learner will be evaluated on ability to identify and use common types of hoistingequipment and operate basic lifting devices to perform a lift, as part of a practical shopproject as per the acceptance criteria the current curriculum module/line RK1-3.Welder Level C Program Outline • Industry Training Authority 120

LINE J:READS WELDING DRAWINGSCompetency: J-1 Perform Mathematical Calculations Involving Angles,Triangles and Geometric ConstructionLearning Objectives:The learner will be able to perform mathematical calculations involving angles, trianglesand geometric construction.LEARNING TASKS1. Solve problems involving angles,triangles and geometricconstructions.CONTENT Basic terms Lines and points Angles and angle terms Basic theorems Apply the principles of angles Read protractor Calculate angles Right angle triangles Apply geometric constructions Roots and powersNOTE: Refer To Current Welder Training Program Curriculum Module/LineRK2B-7.Achievement Criteria:Given a 20 question test on mathematical calculations involving angles, triangles andgeometric construction, the learner will demonstrate knowledge by correctly answering14 questions or more.Welder Level C Program Outline • Industry Training Authority 121

LINE J:READS WELDING DRAWINGSCompetency: J-2 Sketch Basic Objects Using Orthographic ProjectionLearning Objectives:The learner will be able to sketch basic objects using orthographic project and theirknowledge of orthographic drawings, basic lines used in drawings, principles of scaledrawings, principle of sectioning and auxiliary views.LEARNING TASKSCONTENT1. Describe orthographic drawings. Visualization2. Identify basic lines used indrawings.Object linesHidden linesCentre linesDimension and extension linesLeader linesPhantom linesCutting plane linesSection linesBreak lines3. Sketch orthographic projections. Freehand sketching to approximatescale Graph paper Sketching orthographic views Scale rule4. Describe and sketch auxiliaryand sectional views.Auxiliary viewsSectional viewsLocating sectional viewsShowing sectional viewsTypes of sectional viewsFull sectionsHalf-sectionsBroken sectionsRevolved sectionsNOTE: Refer To Current Welder Training Program Curriculum Module/LineRK2A-1.Achievement Criteria:Given a 10 question test on orthographic drawings, the learner will demonstrateknowledge by correctly answering 7 questions or more.Welder Level C Program Outline • Industry Training Authority 122

LINE J:READS WELDING DRAWINGSCompetency: J-3 Sketch Isometric Drawings of Basic ObjectsLearning Objectives:The learner will be able to sketch isometric drawings of basic objects using theirknowledge of pictorial drawings, the principles of orthographic projection, makingisometric sketches of basic rectangular objects and making isometric sketches of basicobjects with circular features.LEARNING TASKSCONTENT1. Describe pictorial drawings. Pictorial drawings Isometric drawings2. Sketch isometric drawings ofbasic objects.3. Sketch isometric drawings ofbasic objects with circularfeatures.Sketching simple rectangular objectsSketching figures using isometric linesSketch objects with circular featuresNOTE: Refer To Current Welder Training Program Curriculum Module/LineRK2A-2.Achievement Criteria:Given a project to sketch an isometric view of an object, the learner will be assessedusing 70% as the passing criteria.Welder Level C Program Outline • Industry Training Authority 123

LINE J:READS WELDING DRAWINGSCompetency: J-4 Sketch Dimensioned DrawingLearning Objectives:The learner will be able to sketch a dimensioned drawing based on their knowledge ofSI metric dimensioning, imperial dimensioning, size, location and notation dimensions,dimensioning of curved surfaces, angular and tolerance dimensioning and how to obtaindimensions from orthographic drawings.LEARNING TASKS1. Identify systems ofmeasurements used ondrawings.CONTENT SI metric units of measurement Imperial system of measurement Dual dimensioning Position method Bracket method Conversion chart method2. Describe methods ofdimensioning.3. Sketch a dimensioned drawing ofa simple object.Types of dimensionsRules for placing dimensionsDimensioning curved surfacesAngular dimensioningTolerance dimensionsDimensioning external chamfers andbevelsRefer to practical competencyNOTE: Refer To Current Welder Training Program Curriculum Module/LineRK2A-3.Achievement Criteria:Given a 10 question test on sketching a dimensioned drawing, the learner willdemonstrate knowledge by correctly answering 7 questions or more. Given a practicalproject to sketch a dimensioned view of an object, the learner will be assessed using70% as the passing criteria.Welder Level C Program Outline • Industry Training Authority 124

LINE J:READS WELDING DRAWINGSCompetency: J-5 Identify Common Welding Symbols and BoltedConnectionsLearning Objectives:The learner will be able to identify the standard welding symbols, supplementarysymbols, the dimensioning of fillet and groove weld symbols, the dimensioning of otherweld symbols and the dimensioning of threaded fasteners used in structural steelconstruction.LEARNING TASKS1. Describe standard weldingsymbols.CONTENT Welding symbols Location of weld symbol Arrows Weld symbols Supplementary weld symbols Weld-all-around symbol Field weld symbol Contour and finish symbols2. Describe the dimensioning offillet and groove welds.3. Identify other basic weld symbolsand their dimensions.Fillet weld sizeLength of fillet weldsIntermittent fillet weldsTypes of groove weldsGroove size (depth of operation)Effective throat size (depth ofpenetration)Root openingGroove or included angleBacking or spacer material symbolBack gouging and its application togroove weldsBack welds and backing weldsMelt-thru weldsPlug weldsPlug sizeAngle of countersinkDepth of fillingSlot weldsSpot weldsSize and strength of spot weldsPitch of spot weldsNumber of spot weldsWelder Level C Program Outline • Industry Training Authority 125

4. Identify the dimensioning ofbolted connections.Seam weldsSize and strength of seam weldsScarf for brazed jointFlange weldsSurface weldsThread symbols on drawingsDesignation of UNC and UNF threadsMetric thread designationsNOTE: Refer To Current Welder Training Program Curriculum Module/LineRK2A-4.Achievement Criteria:Given a 20 question test on identifying the basic welding symbol, supplementarysymbols, the dimensioning of fillet and groove weld symbols, the dimensioning of otherbasic weld symbols and the dimensioning of threaded fasteners used in structural steelconstruction, the learner will demonstrate knowledge by correctly answering 14questions or more.Welder Level C Program Outline • Industry Training Authority 126

LINE J:READS WELDING DRAWINGSCompetency: J-6 Read Structural DrawingsLearning Objectives:The learner will be knowledgeable of structural shapes and how they are specified,types of structural drawings, written information on drawings and how to obtaindimensions and other information from drawings.LEARNING TASKSCONTENT1. Identify structural steel shapes. Plate and sheet Specifying sheet sizes Specifying plate sizes Steel bars Rectangular bar, flat bar and strip stock Square bar Round bar Half oval bar Hexagon bar Octagon bar Shapes W, S and M shapes Angles Equal leg lengths Unequal leg angles Structural tees Channel Structural tubing (hollow structuralsections) Round tubing Structural pipe2. Identify types of structuraldrawings.Engineering drawingsSite plansFoundation plansFraming plansElevation plansSectionsConnection detail drawingsShop drawingsDetail drawingsAssembly drawingsDetail assembly drawingsWelder Level C Program Outline • Industry Training Authority 127

3. Identify bills of material and otherinformation found on structuraldrawings.Title blockRevisions blockNotes and specificationsMaterial listItem numberQuantityDescriptionLengthSpecificationsMaterialRemarks4. Perform a practical exercise. Obtain information from drawings Dimensions Hole locations Part locations Assembly details Welding requirements Prepare material list Prepare cut list Refer to practical competencyNOTE: Refer To Current Welder Training Program Curriculum Module/LineRK2A-5.Achievement Criteria:Given a 20 question test on structural shapes and how they are specified, types ofstructural drawings, written information on drawings and how to obtain dimensions andother information from drawings, the learner will demonstrate knowledge by correctlyanswering 14 questions or more.Welder Level C Program Outline • Industry Training Authority 128

LINE K:LAYOUT AND FABRICATE COMPONENTSCompetency: K-2 Identify Materials RequiredLearning Objectives:The learner will be able to identify applicable standards, codes and specifications andinterpret information to select materials and equipment.LEARNING TASKS1. Interpret information and selectmaterials.CONTENT Material information sources Type of materials Location of information Identify unique or special information Select materials2. Identifies applicable standards,codes and specifications.3. Review documentation andmarkings.4. Interpret information and selectequipment.StandardsCodesSpecificationsMill test reportsTraceability methodsTraceability requirementsEquipment information sourcesSelect equipmentAchievement Criteria:Given a 10 question test on identifying applicable standards, codes and specificationsand interpret information to select materials and equipment the learner will demonstrateknowledge by correctly answering 7 questions or more.Welder Level C Program Outline • Industry Training Authority 129

LINE K:LAYOUT AND FABRICATE COMPONENTSCompetency: K-3 Prepare Work AreaLearning Objectives:The learner will prepare the work area by cleaning, planning sequence of operations,and gathering work materials and equipment.LEARNING TASKS1. Describe work arearequirements.COCNTENT Good housekeeping practices Refer to WorksafeBC regulations andOHS act Access and egress Material and equipment Identify safety hazards2. Plans sequence of operation. Assembly requirements Codes Weld procedure specifications (WPS) Final product Welding sequence Possible distortion Organize sequence of work Visualize final components3. Gather work materials andequipment.Work planFinished componentAssembly of requirementsAchievement Criteria:Given a 10 question test on preparing the work area by cleaning, planning sequence ofoperations, and gathering work materials and equipment, the learner will demonstrateknowledge by correctly answering 7 questions or more.Welder Level C Program Outline • Industry Training Authority 130

LINE K:LAYOUT AND FABRICATE COMPONENTSCompetency: K-4 Layout MaterialsLearning Objectives:The learner will be able to develop templates, transfer dimensions from drawings tomaterials and conform material dimensions.LEARNING TASKSCONTENT1. Develop templates. Construct template Template materials Measuring tools Conform to dimensional tolerances2. Interpret and transfer dimensionsfrom drawings to materials.Transfer methodsMeasuring toolsLayout toolsConform to dimensional tolerancesNOTE: Refer To Current Welder Training Program Curriculum Module/LineRK2A-5.Achievement Criteria:Given a practical project to develop templates, transfer dimensions from drawings tomaterials and conform material dimensions, the learner will be assessed using 70% asthe passing criteria.Welder Level C Program Outline • Industry Training Authority 131

LINE K:LAYOUT AND FABRICATE COMPONENTSCompetency: K-5 Prepare MaterialsLearning Objectives:The learner will be able to prepare materials by cutting, grinding, and cleaning.LEARNING TASKSCONTENT1. Cut materials to dimensions. Safe work practices specific to cutting –refer to WorkSafeBC requirements Identify material Cutting sequence Tolerances Select cutting equipment2. Grind materials. Safe work practices specific to grinding– refer to WorkSafeBC requirements Type of base metal Select abrasives Perform grinding3. Clean materials. Safe work practices specific to cleaning– refer to WorkSafeBC requirements Determine required cleaning method Mechanical cleaning methods Chemical cleaning methods Cleaning materials Cleaning specificationsAchievement Criteria:Given a practical project to prepare materials by cutting, grinding, and cleaning, thelearner will be assessed using 70% as the passing criteria.Welder Level C Program Outline • Industry Training Authority 132

LINE K:LAYOUT AND FABRICATE COMPONENTSCompetency: K-6 Fabricate WeldmentLearning Objectives:The learner will be able to fabricate a weldment using selected processes andmaterials.LEARNING TASKSCONTENT1. Fit and tack components. Select required fitting equipment Dogs and wedges Clamps Jigs and fixtures Hydraulic porta-power Hand tools Welding process and consumables Organize work in sequential order Fitting techniques Use of fitting equipment Tack techniques Distortion control Follow specifications2. Weld weldment. Preheating procedures Welding procedures Welding symbols3. Finish final product. Conforms to dimensions Conforms to specificationsNOTE: Suggest a minimum of two shop projects, one of which must be from thetest projects.Achievement Criteria:Given a practical project to fabricate a weldment using selected processes andmaterials, the learner will be assessed using 70% as the passing criteria.Welder Level C Program Outline • Industry Training Authority 133

LINE N:PERFORMS SUBMERGED ARC WELDING PROCESS (SAW)Competency: N-1 Describe SAW Process and EquipmentLearning Objectives:The learner will be able to describe the SAW process and equipment.LEARNING TASKSCONTENT1. Describe SAW. Principles of operation Advantages and disadvantages of SAW Quality of end product2. Describe equipment for SAWprocess.Automated and semi-automated SAWequipmentPower sourcesCooling systemsCurrent characteristicsDuty cycleCable sizesWire feedersGunsDrive rollsContact tipsNozzlesFlux hoppersDrive systemsMatch equipment to applicationBase metal thicknessAchievement Criteria:Given a 10 question test on describing the SAW process and equipment, the learner willdemonstrate knowledge by correctly answering 7 questions or more.Welder Level C Program Outline • Industry Training Authority 134

LINE N:PERFORMS SUBMERGED ARC WELDING PROCESS (SAW)Competency: N-2 Describe Consumables and FluxesLearning Objectives:The learner will be able to describe consumables and fluxes as required for the SAW.LEARNING TASKSCONTENT1. Select consumables. Electrode wires/fluxes Flux recovery systems Storage requirements for flux andelectrode wires Handling of fluxes and electrode wires Match consumables to welding processAchievement Criteria:Given a 10 question test on describing consumables and fluxes as required for theSAW, the learner will demonstrate knowledge by correctly answering 7 questions ormore.Welder Level C Program Outline • Industry Training Authority 135

LINE N:PERFORMS SUBMERGED ARC WELDING PROCESS (SAW)Competency: N-3 Describe Operating ParametersLearning Objectives:The learner will be able to describe the operating parameters for SAW.LEARNING TASKSCONTENT1. Select operating parameters. Direct current Polarity Alternating current Wire feed speed (current) Wire stick out Current characteristics Voltage characteristics Follow manufacturers’recommendations Make required adjustmentsAchievement Criteria:Given a 10 question test on describing the operating parameters for SAW, the learnerwill demonstrate knowledge by correctly answering 7 questions or more.Welder Level C Program Outline • Industry Training Authority 136

LINE N:PERFORMS SUBMERGED ARC WELDING PROCESS (SAW)Competency: N-4 Set Up SAW EquipmentLearning Objectives:The learner will be able to set-up SAW equipment.LEARNING TASKSCONTENT1. Set up SAW equipment. Welding cable sizes Manufacturers’ recommendations Set-up procedures Connect cables to proper polarityAchievement Criteria:Given a 10 question test on setting up SAW equipment, the learner will demonstrateknowledge by correctly answering 7 questions or more.Welder Level C Program Outline • Industry Training Authority 137

LINE N:PERFORMS SUBMERGED ARC WELDING PROCESS (SAW)Competency: N-5 Use the SAW Process to Weld Fillet Welds on LowCarbonSteel PlateLearning Objectives:The learner will observe the welding of a fillet weld in the 1F position on tee joints onlow carbon steel plate operating SAW equipment.LEARNING TASKS1. Weld fillet welds in the flat (1F)position on tee joint.CONTENT Required task-specific PPE Ventilation requirements Equipment shutdown procedures Weld bead sequence Characteristics of electrodes and fluxesduring welding process Manipulate head Remove flux Remove slag Detect flaws Adjust working parametersAchievement Criteria:Given a 10 question test on the welding of a fillet weld in the 1F position on tee joints onlow carbon steel plate, the learner will demonstrate knowledge by correctly answering 7questions or more.Welder Level C Program Outline • Industry Training Authority 138

SECTION 3TRAINING PROVIDER STANDARDSWelder Level C Program Outline • Industry Training Authority 139

INSTRUCTORSWELDER C TRAINING PROVIDER STANDARDSTrade Qualification‣ Level A welder with an Inter-Provincial “Red-Seal” endorsementWork Experience‣ Must have a minimum of 5 years experience as a journeyperson‣ Must have diverse industry experience including code work such as shopfabrication, heavy construction, and maintenance/repair (ASME or CSA W59)Training Qualifications‣ Instructors Certificate (minimum 30 hr course)‣ Instructors must have or be registered in an Instructor’s Diploma Program, to becompleted within a five year period‣ Or, hold a Bachelors or Masters degree in Education-----------------------------------------------------------------------------------------------------------INSPECTORS for Practical Examinations‣ All final practical fabrication and welding tests as listed in the appendices to beassessed by a Certified Welding InspectorWelder Level C Program Outline • Industry Training Authority 140

WELDER C TRAINING PROVIDER STANDARDS – FACILITIESClassroom Area‣ Comfortable seating and tables suitable for training, teaching, lecturing‣ Compliance with all local and national fire code and occupational safetyRequirements‣ Lighting controls to allow easy visibility of projection screen while also allowingstudents to take notes‣ Windows must have shades or blinds to adjust sunlight‣ Heating / Air conditioning for comfort all year round‣ In-room temperature regulation to ensure comfortable room temperature.‣ In-room ventilation sufficient to control training room temperature.‣ Acoustics in the room must allow audibility of the instructor‣ White marking board with pens and eraser (optional: flipchart in similar size)‣ Projection screen or projection area at front of classroom.‣ Overhead projector and/or multi-media projectorSHOP AREA (fixed properties)‣ One welding booth per student (minimum booth size must be 6’ x 6’) fullyequipped with:o Industrial grade multi-process welding power source or equipment suitable forall Level C required welding processeso Welding table (minimum recommended size “18 x 20”)o One height adjustable positioning armo One 115 volt receptacle or pneumatic air supply for grinderso Ventilation as per WorkSafeBC standardso Task lighting‣ Suitable demonstration area of approximately 7’ x 14’‣ Aisles size must be a minimum of 6’ wide‣ The grinding and test coupon preparation area must be a minimum 300 squarefeet‣ Outside storage fenced area of 2000 square feet (including a secured cylinderstorage area)‣ Ceiling shall be a minimum height of 16’ or as varied by good engineeringpractices and codeWelder Level C Program Outline • Industry Training Authority 141

STUDENT FACILITIES‣ Adequate lunch room as per WorkSafeBC requirements‣ Adequate washroom facilities as per WorkSafeBC requirements‣ Personal storage lockersMINIMUM SHOP EQUIPMENT FOR LEVEL C TRAINING‣ one floor model drill press, ½ hp minimum, ½” x 8”‣ one 3’ x 6’ work bench with two vices‣ one pedestal grinder, 12” x 2” stone‣ one pedestal belt sander with a minimum 3” belt‣ one floor model vertical band saw‣ one horizontal band saw‣ one abrasive chop saw‣ one guided bend test jig as per CSA W47.1 dimensional specifications‣ two track cutters‣ one 5” grinder per student (two recommended—one grinding, one bead brush)‣ four 7” grinders (electric or pneumatic) for general shop use‣ electrode stabilizing oven (minimum 250 lbs)‣ one semi-automatic or automatic submerged arc welderNote: See booth equipment as outlined in Shop AreaOPTIONAL EQUIPMENT—as per the NOA list‣ one press brake (minimum 4’ x 12 gauge mechanical pan brake)‣ one ¼” x 4’ hydraulic shear‣ one iron workerHOISTING AND RIGGING EQUIPMENT‣ one ton overhead jib crane or overhead crane‣ rigging hardware--shackles, cable clamps, swivels, eyebolts, turn buckles, snatchblocks, etc.‣ plate clamps‣ chain, wire rope and synthetic slings‣ come-alongs (chain and cable)‣ connectors‣ tirfor jacks‣ chain fallWelder Level C Program Outline • Industry Training Authority 142

Welder C Tools and Equipment(As recommended in the National Occupational Analysis)Adjustable wrenches (various sizes)Allen wrenches (metric and imperial)AmmeterBench viseBroomBrushes (various bristle brushes for cleaningand scrubbing)C clampsChain hoistsChalk lineChokersCold chisels (various sizes)Combination wrenches (metric and imperial)Come-alongsCylinder cartsCylinder cradlesDolliesElectric cordsFiles (flat, half-round, rat-tail, bastard)FlashlightFriction lighterFunnelsHack sawHammers (chipping, ball peen, claw, sledge,various sizes)Hand shearsJacksKnivesLaddersMagnetsMetal markersMopCalculatorCalipersDepth gaugeFeeler gaugesFillet gaugesLaser levelTorpedo levelMicrometerPlumb bobBasic Tools and EquipmentMeasuring ToolsOil canPails (plastic and metal)Paint brushesPipe cutterPipe wrenchesPliers (needle nose, slip joint)PositionersPry barsPunchesRollersScaffolding (safety)Scrapers (various sizes)Screwdrivers (flat, Phillips, Robertson,various sizes)Shovels (flat mouthed)SlingsSnips (heavy duty sheet metal cutting)Soapstone markersSocket sets (metric and imperial)Soldering ironStamping toolsTemperature sticksTip cleanersTool boxesVice gripsVices (chain vice, pipe vice)Water hoseWire brushWire cutterWrench sets (open and closed ends, bothmetric and imperial)ScribersSpirit levelSquaresStop watchStraight edgesTape measureTri squaresVernier calipersWelding gaugesWelder Level C Program Outline • Industry Training Authority 143

Testing EquipmentAdapter fittingsAmmeterCalibrating gaugesPressure difference gaugesPressure gauge kitTemperature gaugesTemperature sticksPower Tools and EquipmentAir hose and nozzleAir monitoring deviceArc welderOxy-fuel cutting equipmentBand sawBuffersChop saw (cut-off saw)Circular sawCoil heating equipmentCompressorsCranes (overhead, gantry-type, monorail,boom)Drills (portable, magnetic base, drill press)Electric drillsElectronic measuring device (hand-held“electronic tape measure” type)Feeders-wireFork liftsGas detectorGrinders (wire brush, angle grinders)Guns-weldingHammer drillHand-held and stationary radiosHeadphonesHeated hoppersHeaters (electric, natural gas, oil, propane)Heating torchHydraulic press brakeHydraulic shearHydrostatic equipmentImpact wrenches (electric or pneumatic)NibblersOvensOxyacetylene brazing torchOxyacetylene cutting torchPipe-bevelling machinePipe cuttersPlasma consolePneumatic equipmentPower hack sawPower vicePropane torchReamer (hand held or mounted on powerthreader)Reciprocating sawRoutersSand-blast equipmentSandersScissor liftTesting pumpTorchesVacuum (wet/dry)WinchesWire wheel (body grinder or angle grinderwith wire brush)Hoisting and Lifting EquipmentCable clampsChain block hoistChainsChokersCome-alongs (chain or cable)ConnectorsForkliftOverhead hoistPortable boomRopeSlingsSpreader barsStandsSupportsTuggersWelder Level C Program Outline • Industry Training Authority 144

Safety EquipmentAir hoodsApronsBody harnessBootsCoverallsEar-plugs and muffsFace shieldsFire blanketsFire extinguishersFire hosesGlovesGogglesMasks (particle, vapour)RespiratorsSafety glassesSafety helmetWelding shieldResource MaterialCode booksDrawingsEngineering specificationsJob schedulesManufactures’ specifications, manuals, andchartsMaterial Safety Data SheetsPacking slipsPamphletsPrintsRegulatory informationSafety manualsService bulletinsShop manualsSpecificationsWeigh billsWritten informational or instructional materialAir hoodsApronsBody harnessBootsCoverallsEar-plugs and muffsFace shieldsFire blanketsFire extinguishersFire hosesGlovesGogglesMasks (particle, vapour)RespiratorsSafety glassesSafety helmetWelding shieldWelder Level C Program Outline • Industry Training Authority 145

RECOMMENDED REFERENCETEXTBOOKSWELDER TRAINING PROGRAM: PACKAGE LEVEL C (CPUB230M)(7960000058) Toll Free: 1-800-663-6105Queens Printer Web: http://www.publications.gov.bc.ca............……ISBN 0-7719-1783-Package includes:Welder Training Program Level C Module/Line P01 Introduction and Program Orientation (MN1807)(7960002678)Welder Training Program Level C Module/Line P02 Oxy-fuel Cutting (MN1808)(7960002679)Welder Training Program Level C Module/Line P03 Gas Welding and Braze Welding (MN1809)(7960002680)Welder Training Program Level C Module/Line P04 Shielded Metal Arc Welding (SMAW I) (MN1810)(7960002681)Welder Training Program Level C Module/Line P05 Air Carbon Arc Gouging (MN1811)(7960002682)Welder Training Program Level C Module/Line P06 Gas Metal Arc Welding (FMAW I) & Flux Cored Arc Welding(FCAW I) (MN1812)(7960002683)Welder Training Program Level C Module/Line RK01 Material Handling (MN1813)(7960002684)Welder Training Program Level C Module/Line RK02A Blueprint Reading I (MN1814)(7960002685)Welder Training Program Level C Module/Line RK02B Mathematics (MN1815)(7960002686)Welder Training Program Level C Module/Line RK03 Welding Metallurgy I (MN1816)(7960002687)WELDING PRINCIPLES AND APPLICATIONSFifth editionBy Larry JeffusDelmar Learning………………………………………………………..ISBN 1-4018-1046-2GMAW-P: PULSED SPRAY TRANSFERMiller Electric Mfg. Co…………………….…………………………..©1994, Revised 11/95PROCEDURE HAND BOOK OF ARC WELDING DESIGN AND PRACTICELincoln Electric CompanyPIPE FITTER'S AND WELDER'S POCKET MANUALall new 2nd editionAudel ……………………………………………………………..…ISBN 0-7645-4205-2 LBTHE PROCEDURE HANDBOOK OF ARC WELDING14 th editionThe James F. Lincoln Welding FoundationWEBSITESwww.weldinginspectionsvcs.comwww.linclonwelders.comwww.hobartwelders.comwww.millerwelds.comwww.worksafebc.com/publications/default.aspWelder Level C Program Outline • Industry Training Authority 146

GUIDELINES FOR PRACTICAL EXAMINATIONS‣ Contact the Industry Training Authority program development department toobtain original electronic copies of all documents. This will allow enlargement ofdrawings and facilitate multiple copies of forms.‣ Applicants who are not familiar with the facility used for practical examinationswill require safety orientation and/or instruction.‣ Each Apprentice will be required to successfully complete one of the practical(fabrication) examinations and all 3 welding tests.‣ Apprentices should consult with their Instructor when they feel that they areready to attempt a Final Practical Examination or a final Weld Test.‣ Applicants who are unsuccessful on their first attempt at a Final PracticalExamination will be issued a different Final Practical Examination for their secondattempt.‣ Applicants who are unsuccessful on their attempt at all of the 3 enclosed FinalPractical Examinations will be required to upgrade in the applicable area(s) oferror.Welder Level C Apprenticeship Program Outline • Industry Training Authority 147

APPENDIX ONEWELDER LEVEL CFINAL WELD TESTSWelder Level C Apprenticeship Program Outline • Industry Training Authority 148

Welder Level C Apprenticeship Program Outline • Industry Training Authority 149

Welder Level C Apprenticeship Program Outline • Industry Training Authority 150

FINAL PRACTICAL EXAMINATION #1MATERIAL LISTMARK QTY SYM DESCRIPTION LENGTH REMARKS1 1 PL 10mm x 310mm 410mm Cut to Suit1a 1 PL Cut From Mark #1 Cut to Suit1b 1 PL Cut From Mark #1 Cut to Suit2 1 HSS 102mm x 102mm x 6mm 1023 1 PIPE 80mm (3”std) 76mmINSTRUCTIONS:1) All cutting to be done with the OFC process.2) No grinding (unless noted) chip only.3) Parts 1, 1a, and 1b to be cut from the same plate.4) DO NOT WELD any components until assembly is completely fit and tacked.5) DO NOT WELD show Inspector prior to tacking to positioning arm.6) Tack assembly to positioning arm in welding booth where indicated and showInspector.7) Weld in position DO NOT MOVE8) When complete show Inspector for evaluation.Welder Level C Program Outline • Industry Training Authority 151

APPENDIX TWOWELDER LEVEL CPROGRAMFINAL PRACTICAL EXAMINATION #2Welder Level C Program Outline • Industry Training Authority 154

Welder Level C Program Outline • Industry Training Authority 155

Welder Level C Program Outline • Industry Training Authority 156

FINAL PRACTICAL EXAMINATION #2MATERIAL LISTMARK QTY SYM DESCRIPTION LENGTH REMARKS1 1 PL 10mm x 285mm 285mm Cut to Suit1a 1 PL Cut From Mark #1 Cut to Suit1b 1 PL Cut From Mark #1 76mm Dia2 1 HSS 152mm x 152mm x 6mm 366 Cut to Length3 1 PIPE 80mm (3” std) 203mm4 1 PL 6mm x 140mm 140mmINSTRUCTIONS:1) All cutting to be done with the OFC process.2) No grinding (unless noted) chip only.3) Parts 1, 1a, and 1b to be cut from the same plate.4) DO NOT WELD any components until assembly is completely fit and tacked.5) DO NOT WELD show Inspector prior to tacking to positioning arm.6) Tack assembly to positioning arm in welding booth where indicated and showInspector.7) Weld in position DO NOT MOVE8) When complete show Inspector for evaluation.Welder Level C Program Outline • Industry Training Authority 157

Welder Level C Program Outline • Industry Training Authority 160

APPENDIX THREEWELDER LEVEL CPROGRAMFINAL PRACTICAL EXAMINATION #3Welder Level C Program Outline • Industry Training Authority 161

Welder Level C Program Outline • Industry Training Authority 162

Welder Level C Program Outline • Industry Training Authority 163

FINAL PRACTICAL EXAMINATION #3MATERIAL LISTMARK QTY SYM DESCRIPTION LENGTH REMARKS1 1 PL 10mm x 285mm 500mm Cut to Suit1a 1 PL Cut From Mark #1 Cut to Suit1b 1 PL Cut From Mark #1 Cut to Suit1c 1 PL Cut From Mark #1 Cut to Suit2 1 PIPE 150mm (6”std) 51mmINSTRUCTIONS:1) All cutting to be done with the OFC process.2) No grinding (unless noted) chip only.3) Parts 1, 1a, 1b, and 1c to be cut from the same plate.4) DO NOT WELD any components until assembly is completely fit and tacked.5) DO NOT WELD show Inspector prior to tacking to positioning arm.6) Tack assembly to positioning arm in welding booth where indicated and showInspector.7) Weld in position DO NOT MOVE8) When complete show Inspector for evaluation.Welder Level C Program Outline • Industry Training Authority 164

APPENDIX FOURWELDER LEVEL CPROGRAMFINAL WELD TEST - #1Welder Level C Program Outline • Industry Training Authority 167

Level "C" Weld Test #1 Performance Test Procedure (PTP) #1PositionProcesses1 G & 3 G FCAW / AAC / OFCJoint Design (CSA-W59)Suggested Weld Pass Sequence5mm(3/16")060°GTSM123Base Metals (CSA-G40.21)Specification Type and Grade to Specification Type and GradeCSA G40.21 Gr 44W / A36 to CSA G40.21 Gr 44W / A36Filler Metal FCAW GMAW GTAW Shielding Gas Composition(CSA-W48.5) Gas Mixture Flow RateCSA Classification: E 491 T-9 Shielding: C0 2 100% 35 CFHAWS Classification: E 71 T-9 Trailing: N/A N/A N/ASize of Filler Metal 1.2mm (.045") Backing: N/A N/A N/APosition (CSA-W47.1)Technique (CSA-W47.1)Position of Fillet: N/A String or Weave: Stringer Root Weave Fill and CapPosition of Groove: 1 G & 3 G Gas Cup Size: 1/2" or 5/8"Position of Joint: 1 G & 3 G Interpass Cleaning: Chip and Wire WheelWeld Progression: Up: Yes Down: N/AInstructionsBase Metal: 13mm x 250mm x 250mm (1/2" x 10" x 10")1) Manually flame cut plate into two pieces 125mm x 250mm (5" x 10")2) Tack plates ensuring proper alignment3) Present assembly to Inspector for visual inspection and stamping4) Weld arrow side in 1G position (one pass only)5) Back gouge otherside present to Inspector for visual inspection (no grinding)6) Tack assembly to positioning arm and weld otherside in 3G position up hill7) Clean weld areas with chipping hammer and wire brush only and present to Inspector for visual inspection8) Flame cut four 10mm (3/8") coupons as marked by Inspector. Use a grinder to prepare coupons for guidedbend test (side bends)9) Present coupons for guided bend testINSPECTORS NOTE: Results for all bend tests to be recorded on Performance Results Sheet (PRS-C)*C Indicates Level C*SEE WELD ACCEPTANCE CRITERIA ON FINAL PAGE.Welder Level C Program Outline • Industry Training Authority 168

APPENDIX FIVEWELDER LEVEL CPROGRAMFINAL WELD TEST - #2Welder Level C Program Outline • Industry Training Authority 169

Level "C" Weld Test #2 Performance Test Procedure (PTP) #2PositionProcesses3 G GMAW / OFCJoint Design (CSA-W59)Suggested Weld Pass Sequence3mm (1/8")60°321Base Metals (CSA-G40.21)Specification Type and Grade to Specification Type and GradeCSA G40.21 Gr 44W / A36 to CSA G40.21 Gr 44W / A36Filler Metal FCAW GMAW GTAW Shielding Gas Composition(CSA-W48.5) Gas Mixture Flow RateCSA Classification: ER 49 S-6 Shielding: C0 2 100% 30 CFHAWS Classification: ER 70 S-6 Trailing: N/A N/A N/ASize of Filler Metal .9mm (.035") Backing: N/A N/A N/APosition (CSA-W47.1)Technique (CSA-W47.1)Position of Fillet: N/A String or Weave: Stringer Root, Weave Fill and CapPosition of Groove: 3 G Gas Cup Size: 3/8" or 1/2"Position of Joint: 3 G Interpass Cleaning: Wire WheelWeld Progression: Up: Up Down: YesInstructionsBase Metal: 10mm x 200mm x 200mm (3/8" x 8" x 8")1) Machine flame cut plate into two pieces 100mm x 200mm (4" x 8")2) After flame cutting bevels clean using a grinder3) Tack plates ensuring proper alignmnent4) Present assembly to Inspector for visual inspection and stamping5) Tack assembly to positioning arm for welding in the 3G position (assembly must remain in this position until allwelding is complete)6) Root pass DOWN Fill and Cap UP7) Clean weld areas with wire brush and present to Inspector for visual inspection8) Flame cut three 38mm (1 1/2") coupons as marked by Inspector. Use a grinder to prepare coupons for guidedbend test (two root, one face)9) Present coupons for guided bend testINSPECTORS NOTE: Results for all bend tests to be recorded on Performance Results Sheet (PRS-C*)*C Indicates Level CSEE WELD ACCEPTANCE CRITERIA ON FINAL PAGE.Welder Level C Program Outline • Industry Training Authority 170

APPENDIX SIXWELDER LEVEL CPROGRAMFINAL WELD TEST - #3Welder Level C Program Outline • Industry Training Authority 171

Level "C" Weld Test #3 Performance Test Procedure (PTP) #3PositionProcesses4 GF SMAW / OFCJoint Design (CSA-W59)RSuggested Weld Pass Sequence30°13mm (1/2")30°8 75 4263113mm (1/2")6mm x 50mm x 300mm(1/4" x 2" x 10") Flat BarBase Metals (CSA-G40.21)Specification Type and Grade to Specification Type and GradeCSA G40.21 Gr 44W / A36 to CSA G40.21 Gr 44W / A36Filler Metal SMAW GMAW GTAW Shielding Gas Composition(CSA-W48.5) Gas Mixture Flow RateCSA Classification: E 4918 Shielding: N/A N/A N/AAWS Classification: E 7018 Trailing: N/A N/A N/ASize of Filler Metal 3.2mm (1/8") Backing: N/A N/A N/APosition (CSA-W47.1)Technique (CSA-W47.1)Position of Fillet: 4F String or Weave: StringersPosition of Groove: 4 G Gas Cup Size: N/APosition of Joint: 4GF Interpass Cleaning: Chip and Wire WheelWeld Progression: Up: N/A Down: N/AInstructionsBase Metal: 10mm x 150mm x 150mm (3/8" x 6" x 6")1) Machine flame cut plate into two pieces 75mm x 150mm (3" x 6")2) Tack plates ensuring proper alignment.3) Two Tacks on each side of flat bar on the back side of assembly (tacks to be 1 1/2" long equally spaced)4) Present assembly to Inspector for visual inspection and stamping5) Tack assembly to positioning arm for welding in the 4G position (assembly must remain in this position until all weldingis complete)6) Weld fillet weld to point indicated by Inspector stop chip and clean7) Weld groove weld to point indicated by Inspectror, stop chip and clean (weld progression must be in the same direction)8) Have Inspector witness stop points of both fillet and groove welds before proceeding with fill and cap9) Clean weld areas with chipping hammer and wire brush only and present to Inspector for visual inspection10) Flame cut three 38mm (1 1/2") coupons as marked by Inspector. Use a grinder to prepare coupons for guidedbend test (two root, one face)11) Present coupons for guided bend testINSPECTORS NOTE: Results for all bend tests to be recorded on Performance Results Sheet (PRS-C*)*C Indicates Level CSEE WELD ACCEPTANCE CRITERIA ON FINAL PAGE.Welder Level C Program Outline • Industry Training Authority 172

APPENDIX SEVENWELDER LEVEL CPROGRAMACHIEVEMENT CRITERIA FORFINAL WELD TESTWelder Level C Program Outline • Industry Training Authority 173

Level C Final Weld TestsPRS-CWelder Name:_________________________________Registration #:________________________________Using PASS or FAILFill in the Appropriate BoxTest #1Guided Bend Test Type Side Bend Results Root & Face Bend ResultsSideSideSideVisual Inspection:Inspector: Print_________________________ Initial_______Test #2Guided Bend Test Type Side Bend Results Root & Face Bend ResultsTwo RootTwo FaceVisual Inspection:Inspector: Print_________________________ Initial_______Test #3Guided Bend Test Type Side Bend Results Root & Face Bend ResultsTwo RootOne FaceVisual Inspection:Inspector: Print_________________________ Initial_______Final Practical ExaminationTest # AttemptedResultsResults: Pass/FailTesting Institution:______________________________________Date:______________________________________ (mm/dd/yyyy)Institution Representative:_____________________________________________________Welder Level C Program Outline • Industry Training Authority 174

PrintSignWeld Acceptance CriteriaEvaluation CriteriaIt is expected that the welder will perform welds that meet the requirements of Canadian StandardsAssociation W59 Welded Steel Construction (Metal Arc Welding) Section 12.5.4 “Quality-of welds forDynamically Loaded Structures.”Inspection of welds will be broken down onto two categories, Structural (Lap, Tee and Corner) andGroove Welds (Open root and Backing strip). The Open root Groove Welds will be expected to meet therequirements of the American Society of Mechanical Engineers Section IX.Non-destructive inspection (NDT) is the term used to evaluate welds without destroying theirusefulness. At this level the following methods of NDT will be used:1. Visual – used 100%2. Penetrant – may be used at Inspector’s discretion for spot (random) checks3. Magnetic Particle – may be used at Inspector’s discretion for spot (random) checksDestructive Testing – is the term used to test welds for soundness by taking a sample specimen fromthe weld and damage it beyond use. The following methods will be used:1. Guided bend test – used on butt joints2. Nick break test – used on butt joints3. Fillet weld fractures – random checks4. Etching – random checks or class interactive discussionVisual Criteria for Weld acceptanceType of Discontinuity Fillet Butt/groove1. Porosity none none2. Slag inclusions none none3. Incomplete fusion none none4. Incomplete penetration max 2 mm per 56 mm none5. Roll over none none6. Undercut max depth0.250.25 mm max length2 mm2 mm max space between20 mm20 mm7. Insufficient throat none none8. Weld reinforcement minnominal fillet sizeflush max*3 mm9. Insufficient leg none N/A10. Lack of fusion none none11. Cracks none none* Convexity of the surface bead shall not exceed 0.07 times the actual face width of the weld respectivelyplus 1.5 mmWelder Level C Program Outline • Industry Training Authority 175

In addition to the above requirements, the weld being inspected for visual pass must display thefollowing:Straight and uniform toesConsistency of Freeze line (ripples) overlap. Consistent and regular in appearance. CorrectalignmentAbsence of stray arc strikes Absence of distortionAll welds shall have equal leg lengths unless otherwise specifiedWelding Coupon Preparation for Destructive Face and Root Bend TestsTools and EquipmentCombination squareSoap stoneStampsHammerGrinderGuided bend jigOxy-fuel cutting equipmentWelder Level C Program Outline • Industry Training Authority 176

Coupon Preparation1. For back-up strip groove welds remove backing with AAC or OFC equipment (ensure thatyou do not gouge into base metal of weldment).2. Flame cut the required number and size of coupons from weldment (ensure that you maintainproper width dimension of coupon).3. On each coupon de-slag and grind a maximum 3.2 mm (1/8”) radius on all corners.Root Coupon – Grind down reinforcement of cap to the point where there is still evidence oftoes of weld. Grind root side flush and polish/dress with the (grinding, sanding, filing) linesrunning parallel with the coupon length ways.Face coupon – Grind down root flush to the point where there is still evidence of toes of weld.Grind face flush and polish/dress with (grinding, sanding, filing) lines run parallel with thecoupon lengthways.Visual Inspection Criteria for Face, Root, and Side BendsContact the Inspector who will inspect your coupon in accordance with CSA W47.1 for back-up stripwelds and ASME Section 1X for open root welds, as follows:Root, face, and side bend tests shall be examined for the presence of cracks or other opendiscontinuity exceeding 3 mm (1/8”) in any direction in present after bending, shall have failed.Cracks appearing at the corners or the specimen during testing shall be disregarded unless thereis definite evidence that they result from slag inclusions or other external defects.In addition to:The weld and heat-affected zone of the transverse weld bend specimen shall be completelywithin the bent portion of the specimen after testing.The weld and heat-affected zone of the transverse weld bend specimen shall be completelywithin the bent portion of the specimen after testing.Welder Level C Apprenticeship Program Outline • Industry Training Authority 177