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ASSESSMENT:

MMA, TAGS AND WELDING

ASSESSMENT NO: TITLE:

CODE LETTER BOX NUMBER MODULE CODE LETTER BOX NUMBER

I/C

MMA1

Installation of LCS LPHW Heating mains and header

LINK: MODULE

6088-06

MMA Welding Industrial/commercial 6088 NVQ Level 3 ORGANISATION

PEOPLE

WELDING

TESTING

SAFETY

SYSTEMS

(A)

(B)

(C)

(E)

(F)

(H)

1,2,3,5,6,7,8,9,10, 11,12,13,14,15,16

1,2,4

1,2,3,4,5,6

1,2,3

1,2,3,5,6,7,8,9,10 , 11,12,13

1

QUALITY

ENVIRONMENT

ELECTRICS

SITES

(I)

(J)

(K)

RECORDS & INFORMATION (L)

1,2,3

1,2

1

1,2,3,4,5,6,7,8,9,10

1,2,3,4,5

(M)

INTRODUCTION: This assessment covers the installation of LPHW heating, distribution header and branch connections. The main purpose of this assessment is to test the candidates competence in working without supervision in the areas of planning, preparation, installation and testing of LCS pipework with MMA welded joints. This assessment should be carried out in a realistic working environment with all the restraints that site work involves. SPECIFICATION: 100 mm distribution header and 65 mm branch connections are to be installed in LCS BS 1387 heavy weight pipe. The system has a high level flow and return to a low level distribution header. Jointing of pipework will be: Manual Metal Are (MMA) welding with general purpose fittings to BS 1965 and welding flanges to BS 459. All welds to be in accordance with NJIC test specifications. The preparation and testing of MMA and TAGS welded joints should be in accordance with HVAC publication TR 5/6 Welding of carbon steel pipework. All work carried out should have due regard to the HSWA 1974.

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INSTRUCTION: Candidates are advised to study all the assessment details and drawings for the specified task before starting. Reference sources will need to be consulted for certain aspects of the tasks, the references used should be noted next to your answers. The assessor will be your customer/client or main contractor for the purpose of this assessment.

SECTIONS: 1.

1.1

PLANNING Organising, Records

The following hazards have been identified in the immediate working area: a. b. c. d.

Fire risk from welding process Ultra violet light from MMA/TAGS welding process Portable; electric hand tools (grinder) Personal protection of operatives (PPE)

Under current regulations you the employee have a responsibility to your employer and fellow operatives to state the safety requirements and equipment need to limit the risk level of the four hazards above. ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________

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1. 1.2

PLANNING Organising, Records As TAGS is not yet a common welding process on most sites you will need to hire the additional equipment: a.

Make a list of the equipment necessary to complete the weld ready to pass to your employer. Answer ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________

b.

State the procedure for setting-up this equipment ready for use. Answer ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________

1.3

The fumes from the MMA/GAGS welding process creates special hazards to the welder if they rely on general ventilation systems. What advice and recommendations would you suggest to overcome this problem. Answer ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________

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2. 2.1

PREPARATION: Sites, Records Slip on bossed flanges are to be welded to the 100 mm diameter LCS distribution header having a wall thickness of 6 mm. to enable other welder to complete the headers the following information is required by your employer: a. Sketch the joint setup, showing all dimensions and detail prior to welding. Answer

b. List a selection of electrode diameters used for this weld and their approximate current values. Answer ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________

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2.

3.1

PREPARATION: Sites, Records

Clarification of manual metal arc electrodes BS 639 is important especially on sites were different types of electrodes are used. The client requires a brief explanation of the following: a. The letters and numbers given to electrodes. Answer ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________

b. The composition, characteristics and uses of different types of flux coatings. Answer ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ Reference:

Welding Schedule 5.3 may be used as the answers for the above questions, so long as the standards of competency have been reached in the schedule.

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3.

3.1

DOING: Installation, Records

This assessment must be installed in position from the fixed heights shown in the working drawing. b.

The installation of MMA welded 100 mm header with slip on bossed flange, fixed butt, horizontal vertical on 65 mm branch with welding elbow, terminating on the flow with a screwed flange. A horizontal vertical on the branch pipe must be welded in position using the MMA welding process. Please note the 100 mm slip-on boss flange may be welded off-site.

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4.

4.1

FINISHING: Testing, Commissioning

On completion of the installation all mechanical and welded joints must be tested in accordance with HVCA publications TR 5/6 , Welding of Carbon Steel and Site Pressure Testing of Pipework. This to include hydraulic pressure test, bend tests, macro etching and visual examination For future reference you are required to record the results of your testing on the form provided drawing.

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5

1195

Weld No

4

1

100mm fixed but

2

65 mm ONTO 100mmm vertical branch

3,4

3

6

1

2

Description

65mm Horizontal Vertical

5

65mm Fixed Butt

6

Slip on boss flange onto 100mm pipe

Detail drawing of pipework Pipe installation all measurements are approximate.

450

1040

Drawing not to scale

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TEST CERTIFICATE OPERATIVE’S NAME: CLIENT’S NAME: DATE OF 1ST TEST:

DATE OF 2 nd TEST

SYSTEM WORKING PRESSURE:

Bar

TEST PRESSURE: 1½ times maximum working pressure

Bar

TEST DURATION:

Minutes

WELD NUMBER

COMPETENT 

ACTIONS/OBSERVATIONS

1. Fixed Butt Bend Tests a) Top b) Side c) Bottom Visual a) Penetration b) Appearance 2. Branch Macro Etch a) Crotch b) Flank Visual a) Penetration b) Appearance 3. Horizontal/Vertical Bend Test a) Stop & Start b) Directly Opposite Visual a) Penetration b) Appearance 4. & 5. Weld-on Elbow Subject to visual Examination 6. Slip-on Boss Flange Subject to visual Examination

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NVQ LEVEL 3

5.1

6088-06

IC

MMA

Supplementary Assessment questions, objective type:

KNOWLEDGE ASSESSMENT Answer all the questions in the assessment. Please circle the appropriate answer after carefully reading each question. 1.

Which ONE of the listed articles of legislation applies to all places of work? a) b) c) d)

Electricity at Work Regulations 1988 Gas safety (Installation & Use) Regulations 1998 Part P of the Building Regulations 2000 Electricity Supply Regulations 1988 PC: 9.1 (All)

2.

What MINIMUM period of time must elapse after an acetylene cylinder has been up righted from the horizontal position before being used? a) b) c) d)

120 minutes 90 minutes 60 minutes 30 minutes PC: 9.2.1; 9.2.2; 9.2.3; 9.2.6

3.

What Grade of BS 1387 LCS tube is best suited to jointing by the welding process? a) b) c) d)

Heavy – red band Medium – blue band Heavy – blue band Medium – red band PC: 9.1.5

4.

What preparation technique is necessary after flame cutting LCS tube before carrying out welding? a) b) c) d)

Painting with oxide paint Application of a flux Removal of oxide coating None required PC: 9.1.1 to 9.1.6

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5.1 5.

Supplementary Assessment questions, objective type: What component must be installed between cylinder regulators and the gas hose? a) b) c) d)

None required Flashback arrester Flexible joint Non-return PC: 9.1 (all)

6.

When welding in confined spaces which item of safety plant listed MUST be used? a) b) c) d)

Mechanical extraction Natural ventilation system Fire blanket Bucket of water PC: 9.1 (all)

7.

Before MMA welding work commences, WHICH of the following must be carried out? a) b) c) d)

General tidying up Take a break Install screens Risk assessment PC: 9.1.1 to 9.1.6

8.

Before work starts the welding area must be shielded to prevent? a) b) c) d)

The SSR watching Other people getting arc eye The welder getting arc eye Welding fumes escaping PC: 9.2.3

9.

Information on the Company’s safety procedures for the welding process can be found in the a) b) c) d)

Site induction video Local library Site diary Safety guidance sheets PC: 9.2 (all)

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5.1 10.

Supplementary Assessment questions, objective type: Before using angle grinders which of the following are essential checks? a) b) c) d)

Fire extinguisher type Tightness of vice Abrasive wheel and cable Type of pipe and fittings PC: 9.2.2; 9.2.3

11.

To whom would you report defects in welding equipment? a) b) c) d)

Foreman Branch Manager Site Agent Contracts Manager PC: 9.2 (all)

12.

For general purpose cutting using compressed gas cylinders which of the following blowtorch would be used? a) b) c) d)

Propane/air High pressure Low pressure Single gas PC: 9.2 .2; 9.2.3

13.

Which document is used to acknowledge the competence of a pipe welder on site? a) b) c) d)

Driving licence HASAWA 1974 ADVANCED Craft Certificate Engineering Services SKILLcard PC: 10.1 (all)

14.

The recognised industry standard for the welding of LCS pipe is: a) b) c) d)

JTC specification BS6644: Part 1 HVCA TR 5 BS5440: Part 2 PC: 10.1.1 to 10.1.3

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5.1

15.

Supplementary Assessment questions, objective type:

A certificate of Competency for Manual Arc Welding permits an operative to weld on systems with maximum temperatures and pressures of: a) b) c) d)

100oC and 10 bar 100oC and 17 bar 220oC and 10 bar 220oC and 17 bar PC: 10.1.1 to 10.1.3

16.

Slag inclusions can be caused by? a) b) c) d)

Amperage too low Correct type of electrode Correct technique Welding in flat position only PC: 10.1.1; 10.1.4 to 10.1.7

17.

Undercut can be caused by? a) b) c) d)

Correct current Correct technique Amperage too low Amperage too high PC: 10.1.1; 10.1.4 to 10.1.7

18.

During positional welding the electrode angles are important because ...................................... tends to work against the welder. a) b) c) d)

The base metal The electrode holder The force gravity The current amperage PC: 10.1.1; 10.1.4 to 10.1.7

19.

Root penetration must not enter the pipe bore more than? a) b) c) d)

1 mm 2 mm 3 mm 4 mm PC: 10.1.1; 10.1.4 to 10.1.7

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5.1

20.

Supplementary Assessment questions, objective type:

For the protection of the welder the electrode holder must be a) b) c) d)

black cracked insulated hot PC: 10.1.1; 10.1.4 to 10.1.7

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No

Question

Ref PC

Comp

1.1

Planning

1.2 1.3

Planning Planning

2.1 2.2 3.1 4.1

Preparation Preparation Doing Finishing

9.1.1,9.1.2,9.1.5,9.1.6,9.1.7, 9.1.8 9.2.1 – 9.2.6 9.1.1,9.1.2, 9.1.3,9.1.4,9.1.5,9.1.6,9.1.8 9.1.2,9.1.7,1.1.8 9.1.2,9.1.7,1.1.8 10.1.1 -10.1.9 10.2.1 – 10.2.6

N.Y.C.

Inv Ev

Supplementary Assessment Questions 5.1

Objective Questions 1 - 20

9.1.1 – 9.1.8 9.2.1 – 9.2.6 10.1.1 – 10.1.9 10.2.1 – 10.2.6

KEY SKILLS Communication Application of number Information Technology

Confirmation of Completion of Assessment Competent: ........................................... Not Yet Competent: .............................. Candidate: ............................................. Signature: ............................................. Assessor: .............................................

Signature: ............................................

Internal Verifier: ....................................

Signature: ...........................................

Date of Assessment: ...........................

Date of Verification: ...........................

Feed back to candidate: ...................................................................................................................................... ...................................................................................................................................... ...................................................................................................................................... ...................................................................................................................................... 15

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Level 3 welding project