Plate welder

Knowledge

K1: Dimensional and mechanical properties (strength, toughness, thermal expansion etc.) of materials to be welded. Back to Duty

K2: Fundamentals of welding metallurgy (weld solidification and Heat Affected Zone) and how this can affect the weldability of materials and final joint integrity. Back to Duty

K3: Common manual arc welding processes and the relative merits for a given application, including Manual Metal Arc (MMA),Metal Inert Gas (MIG), Metal Active Gas (MAG), Flux Cored Arc Welding (FCAW), Tungsten Inert Gas (TIG), Plasma Arc Welding (PAW) Back to Duty

K4: Common joint types associated with welding plate and structural components (Fillet, Butt, T-Butt, Corner/Lap; Single-Sided, Double-Sided, Metallic Backed, Ceramic Backed). Back to Duty

K5: Welding positions and progressions associated with plate and structural components and their international designations including Flat; Horizontal-Vertical; Horizontal; Vertical (upward and downward progressions); Overhead. Back to Duty

K6: The major components of welding equipment, ancillary equipment, cabling and their assembly, including Power Source, Wire Feed System, TIG & PAW Arc Initiation Systems, interconnecting communications cables, torches, tongs, gas equipment etc. Back to Duty

K7: Set, modify and monitor welding controls (e.g. Current, Arc Voltage, Wire Feed Speed, Gas Flow Rates, Polarity) and secondary controls (e.g. Heat Input, Interpass Temperature). Back to Duty

K8: Welding Procedure Specification requirements, contents, and information derived to establish specific production information Back to Duty

K9: The relative merits, applications and limitations of material preparation methods and manual material removal processes including powered and non‐powered tools. Back to Duty

K10: Performance success factors in production, inspection reporting, productivity including time and duration, dimensional, Non-Destructive Examination, defect rates etc. Back to Duty

K11: Causes and detection of typical welding defects and how their occurrence can be reduced. Back to Duty

K12: Types and functions of welding consumables, fluxing systems and the requirement for correct identification, storage, conditioning, handling, recycling and disposal. Back to Duty

K13: Requirements for correct storage, handling and segregation of materials and tooling to prevent cross contamination. Back to Duty

K14: Organisational quality documentation, reporting systems, procedures and their role within the overall quality process Back to Duty

K15: Continuous improvement processes, performance review and how this is undertaken within their organisation. Back to Duty

K16: The importance of only using approved processes, procedures, documentation and the potential implications for the organisation if this is not followed. Back to Duty

K17: Non-destructive testing reports and radiographs to identify particular defect types and the associated improvements to process and technique needed to prevent recurrence. Back to Duty

K18: Risks and mitigation measures associated with welding and the working environment, and the organisational risk management processes. Back to Duty

K19: The importance of complying with statutory, quality, organisational and health, safety and environmental regulations. Back to Duty

K20: Typical problems that may arise within their normal work activities/environment. Back to Duty

Skills

S1: Work safely at all times, comply with health, safety and environmental legislation, regulations and organisational requirements. Back to Duty

S2: Can obtain, check and use appropriate documentation (such as job instructions, drawings, quality control documentation). Back to Duty

S3: Plan and prepare welding activities before commencing the work. Back to Duty

S4: Obtain, position and assemble welding equipment and associated safety protection needed for activity. Back to Duty

S5: Prepare, check and protect materials and work areas ready for welding. Back to Duty

S6: Inspect assembly to be welded and undertake remedial work to comply with specification, or implement quality steps if rejected. Back to Duty

S7: Receive, inspect, condition and maintain consumables. Back to Duty

S8: Set, test and monitor key welding parameters as detailed within the Welding Procedure Specification. Back to Duty

S9: Deal promptly and effectively with problems within the limits of their responsibility using approved diagnostic methods and techniques and report those which cannot be resolved to the appropriate personnel. Back to Duty

S10: Use manual processes and equipment to remove material (powered and non‐powered). Back to Duty

S11: Achieves a quality of work to meet international standards e.g. ISO5817, ISO9606, ASME IX, AWS D1.1 for dimensional, surface inspection (e.g. Visual, Magnetic Particle, Dye Penetrant) and volumetric inspection (e.g. Radiography, Ultrasonic inspection). Back to Duty

S12: Complete progressive and final checks on the weld prior to release for formal inspection and report into the production control system at the appropriate stages of the work activity. Back to Duty

S13: Restore the work area on completion of the activity and where applicable return any resources and consumables to the appropriate location. Back to Duty

S14: Produce welds in plate and/or structural components using two welding processes from TIG, PAW, MMA, MIG/MAG, FCAW. Back to Duty

S15: Produce welds in plate and/or structural components using two materials from Carbon Steel, Low Alloy Steel, High Alloy Ferritic/Martensitic Steel, Austenitic Stainless Steel, Nickel & Nickel Alloys, Aluminium & Aluminium alloys, Titanium & Titanium Alloys, Copper & Copper Alloys. Back to Duty

S16: Produce welds in plate and/or structural components covering three plate welding positions which must include Vertical (either upward or downward progression) and overhead. Back to Duty

S17: Produce plate welds in 3 main joint configurations (Single or Double Sided Butt, Single or Double Sided T‐Butt & Fillet) Back to Duty

Behaviours

B1: Takes responsibility for decision-making, without autonomy and within the guidelines of the work instruction, for their workplace, the application of welding processes, and for their productivity. Back to Duty

B2: Enquires and to seeks guidance, in order to understand the processes and associated industrial applications. Back to Duty

B3: Committed to maintaining competence through Continuing Professional Development planning, preparation and reflection to ensure safety, quality and production and ensuring Continuing Professional Development goals are achieved. Back to Duty

B4: Intervene and challenge poor practices and have confidence to channel feedback to the appropriate authorities to implement change. Back to Duty

B5: Consistently and reliably delivers in accordance with expectations in safety, production, quality, ethics and self-development. Back to Duty

B6: Encourages and supports the development of others and completes point of work risk assessments. Back to Duty

B7: Follows the specified procedures and controls and be personally responsible and accountable for their production work and personal development. Back to Duty

B8: Reflects on current and past performance and provide information and recommendations for continuous improvements in efficiency and effectiveness of working practices, and training and development requirements. Back to Duty