Learner Statement of Authenticity - ABC Awards · Web viewPart 1: Visual Examination of Product Grade Awarded Defect type Specification and assessment criteria D M P F 1 Cracks Cracks

FABRICATION AND WELDING PRACTICELevel 3 Award in Fabrication and Welding Practice 60051498

Level 3 Diploma in Fabrication and Welding Practice 60051309

Assessment Requirements Level 3 Unit Y/503/9518

Manual Metal-Arc Welding - Overhead(Stainless Steel)

Learner Name .........................................................................................................

Centre Name ......................................................................................

ABC Enrolment No. ........................................................

Y5039518 L3 Manual Metal-Arc Welding-Overhead (Stainless Steel) Assessment Pack Issue 2Fabrication and Welding Practice Sept 12

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Level 3 Unit Y/503/9518Manual Metal-Arc Welding - Overhead

(Stainless Steel)

Level 3 Award in Fabrication and Welding Practice 60051498Level 3 Diploma in Fabrication and Welding Practice 60051309

ASSESSMENT REQUIREMENTS


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Information on Assessment Requirements

for Learners

Level 3 Unit Y/503/9518 Manual Metal-Arc Welding – Overhead(Stainless Steel)

UNIT SUMMARY:This unit covers both theoretical and practical aspects of producing manual metal arc welds in the overhead position. Learners will produce a single vee butt and tee fillet weld from drawings. They will be required to demonstrate competence when assembling and welding to ensure that the welds meet specific criteria. Meeting health and safety requirements will be strongly emphasised throughout this unit.

ASSESSMENT CRITERIA:The assessment of this unit is designed to confirm the learner’s ability to satisfactorily complete a range of tasks relating to manual metal arc welding. The tasks cover both practical and written elements which the learner shall complete over a given time.

In order to achieve this unit, learners will be required to complete THREE tasks, which are:

Task No 1 – A. Practical MMA tee fillet weld task overhead Pass, Merit or DistinctionandB. Practical MMA single vee butt weld task overhead Pass, Merit or Distinction

Task No 2 – Written Report - Completion of TWO weld procedure sheets Must satisfy relevant assessment criteria

Task No 3 - Short answer assignment Must satisfy relevant assessment criteria

Safety:The learner will work in a safe manner considering their own and other people’s safety at ALL times during the assessment of this unit.

Task No 1 - This involves 2 Practical tasks (A and B)This will provide evidence of achievement for the assessment criteria covering 1:1, 1:2, 1:1, 1:4, 1:5, 2:3, 3:1, 4:1, 4:2, 5:1, 5:2, 5:3, 6:1, 7:1.

The practical tasks for this unit will be the production of a:Tee Fillet Weld(Detailed on Task sheet A)Single Vee Butt Weld(Detailed on Task B)

The assignments cover FOUR elements of manual metal arc welding practice.Element No 1 Identify health and safety aspects associated with the production of a single vee butt and tee

fillet weld in materials greater than 3 mm in thickness in the overhead position.Element No 2 Read drawings for the production of a single vee butt and tee fillet weld Plan a logical sequence of the stages required for the production of the weldsElement No 3 Select suitable welding equipment, and prepare for use Produce the required welds to a given tolerance


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Element No 4 Assemble component parts by tack welding Inspect the completed welded joints against specificationsOn completion, these practical assignments will be graded against the marking scheme.

Task No 2 - Prepare weld procedure sheetsThis will provide evidence of achievement for the assessment criteria covering 6:1.

Learners are required to prepare TWO weld procedure sheets to cover ALL aspects of the production of the single vee butt and tee fillet welds in the overhead position. The style and format of the weld procedure sheets are to be determined by the learner.

As a minimum the following aspects should be covered: Title block - date, title of weld, reference number etc Health and safety requirements adding any special considerations needed Welding consumables Weld parameters Welding joint geometry Joining of parts - welding process used, location and length of tack welds Inspection of completed welds, testing equipment used and critical features to be inspected

Task No 3 - Short answer assessment This will provide evidence of achievement for the assessment criteria covering:1:2, 1:3, 1:4, 1:5, 2:1, 2:2, 2:3, 3:1, 4:2, 5:2, 5:3, 7:1 and 8:1.

Learners are required to answer ALL the questions. These are designed to assess the learner’s knowledge on areas not covered by the practical task. Only short answers are required to the questions. If Centres wish, this assessment can be carried out at any time whilst the learners are working on this unit or as an end test.

In the event of a learner not achieving an acceptable pass at the first attempt, there is an additional sheet supplied where a second attempt at the question/s can be taken. There are three second attempt answer boxes. Others can be added if needed.

The overall grade will be determined by the practical tasks. This will be graded as a Pass, Merit or Distinction over the 2 practical exercises A and B

(A+B) 2 x Pass = Pass (A+B) 2 x Merit = Merit (A+B) 2 x Distinction = Distinction

(A+B) Merit & Distinction = Merit

(A+B) Pass & Distinction = Pass (A+B) Pass & Merit = Pass

Evidence required for assessment:The following evidence will need to be available to the Assessor for assessment and Internal Verifier for the Internal Quality Assurance Process The practical assignments (A. MMA Tee Fillet Weld and B. MMA Single Vee Butt Weld) Completed mark scheme for the practical assignments TWO completed weld procedure sheets Written answers to the short answer assessment task Declaration of authenticity


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(Stainless Steel)




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Task No 1

Practical Exercise A

MMA TEE FILLET WELD TASKSTAINLESS STEEL

AB

C

SPECIMEN CUTTING AND TESTING REQUIREMENTS

Cut test sample into THREE equal pieces A, B and CMacro-etch the stop/restart position (this being 13 distance from one end)

Visually inspect the weld and mark as appropriateNick-break fracture ALL THREE test pieces

All fillet welds are dimensioned by leg length

L/L L/L Leg Length

T/T Throat thickness

40"T"

Specimen length of 200 mm must be adhered to.

For MMA and MAGS material thickness "T" = 6 mmFor TAGS and O/A material thickness "T" = 3 mm

These are the preferred material thickness. Any changes to thisMUST be approved by the External Moderator

FILLET WELDREQUIREMENTS

Welding Processes:Manual Metal Arc

Metal Arc Gas ShieldedTungsten Inert Gas Shielded

Oxy/Acetylene

FABRICATION AND WELDING PRACTICE


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PRACTICAL TEST MARK SHEET FOR


(Stainless Steel)

PRACTICAL EXERCISE A

MMA TEE FILLET WELD


It is recommended that this assessment sheet is marked in the presence of the learner. Comments relating to the assessment of the weld should be discussed and feedback given to the learner as soon as possible on completion of this assignment.

The internal verification process is a vital part of this assessment process and the comments made by the Internal Quality Assurance process should reflect this.


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MANUAL METAL-ARC WELDING

FILLET WELD

This sheet covers the following Units:

Level 2 Award and Certificate in Fabrication and Welding Practice

F/503/9495 Manual Metal-Arc Welding

Level 3 Award, Certificate and Diploma in Fabrication and Welding Practice

D/503/9505 Manual Metal-Arc Welding – Vertical

L/503/9516 Manual Metal-Arc Welding - Overhead

Y/503/9518 Manual Metal-Arc Welding – Overhead (Stainless Steel)

D/503/9519 Manual Metal-Arc Welding – Overhead (Pipe)

Learner Name: …………………………………………………………………………

ABC Enrolment No. …………………………………………………………………………

Centre Name: ……………………………………………………………………………..


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Grade Awarded

Part 1: Visual Examination of Product

Grade Awarded

Defect type Specification and assessment criteria D M P F

1 Cracks Cracks are NOT permitted.

Pass or Fail only. If a Fail then do not proceed.

2 Porosity Total joint length to be free of porosity:

Distinction = 200mm Merit = 190mm

Pass = 180mm Fail = < 180mm

3 Solid inclusions

Intermittent only permitted. Maximum diameter of 3mm; up to 8mm length.

Total joint length free of solid inclusions:



4 Undercut

(measurable on both sides, i.e. 400mm)

Maximum permitted depth = 10% of thickness.

Total joint length to be free of undercut:



5 Excessive convexity

Maximum permitted height to be 30% of thickness. Smooth even ripples.

Total joint length free within given range:



6 Uneven throat thickness (concave fillet)

Maximum depth of 10% thickness, but only intermittent.

Total joint length with completely filled groove:




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7 Angular misalignment

Angular misalignment at any point along the length not to exceed the following:

Distinction = none Merit = up to 15% thickness

Pass = up to 20% thickness Fail = > 20% thickness

8 Linear misalignment

Linear misalignment at any point along the length not to exceed the following:


Pass = up to 20% thickness Fail = > 20% thickness

9 Excessive asymmetry

Uniform and equal leg length.

Total joint length with complete and even leg lengths:

Correct weld size



How to determine the grade for Part 1: D M P F

Distinction = 7 Distinctions and the other grade a Merit or higher.

Merit = 6 Merits or greater and all the other grades to be a Pass or higher.

Pass = No Fail grade

Fail = Any Fail grade

Grade Awarded

for Part 1

Key:

D = Distinction M = Merit P = Pass F = Fail

To be completed by the learner, by hand:

1 Thickness of parent material

2 Electrode specification and diameter

3 Current and Voltage used


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Part 2: Destruction Examination

Grade

Awarded

Test Assessment Criteria (Pass / Fail only) D M P F

1 Macro-etch examination

To be carried out at a stop/start position.

Adequate side/root fusion.

Internal defects – total cumulative faults no more than 10% of the surface area

2 Fracture test Slag, porosity, gas pores, lack of fusion to walls.

Total cumulative faults to be no more than 25% of the surface area

Penetration 50% of root


Pass = 6 Passes


Grade Awarded

for Part 2


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How to determine the overall grade for this practical test:

Part 1 Part 2 Overall Grade AchievedCourse Tutor Signature

Distinction Pass Distinction

Merit Pass Merit

Pass Pass Pass

Any Fail Grade Fail

Course Tutor FeedbackComment:

Learner’s Signature:

Date:

Course Tutor Signature:

Date:Internal Moderator / Verifier Feedback (if sampled)Comment:

Internal Moderator / Verifier Signature: Date:

External Moderator (if sampled)I have checked the information recorded in this document and am* / am not* satisfied of its accuracy, authenticity and validity (* Delete as appropriate and comment if required)

External Moderator Signature: Date:


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(Stainless Steel)




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Task No 2

Practical Exercise B

MMA SINGLE VEE BUTT WELD TASKSTAINLESS STEEL

A

B

C

75 mm of continuouspenetration

Specimen length of 200 mm must be adhered to

MATERIAL THICKNESS 6 mmThis is the preferred thickness. Any change to this MUST be approved

by the External Moderator

SPECIMEN CUTTING AND TESTING REQUIREMENTS

Following visual inspection and marking. Cut a 75 mm long section of continuous penetration from the test piece to accommodate TWO bend test samples each at

25 mm wide - one FACE bend and one ROOT bend.

From the remaining test sample cut a 25 mm wide sample to be used as anick-break fracture test sample.

In summary. THREE 25 mm wide sections are required for the following:

ONE root bend test prepared and bent at 90 degrees e.g A

ONE face bend sample prepared and bent to 90 degrees e.g B

ONE fracture to include a marked stop/start position e.g C

BUTT WELDREQUIREMENTS

(Single Vee)

Welding Processes:

Manual Metal ArcMetal Arc Gas Shielded

FABRICATION AND WELDING PRACTICE


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(Stainless Steel)

PRACTICAL EXERCISE B

MMA SINGLE VEE BUTT WELD


It is recommended that this assessment sheet is marked in the presence of the learner. Comments relating to the assessment of the weld should be discussed and feedback given to the learner as soon as possible on completion of this assignment.

The internal verification process is a vital part of this assessment process and the comments made by the Internal Quality Assurance process should reflect this.


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MANUAL METAL-ARC WELDING

BUTT WELD

This sheet covers the following Units:

Level 2 Award and Certificate in Fabrication and Welding Practice

F/503/9495 Manual Metal-Arc Welding

Level 3 Award, Certificate and Diploma in Fabrication and Welding Practice

D/503/9505 Manual Metal-Arc Welding – Vertical

L/503/9516 Manual Metal-Arc Welding - Overhead

Y/503/9518 Manual Metal-Arc Welding – Overhead (Stainless Steel)

D/503/9519 Manual Metal-Arc Welding – Overhead (Pipe)

Learner Name …………………………………………………………………………

ABC Enrolment No. …………………………………………………………………………

Centre Name ……………………………………………………………………………..


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Grade Awarded

Part 1: Visual Examination of Product

Grade Awarded

Defect type Specification and assessment criteria D M P F

1 Cracks Cracks are NOT permitted.

Pass or Fail only. If a Fail then do not proceed.

2 Porosity Length of weld free of porosity:



3 Solid inclusions

Intermittent only permitted. Maximum diameter of 3mm; up to 8mm length.

Total joint length free of solid inclusions:



4 Lack of penetration

Total length of full penetration:



5 Undercut


Maximum permitted depth = 10% of thickness.

Total joint length to be free of undercut:



6 Excess weld metal

Maximum permitted height to be 30% of thickness.

Maximum permitted width of weld to be 2mm either side of the preparation.

Total joint length to be free within the given range:




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7 Excessive penetration

Maximum permitted is 30% of thickness, or 3mm, whichever is the smaller.

Total joint length to be free within given range:



8 Linear misalignment

Misalignment at any point along the length not to exceed:


Pass = up to 15% thickness

Fail = greater than 15% thickness

9 Incompletely filled groove

Maximum depth of 10% thickness, but only intermittent.

Total joint length with completely filled groove:



10 Overlap


Total joint length to be free from overlap:



How to determine the grade for Part 1: D M P FDistinction = 8 Distinctions and the other grade a Merit or higher. Merit = 7 Merits or greater and all the other grades to be a Pass or higher. Pass = No Fail grade Fail = Any Fail grade

Grade Awardedfor Part 1

Key:

D = Distinction M = Merit P = Pass F = FailTo be completed by the learner, by hand:

1 Thickness of parent material

2 Electrode specification and diameter

3 Current and Voltage used


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Part 2: Destruction Examination

Grade

Awarded

Test Assessment Criteria (Pass / Fail only) D M P F

1 Bend tests

1 root test

No fracture is permitted.

Maximum tear or rupture permitted is 10mm accumulative.

Former size 4x thickness.

Angle of bend test not less than 90º.

1 face test

No fracture is permitted.

Maximum tear or rupture permitted is 10mm accumulative.

Former size 4x thickness.

Angle of bend test not less than 90º.

2 Fracture test Slag, porosity, gas pores, lack of fusion to walls.

Total cumulative faults to be no more than 25% of the surface area.

Must include stop/start, 35mm width.


Pass = 3 Passes


Grade Awarded

for Part 2


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How to determine the overall grade for this practical test:

Part 1 Part 2 Overall Grade AchievedCourse Tutor Signature

Distinction Pass Distinction

Merit Pass Merit

Pass Pass Pass

Any Fail Grade Fail

Course Tutor Feedback

Comment:

Learner’s Signature:

Date:

Course Tutor Signature:

Date:Internal Moderator / Verifier Feedback (if sampled)

Comment:


External Moderator (if sampled)

I have checked the information recorded in this document and am* / am not* satisfied of its accuracy, authenticity and validity (* Delete as appropriate and comment if required)



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(Stainless Steel)




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Task No 2

WELD PROCEDURE SHEETS MMA TEE FILLET WELD

ANDMMA SINGLE VEE BUTT WELD

STAINLESS STEEL

Task No 2 – Written Report - Completion of weld procedure sheets This will provide evidence of achievement for the assessment criteria covering 6:1.

Learners MUST prepare TWO weld procedure sheets to cover ALL aspects of the production of the single vee butt and tee fillet welds in the overhead position performed in Task 1.

The style and format of the weld procedure sheets are to be determined by the learner.

As a minimum the following aspects should be covered:

Title block - date, title of weld, reference number etc Health and safety requirements adding any special considerations needed Welding consumables Weld parameters

Welding joint geometry

Joining of parts - welding process used, location and length of tack welds

Inspection of completed welds, testing equipment used and critical features to be inspected


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(Stainless Steel)



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Task No 3

SHORT ANSWER QUESTIONS FOR MMA WELDING

STAINLESS STEEL

Answer the following questions in the spaces provided. Assessors tick box if achieved or referred, initial and date.

Learner Name ______________________________ Date ____________________________

ABC Enrolment No. _____________________ Centre Nmae___________________________

Learning Outcome 1 - Be able to ensure safe conditions for manual metal arc weldingAC 1.2 Explain the precautions to be observed and procedures to be followed when welding on containers which have held chemicals or inflammable liquids

Date Achieved Referred Assessor initials

AC 1.3 Describe the precautions to be taken when welding in confined spaces with regard to fumes



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AC 1.4 Explain the hazards associated with manual metal arc welding.


AC 1.5 Explain the types of ventilation available for manual metal arc welding in all positions.


Learning Outcome 2 - Understand the importance of maintaining manual metal arc welding equipmentAC 2.1 Describe the importance of maintaining manual metal arc welding equipment


AC 2.2 Explain the function of the steeply drooping characteristics, arc voltages, open circuit voltages and duty cycles with regards to a manual metal arc welding power source.Y5039518 L3 Manual Metal-Arc Welding-Overhead (Stainless Steel) Assessment Pack Issue 2Fabrication and Welding Practice Sept 12

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AC 2.3 Explain reasons for the choice of manual metal arc welding power sources.


Learning Outcome 3 – Understand welding consumablesAC 3.1 Explain the reasons for the selection of manual metal arc welding consumables when producing welded joints on stainless steel in the overhead position.



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Learning Outcome 4 - Understand welding parametersAC 4.2 Identify which parameters may need different selection for manual metal arc welding of materials other than stainless steel.


Learning Outcome 5 - Understand welding and distortion control proceduresAC 5.2 Explain the effects of weaving and stringer bead techniques on a welded joint and surrounding material.


AC 5.3 Explain the procedures to be followed when controlling distortion in manual metal arc welded fabrications



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Learning Outcome 7 - Understand the techniques for overcoming defects revealed by inspectionAC 7.1 Describe the techniques used for overcoming weld defects created when manual metal arc welding as revealed by inspection techniques


Learning Outcome 8 - Understand the applications and limitations of the manual metal-arc welding processAC 8.1 Describe the applications and limitations of the manual metal arc welding process compared with other arc welding processes.



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Assessor’s comments/feedback:

..................................................................................................................................................

.................................................................................................................................................

.................................................................................................................................................

Assessor’s signature _____________________________

Completion date ________________________

Internal moderator’s comments/feedback:

..................................................................................................................................................

.................................................................................................................................................

..................................................................................................................................................

.................................................................................................................................................

..................................................................................................................................................

.................................................................................................................................................

..................................................................................................................................................

.................................................................................................................................................

Internal moderator’s signature _____________________________

Completion date ________________________


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This sheet is to be used for learners who have not achieved one or more of the short answer questions.

Enter the question number and re-answer the question that was marked as a referral on the first attempt.

Question No


Question No


Question No


Additional sheets may be copied if needed


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ASSESSMENT SUMMARYLevel 3 Y/503/9518 Manual Metal-Arc Welding - Overhead (Stainless Steel)

Assessors Signature ResultTask No 1 Pass, Merit, DistinctionTask No 2 Pass/FailTask No 3 Pass/Fail

Assessors FeedbackComment:

Learner Signature:

Date:

Assessors Signature:

Date:Internal Moderator / Verifier Feedback (if sampled)Comment:


External Moderator (if sampled)I have checked the information recorded in this document and am* / am not* satisfied of its accuracy, authenticity and validity (* Delete as appropriate and comment if required)



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ABC Awards Authenticity Statement

DECLARATION OF AUTHENTICITY

This declaration must be completed and signed by the learner and countersigned by the tutor/assessor.

Learner Name: …………..……………….……………………………………………………

Learner Number: ………………………………………………………………………………

Centre: …………………………………………………………………………………………

Learner Statement of AuthenticityI confirm that the attached assignment/portfolio is all my own work* and does not include any work completed by anyone other than myself. I have completed the assignment/portfolio in accordance with the Awarding Body instructions and within the time limits set by my Centre.

Signature: ………………………………….. Date: ………………………………

Centre Confirmation of AuthenticityOn behalf of …………………………………….(insert centre name), I confirm that the above mentioned learner, to the best of my knowledge, is the sole author of the completed assignment/portfolio attached.

Signed: ……………………………………. Date: ………………………………

Name: ………………………………………………………………………………………..

Job Description: ………………………………………………………………………………

*Unless otherwise stated e.g. for some entry level qualifications learner can work together but should show sections which are their own work.


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Documents

Learner Statement of Authenticity - ABC Awards · Web viewPart 1: Visual Examination of Product Grade Awarded Defect type Specification and assessment criteria D M P F 1 Cracks Cracks