Level 3 Certificate in Engineering Construction · 4 Level 3 Certificate in Engineering Construction Level 3 Certificate in Engineering Construction (2456-21 to 2456-25) Introduction

Level 3 Certificate in Engineering Construction Scheme handbook 2456

Version 1.3 September

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Level 3 Certificate in Engineering Construction 3

Contents Page

Introduction 4 General information and structure of the award 5 Assessment and quality assurance 7 Course design 8 Centre and scheme approval 9 Registration and Certification 9 Guidance on assessment 13 Test specification 16 Relationship to S/NVQ 19 Key skills signposting 22 Generic Grading descriptor for Assignments 23 Education and Health and Safety 23

Unit 1 Develop self and comply with legal and safety requirements Unit 2 Interpreting information and marking out fabrication materials (steel erecting) Unit 3 Hand cutting and shaping processes Unit 4 Assembly and erection of structural steelwork Unit 5 Interpreting information and marking out fabrication materials (platework) Unit 6 Preparation, joining and erection of fabrication material Unit 7 Forming of thick plate and sections Unit 8 Interpreting information and marking out pipe work Unit 9 Preparation joining and erection of pipe work assemblies Unit 10 Fabrication and installation of pipe work systems Unit 11 Preparing for and inspecting fitting operations Unit 12 Fitting by filing and sawing Unit 13 Fitting by drilling, reaming and threading Unit 14 Fitting by machining and assembling components Unit 15 Preparing and quality controlling the welding operation Unit 16 Welding with manual metal-arc process Unit 17 Welding with tungsten inert gas/tungsten arc gas shielded process

4 Level 3 Certificate in Engineering Construction

Level 3 Certificate in Engineering Construction (2456-21 to 2456-25) Introduction This award is aimed at candidates who • need to obtain the vocational element of the Modern

Apprenticeship or the Foundation Modern Apprenticeship • do not have access to an N/SVQ • wish for career progression within the engineering construction

industry • wish to develop the skills learnt from GNVQs and other

qualifications. This award is designed to contribute towards the knowledge and understanding for the N/SVQ in Engineering Construction, while containing additional skills and knowledge which go beyond the scope of the National Occupational Standards. It provides a valuable alternative for those candidates who do not have access to the N/SVQ. It is intended to support those enrolled on the National Apprenticeship Scheme Engineering Construction (NASEC) as controlled by the Engineering Construction Industry Training Board (ECITB). ECITB currently supports technical training within the sector within craft and technician fields. Candidates for this award should have the ability to fulfil the expectations of the outcomes. Successful candidates will have the opportunity to maximise their potential and ECITB provides routes into technician qualifications with related higher level qualifications. City & Guilds Certificates are available in a range of vocational areas, please contact Customer Relations unit at City & Guilds for further information.


General information

This award has been designed by City & Guilds to support government initiatives towards the National Qualifications Framework. It can contribute towards the knowledge and understanding required for the related N/SVQ while not requiring or proving evidence of occupational competence. General structure

The certificate is made up of units expressed in a standard format. Each unit is preceded by details of the structure of the unit the aims and general coverage of the unit the relationship of the unit to the appropriate N/SVQ/ National Occupational Standards the outcomes the assessment methods signposting of opportunities to generate evidence for Key Skills. For the Level 3 Certificate in Engineering Construction the award is offered in five occupational areas

Fabrication steel erecting Fabrication platework Fabrication pipefitting Mechanical fitting Welding Core Unit Unit 1 Develop self and comply with legal and site safety requirements Optional Units Unit 2 Interpreting information and marking out fabrication materials (steel erection) Unit 3 Hand cutting and shaping processes Unit 4 Assembly and erection of structural steelwork Unit 5 Interpreting information and marking out fabrication materials (platework) Unit 6 Preparation, joining and erection of fabrication material Unit 7 Forming of thick plate and sections Unit 8 Interpreting information and marking out pipework Unit 9 Preparation joining and erection of pipework assemblies Unit 10 Fabrication and installation of pipework systems Unit 11 Preparing for and inspecting fitting operations Unit 12 Fitting by filing and sawing Unit 13 Fitting by drilling, reaming and threading Unit 14 Fitting by machining and assembling components Unit 15 Preparing and quality controlling the welding operation Unit 16 Welding with manual metal-arc process Unit 17 Welding with the tungsten inert gas/tungsten arc gas shielded welding process


To gain the certificate for Level 3 in Engineering Construction candidates must undertake the assessments for the core unit and the selected units for each occupation. The assessment for the occupational units is undertaken through a practical assignment and written test. The reporting and administration for these is outlined within the sections on registration and certification and assessment. Engineering Construction (Fabrication steel erection) Unit 1 and units 2, 3 and 4 Assessment components 101, 102 and 107 Engineering Construction (Fabrication platework) Unit 1 and units 5, 6 and 7 Assessment components 101, 103 and 108 Engineering Construction (Fabrication pipefitting) Unit 1 and units 8, 9 and 10 Assessment components 101, 104 and 109 Engineering Construction (Mechanical fitting) Unit 1 and units 11, 12, 13 and 14 Assessment components 101, 105 and 110 Engineering Construction (Welding) Unit 1 and units 15, 16 and 17 Assessment components 101, 106 and 111


Assessment and quality assurance

National standards and rigorous quality assurance are maintained by the use of City & Guilds set and marked written test Centre set and marked written tests Assignments, marked by the centre according to externally set marking criteria, with quality assurance provided by the centre and monitored by City & Guilds’ external verification system, to ensure that national standards are maintained. Quality assurance includes initial centre approval, scheme approval, the centre's own procedures for monitoring quality and City and Guilds' ongoing monitoring by an External Verifier. Details of City & Guilds criteria and procedures, including roles of centre staff and External Verifiers can be found in Providing City & Guilds Qualifications - a guide to centre and scheme approval.

There is an externally set and marked written test for the core unit and a centre set written test for the award specific unit, these will assess knowledge and understanding (see Registration and Certification page 14). Assignments assess practical activities. City & Guilds provides a format for the setting and marking for the assignments. As assignments are designed to sample practical activities, it is essential that centres ensure that candidates cover the content of the whole unit. Assessment components are graded (Pass, Credit, Distinction). A pass is the achievement level required for the knowledge and understanding in an NVQ and generally represents the ability to follow instructions and procedures. Credit and distinction represent increasing levels of ability to adapt to changing circumstances and to independently resolve problems. Generic grading criteria for Pass, Credit and Distinction are given on page 27. Details of the availability of assessments and of the general regulations for their conduct are given in the ‘Directory of Assessments and Awards’. If there is any inconsistency between the scheme regulations in this pamphlet and the Directory of Assessments and Awards, the Directory shall prevail.

For candidates with particular requirements, centres should refer to City & Guilds policy document Access to assessment, candidates with particular requirements. This also applies to candidates who wish to seek examinations in language other than English.


Course Design

Tutors/assessors should familiarise themselves with the structure and content of the award before designing an appropriate course; in particular they are advised to consider the knowledge and understanding requirements of the relevant N/SVQ. City & Guilds does not itself provide courses of instruction or specify entry requirements. As long as the requirements for the award are met, tutors/assessors may design courses of study in any way that they feel best meets the needs and capabilities of the candidates. Units are broadly the same size and centres may deliver them in any order they wish. Centres may wish to introduce other topics as part of the programme which will not be assessed through the qualifications, e.g. to meet local needs. It is recommended that centres cover the following in the delivery of the course, where appropriate: Health and safety considerations, in particular the need to impress to candidates that they must preserve the health and safety of others as well as themselves Key Skills (such as Communication, Application of Number, Information technology, Working with others, Improving own learning and performance, Problem solving) Equal opportunities Spiritual, moral, social and cultural issues Environmental education, related European issues. It is recommended that 500 hours should be allocated for the core and optional units required for certification. Entry to qualification

No specific prior qualifications, learning or experience are required for candidates undertaking the qualification(s). However, centres will need to make an initial assessment of each candidate to ensure that the level of the scheme is appropriate. As this is a level 3 award it is considered that candidates may have gained qualifications at a lower level. The nature of both the learning and assessment required for the qualification is such that candidates will need basic literacy and numeracy skills: i.e. the ability to read and interpret written tasks and to write answers in a legible and understandable form. Candidates will also need to be able to organise written information clearly and coherently, although they will not be assessed for spelling or grammatical accuracy unless this is part of the assessment criteria. City and Guilds recommends that candidates entering for a qualification of the same level and of the same content as that of a qualification they already hold, should not apply to take the qualification.


Centre and scheme approval

Centres wishing to offer City & Guilds qualifications must gain approval. New centres must apply for centre and scheme approval. Existing City & Guilds centres will need to get specific scheme approval to run this Award. Full details of the process for both centre and scheme approval are given in Providing City & Guilds qualifications - a guide to centre and scheme approval which is available from City & Guilds’ regional offices. City & Guilds reserves the right to suspend an approved centre, or withdraw its approval from an approved centre to conduct a particular City & Guilds scheme or particular City & Guilds schemes, for reasons of debt, malpractice or for any reason that maybe detrimental to the maintenance of authentic, reliable and valid qualifications or that may prejudice the name of City & Guilds. External verifiers act on behalf of City & Guilds to ensure that national standards are maintained. Full details of their role can be found in Providing City & Guilds’ Qualifications - a guide to centre and scheme approval.

Registration and certification

There are FIVE awards within this scheme reflecting occupational groupings within the industry. In order to achieve a certificate a candidate must be successful in three assessments, the written test for the core unit and both the occupational specific written test and assignment. The assessment requirements are as follows Level 3 Certificate in Engineering Construction (Fabrication Steel Erection) 2456-101 Develop self and comply with legal and site safety requirements 2456-102 Fabrication Steel Erection Written 2456-107 Fabrication Steel Erection Assignment Level 3 Certificate in Engineering Construction (Fabrication Platework) 2456-101 Develop self and comply with legal and site safety requirements 2456-103 Fabrication Platework Written 2456-108 Fabrication Platework Assignment Level 3 Certificate in Engineering Construction (Fabrication Pipe fitting) 2456-101 Develop self and comply with legal and site safety requirements 2456-104 Fabrication Pipe fitting Written 2456-109 Fabrication Pipe fitting Assignment


Level 3 Certificate in Engineering Construction (Mechanical Fitting) 2456-101 Develop self and comply with legal and site safety requirements 2456-105 Mechanical fitting Written 2456-110 Mechanical fitting Assignment Level 3 Certificate in Engineering Construction (Welding) 2456-101 Develop self and comply with legal and site safety requirements 2456-106 Welding Written 2456-111 Welding Assignment


Core unit Assessment components required Unit 1 Develop self and comply with legal and

site safety requirements 2456-101 Short answer written

question paper

Occupational units Unit 2 Interpreting information and marking out

fabrication materials (steel erecting) Unit 3 Hand cutting and shaping processes

Unit 4 Assembly and erection of structural steelwork

2456-107 Assignment for units 1, 2, 3 and 4

Fabrication – steel erection written paper 2456-102 Short answer written question paper for units 2, 3 and 4

Unit 5 Interpreting information and marking out fabrication materials (platework)

Unit 6 Preparation, joining and erection of fabrication material

Unit 7 Forming of thick plate and sections

2456-108 Assignment for units 1, 5, 6, and 7.

Fabrication – platework written paper 2456-103 Short answer written question paper for units 5, 6 and 7

Unit 8 Interpreting information and marking out pipework

Unit 9 Preparation, joining and erection of pipework assemblies

Unit 10 Fabrication and installation of pipework systems

2456-109 Assignment for units 1, 8 9, and 10

Fabrication – pipefitting written paper 2456-104 Short answer written question paper for units 8, 9 and 10

Unit 11 Preparing for and inspecting fitting operations

Unit 12 Fitting by filing and sawing

Unit 13 Fitting by drilling, reaming and threading

Unit 14 Fitting by machining and assembling components

2456-110 Assignment for units 1, 11, 12, 13 and 14

Mechanical fitting written paper 2456 - 105 Short answer written question paper for units 11, 12, 13 and 14


Unit 15 Preparing and quality controlling the welding operation

Unit 16 Welding with manual metal-arc processes

Unit 17 Welding with the tungsten inert gas/tungsten-arc gas shielded welding process

2456-111 Assignment for units 1, 15, 16 and 17

Welding written paper 2456-106 Short answer written question paper for units 15, 16 and 17

Candidates must be registered at the beginning of their course. Centres should submit registrations using Form S (Registration). When assignments have been successfully completed, candidate results should be submitted on Form S (Results submission). Centres should note that results will NOT be processed by City & Guilds until verification records are complete. Written tests are available twice each year during March and June. Candidates must be entered for written (timetabled) assessment components using Form S (and examination month entered in the ‘dated entry’ box).

Candidates achieving one or more assessment components will receive a Certificate of Unit Credit listing the assessment components achieved. Candidates achieving the number and combination of assessment components required for the Certificate will, in addition, be issued a Certificate.

City & Guilds has a policy in respect of candidates who may have particular assessment requirements. In order to provide access for such candidates special provision may be made. Full details can be found in Access to Assessment – candidates with particular requirements, published by City & Guilds.

Full details on all the above procedures, together with dates and times of written tests can be found in the Directory of Vocational Awards published annually by City & Guilds. This information also appears on City & Guilds Website http://www.city-and-guilds.co.uk


Guidance notes on assessment

Section 1 – Introduction These awards are designed to provide opportunities for candidates to gain accreditation for their individual level of understanding of the underpinning knowledge relevant to an appropriate NVQ within Engineering Construction. The emphasis is on ‘learning by doing’, not on competence. For this reason candidates are required to complete an assignment to show their attainment of practical skills which in turn implies understanding of the theoretical knowledge required to complete a number of activities successfully. Section 2 – Assessment In order to gain the certificate candidates must complete ONE written test for the core unit. ONE written test for the related occupational award assessed by a centre set question paper. ONE centre devised assignment based on an assignment template and related to the outcomes of the detailed occupational units. Assessment of core unit The core unit will be assessed by an externally set short answer written question paper. The examination will be available in the March and May/June series. The paper will be set in accordance with the test specification provided in this section. Assessment of occupational units The occupational units are assessed through written papers and assignments. The units are grouped together for assessment purposes. Written paper The assessment will consist of a centre set written paper covering all the units within the occupational award. Centres will need to prepare a test paper according to the specification with an appropriate marking scheme. City & Guilds centre devised team will approve all papers prior to use. Assignment Within each optional unit there are a number of learning outcomes and each of these specifies a number of practical activities. The assignment is intended to assess these outcomes. The assignment should be produced by the centre in accordance with the template provided by City & Guilds. It will be made up of a number of practical tasks; these will sample the practical activities for the units.


Assignments normally consist of several tasks and candidates must pass all the tasks within the assignment. City & Guilds will provide assignment templates from which centres should produce the assignments. City & Guilds centre devised team must approve all assignments prior to use by the centre. Centres must have sufficient resources to deliver the scheme. This includes appropriate equipment to assess practical outcomes. Centres may use specially designated areas within or outside the college or training centre to undertake delivery and assessment. Equipment should be of an appropriate industrial standard and be capable of being used under normal working conditions. Assignments are to have three elements. Assessor’s guidance notes This section is intended for use by the assessor only. It should contain •a health and safety statement •an indication of where the assignment should be undertaken •the requirements for tools, equipment, materials and data •notes on the content of the assignment to include any preparatory

work required •details of evidence and recording requirements •time consideration All assignments must follow the general specification and have the recommended time allocation Candidate’s guidance notes The candidate’s instructions should contain •general advice about the need to understand the assignment before

starting and the need to seek guidance if clarification is required •guidance on the time allowed •the importance of health and safety and the fact that any unsafe

practices will mean the assignment being stopped and the candidate failing

•an assignment brief which sets out the scenario and explains the tasks •clearly defined tasks with measurable outcomes •recording/reporting sheets for completing progress/outcomes •notes indicating how evidence should be presented


Marking scheme Assignments will be graded at Pass, Credit and Distinction. The use of grading helps to distinguish those candidates who show greater degrees of autonomy in the way they organise themselves or apply reflective thinking and originality in the completion of tasks. Detailed marking schemes will need to be provided with each assignment. These will need to take into account candidates performance in respect of the tasks. In general these will be covered in two areas planning preparation and recording practical ability Each area must be marked as a separate part, candidates must achieve a pass in both. Specific guidance is within the assignment template Marks for planning, preparation and recording are as follows

Pass 1 Credit 2 Distinction 3

Marks for practical activities are as follows

Pass 2 Credit 4 Distinction 6 To record the overall grade the marks are totalled and the grade is determined as follows

GRADE MARKS Pass 3-4 Credit 5-7 Distinction 8-9 Feedback The assignments are intended as a formal assessment of candidates’ practical skills. They are not designed as teaching aids and candidates should not be entered until ready. Should a candidate fail any of the parts other than on health and safety grounds they should be given appropriate feed back. The candidate will need to undertake a new assignment.


Test Specification Written papers The knowledge requirements will be assessed by written papers based on the following test specifications. Core Unit Externally set and marked

Paper title: Develop self and comply with legal and site safety requirements

Paper Number: 2456-101 Paper type: short answer

Test duration: 45 minutes Total number of questions: 10 Unit Outcome No of items

1 Apply legal safety requirements 3

2 Site safety requirements 3 3 Develop self and be aware of work relationships and

their importance 1

1

4 Prepare and reinstate the work area for safe engineering construction operations

3

Occupational units Centre set and marked Paper title: Fabrication - Steel erection written paper Paper Number 2456-102 Paper type: short answer

Test duration 1 ½ hours Total number of questions: 15 2 Interpreting information and marking out fabrication

materials 5

3 Hand cutting and shaping processes 5

Units

4 Assembly and erection of structural steelwork 5

Paper title: Fabrication - Platework written paper Paper number: 2456-103 Paper type short answer Test duration: 1 ½ hours Total number of questions: 15

5 Interpreting information and marking out of fabrication materials

5

6 Preparing, joining and erection of fabrication material 5

Units

7 Forming of thick plate and sections 5

Paper title: Fabrication - Pipefitting written paper Paper number: 2456-104 Paper type short answer Test duration: 1 ½ hours Total number of questions: 15

8 Interpreting information and marking out pipe work 5 9 Preparation, joining and erection of pipe work

assemblies 5

Units

10 Fabrication and installation of pipe work systems 5


Paper title: Mechanical Fitting written paper Paper number: 2456-105 Paper type: short answerTest duration: 1 ½ hours Total number of questions: 15

11 Preparing for and inspecting fitting operations 5 12 Fitting by filing and sawing 213 Fitting by drilling, reaming and threading 3

Units

14 Fitting by machining and assembling components 5

Paper title: Welding written paper Paper number: 2456-106 Paper type: short answerTest duration: 1 ½ hours Total number of questions: 15

15 Preparing and quality controlling the welding operation

5

16 Welding with manual metal-arc processes 5

Units

17 Welding with the tungsten inert gas/tungsten-arc gas shielded welding process

5

Assignments The practical requirements will be assessed by an assignment for each occupational sector. The weightings indicate the minimum and maximum percentages of each outcome which should be covered in an individual assignment. Optional Units

Fabrication – steel erection Assignment: 2456-107

Maximum assignment duration 8 hours

Unit Weighting of assignment Min Max

1 Develop self and comply with legal and site safety requirements 10 20 2 Interpreting information and marking out fabrication materials 20 40 3 Hand cutting and shaping processes 20 40 4 Assembly and erection of structural steelwork 20 40

Fabrication - platework Assignment: 2456-108



1 Develop self and comply with legal and site safety requirements 10 20 5 Interpreting information and marking out fabrication materials 20 40 6 Preparation, joining and erection of fabrication material 20 40 7 Forming of thick plate and sections 20 40


Fabrication - pipefitting Assignment: 2456-109



1 Develop self and comply with legal and site safety requirements 10 20 8 Interpreting information and marking out pipework 20 40 9 Preparation, joining and erection of pipework assemblies 20 40 10 Fabrication and installation of pipework systems 20 40

Mechanical fitting Assignment: 2456-110



1 Develop self and comply with legal and site safety requirements 10 20 11 Preparing for and inspecting fitting operations 15 30 12 Fitting by filing and sawing 15 30 13 Fitting by drilling, reaming and threading 15 30 14 Fitting by machining and assembling components 15 30

Welding Assignment: 2456-111

Maximum assignment duration 8 hours NB The assignment must cover both welding processes from units 16 and 17 either within one assignment or by two separate assignments of 4 hours each.


1 Develop self and comply with legal and site safety requirements 10 20 15 Preparing and quality controlling the welding operation 20 40 16 Welding with manual metal-arc processes 40 60 17 Welding with the tungsten inert gas/tungsten-arc gas shielded welding

process 40 60


Relationship to N/SVQ

Core unit Unit 1 Develop self and comply with legal and site safety requirements Occupational Units Unit 2 Interpreting information and marking out fabrication materials (steel erecting) Unit 3 Hand cutting and shaping processes Unit 4 Assembly and erection of structural steelwork Unit 5 Interpreting information and marking out fabrication materials (platework) Unit 6 Preparation, joining and erection of fabrication material Unit 7 Forming of thick plate and sections Unit 8 Interpreting information and marking out pipework Unit 9 Preparation, joining and erection of pipework assemblies Unit 10 Fabrication and installation of pipework systems Unit 11 Preparing for and inspecting fitting operations Unit 12 Fitting by filing and sawing Unit 13 Fitting by drilling, reaming and threading Unit 14 Fitting by machining and assembling components Unit 15 Preparing and quality controlling the welding operation Unit 16 Welding with manual metal-arc process Unit 17 Welding with the tungsten inert/tungsten-arc gas shielded process

Unit Title

Element of Engineering Competence Standards for which knowledge and understanding is covered

ECITB contextualised unit

1 Develop self and comply with legal and site safety requirements

2.10, 2.11, 2.12, 2.15, 2.16, 8.01, 8.02

CO1:8.02 CO2:7.06 CO3:7.04 E6:2.15 E7:2.16 E11:2.11 E12:2.12 ML5:2.16 ML8:2.11 ML10:2.15 ML11:7.08 ML12:7.07 FSS2:2.11 FSS3:2.12 FSS5:2.15 FSS7:2.16 IPS Pipe 6:2.11 IPS Pipe 7:2.12 IPS Pipe 9:2.15 IPS Pipe 10:2.16 IPS Mech 8:4.02 IPS Mech 9:2.11 IPS Mech 10:2.12 W1:2.11 W2:2.12 W4:2.15 W5:2.16


2 Interpreting information and marking out fabrication materials (steel erector)

2.06, 2.12, 2.13, 2.17, 2.18, 3.03, 3.12, 3.16

E12:2.13 E13:2.13 ML9:2.13

3 Hand cutting and shaping processes

2.06, 2.10, 2.12, 2.13, 3.03, 6.01 E8:6.01 E12:2.12 E13:2.13 ML9:2.13 CO2:7.06 CO3:7.04

4 Assembly and erection of structural steelwork

2.10, 2.11, 2.12, 2.13, 3.09, 3.12, 6.01, 8.02

E1:2.14 E2:4.08 E3:4.02 E4:4.05 E5:4.06 E8:6.01 E9:1.17 E10:1.18 E11:2.11 E12:2.12 E13:2.13 ML1:2.14 ML2:4.08 ML3:1.18 ML4:4.05 ML6:1.17 ML7:4.06 ML8:2.11 ML9:2.13 ML11:7.08 CO1:8.02 CO2:7.06 CO3:7.04

5 Interpreting information and marking out fabrication materials (platework)

2.10, 2.11, 2.12, 2.15, 2.16, 8.01, 8.02

FSS1:3.03 FSS3:2.13 FSS4:2.13 FSS6:3.12 FSS8:3.16

6 Preparation, joining and erection of fabrication material

2.10, 2.11, 2.12, 2.13, 3.03, 3.09, 3.12, 6.01.

FSS2:2.11 FSS3:2.12 FSS4:2.13 FSS6:3.12 QSE9:3.09 CO2:7.06 CO3:7.04

7 Forming of thick plate and sections

2.06, 2.10, 2.12, 2.13, 3.06, 3.16, 6.01

FSS3:2.12 FSS4:2.13 FSS8:3.16 CO2:7.06 CO3:7.04

8 Interpreting information and marking out pipe work

2.01, 2.06, 2.10, 2.12, 2.13, 3.03, 3.12, 3.16,

IPS Pipe 1:3.03 IPS Pipe 2:3.13 IPS Pipe 4:2.04 IPS Pipe 7: 2.12 IPS Pipe 8:2.13 IPS Pipe 12:3.16

9 Preparation, joining and erection of pipe work assemblies

2.10, 2.11, 2.12, 2.13, 3.03, 3.09, 3.12, 6.01

IPS Pipe 1:3.03 IPS Pipe 2:3.12 IPS Pipe 5:6.01 IPS Pipe 6:2.11 IPS Pipe 7:2.12 IPS Pipe 8:2.13 CO2:7.06 CO3:7.04


10 Fabrication and installation of pipe work systems

2.06, 2.10, 2.11, 2.12, 2.13, 2.15, 3.06, 3.12, 3.16, 6.01

IPS Pipe 2:3.12 IPS Pipe 3:4.02 IPS Pipe 5:6.01 IPS Pipe 6:2.11 IPS Pipe 7:2.12 IPS Pipe 8:2.13 IPS Pipe 9:2.15 IPS Pipe 11:6.02 CO2:7.06 CO3:7.04

11 Preparing for and inspecting fitting operations

2.06, 2.10, 2.11, 2.12, 2.13, 3.03, 6.01, 6.02, 6.03

IPS Mech 1:3.03 IPS Mech 6:2.04 IPS Mech 9:2.11 IPS Mech 10:2.12 IPS Mech 11:2.13 IPS Mech 12:6.02

12 Fitting by filing and sawing 3.03, 6.01, IPS Mech 1:3.03

13 Fitting by drilling, reaming and threading

2.01, 2.02, 2.03, 3.03 IPS Mech 1:3.03 IPS Mech 2:2.01 IPS Mech 3:2.02 IPS Mech 4:2.03 CO2:7.06 CO3:7.04

14 Fitting by machining and assembling components

2.01, 2.02, 2.03, 3.11, 3.12, 3.13 IPS Mech 2:2.01 IPS Mech 3:2.02 IPS Mech 4:2.03 IPS Mech 5:3.04 IPS Mech 7:3.12 IPS Mech 8:4.02 CO2:7.06 CO3:7.04


2.09, 2.10, 2.11, 2.13, 2.15, 2.16, 3.09, 3.10, 3.12, 6.01, 6.02, 6.03

W1:2.11 W3:2.13 W4:2.15 W6:1.12 CO3:7.04

16 Welding with manual metal-arc processes

2.09, 2.10, 2.11, 2.13, 2.15, 2.16, 3.09, 3.10

W1:2.11 W3:2.13 W6:1.12 W16-17.3.09 W23 & W25:3.09 W31-34:3.09 W40:3.09 W42:3.09 W43:3.03 CO2:7.06 CO3:7.04

17 Welding with the tungsten inert gas/tungsten-arc gas shielded welding process

2.09, 2.10, 2.11, 2.13, 2.15, 2.16, 3.09, 3.10, 6.01

W1:2.11 W3:2.13 W6:1.12 W10-15:3.09 W27-32:3.09 W34:3.09 CO2:7.06 CO3:7.04


Level 3 Certificate in Engineering Construction

Identification of Key Skills summary relationship table

Unit Title Communication Application of

Number Information Technology

1 Develop self and comply with legal and safety requirements

C2.1b C2.2 C2.3

Level 2

2 Interpreting information and marking out fabrication materials (steel erector)

C2.2 C2.3

N2.1 N2.2 N2.3

IT2.1

3 Hand cutting and shaping processes

C2.2, 2.3

4 Assembly and erection of structural steelwork

C2.2 C2.3

N2.1 N2.2 N2.3

5 Interpreting information and marking out fabrication materials (platework)

C2.1b C2.2 C2.3

N2.1 N2.2 N2.3

6 Preparation, joining and erection of fabrication material

2.3

7 Forming of thick plate and sections

8 Interpreting information and marking out pipe work

C2.2 C2.3

N2.1 N2.2 N2.3

9 Preparation, joining and erection of pipe work assemblies

C2.2 C2.3

10 Fabrication and installation of pipe work systems

C2.2 C2.3

11 Preparing for and inspecting fitting operations

C2.2 C2.3

12 Fitting by filing and sawing

N2.2

13 Fitting by drilling, reaming and threading

N2.2

14 Fitting by machining and assembling components



C2.2 C2.3

IT2.1

16 Welding with manual metal-arc process

C2.3

17 Welding with tungsten inert gas/tungsten-arc gas shielded process

C2.3

Generic grading descriptor for Assignments

Pass In a practical activity involving some non-routine operations, the candidate demonstrated the use of skills in meeting the essential requirements of the outcomes of the unit. Credit In a practical activity involving some non-routine operations, the candidate demonstrated the use of skills in meeting the substantial majority of requirements of the outcomes of the unit. Distinction In a practical activity involving some non-routine operations, the candidate demonstrated the use of skills in meeting the comprehensive requirements of the outcomes of the unit.

Educational Health and safety

The requirement to follow safe working practices is an integral part of all City & Guilds qualifications and assessments, and it is the responsibility of centres to ensure that all relevant health and safety requirements are in place before candidates start practical assessments. Should a candidate fail to follow health and safety practice and procedures during an assessment (eg practical assessment, assignment) the test must be stopped and the candidate advised of the reasons why. The candidate should be informed that they have failed the assessment. Candidates may retake the assessment at a later date.


Unit 1: Develop self and comply with legal and site safety requirements

Rationale This mandatory unit is common to all the occupational awards. It is concerned with developing safety awareness as well as developing the communication skills required to work effectively with other employees in an engineering construction environment. The unit covers four performance outcomes. The candidate will be able to 1. comply with legal safety requirements 2. apply safe working practices 3. develop self and be aware of work relationships and their importance 4. prepare and reinstate the work area for safe engineering construction operations Connections with other awards The unit combines and extends the knowledge within the following ECITB units and equivalent ECS E6:2.15, E7:2.16, E11:2.11, E12:2.12 CO1:8.02, CO2:7.06, CO3:7.04 ML5:2.16, ML8:2.11, ML10:2.15, ML11:7.08, ML12:7.07 Assessment This is a core unit, practical outcomes will be assessed within the relevant occupational assignment. The underpinning knowledge will be assessed by an externally set short answer question paper.


Outcome 1: Comply with legal safety requirements

Practical activities 1. Ensure regulations are current issue. 2. Identify personal protective equipment for appropriate practical activities. 3. Interpret warning signs and labels. 4. Undertake manual handling operations. 5. Locate and identify types of fire extinguishers and intended application. 6. Carry out emergency/fire drill.

Underpinning Knowledge The candidate will be able to 1. state the laws in regard to Health and Safety a. health and safety at work Act 1974 including the duties of employers and employees under the act b. noise at work regulations 1989 c. personal protective equipment at work regulations 1992 d. electricity at work regulations 1989 e. the construction (head protection) regulations 1989 f. the provision and use of work equipment regulations 1998 g. the pressure equipment regulations 1999 h. implications of not following legal requirements and employers health and safety policy 2. describe Personal Protective Equipment (PPE) a. as required by the Personal Protective Equipment regulations 1992 i. approved overalls ii. safety clothing, including gloves, aprons, leggings and footwear iii. eye protection, including welding screens and filtered shades and eye protection during grinding operations iv. safety helmets v. ear protection vi. respirators vii. breathing apparatus viii. welding fume extraction: filtered and diluted ix. safety lines and harnesses b. protective clothing, as required by the construction (health, safety and welfare) regulations 1996 c. personal hygiene, including the use of i. barrier creams ii. skin cleansers d . use of safety screens and barriers


3. state the requirements for the safe use, storage and disposal of substances hazardous to health including a. requirements of the Control of Substances Hazardous to Health Regulations (COSHH 1999) b. information on the safe handling and use of materials within material manufacturers instructions c. recognition of hazardous substances, including hazard markings on data sheets and product labels d. identifying hazardous and dangerous substances warning signs and labels i. toxic ii. corrosive iii. harmful/irritant iv. flammable v. explosive

vi. oxidising vii. radioactive e. safety precautions and procedures relating to i. handling and storage ii. spillage and disposal of hazardous substances iii. reporting defects in the prescribed control measures 4. state the requirements for first aid at work as set out in the Health and Safety (First Aid) regulations 1981 including a. location of first aid facilities and identify qualified first aiders b. action to be taken, when expert help is not available, in the event of i. electric shock ii. suspected spinal injuries iii. excessive bleeding iv. head injuries v. unconsciousness vi. burns and scalds c. mouth to mouth resuscitation d. the recovery position e. summoning expert help f. personal hygiene g. instruction and information on the requirements of the Reporting of Injuries, Diseases and Dangerous Occurrence Regulations 1995 (RIDDOR) including i. procedures for reporting accidents and damage ii. sources of advice and assistance 5. describe the guidelines contained within the Manual Handling Operations Regulations 1992, instruction and practice in safe methods of manual lifting and carrying including a. determining whether load is suitable for manual handling b. planning the lift c. correct stance d. lifting posture e. gripping the load f. lifting posture and action g. carrying and positioning h. dual and team handling


6. state emergency procedures and fire precautions a. types of emergency alarms, signals, PA announcements and status lights used on site b. location of fire/emergency alarm points, escape routes and assembly points c. sounding emergency alarm/warnings d. emergency evacuation procedures e. common causes of fire, classification of fires and prevention of fire hazards f. how fires can spread and methods of extinguishing a fire g. identification of types of fire extinguisher and their intended application on different classifications of fire including i. water ii. foam iii. dry powder iv. carbon dioxide v. vaporising liquid h. location, identification and correct use of various types of ‘first aid’ fire extinguishing equipment including i. extinguishers ii. fire blankets i. circumstances in which personal action may be taken to control the spread of fire j. routine emergency/fire drills/toxic gas alert.


Outcome 2: Apply safe working practices

Practical activities 1. Carry out procedures to be followed in the event of injury, electric shock and fire. 2. Carry out risk assessment in work areas. 3. Ensure equipment and services required in a work area are available and in a suitable condition. 4. Ensure equipment and tools are used correctly and appropriately stored after use. 5. Inspect sets of ladders for faults, followed by drawing up a cause, effect and required action chart. 6. Undertake scaffolding and ladder identification.

Underpinning knowledge The candidate will be able to 1. describe human and environmental conditions leading to accidents on site and preventative measures including a. electrical supplies: avoiding trailing leads and dangers associated with high voltage b. moving loads: avoid swinging unbalanced load, overloading slings, use of clamps, shackles and beams when lifting heavy loads c. noise and vibration: effect in communication and personal injury and methods of overcoming d. site radiography: need for warning signs at safe distance from source, undertaking work during low site occupation e. working at heights: need for inertia reel safety lines, harnesses/ropes 2. describe the use of ladders a. how to identify defects/possible safety hazards when inspecting ladders, the effect on each fault and necessary action to be taken b. the techniques for lifting and carrying ladders and procedures for erecting and securing ladders in position 3. state safety precautions specific to scaffolding a. inspection of scaffold boards prior to use and removal of unsuitable boards b. rules for limiting overhang of boards c. reasons for and methods to secure boards to prevent movement d. need to inspect lashings for fraying e. reasons for having a minimum number of ladder rungs above platform level f. having guard rails near the top of the platform g. the open space around circular constructions h. importance of wrapping projecting steelwork with coloured rag/plastics sheet


4. describe general safe working practices a. avoidance of accidents by maintaining satisfactory standards of cleanliness and good housekeeping b. ensuring safe access and egress on sites by maintaining clear entrances, exits, roadways, stairways, passageways and gangways c. precautions to be taken when working in confined spaces and where access to the workspace is limited or restricted d. use of machinery guarding, safety switches and fencing e. safe use and storage of tools and equipment f. observing all safety rules and signs warning of hazards on site g. procedures for reporting faults in tools, machines, equipment and components h. procedures for reporting unsafe methods and working practices i. safety precautions and avoidance of hazards when using gas supplies from cylinders or piped installations j. safety precautions when storing and moving gases and fluids k. safety precautions to be observed when using compressed air, degreasing, grinding and other ancillary equipment l. safety rules affecting visitors within the work area. 5. state safety precautions to be taken when working at height, including the use of a. ladders b. work platforms c. general access scaffolds d. guard rails and toe boards e. scafftag systems (responsibilities and requirements) f. tower scaffolds g. mobile and suspended access equipment h. mobile elevating work platforms (mewps) i. mast platforms j. roof ladders and crawling boards 6. state the identification and control of hazards associated with working in or near trenches and excavations a. use of shoring, benching and battering methods for trenches and excavations b. safety protection around excavations c. locating underground services d. dangers of water ingress and flooding e. hazards of spoil and vehicles near excavations f. lighting of trenches g. danger of harmful gases h. maintaining safe access and egress i. inspection of trenches and excavations 7. state the types and purposes of Permit To Work a. trench work/tunnels and shaft b. vessel entry/confined space c. hazardous areas d. clearance certificates e. electrical isolation f. hot work g. roof work


8. describe potential safety hazards associated with thermal cutting welding and gouging and actions which should be taken a. use of protective clothing and equipment required to guard against: glare, ultra-violet light (arc eye), heat, hot flying particles, asphyxiation, noise and fumes i. face shields and goggles using appropriate BS/EN 169 (1992) recommendations ii. filters iii. gauntlets iv. aprons v. caps and hoods vi. spats/boots vii. respirators b. precautions required to protect fellow workers from hazards arising from i placing of cables, leads and hoses ii direct or reflected radiation, use of screens iii working on staging, need for roping off, posting of warning notices c. procedures to be followed in the event of personal accident by electric shock, falling, burning, or asphyxiation, extent of first aid to be given 9. state precautions to be taken on site a. due to operations near degreasing plant- danger from toxic gases b. adverse weather conditions- risk of electric shock and falling objects c. dismantling steel structures- dangers from fires and falling objects d. working in confined spaces- risk of asphyxiation, need for adequate ventilation e. when welding with high frequency current 10. state conditions that lead to accidents in the workplace and means of recording them a. human i. carelessness ii. improper behaviour and dress iii. lack of training, supervision and experience iv. fatigue v. drug taking and drinking b. environmental i. unguarded or faulty machinery and tools ii. inadequate ventilation iii. untidy, dirty, overcrowded, badly lit workplaces iv. spillages c. accident prevention measures i. eliminating the hazard by replacing with something less dangerous ii. guard the hazard iii. personal protection iv. safety education and publicity


11. state necessity of developing a positive personal attitude to safety including a. dangers that can occur b. what protection is available c. how to prevent accidents d. need for a risk assessment policy 12. state general rules for the observation of safe practices a being alert b. maintaining personal hygiene c. protecting yourself and other people d. knowing emergency stop procedures e. reporting all hazards.


Outcome 3: Develop self and be aware of work relationships and their importance Practical Activities 1. Define current competence and areas of development required. 2. Set objectives. 3. Review performance and resetting objectives. 4. Seek feed back and advice. 5. Agree action plan. 6. Establish and maintaining work relationships. 7. Deal with employment rights and responsibilities (ERR). 8. Request assistance from others and assist others. Underpinning Knowledge The candidate will be able to 1. state responsibilities a. who is responsible for employee training, welfare and supervision b. how employee training is organised c. employee responsibilities i. evidence gathering ii. completing work from development and/or training plan iii. behaviour, dress and language iv. act in professional manner to customers and other staff 2. state the meaning of competence a. how to identify competence b. where to find information that describes competence requirements 3. describe training and development objectives a. setting for future requirements b. updating c. resources required and who agrees them d. opportunities available e. engineering training courses and qualifications available f. which skills can be developed by different courses g. who to ask advice from 4. state how to review a. methods b. importance of constructive feedback


5. describe working relationships a. different relationships within an organisation b. what an effective working relationship is c. importance of maintaining effective working relationships d. how to work as a team member e. difficulties that can occur f. who to approach if there are problems g. attitudes and requests that could cause conflict or create a negative response h. how to obtain help, ensuring a positive response 6. describe communication a. methods and when used (written, verbal, electronic) b. lines of communication c. keeping others informed d. type of disruption caused by poor, incorrect and inaccurate requests 7. state types of documentation and identify key points a. delivery notes b. invoices c. time sheets d. rotas e. accident reports f. permits to work g. simple work schedules 8. state employment rights and responsibilities a. employment law i. main legal responsibilities and rights of employer and employee ii. how employees and employers are protected through documented procedures iii. sources of information and advice b. organisation and representation i. jobs in the engineering construction industry ii. organisational structures iii. job roles and career paths iv. representation in the engineering construction industry v. sources of information and advice c. public law and policies affecting the engineering construction industry i. basic principles of current legislation A. Race Relations Act B. Sex Discrimination Act C. Equal Opportunities Act D. Disability Discrimination Act E. Employment Relations Act ii. work place ethics and values iii. issues of public concern


9. describe organisations a. how an organisation is structured in relation to departments and departmental and management functions b. roles and responsibilities of personnel eg directors, managers, foreman, trade unions, craftsmen, trainees and apprentices c. the elements of construction/production department eg labour, equipment, materials, land, contracts and employment law d. the relationship between products and elements of engineering construction/production systems in terms of investment, competitiveness, production efficiency, profit and loss.


Outcome 4: Prepare and reinstate the work area for safe engineering construction operations

Practical Activities 1. Identify procedures for minimising dangers in workshops. 2. Identify the activities governed by legislation which affect preparation of work areas. 3. Ensure services required in a work area are available. 4 Ensure materials and tools are available for engineering operations. 5. Check appropriate storage methods and locations for tools and materials. 6. Restore work areas used for engineering and other activities to a clean and safe state after work has been carried out. 7. Identify hazardous substances which could be used in work areas and giving the safe disposal method for each one. 8. Identify remedial actions required to solve any problems in restoring work areas. 9. Carry out a risk assessment.

Underpinning Knowledge The candidate will be able to 1. describe constraints set down by existing national and international legislation, statutory and non-statutory regulations, industry standards and guidelines, and professional codes of practice 2. state the implications of not following legislation, regulations, standards and guidelines 3. state what sections most apply to their specific activities, and why 4. describe the types of obstruction that can affect a work area a. by self b. by others 5. describe the types of disruption that can occur with the preparation of the work area a. by self b. by others 6. state the reasons for keeping work area free from obstruction a. responsibility of self b. employers’ responsibility 7. state if there are variations to work area conditions a. what action should be taken b. who should be informed


8. state how to check required services a. are available b. are suitable for use c. who to inform if not 9. state the specific health and safety issues related to work area 10. state the importance of storing materials correctly a. before engineering operations b. during engineering operations c. after engineering operations 11. describe the inspection of tools and equipment prior to use 12. state the storage methods for materials and tools 13. state why it is important to store materials and tools correctly

14. state what is required to restore work area 15. state the needs of other users 16. state when and why it may not be possible to always meet requirements 17. describe the processes in maintaining the cleanliness of machinery, equipment, tools and work area a. immediately after job completion and daily routines for cleaning b. cleanliness safety procedure i. manual cleaning ii. manufacturers’ information c. isolating machinery d. inspection of equipment, tools, material and components after job completion e. how to sort into reusable and waste f. correct cleaning techniques g personal protection equipment for cleaning purposes 18. state how to deal with waste material from engineering operations a. types of waste material b. storage of waste c. methods of identifying waste d. labelling of waste e. disposal methods for waste i. re-cycling ii. solid waste iii. liquid waste f. equipment and materials for waste disposal g. how different materials and products require different waste disposal methods h. reasons for using some waste disposal methods and techniques and not others i. who can assist with waste disposal j. which materials are hazardous


k. the disposal methods appropriate to materials and products and the reasons for each one l. health and safety/environmental legislation related to waste

m. problems that can occur during restoration of work area i. types of problem ii. how to rectify them n. action to be taken in the event of a spillage i. correct personal protection equipment ii. aids to spillage containment and cleaning iii. prevention of spillage to water course 19. state the practical actions to be taken to protect the environment a. prevention: using different methods, materials, procedures b. reduction: minimising waste, preventing corrosion c. recycling d. handling and disposal of waste (reporting methods) e. the purpose and importance of keeping up to date documentation 20. state environmental issues in general terms and the impact of engineering on the environment a. ozone layer b. global warming c. acid rain d. smog e. solid waste f. water pollution g. contamination h. resource depletion i. airborne particulate fumes from welding operations eg Nickel and Chromium effects contained in fumes during the welding of alloy steels (threshold limit values).


Unit 2: Interpreting information and marking out fabrication materials Rationale This optional unit is part of the occupational award for steel erecting. The unit is concerned with using drawings and specifications to identify materials and prepare for fabrication activities. The unit covers four performance outcomes. The candidate will be able to 1. interpret drawings, specifications, data and procedures 2. identify common engineering materials used in fabrication engineering 3. identify the structure and basic working properties of materials 4. use information technology. Connection to other awards This unit combines and extends the underpinning knowledge within the following ECITB units and ECS E12:2.12, E13:2.13, ML9:2.13 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Interpret drawings, specifications, data and procedures

Practical Activities 1. Read and interpret working drawings, fabrication specifications/procedures to extract necessary information to prepare the work piece and related processes for assembly and erection operations. 2. Identify safety requirements. 3. Identify metric and imperial systems of measurement. 4. Select and use suitable measuring equipment for required work, having regard to accuracy requirements. 5. Measure and mark out components. Underpinning Knowledge The candidate will be able to 1. state the importance and purpose of a drawing or specification: a determine shape and characteristics of fabricated products b material, tools, equipment and fabrication requirements 2. describe how to obtain drawings, specifications and data 3. state basic concept of standards for communicating technical information in terms of providing a universal language relevant to engineering 4. state the means of communicating technical information a technical drawings b operation sheets c data sheets and wall charts d standard/manufacturers’ tables and servicing/repair manuals e microfilm, microfiche, video tapes and VDUs 5. state how to interpret drawings of plate and structural sections to BSEN ISO 1660 (1996) and BS/EN22553 (1995) a assembly detail and general arrangement drawings b basic and additional information to be found on drawings i projection ii unit of measurement iii scale iv material and specification v heat and protective treatment vi general tolerance vii issue reference viii warning notes e.g. machining allowance c distinguish between i orthographic: first and third angle projections ii pictorial: isometric and oblique views iii single plane sectioned and auxiliary views


d standard conventions i types of line ii representation of common features e dimensioning techniques 6. state how to identify components from drawings, specifications and data a technical drawings, sections, exploded views and diagrams b manufacturers’ servicing, repair and parts data c data sheets and wall charts 7. describe the importance of accurate measurement and use of measuring equipment a the danger of accumulated errors in marking out components and the importance of working from centre lines and datum faces/edges b use of rules and tapes in metric and imperial systems.


Outcome 2: Identify common engineering materials used in fabrication engineering Practical Activities

1. Identify and carry out initial assessment of commonly used engineering materials. 2. Classify materials and identify appropriate grouping and category. Underpinning Knowledge The candidate will be able to 1. state the basic techniques for identifying type of material a visual b tactile c assessment of relative density d magnetic properties 2. state the use of work shop techniques to classify materials into the following groups a metals i. ferrous ii. non ferrous materials b polymers i. thermoplastics ii. thermosetting materials c ceramics i. glass ii. porcelain iii. carbides d composites i. fibre reinforced plastics (FRP) ii. reinforced concrete 3. common forms of supply for a pipe and tube b plate c sheet d sections e castings f extrusions 4. state the safe working pressure in tonnes/metre² of types of soil a ordinary earth b back filling c muddy clay d soft clay e hard clay f gravel.


Outcome 3: Identify the structure and basic working properties (mechanical and thermal) of the materials Practical activities 1. Identify material structure by applying tests, examining performance or supplied data. 2. Assess the properties of materials by conducting examinations or applying tests. 3. Report the significance of the properties on material behaviour in both a mechanical and thermal context. Underpinning Knowledge The candidate will be able to 1. state variations in material structures a crystal nature b grain size and alignment 2. state the procedure for determining the properties of materials a specifications b magnetic c thermal d physical e mechanical tests f micro/macro-examination 3. describe the properties influencing the selection of materials for given applications a density b strength i ductility ii toughness iii elasticity iv hardness v malleability vi appearance vii cost c conductivity d resistance to i environmental degradation ii corrosion iii heat 4. state the influence of hot and cold working during fabrication on the mechanical properties of materials, requiring selected treatments during fabrication operations 5. state the types of heat treatment and their application a annealing b normalising c stress relief d pre/post heating


6. state types of corrosion a atmospheric b stress c aquatic 7. state the types of corrosion protection a cathodic b sacrificial anode c impressed current 8. state the types of surface treatment and their application a galvanising b surface plating c anodising/sheradizing d painting e cladding/lining f other coatings g cleaning methods.


Outcome 4: Use information technology

Practical Activities

1. Use commercial software to sort materials and components. 2. Use a computer system to perform a simple engineering administrative task. Underpinning knowledge The candidate will be able to 1. state the inter-relationship of hardware and software of a basic computer system a basic components of hardware i screen ii terminal iii mouse iv connecting leads v drives vi printers b different types of information i textural ii graphical iii numerical 2. state the main characteristics of memory and back up memory a read/write and ROM b relationship of CPU memory, interfaces and peripherals c differentiate between directories, folders, file storage systems and security routines (password, knowledge of Data Protection Act) 3. describe the use of commercial software to sort materials and components a the use of a computer system to perform a simple engineering administrative task e.g. scheduling or store controls b the use of software to compile/produce simple report (hard copy) using basic edit format options c compare systems with and without information technology in terms of improvement in day to day working e.g. saving time, reducing cost, increasing efficiency, improving accuracy.


Unit 3: Hand cutting and shaping processes Rationale This optional unit is part of the occupational award for steel erecting. The aim of this unit is to provide the skills and knowledge required to produce components and assemblies by using hand fitting techniques. The unit covers three performance outcomes. The candidate will be able to 1. specify cutting and shaping processes for given applications 2. apply safe working practices 3. prepare equipment and carry out the cutting operation Connections with other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS CO2:7.06, CO3:7.04 E8:6.01, E12:2.12, E13:2.13 ML9:2.13 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assess by means of a short answer written test covering the occupational units.


Outcome 1: Specify cutting and shaping processes for given applications, stating

Practical activities 1. Select and set up suitable shaping equipment to meet component specification. 2. Compare methods of hand and machine cutting used for a range of products, justifying selection on the basis of production efficiency and the ability to meet the product specification. 3. Inspect shaped product for freedom from defects.

Underpinning knowledge The candidate will be able to 1. describe how to select hand and powered cutting tools for specific shaping applications a low cost high portability of hand tools b potential for higher production efficiency, greater accuracy and ability to cut thicker sections with power tools 2. describe how to refer to manufacturers’ tables and charts to select hand tools capable of making cuts which conform to product specification requirements a the shape and dimensions of tools to meet dimensional requirements of the specification b design and dimensions of the tools cutting action i point angle of chisel ii teeth per centimetre (files and saw blades) iii helix angle of drills iv clearance angle/rake angle and face clearance of shear blades selected according to the material to be cut and the accuracy of cut required 3. state how to select mechanical and powered tools for specific applications a notching straight cuts b external and internal circular shapes c irregular shapes 4. state the benefits, applications and limitations influencing selection of cropping machines and machine saws used for cutting straight edges or curves in sheet/plate and sectional materials 5. state how to refer to manufacturers’ tables and charts to select drills and drilling equipment for general and specialist applications a twist drills in imperial and metric size for general purpose applications b reamers for accurately finishing holes to an exact size and circular shape


6. state factors influencing the selection of thermal cutting processing (oxy-gas/arc plasma) a material to be cut: i low-carbon steel ii low-alloy steel iv stainless steels v non ferrous metals and alloys b influence i oxide melting point ii thermal conductivity iii electrical conductivity c no limit on material thickness and/or size of product which can be cut

d oxy-gas cutting high portability and relatively low cost for workshop/site operations e compare oxy-gas and arc plasma cutting in terms of: i equipment requirements ii speed of cutting and ability to cut a range of materials iii quality of the cut edge iv noise and fumes produced 7. state the optimum method for a particular shaping operation a cropping and shearing b drilling and punching c sawing and oxy-fuel cutting.



Practical Activities 1. Plan and undertake cutting and shaping operations safely. 2. Write a risk assessment for a fabrication cutting and shaping operation to include work area, tools, equipment and components being shaped. Underpinning knowledge The candidate will be able to 1. state how to identify defects/potential safety hazards in the use and condition of hand tool a damaged equipment: repair or replace b use of non-sparking tools when working in flammable and explosive environment c ensuring shaping tools are handled carefully 2. state requirements applicable to portable shaping equipment a use of low voltage portable electrical equipment b safety checks on electrical equipment i good insulation ii appropriate guarding c working within the thickness range of the equipment 3. state the safety precautions specific to cutting by shear a handling of sheet and plate, use of gloves and protective footwear b importance of following specific instructions and regulations related to cutting equipment, use of guards 4. state the safety precautions to be observed when using power tools a angle grinder b cutting discs 5. state the potential safety hazards associated with guillotines, sawing, nibbling, drilling, and routing operations a correct use of work holding devices when shearing, sawing and drilling component parts b the need for personal protective clothing and eye protection required to protect against hot metals and air born particles 6. state the potential safety hazards associated with grinding and sanding.


Outcome 3: Prepare equipment and carry out the cutting operation Practical activities

1. Write a risk assessment for workshop/site based hand cutting operations to include work area, tools, equipment and components being shaped. 2. Plan and undertake cutting and shaping operations safely. 3. Select and set up suitable shaping equipment to meet component specification. 4. Set up non chip forming and chip forming cutting processes. 5. Produce components using standard cutting tools. 6. Use thermal cutting processes to cut material to size and shape. 7. Use a range of joining techniques. Underpinning knowledge The candidate will be able to 1. state how to prepare hand tools for cutting and shaping operations a tools selected to meet specification requirements and checked for freedom from defects, degree of sharpness, loose parts, chips and cracks b trial tests on scrap materials to optimise cutting action and allow dimensional checks to confirm degree of accuracy 2. state the difference and action of chip and non chip forming cutting processes 3. state how to refer to manufacturers’ tables and charts to select hand tools capable of making cuts which conform to product specification requirements, factors to be considered include a the shape and dimensions of tools to meet dimensional requirements of the specification b design and dimensions of the tools cutting action eg point angle of chisel, scraper, teeth per centimetre (files and saw blades), helix angle of drills selected according to the material to be cut and the accuracy of cut required c equipment for general and specialist applications eg twist drills in imperial and metric sizes for general purpose applications, reamers for accurately finishing holes to an exact size and circular shape 4. describe how to select mechanical and powered tools for specific applications; notching, straight cuts, external and internal circular shapes, irregular shapes 5. state how to prepare powered tools for cutting and shaping operations a power tools checked for correct operation of self centring chucks, position of holding handle and secure positioning of cutting tools b correct setting of speeds and feeds for the type and thickness of material to be cut c the work piece is securely clamped to i work tables for fixed cutting operations ii templates/guides for moveable work pieces


6. describe an understanding of oxy-fuel gas cutting in terms of a exothermic chemical action b the influence of oxide combustion temperature c the functions of the pre-heat flame d the action of the cutting flame 7. state the set up of oxy-fuel gas cutting blowpipes, in terms of a control of blowpipe, oxygen and fuel gas pressure and flow rate b control of cutting oxygen flow rate c arrangements for mixing of oxygen and fuel gas for pre-heating d the construction and application of typical cutting nozzles e procedures for lighting, adjusting and extinguishing the cutting flame 8. state the factors influencing quality of the thermal cut edge a relationship between cutter nozzle size and thickness of material being cut b material to be cut and materials susceptible to hardening and cracking c cutting torch oxygen pressure d material condition: surface scale, internal defects e speed of cutting torch travel f distance of nozzle from the surface to be cut g consistency of angle of nozzle to surface during cutting h cutting path control for straight line and circles i methods of distortion control 9. describe the arc plasma cutting process, in terms of a the use of pressurised high temperature plasma stream as the cutting medium i the generation of ionised plasma by an electric arc struck between a tungsten electrode and a copper torch nozzle ii focusing plasma gas at the cutting zone by arc transfer: distinction iii between main and pilot arc: arc transfer technique iv devices for avoiding double arcing, action to be taken in the event of double arcing b gases used for plasma cutting and outline reasons for their selection i need for inert, non combustible gas ii gases used: argon/hydrogen/nitrogen combinations iii reasons for selection in terms of materials to be cut, material thickness gas cost 10. describe the operation of oxy-fuel gas and arc plasma cutting techniques, in terms of a free hand cutting procedures for starting cut from edge of plate and away from edge, procedures for cutting round bar and typical sections b guided hand cutting use of: single and double cutting supports, circle attachments c cutting equipment used for bevelling pipe and plate d safety precautions to protect eyes and prevent inhalation of fumes


11. state the purpose of inspection and method of checking the accuracy of dimensions, form and fitness of the shaped component a the function of a datum surface and datum line b the function of standard measuring equipment c the methods of checking the accuracy of shaped components in terms of i linear dimensions ii alignment iii squareness and freedom from twist iv circularity.


Unit 4: Assembly and erection of structural steelwork Rationale This optional unit is part of occupational award for steel erecting. It is concerned with the assembly and erection of structural steelwork and includes preparation, assembly and fabrication The unit covers three performance outcomes. The candidate will be able to 1. prepare work areas for structural steelwork 2. assemble and join fabricated assemblies 3. move engineering structures Connection with other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS E1:2.14, E2:4.08, E3:4.02, E4:4.05, E5:4.06, E8:6.01, E9:1.17, E10:1.18, E11:2.11, E12:2.12, E13:2.13 ML1:2.14, ML2:4.08, ML3:1.18, ML4:4.05, ML6:1.17, ML7:4.06, ML8:2.11, ML9:2.13, ML11:7.08 CO1:8.02, CO2:7.06, CO3:7.04 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Prepare work areas for structural steelwork

Practical Activities

1. Prepare work areas for fabricating and assembling structural steelwork. 2. Identify all of the component parts of tubular scaffold. 3. Use models to demonstrate procedures for a alignment of columns b erecting roof trusses c erecting platforms or mobile towers d assembling, positioning and securing ladders for specific applications. Underpinning Knowledge The candidate will be able to 1. state basic terminology used in erecting a lifting equipment b lifting appliance c temporary working platform 2. state principal duties of a rigger/erector in terms of a applying safe working practices for self and others and as a member of a team in the erection of major equipment and components b working as a member of a team during the assembly, erection and alignment of structural steel sections, temporary working platforms, rigging of lifting gear/lifting appliances 3. state the purpose of and techniques for using general erecting equipment a tensioning screws b beam clamps c chain blocks d pull lift e sheave blocks f hand/power operated winches g Tirfors h spanners, including podger i drift and wedges j hammers 4. state the techniques for erection and dismantling in terms of a ladders i single, double and triple extensions ii aluminium and wood 5. state the purpose and techniques for using tubular scaffold including fixed platforms and mobile towers a applications b component parts c working requirements of platforms and ladder position d sequence of erection and dismantling


6. describe preparatory requirements for site assembly including reference to site assembly drawings to identify suitable site for positioning steelwork, area to be cleared of structural materials, obstacles and debris 7. state techniques for erecting steelwork structures in terms of the main stages in erecting a vertical columns, including adjustment of alignment b ties and intermediate members c roof trusses 8. describe factors involved in planning the handling and erection of heavy steel work plate girders, pre-assembled structures and vessels a planning operations i use of models when moving structures around obstacles ii briefing individuals and teams iii preparation prior to erection including A. stiffening unstable components prior to lifting B. use of corseting and internal bracings C. use of crane mats to improve stability by spreading load bearing and pressure b estimation of centre of gravity for components/assemblies.


Outcome 2: Assemble and join fabricated assemblies

Practical Activities 1. Select assembly methods for specific applications. 2. Evaluate the suitability of assembly and joining methods for the selected application. 3. Use assembly procedures, tools and processes for assembling and joining products. 4. Interpret assembly drawings and recording the sequence of operations and processing requirements. 5. Use appropriate process to make fabricated joints. Underpinning Knowledge The candidate will be able to 1. state how to identify with the aid of manufacturers’ tables, mechanical fastening devices; their general characteristics and applications 2. describe nuts, bolts and washers used in structural steelwork, plate and pipe work a black b turned barrel c high strength friction grip d common forms of locking devices 3. state methods of bolt tensioning and tightening sequences a tensioning method i torque and impact wrenches ii load indicating bolts and washers iii part turn methods b tightening sequences for i back to back angle bracing ii column splicing iii pipe flanges c read and use information on site bolts lists 4. state the importance of cleanliness of surfaces in contact, correct tensioning, sequence of tightening, hole diameters to specific tolerances and need for correct alignment of holes 5. describe how to ensure assembly area is clean and free from obstructions 6. state that component parts to be assembled are located in a safe accessible position and are checked for compliance with specification 7. state that component shortages are recorded and appropriate authority notified 8. describe how to ensure correct sequence of assembly to specification, the reason for sub-assemblies, trial assemblies and aids to support dimensional accuracy


9. describe methods used to set up frames and structures with reference to a logical sequence of assembly to avoid twist and distortion b use of tack bolts and tack welds c use of stays to maintain shape d use of spirit levels, piano wire and bubble level, water level and tilting level, laser level 10. describe procedures used for operational shut down of live plants prior to assembly operations 11. state the purpose of, and techniques of in-process and final inspection a the function of datum surface or datum line b the function of standard measuring equipment c the tolerance to accuracy and relation to specific tolerance and function d methods of checking correct sequence of assembly, the accuracy of dimensions, alignment, squareness, and freedom from twist or distortion 12. state the particular health and safety hazards associated with fabrication assembly a safe lifting methods and use of lifting aids eg reasons for having a maximum included angle for a two leg sling b dangers when working at heights i use of staging and roping off to prevent personal falls ii use of warning signs and hard hats and other personal protective equipment to reduce risk of injury iii securing of ladders and ancillary equipment 13. state the component parts of frames and structures in terms of a columns and stanchions b beams and girders c portal frames d structural frames, bracing and purlins e cladding f staircases, landings and handrails g hoppers, bunkers and vessels h pipe work and ducting 14. state the reasons for machining critical components prior to assembly a stanchions b columns c pipe flanges d joint edge preparation


15. state the common thermal joining processes used in fabrication a manual metal-arc welding b metal-arc gas-shielded welding i gases, electrodes and filler wires ii set up and use c the action of the flux constituents in terms of i protective gaseous shield ii stabilise the arc iii provide deoxidisers iv provide alloying elements 16. state the types of basic joints and positions a butt, fillet b flat, vertical, horizontal, vertical, overhead 17. state the importance of removal of protective coatings prior to thermal joining 18. state the appropriate process technology to carry out tack welding 19. describe assembly and correct set up and shut down procedures 20. state causes of distortion in respect of a weld metal cooling from liquid to solid at room temperature b expansion of restrained metal when heated above plastic yield and subsequent contraction 21. describe methods of controlling and acceptable methods of rectifying distortion of welded structures.


Outcome 3: Move engineering structures

Practical Activities 1. Prepare knots, hitches, and bends used in ropes and slings for practical applications: reef knot, bowline, running bowline, sheepshank, clove hitch, timber hitch, rolling hitch, round turn and two half hitches, figure of eight, sheep bend, double sheep bend. 2. Identify an irregular shaped load and estimating a the mass of the component and the forces in the slings b the centre of gravity and required positions to attach lifting equipment. 3. Select lifting appliances, lifting techniques and equipment for a range of site applications, for confirmation with supervisor. 4. Use models to identify potential hazards on site prior to erection operations. 5. Survey a working site to identify actual safety hazards and make recommendations for improvement. 6. Identify site safety requirements and equipment by reference to legislative documents and brochures provided by suppliers of safety equipment. Underpinning Knowledge The candidate will be able to 1. state how to identify types, applications, and advantages of specific lifting equipment a wire rope slings and attachments including thimble, reeving thimble, soft eye, endless and brother types b flat belt slings including woven nylon/terylene wire mesh plastics covered, plaited, nylon wound c the main types of lifting equipment i chain slings ii rope slings iii shackle iv swivel hook v plate clamp vi ring link/eye bolt d sling attachments including bow and dee shackles lugs, plain and collar eye bolts, pipe and plate clamps, dynamometer e the advantages of belt slings as providing breadth of bearing to a load, reducing risk of load damage f main types of fibre ropes as manilla, sisal, nylon, terylene, polypropylene 2. describe knots, hitches and bends used in ropes and slings and their applications for slinging and lifting 3. describe splices used in fibre ropes and their applications for slinging and lifting


4. state how to determine loadings and forces on lifting equipment a use of manufacturers’ tables to determine diameter of chain links, SWL and angle of slings for single and double chain slings b estimate and calculate mass of simple plate shapes and section material c calculate mass of more complex plate shapes and built up components d identify alternative methods of estimating loads i advice/delivery notes ii markings on load to be lifted iii crane weight load devices iv crane attached weighing machines e how to determine weights of plate, pipe, and sections from manufacturers’ tables 5. state the techniques required for lifting equipment including use of a plate clamps b choke and basket hitches/slings including soft eye types, with single and double thimbles, endless types, brother wire rope and chain type slings 6. state the techniques for loading crane hooks with slings 7. state procedures for lifting unbalanced loads in relation to positioning of crane hook with equal slings, positioning of crane with unequal length slings, use of stretching screw/turn buckle 8. state how to determine by estimating and calculating centre of gravity of simple and built up complex shapes in order to locate lifting positions 9. state the main use of a range of lifting appliances in common use on engineering construction sites a winches b mobile derrick c tower crane d truck mounted light duty mobile crane truck e crawler mounted heavy duty mobile crane f skyhorse g fly jib h the main component parts of each lifting appliance i the terminology applicable to lifting appliances i hoisting and lowering ii slewing iii derricking iv luffing 10. state the rules for power lifting of loads with particular emphasis on a minimum and maximum safe working loads b stability of lifted loads during and immediately after lifting c avoidance of pushing/pulling loads d transporting loads over the heads of workers and others


11. state the potential health and safety hazards and appropriate actions in respect of construction lifting equipment regulations 1998 (LOLER) a the condition, suitability, inspection and identification of lifting chains, rope or lifting equipment b conditions relating to SWL of rope slings c type of faults in wire ropes which render them unserviceable in relation to worn, broken, fraying, kinked, or corroded strands d identify chain sling defects by visual examination i stretched links ii wear iii distortion e identify belt sling defects by visual examination i cuts ii fraying iii blistering f safety precautions to be taken when using flat belts, slings, in relation to i desired curvature ii care of hooks and eye bolts iii avoiding rough/sharp edges when using ropes and slings iv need to avoid contact with heat or chemicals v storage in dry well ventilated areas vi observing maximum bite and slinging angles.


Unit 5: Interpreting information and marking out fabrication materials Rationale This optional unit is part of the occupational award for plating. It is concerned with the interpretation of specifications, and measurement and marking out of sheet metal. The unit covers four performance outcomes. The candidate will be able to 1. interpret drawings, specifications, data and procedures 2. measure and mark out components, templates and patterns 3. identify common engineering materials used in fabrication engineering 4. identify the structure and basic working properties of engineering materials Connection to other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS FSS1:3.03, FSS3:2.12, FSS4:2.13, FSS6:3.12, FSS8:3.16 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Interpret drawings, specifications, data and procedures Practical Activities 1. Read and interpret working drawings, fabrication specifications and/or procedures to extract necessary information to prepare the work piece and related processes for fabrication operations. 2. Identify component and material requirements through the preparation of parts lists and sketches, taking into consideration working tolerances and material allowances for subsequent fabrication operations. 3. Identify working constraints including a set-out requirements b nesting arrangements c sub-assemblies d mirror images e quantities required. 4. Identify safety requirements. 5. Produce operation sheets, selecting the most effective and efficient method and sequence of manufacture. 6. Inspect finished product to assess compliance with specification requirements. Underpinning Knowledge The candidate will be able to 1. state the importance and purpose of a drawing or specification a determine shape and characteristics of fabricated products b material, tools, equipment and fabrication requirements 2. state how to obtain drawings, specifications and data 3. state the basic concept of standards for communicating technical information in terms of providing a universal language relevant to engineering 4. state the means of communicating technical information a technical drawings b operation sheets, weld procedure sheets c data sheets and wall charts d standard/manufacturers’ tables and servicing/repair manuals e microfilm, microfiche, video tapes and VDUs


5. describe how to interpret drawings of plate and structural sections to BSEN ISO 1660(1996) and BS/EN22553 (1995) a assembly detail and general arrangement drawings b basic and additional information to be found on drawings i projection ii unit of measurement iii scale iv material and specification v heat and protective treatment vi general tolerance vii issue reference viii warning notes eg: machining allowance c distinguish between i orthographic: first and third angle projections ii pictorial: isometric and oblique views iii single plane sectioned and auxiliary views d standard conventions i types of line ii representation of common features

e dimensioning techniques for i notching ii drilling iii folding 6. state how to identify components from drawings, specifications and data a technical drawings, sections, exploded views and diagrams b manufacturers’ servicing, repair and parts data c data sheets and wall charts 7. state how to interpret standard/manufacturers tables and/or graphs to a select materials for a particular application b standard edge distance pitch, cross centres and standard back marks for holes on structural sections c select appropriate cutting and forming equipment i mechanical cutting (chip forming) ii mechanical cutting (non-chip forming) iii thermal cutting A. oxy-fuel gas B. arc plasma iv forming d select joining methods i mechanical ii thermal.


Outcome 2: Measure and mark out components, templates and patterns Practical Activities 1. Identify metric and imperial systems of measurement. 2. Select and use suitable measuring equipment for required work, having regard to accuracy requirements. 3. Measure and mark out components, templates and patterns. 4. Develop templates and patterns. 5. Make card or metal models from templates and patterns. Underpinning Knowledge The candidate will be able to 1. state the importance of accurate measurement and use of measuring equipment a the danger of accumulated errors in marking out components, templates, and patterns, and the importance of working from centre lines and datum faces/edges b how to select appropriate measuring equipment for given applications including the use of rules, callipers, dividers, beam trammels, micrometer and vernier callipers, surface plate, vernier height gauges and protractors and standard sheet gauges, in metric and imperial systems 2. state the reasons for using templates to avoid repetitive measuring and marking out of similar parts, material optimisation, guiding equipment 3. state the materials used for template making and the factors influencing selection and processing allowances 4. state methods used to determine the circumferences of pipes 5. state how to calculate and check blank sizes to ensure compliance with forming allowances and specification requirements 6. describe the methods of constructing lines and curves of intersection a construction of regular geometrical shapes such as ellipse, oval, and polygon b construction of sectional views through cylinders pyramids and cones c projection of auxiliary sections and views to clarify drawings and simplify surface developments 7. state how to determine the lines of intersection by means of a the use of projection b common central spheres c cutting planes 8. describe how to develop templates and patterns by the parallel line method of pattern development for cylindrical, square, and rectangular sections


9. state how to develop templates and patterns by the radial line method of pattern development for right and oblique cones and pyramids 10. state how to develop templates and patterns by the triangulation method of pattern development for a hoods b hopper c kinked plates d transforming pieces between parallel and non parallel planes and long tapers 11. state the method of marking out material for cutting, forming and joining operations a function of a template loft and/or similar area b concept of neutral surface to determine cutting dimensions for rolling and forming operations

c methods of locating welded, bolted and riveted fitments d methods of marking out plate/chequer plate and the danger of wrong hand image error which may result from this operation e the methods of marking off material with reference to i allowances for thickness of plate and variations of size and shape of sections ii dimensional accuracy iii quantity required f how to derive connection plate shape for components using standard pitch and edge distances g how to locate hole centres from standard back marks and cross- centres h the function of setting points (S.O.P) for full size layouts i methods applied to batch or one off production j methods of setting out cambers, including calculation method k methods of setting out rectangles i using trammels ii 3:4:5 method iii checking diagonals iv use of chalk line.


Outcome 3: Identify common engineering materials used in fabrication Practical Activities 1. Identify and carry out initial assessment of commonly used engineering materials. 2. Classify materials and identifying appropriate grouping and category. Underpinning Knowledge The candidate will be able to 1. state the basic techniques for identifying type of material a visual b tactile c assessment of relative density d magnetic properties 2. describe the use of workshop techniques to classify materials into the following groups a metals i ferrous ii non ferrous materials b polymers i thermoplastics ii thermosetting materials c ceramics i glass ii porcelain iii carbides d composites i fibre reinforced plastics (FRP) ii reinforced concrete 3. state common forms of supply for a pipe and tube b plate c sheet d sections e castings f extrusions.


Outcome 4: Identify the structure and basic working properties (mechanical and thermal) of the materials Practical Activities 1. Identify material structure by applying tests, examining performance or supplied data. 2. Assess the properties of materials by conducting examinations or applying tests. 3. Report the significance of the properties on material behaviour in both a mechanical and thermal context. 4. Identify defects found by visual and NDT methods. Underpinning Knowledge The candidate will be able to 1. describe variations in material structures a solidification b crystal nature c grain size and alignment 2. describe the procedure for determining the properties of materials a specifications b magnetic c thermal d physical e mechanical tests including tensile, impact, hardness f micro/macro-examination 3. state the properties influencing the selection of materials for given applications a density b strength i ductility ii toughness iii elasticity iv hardness v malleability vii appearance viii cost c conductivity d resistance to i environmental degradation ii corrosion iii heat 4. state the influence of hot and cold working during fabrication on the mechanical properties of materials, requiring selected treatments during fabrication operations, re-crystallisation


5. state types of heat treatment and their application a annealing b normalising c stress relief d pre/post heating 6. describe defects visible to the eye and defects revealed by NDT inspection (process description not required) a radiographic b ultra-sonic c magnetic particle d dye penetrant 7. state types of corrosion a atmospheric b stress c aquatic 8. state the types of corrosion protection a cathodic b sacrificial anode c impressed current 9. state types of surface treatment and their application a galvanising b surface plating c anodising/sheradizing d painting e cladding/lining f other coatings g cleaning methods 10. state the function of columns, beams, stanchions and bases as component parts of frames and structures 11. state tension and compression members.


Unit 6: Preparation, joining and erection of fabrication materials

Rationale This optional unit is part of the occupational award for platework. It covers the requirements for cutting, shaping, joining and fabrication of materials The unit covers four performance outcomes. The candidate will be able to 1. specify cutting and shaping processes for given applications 2. prepare equipment and shape products to required specification 3. assemble and join fabricated assemblies 4. erect fabricated assemblies Connection with other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS FSS2:2.11, FSS3:2.12, FSS4:2.13, FSS6:3.12 CO2:7.06, CO3:7.04 QSE9:3.09 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be by means of a short answer written test covering the occupational units.


Outcome 1: Specify cutting and shaping processes for given applications, stating the factors influencing selection Practical activities 1. Select and set up suitable shaping equipment to meet component specification. 2. Compare methods of hand and machine cutting used for a range of products, justifying selection on the basis of production efficiency and the ability to meet the product specification. 3. Inspect shaped product for freedom from defects. Underpinning knowledge 1. state the equipment used in oxy-fuel gas cutting a compressed gas cylinders, colour, transport, storage b regulations c hose d blowpipes e safety equipment i flash back arrestors ii non-return valves 2. state factors influencing the selection of thermal cutting processing (oxy-gas/arc plasma) a material to be cut: process applications for low-carbon steel, high carbon steel, alloy steels, non ferrous metals and alloys in terms of the materials i oxide melting point ii thermal conductivity iii electrical conductivity b limits on material thickness and/or size of product which can be cut c oxy-gas cutting high portability d relatively low cost for workshop/site operations 3. state the understanding of oxy-fuel gas cutting in terms of a exothermic chemical action b the influence of oxide combustion temperature c the functions of the pre-heat flame d the action of the cutting flame 4. state the factors influencing quality of the thermal cut edge a relationship between cutter nozzle size and thickness of material being cut b material to be cut and materials susceptible to hardening and cracking c cutting torch oxygen pressure d material condition: surface scale, internal defects

e speed of cutting torch travel f distance of nozzle from the surface to be cut g consistency of angle of nozzle to surface during cutting h cutting path control for straight line and circles i methods of distortion control


5. state the understanding of arc plasma cutting process, in terms of a equipment required b application c gases used for plasma cutting and outline reasons for their selection 6. state the methods of cutting by shear a guillotine b nibbler c rotary shears d universal metal worker section cutting, punching, cropping, notching 7. describe the method and equipment used for cutting by shear in terms of a the compression and shear force exerted during cutting action b the cutting action c clearance angle d cutting (wedge) angle e rake angle f face clearance between the cutting edges as applied to the upper and lower edges when cutting different material/thickness g the relative movement between the cutting edges h the application of shear force by i lever ii direct acting force iii rotating bevelled cutting wheels i the effect of the material properties, thickness and length of cut on i cutting by hand shears ii machine capacity for manually and power operated machines j describe special forms of shearing i section profiling machine ii machinery for profiling sheet and plate iii punching, blanking and combined cutting and forming press tools 8. state equipment used for cutting by shear a interpret cutting machine information in terms of i capacity ii application 9. state how to select hand and powered cutting tools for specific shaping applications including a low cost high portability of hand tools b potential for higher production efficiency, greater accuracy and ability to cut thicker sections with power tools


10. state how to refer to manufacturers’ tables and charts to select hand tools capable of making cuts which conform to product specification requirements. Factors to be considered include: a the shape and dimensions of tools to meet dimensional requirements of the specification b design and dimensions of the tools cutting action i point angle of chisel ii teeth per centimetre (files and saw blades) iii helix angle of drills iv clearance angle/rake angle and face clearance of shear blades selected according to the material to be cut and the accuracy of cut required 11. state how to select mechanical and powered tools for specific applications a notching b straight cuts c external and internal circular shapes d irregular shapes 12. state that guide templates can be used as a production aid when cutting irregular shapes using powered tools 13. state why powered guillotines with guides, back stop and front stop production aids are suitable for batch production of uniform shaped components 14. describe the advantages, applications and limitations influencing selection of cropping machines and machine saws used for cutting straight edges or curves in sheet/plate and sectional materials 15. state how to refer to manufacturers’ tables and charts to select drills and drilling equipment for general and specialist applications to include a twist drills in imperial and metric size for general purpose applications b reamers for accurately finishing holes to an exact size and circular shape


16 state factors influencing the selection of thermal cutting processing (oxy-gas/arc plasma) a material to be cut i low-carbon steel ii low-alloy steel iii stainless steels iv non ferrous metals and alloys b influence i oxide melting point ii thermal conductivity iii electrical conductivity c no limit on material thickness and/or size of product which can be cut d oxy-gas cutting high portability and relatively low cost for workshop/site operations e compare oxy-gas and arc plasma cutting in terms of i equipment requirements ii speed of cutting and ability to cut a range of materials iii quality of the cut edge 17. state the optimum method for a particular shaping operation including a cropping and shearing b drilling and punching c sawing and oxy-fuel cutting d planing and oxy-fuel cutting e milling and ending.


Outcome 2: Prepare equipment and shape the product to the required specification Practical Activities 1. Plan and undertake cut and shape operations safely. 2. Write a risk assessment for a fabrication cutting and shaping operation to include work area, tools, equipment and components being shaped. 3. Produce components using standard cutting tools. 4. Show the effect of different equipment settings on the quality of cut edge. 5. Compare the products dimensional accuracy of different cutting methods, with and without the use of templates/guides/machine stops. 6. Use standard cutting tools to give special purpose results and compare for accuracy, finish, and freedom from distortion. 7. Check the function and action of moving parts on equipment and relate to manufacturers’ instruction manuals. 8. Set up non chip forming and chip forming cutting processes. Underpinning knowledge The candidate will be able to 1. state how to identify defects/potential safety hazards in the use and condition of hand tools a damaged equipment, repair or replace b use of non-sparking tools when working in flammable and explosive environments c ensuring shaping tools are handled carefully 2. state requirements applicable to portable shaping equipment a use of low voltage portable electrical equipment b safety checks on electrical equipment i good insulation ii appropriate guarding c working within the thickness range of the equipment 3. state the safety precautions specific to cutting by shear a handling of sheet and plate, use of gloves and protective footwear b importance of following specific instructions and regulations related to cutting equipment, use of guards 4. state the potential safety hazards associated with guillotines, sawing, nibbling, drilling operations a correct use of work holding devices when shearing, sawing and drilling component parts


5. describe how to interpret written and graphical instructions and plan a logical sequence of operations to produce a finished shape by hand cutting a the sequence of operations required to manufacture a product i economy of materials ii simplicity of cutting and shaping (use of stops and guides) iii quantity required (batch or one off iv the full use of production aids and equipment v preservation of coated or polished surfaces vi accuracy of dimension and form vii standard of finish required viii opportunities for stack processing (drilling/flame cutting ix setting of optimum process settings to maximise production efficiency 6. describe the set up of oxy-fuel gas cutting blowpipes a control of blowpipe, oxygen and fuel gas pressure and flow rate b control of cutting oxygen flow rate c arrangements for mixing of oxygen and fuel gas for pre-heating d the construction and application of typical cutting nozzles e procedures for lighting, adjusting and extinguishing the cutting flame 7. describe the operation of oxy-fuel gas and arc plasma cutting techniques, in terms of a free hand cutting procedures for starting cut from edge of plate and away from edge, procedures for cutting round bar and typical sections b guided hand cutting use of: single and double cutting supports, circle attachments c cutting equipment used for bevelling pipe and plate 8. state how to prepare hand tools for cutting and shaping operations a tools selected to meet specification requirements and checked for freedom from defects, degree of sharpness, loose parts, chips and cracks b trial tests on scrap materials to optimise cutting action and allow dimensional checks to confirm degree of accuracy 9. state the difference and action of chip and non chip forming cutting processes 10. describe how to prepare powered tools for cutting and shaping operations a powered tools checked for correct operation of self centring chucks, position of holding handles, and secure positioning of cutting tools b correct setting of speeds and feeds for the type and thickness of material to be cut c the work piece is securely clamped to i work tables for fixed cutting operations ii templates/guides for movable work pieces


11. describe the setting up of cutters in shearing machines to achieve a the correct face clearance between the cutters b no overlap between the cutter points c correct distance between the cutters d correct depth of travel of cutters 12. describe the setting up of punches and dies in nibbling machines to achieve the correct a size punch and die to suit material thickness b length of stroke to suit material thickness c alignment of punch when cutting edge facing the direction of feed and to give concentricity with the die d depth of punch insertion into die 13. state the purpose of inspection and method of checking the accuracy of dimensions, form and fitness of the shaped component a the function of a datum surface and datum line b the function of standard measuring equipment c accuracy with regard to specified tolerance d standard tolerances for specific purposes e relate function to specific tolerances f the methods of checking the accuracy of shaped components in terms of: i linear dimensions ii alignment iii squareness and freedom from twist iv circularity g batch to batch conformity, the condition for which i defects are critical and cannot be re-worked ii components can be brought back within specification through re-working.


Outcome 3: Assemble and join fabricated assemblies

Practical Activities 1. Select assembly methods for specific applications. 2. Evaluate the suitability of assembly and joining methods for the selected application. 3. Use assembly procedures, tools and processes for assembling and joining products. 4. Interpret assembly drawings and recording the sequence of operations and processing requirements. 5. Use appropriate process to make fabricated joints. 6 Obtain specification. 7. Select method and equipment required to check conformance. 8. Ensure equipment and methods are approved for checking. 9. Ensure all aspects checked for compliance to include a linear dimensions b angles c profiles d surface finish. 10. Assess compliance, defects and variations identified and dealt with. 11. Record checks made. Underpinning Knowledge The candidate will be able to 1. state how to identify with the aid of manufacturers’ tables, mechanical fastening devices; their general characteristics and applications 2. describe the types and categories of fastening devices and fittings used for a solid rivets b black, fitted and high strength friction grip bolts c lock, castellated and self locking nuts d flat, taper, spring and tab washers e lindapters 3. state essential tools required to secure mechanical fastening devices 4. state the importance of cleanliness of surfaces in contact, correct tensioning, sequence of tightening, hole diameters to specific tolerances and need for correct alignment of holes 5. describe how to ensure assembly area is clean and free from obstructions 6. state component parts to be assembled are located in a safe accessible position and are checked for compliance with specification 7. describe component shortages are recorded and appropriate authority notified


8. state the reasons for and methods of surface protection of materials to be assembled, prior to, during and after assembly a painting b use of heat resistant materials c lagging 9. state how to ensure correct sequence of assembly to specification, the need for component tolerance/allowances, reason from sub- assemblies, trial assemblies and aids to support dimensional accuracy 10. describe the reasons for and methods used to obtain a level surface for assembly a spirit level and straight edge b water level c piano wire and bubble level d tilting level e laser level 11. state the reasons for machining critical components prior to assembly a stanchions b columns c pipe flanges d joint edge preparation 12. state methods used to set up frames, structures with reference to a logical sequence of assembly to avoid twist and distortion b use of tack bolts and tack welds c use of jigs and fixtures d use of stays and spiders to maintain shape e use of spirit levels, piano wire and bubble level, water level and tilting level 13. state when to use jigs and other assembly aids to improve standardisation and limit distortion and other assembly defects 14. describe assembly procedures related to specific fabrication contexts a pipe fabrication i setting up equal and unequal diameter branch pipes on perpendicular and inclined planes, use of quarter lines b structural and steel plate fabricated assembly i portal leg, raker, valley, knee and apex joints ii plate beams, castellated beams and machine bases iii roof trusses and lattice girders iv stairways and platforms 15. state the common thermal joining processes used in fabrication a manual metal-arc welding b metal-arc gas-shielded welding in terms of i gases, electrodes and filler wires ii set up and use


16. state the action of the flux constituents in terms of a protective gaseous state b stabilise the arc c provide deoxidisers d provide alloying elements 17. state the types of basic joints and positions a butt, fillet b flat, vertical, horizontal/vertical, overhead 18. state the importance of removal of protective coatings prior to thermal joining relevant health and safety requirements and PPE equipment required for the joining methods listed in 15

19. state the appropriate process technology to carry out the following simple joining operations a tack welding b butt and fillet welds in a flat position 20. describe assembly and correct set up and shut down procedures 21. describe causes of distortion in respect of a weld metal cooling from liquid to solid at room temperature b expansion of restrained metal when heated above plastic yield and subsequent contraction 22. state methods of controlling and acceptable methods of rectifying distortion of welded structures 23. state the sequence of operation to fabricate a steel work structure in terms of a economy in the use of material b simplicity of construction c quantity required d full use of production aids/equipment e dimensional accuracy f accuracy g standard of finish 24. state how and where to obtain specification and/or quality control documentation 25. describe the methods and techniques used for checking fabricated components 26. state the typical fabrication defects and variations which may arise when a mechanical cutting b thermal cutting c forming d joining 27. state how to identify typical fabricated defects 28. state how to identify typical checking defects


29. state the procedures for dealing with defects and variations 30. state the factors taken into account to determine what action should be taken a relative costs of re-working b scrapping the defective item 31. state who to approach for assistance in applying inspection methods and techniques.


Outcome 4: Erect fabricated assemblies

Practical activities 1. Identify an irregular shaped load and estimating a the mass of the component and the force on the slings b the centre of gravity and required positions for lifting lugs. 2. Select lifting appliances, lifting techniques and equipment for a range of site applications, for confirmation with supervisor. 3. Use models to identify potential hazards on site prior to erection operations. 4. Survey a work site to identify actual safety hazards and make recommendations for improvement. 5. Identify site safety requirements and equipment by reference to legislative documents and brochures provided by suppliers of safety equipment. Underpinning knowledge The candidate will be able to 1. state potential health and safety hazards and appropriate actions in respect of construction lifting equipment regulations 1998 (LOLER): a the condition, suitability, inspection and identification of lifting chains, rope or lifting equipment b conditions relating to SWL of rope slings c type of faults in wire ropes which render them unserviceable in relation to worn, broken, fraying, kinked, or corroded strands d identify chain sling defects by visual examination i stretched links ii wear iii distortion e identify belt sling defects by visual examination i cuts ii fraying iii blistering f safety precautions to be taken when using flat belts, slings, in relation to i desired curvature ii care of hooks and eye bolts iii avoiding rough/sharp edges when using fibre ropes and slings iv need to avoid contact with heat or chemicals v storage in dry well ventilated areas vi observing maximum bite and slinging angles 2. state rules for power lifting of loads with particular emphasis on a minimum and maximum safe working load b stability of lifted loads during and immediately after lifting c avoidance of pushing/pulling loads d transporting loads over the heads of workers and others


3. describe how to identify types, applications, and advantages of specific lifting equipment a wire rope slings and attachments b flat belt slings including woven nylon/terylene wire mesh plastics covered, plaited, nylon wound c the main types of lifting equipment i chain slings ii rope slings iii shackle iv swivel hook v plate clamp d sling attachments including bow and dee shackles lugs, plain and collar eye bolts, pipe and plate clamps, dynamometer e the advantages of bolt slings as providing breadth of bearing to a load, reducing risk of load damage f main types of fibre ropes as manilla, sisal, nylon, terylene, polypropylene 4. state how to determine loadings and forces on lifting equipment a use of manufacturers’ tables to determine diameter of chain links, SWL and angle of slings for single and double chain slings b markings on load to be lifted c estimation of centre gravity for components/assemblies d how to determine weights of plate, pipe and sections from manufacturers’ tables 5. state the purpose of and techniques for using general erecting equipment a tensioning screws b beam clamps c chain blocks d pull lift e sheave blocks f hand/power operated winches g Tirfors h spanners, including podger i drifts and wedges j jacks 6. state preparatory requirements for site assembly including reference to site assembly drawings to identify suitable site for positioning steelwork, area to be cleared of structural materials, obstacles and debris 7. describe techniques used for erecting steelwork structures in terms of the main stages in erecting a vertical columns, including adjustment of alignment and levelling base b ties and intermediate members c roof trusses 8. state procedures used for operational shut down of live plants prior to assembly operations


9. state the purpose of, and techniques of in-process and final inspection a the function of datum surface or datum line b the function of standard measuring equipment c the tolerance to accuracy and relation to specific tolerance and function d methods of checking correct sequence of assembly, the accuracy of dimensions, alignment, squareness, and freedom from twist or distortion 10. state the particular health and safety hazards associated with fabrication assembly a safe lifting methods and use of lifting aids eg reasons for having a maximum included angle for a two leg sling b dangers when working at heights i use of staging and roping off to prevent personal falls ii use of warning signs and hard hats and other personal protective equipment to reduce risk of injury iii securing of ladders and ancillary equipment

11. state the techniques used for loading crane hooks with slings 12. state the procedures used for lifting unbalanced loads in relation to positioning of crane hook with equal slings, positioning of crane with unequal length slings 13. describe how to determine by estimating and calculating centre of gravity of simple and built up complex shapes in order to locate lifting positions a the main use of a range of lifting appliances in common use on engineering construction sites i winches ii mobile derrick iii tower crane iv truck mounted light duty mobile crane truck v crawler mounted heavy duty mobile crane vi skyhorse vii fly jib b identify the main component parts of each lifting appliance c the terminology applicable to lifting appliances i hoisting and lowering ii slewing iii derricking iv luffing.


Unit 7: Forming of thick plate and sections

Rationale This optional unit is part of the occupational award for platework. It covers the processes of forming using hand and mechanised equipment. The unit covers four performance outcomes. The candidate will be able to 1. specify forming processes for thick plate and section 2. apply safe working practices 3. produce components using a range of forming and shaping techniques 4. form products to required specifications Connection with other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS FSS3:2.12, FSS4:2.13, FSS8:3.16 CO2:7.06, CO3:7.04 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Specify forming processes for thick plate and sections, stating the factors influencing selection

Practical Activities 1. Show the effect of different equipment settings and formers on the form and accuracy of the product. 2. Compare different forming processes to form a given product. 3. Evaluate dimensional accuracy, freedom from surface defects and production efficiency of each method. 4. Use standard and non-standard forming tools to give special purpose results and compare the product form, strength and rigidity. Underpinning Knowledge The candidate will be able to 1. state how to distinguish between hand forming and mechanised processes in terms of equipment and typical applications 2. describe hand forming processes used for hot and cold forming of plate work a use of hammers and flattening devices for levelling plate and stretch forming flat strip b spot heating to correct distortion using the principles of expansion/contraction c hot bending of flat bar (X and Y planes) using hand tools and selected radius formers 3. describe hand forming processes used for hot and cold forming of structural steel sections including a use of hammers to stretch form rolled steel angles, important applications include straightening or cambering b localised vee shaped heating of beams and columns to straighten or camber 4. state that the selection of mechanised equipment for mechanised powered forming of platework structural steel is influenced by a mechanical properties of material to be formed b plate thickness and plate dimensions c finished shape of product (single or double curvature) d design specification of forming equipment e plate handling facilities


5. state the factors influencing the selection of rolling machines a thickness of material b radius of formed product c batch production requirements related to forming leading and trailing edges d shape of form and type of product i cylindrical ii conical iii sectional components iv work which requires straightening v pipe over 20 mm diameter e surface finish.



Practical Activities 1. Promote safe and efficient operation. 2. Identify dangers and relevant safety features used on forming equipment. 3. Identify general features capable of improvement in the immediate working environment of forming operations. Underpinning Knowledge The candidate will be able to 1. state how to refer to current regulations and codes of practice regarding the use and guarding of a power bending rolls b press brakes c presses d folding machines e pipe bending equipment 2. state the required personal protective clothing and equipment to guard against dangers to the body, hands and feet when handling hot and cold sheet materials a the reasons for electrical isolation of powered equipment during set-up b ensuring emergency stops and guards are in place and working efficiently 3. describe how to check the condition of hand forming tools for safe and efficient operation 4. describe how to apply good housekeeping practice ensuring the immediate work area is kept clean and tidy 5. state how to record work related accidents.


Outcome 3: Produce components using a range of forming and shaping techniques

Practical Activities 1. Check the function and action of moving parts of equipment and relate to manufacturer’s instruction manuals. 2. Promote safe and efficient operation of equipment. 3. Carry out trial forming tests on material to establish accuracy of blank sizes, correct position of bending line and correct bending sequence. Underpinning Knowledge The candidate will be able to 1. state how to select machines and equipment to carry out the forming operations 2. state how to check blank sizes to ensure compliance with forming allowances and specification requirements 3. describe the importance of checking the linear dimensions and relevant plate surface of forming/bend lines to a meet specification requirements b ensure correct numbered sequence of forming operations c determine size and shape of any notching d prevent the dangers of wrong hand or mirror image caused by the forming operation 4. state work instructions to be incorporated with forming such as leading and trailing edges of cylinder blanks to be pre-formed prior to rolling 5. describe the setting up of hand forming equipment to achieve a the required selection of hand tools free from defects, laid out in correct sequence for forming operations b securing of formers in vices and locating holes c prepared access to any ancillary facilities such as heating and quenching equipment d access to forming templates to check each stage of forming 6. describe the setting up of folding and bending equipment to achieve: a top and bottom forming tools of the correct dimensions and forming radius b the correct position of top forming tool relative to the bottom tool c correct positioning of material to be formed or stops and guides to improve production efficiency on batch production d machine adjustments to accommodate metal thickness and material spring back e access to appropriate lifting facilities


7. describe the setting up of bending rolls to achieve a correct radius of form for successive operations b addition of ancillary devices to assist rolling of special shapes such as cone guide roller c access to forming templates to check radius of form d clear access on either side of machine to allow for freedom of plate movement 8. state the factors affecting spring-back allowance and minimum bend radius 9. state the difference between mean and neutral surface 10. state the neutral surface and bending allowance for plate, pipe and sectional material 11. state the location of bend lines for different metals and thickness.


Outcome 4: Form the product to the required specification

Practical Activities 1. Show the effect of different equipment settings and formers on the form and accuracy of the product. 2. Compare different forming processes to form a given product. 3. Evaluate dimensional accuracy, freedom from surface defects and production efficiency of each method. 4. Use standard and none standard forming tools. 5. Test sequence of forming activities on material. 6. Produce components using a range of forming and shaping techniques. Underpinning Knowledge The candidate will be able to 1. state how to interpret written and graphical instructions and plan a logical sequence of operations to form plate or structural products in terms of a quantity required (batch/one off) b the full use of production aids and equipment c preservation of surface finish/coating d sequence of forming operations e accuracy of form 2. state how to carry out the forming operation a correct positioning of forming lines marked on the sheet or section with appropriate position of i work piece and formers when hand forming ii set position on the forming machine or use of stops and guides for batch forming b bending/forming action completed i in one operation for angular bends using bending and folding equipment ii in a series of progressive forming operations requiring continuous increments of pressure using hand tools or producing curved shapes, in components with and without standard formers iii discrete stages when forming articles such as deep pressed products c the sequence of forming operations required i centre outwards for stretch forming using hand tools ii working away from one or more datum edges for bending/folding, turning the plate over for bends on opposite sides according to the numbered sequence iii in progressive stages from one plate edge to the other when using rolling equipment iv requirements increments of pressure for every pass through the rolls v edges of the plate or section require pre setting to the correct radius prior to rolling


3. state the purpose of inspection and method of checking the accuracy of dimensions form and finish of the formed component a the function of datum surface, datum lines b the function of standard measuring equipment c accuracy with regard to specified tolerance d standard tolerance for specific purposes e relate function to specific purposes f the method of checking the accuracy of i linear dimensions ii alignment iii squareness iv freedom from twist v circularity vi batch to batch conformity g the conditions for which i defects are critical and cannot be re-worked ii components can be brought back within specification through re-working.


Unit 8: Interpreting information and marking out pipe work materials Rationale This optional unit is part of the occupational award for pipefitting. It is concerned with the use of drawings and specifications to identify materials and prepare for pipefitting operations The unit covers four performance outcomes 1. interpret drawings, specifications data and procedures 2. measure and mark out components, templates and patterns 3. identify common engineering materials used in fabrication engineering 4. identify the structure and basic working principles of materials Connection with other awards This unit combines and extends the underpinning knowledge contained in ECITB and equivalent ECS IPS Pipe 1:3.03, IPS Pipe 2:3.12, IPS Pipe 4:2.04, IPS Pipe 7:2.12, IPS Pipe 8:2.13, IPS Pipe 12:3.16 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed means of a short answer written test covering the occupational units.


Outcome 1: Interpret drawings, specifications, data and procedures Practical Activities 1. Read and interpret working drawings, fabrication specifications and/or procedures to extract necessary information to prepare the work piece and related processes for fabrication operations. 2. Identify component and material requirements through the preparation of parts lists, and sketches, taking into consideration working tolerances, and material allowances for subsequent fabrication operations. 3. Identify working constraints including a set-out requirements b nesting arrangements c sub-assemblies d mirror images e quantities required. 4. Identify safety requirements. 5. Produce operation sheets selecting the most effective and efficient method and sequence of manufacture. 6. Inspect finished product to assess compliance with specification requirements. Underpinning Knowledge The candidate will be able to 1. state the importance and purpose of a drawing or specification a determine shape and characteristics of fabricated products b material, tools, equipment and fabrication requirements 2. state how to obtain drawings, specifications and data 3. state the basic concept of standards for communicating technical information in terms of providing a universal language relevant to engineering 4. state the means of communicating technical information a technical drawings b operation sheets c data sheets and wall charts d standard/manufacturers’ tables and servicing/repair manuals e microfilm, microfiche, video tapes and VDUs


5. state how to interpret drawings of plate and structural sections to BSEN ISO 1660(1996) and BS/EN22553 (1995) a assembly detail and general arrangement drawings b basic and additional information to be found on drawings i projection ii unit of measurement iii scale iv material and specification v heat and protective treatment vi general tolerance vii issue reference viii warning notes e.g. machining allowance c distinguish between i orthographic: first and third angle projections ii pictorial: isometric and oblique views iii single plane sectioned and auxiliary views iv isometric pipe work drawings d standard conventions

i types of line ii representation of common features e dimensioning techniques for i notching ii drilling

iii folding 6. state how to identify components from drawings, specifications and data a technical drawings, sections, exploded views and diagrams b manufacturers’ servicing, repair and parts data c data sheets and wall charts 7. describe how to interpret technical drawings of pipe systems to BSEN ISO 1660(1996), BS/EN22553 (1995) and BS 1553 a block plans/plant layout drawings to determine i the pipeline function ii basic equipment iii schematic detail iv constraints/safety hazards arising from the site/location b pipe assembly drawings to i determine pipe system specifications ii determine bend, joint and fitting requirements iii orientate branches and turns iv discriminate between assembly, sub-assembly and components v pipe support arrangements c fabrication component drawings to determine i welding requirements in accordance with BS2633 (1987), 2640 (1982), 2971 (1991) ii the development of cut and shut bends and pipe reinforcements iii set on and set in branches in the perpendicular and inclined planes iv pipe support details.


Outcome 2: Measure and mark out components, templates and patterns Practical Activities 1. Identify metric and imperial systems of measurement. 2. Select and use suitable measuring equipment for required work, having regard to accuracy requirements. 3. Measure and mark out components, templates and patterns. 4. Develop templates and patterns. 5. Mark card or metal models from templates and patterns. Underpinning Knowledge The candidate will be able to 1. state the importance of accurate measurement and use of measuring equipment a the danger of accumulated errors in marking out components, templates, and patterns, and the importance of working from centre lines and datum faces/edges b how to select appropriate measuring equipment for given applications including the use of rules, callipers, dividers, beam trammels, micrometer and vernier callipers, surface plate, vernier height gauges and protractors and standard sheet gauges, in metric and imperial systems 2. state the reasons for using templates to avoid repetitive measuring and marking out of similar parts, material optimisation, guiding equipment 3. describe the materials used for template making and the factors influencing selection and processing allowances 4. state methods used to determine the circumferences of pipes 5. state how to calculate and check blank sizes to ensure compliance with forming allowances and specification requirements 6. describe the methods of constructing lines and curves of intersection in terms of a construction of regular geometrical shapes such as i circle ii ellipse iii oval b construction of sectional views through cylinders c projection of auxiliary sections and views to clarify drawings and simplify surface developments 7. state how to determine the lines of intersection by means of a projection using full layouts b projection using short cut methods


8. state how to develop templates and patterns by parallel line methods of surface development, for a mitred turns b segmental bends c set on branch i square ii lateral (inclined) iii equal iv unequal v off centre d set in branch i square ii lateral (inclined)

iii equal iv unequal v off centre 9. state how to mark out pipe fabrications in terms of a bend lines (centre line and outside line) b off sets (centre line and outside line) 10. state how to sketch a weld preps at crotch and flank for branches and butts b system components 11. state how to draw out piping arrangements using designated symbols to indicate a pipe systems and their function b basic equipment and collection of equipment for specific arrangements i valves ii control iii trapping iv pumping

c schematic to arrangement drawings 12. state how to produce from drawings a material lists b cutting lists.


Outcome 3: Identify common engineering materials used in fabrication engineering Practical Activities 1. Identify and carry out initial assessment of commonly used engineering materials. 2. Classify materials and identify appropriate grouping and category. Underpinning Knowledge The candidate will be able to 1. state the basic techniques for identifying type of material a visual b tactile c assessment of relative density d magnetic properties 2. state the use of work shop techniques to classify materials into the following groups a metals i ferrous ii non ferrous materials b polymers i thermoplastics ii thermosetting materials c ceramics i glass ii porcelain iii carbides d composites i fibre reinforced plastics (FRP) ii reinforced concrete 3. state the criteria for selecting a material for a given application a strength b ductility c malleability d density e appearance f resistant properties g cost 4. state common forms of supply for a plate b pipes c structural sections d sheet e castings f extrusions


5. state the materials used for the external and internal protection of pipe systems and other methods used for conveying a solids b common liquids c gases.


Outcome 4: Identify the structure and basic working properties (mechanical and thermal) of the materials Practical Activities 1. Identify material structure by applying tests, examining performance or supplied data. 2. Assess the properties of materials by conducting examinations or applying tests. 3. Report the significance of the properties on material behaviour in both a mechanical and thermal context. Underpinning Knowledge The candidate will be able to 1. describe variations in material structures a crystal nature b grain size and alignment 2. state the procedure for determining the properties of materials a specifications b magnetic c thermal d physical e mechanical tests f micro/macro-examination 3. state the properties influencing the selection of materials for given applications a density b strength i ductility ii toughness iii elasticity iv hardness c conductivity d resistance to i environmental degradation ii corrosion iii heat/low temperature 4. state the influence of hot and cold working during fabrication on the mechanical properties of materials, requiring selected treatments during fabrication operations 5. state types of heat treatment and their application a annealing b normalising c stress relief d pre/post heating


6. state types of corrosion a atmospheric b stress c aquatic 7. state types of corrosion protection

a cathodic b sacrificial anode c impressed current 8. state the conditions for which pipe work would require protection a corrosion inside of the pipe b corrosion outside of the pipe c erosion inside of the pipe d erosion outside of the pipe e prevention of contamination of the product 9. describe types of surface treatment and their application a galvanising b surface plating c anodising/sheradizing d painting e cladding/lining f other coatings g cleaning methods 10. state the purpose of insulation and the types of insulation material 11. state the forms of external covering used to protect insulation 12. describe the methods of applying insulation to equipment which may require frequent access.


Unit 9: Preparation, joining and erection of pipe work assemblies Rationale This optional unit is part of the occupational award for pipefitting. It is concerned with the skills and knowledge in respect of assembly methods, safe movement and joining of pipe work.

The unit covers three performance outcomes. The candidate will be able to 1. assemble fabricated pipe work assemblies 2. lift and erect pipe work 3. prepare join and inspect pipe work

Connection with other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS IPS Pipe 1:3.03, IPS Pipe 2:3.12, IPS Pipe 5:6.01, IPS Pipe 6:2.11, IPS Pipe 7:2.13, IPS Pipe 8:2.13 CO2:7.06, CO3:7.04 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Assemble fabricated pipe work assemblies

Practical Activities 1. Select assembly methods for specific applications. 2. Evaluate the suitability of assembly and joining methods for the selected application. 3. Use assembly procedures, tools and processes for assembling and joining products. 4. Interpret assembly drawings and record the sequence of operations and processing requirements. 5. Use appropriate process to make fabricated joints. Underpinning Knowledge The candidate will be able to 1. state how to identify with the aid of manufacturers’ tables, mechanical fastening devices; their general characteristics and applications 2. describe the types and categories of fastening devices and fittings used for plate, tube and pipe work a black fitted and high strength friction grips b lock, castellated and self locking nuts c flat, taper, spring and tab washers 3. state the sequence of tightening bolts and methods of tensioning 4. state essential tools required to secure mechanical fastening devices 5. describe the importance of cleanliness of surfaces in contact, correct tensioning, sequence of tightening, hole diameters to specific tolerances and need for correct alignment of holes 6. state how to ensure assembly area is clean and free from obstructions 7. state the component parts to be assembled are located in a safe accessible position and are checked for compliance with specification 8. state the component shortages are recorded and appropriate authority notified 9. state the reasons for and methods of surface protection of materials to be assembled, prior to, during and after assembly a painting b use of heat resistant materials c lagging 10. state how to ensure correct sequence of assembly to specification, the need for component tolerance/allowances, reason from sub- assemblies, trial assemblies and aids to support dimensional accuracy


11. state the reasons for and methods used to obtain a level surface for assembly a spirit level and straight edge b water level c piano wire and bubble level d tilting level e laser level 12. state the method of producing a working sequence for fabrication and installation of pipe work e.g. fixed end to free 13. state the reasons for machining critical components prior to assembly a pipe flanges b joint edge preparation 14. state when to use jigs and other assembly aids to improve standardisation and limit distortion and other assembly defects 15. describe assembly procedures related to specific fabrication contexts a pipe fabrication i setting up equal and unequal diameter branch pipes on perpendicular and inclined planes 16. state how to produce work schedules for simple pipe assemblies 17. describe how to fabricate a jacketed pipe b pipe work reinforcement 18. state how to calculate pipe end-to-end lengths from measurements a centre to centre b face to face c face to centre measurements 19. state the range of fittings available for non-metals used in joining pipe work 20. state the factors to be considered when installing pipe work a reasons for pipe, level and slope in b describe the use of plumb bobs and levels 21. state the reasons for minimum distance between pipes as space for a fittings b insulation c access and routings of pipe work, which avoids walkways 22. state the reasons for positioning joints a access b ensure positional welds are kept to a minimum


23. describe the forms of pipe joints in terms of permanent/demountable joints a thread b flange c weld d compression e soldering, brazing 24. state the benefits and limitations of pipe bending over the use of pipe work fittings 25. state the equipment, materials, procedures and their use for making the following pipe joints a thread b flange c weld d compression e soldering, brazing 26. state the range of fittings used in joining pipe work. State the forms of non-metallic joints in terms of a thread b flange c weld d compression e solvent, cement 27. state the equipment materials and procedures for making the following joints in non-metals a thread b flanged c weld, socket fusion, butt fusion d compression 28. state the types of pipe support a hangers b pipe bridges c anchors

d guides e variable and constant loading 29. state size and type of pipe in relation to span between supports.


Outcome 2: Lift and erect pipe work

Practical Activities 1. Prepare work areas for fabricating and assembling pipe work. 2. Use models to demonstrate procedures for erecting pipelines. 3. Identify an irregular shaped load and estimate a the mass of the component and the forces in the slings b the centre of gravity and required positions to attach lifting equipment. 4. Select lift appliances, lift techniques and equipment for arrange of site applications, for confirmation with supervisor. 5. Use models to identify potential hazards on site prior to erection operations. 6. Survey a work site to identify actual safety hazards and make recommendations for improvement. 7. Identify site safety requirements and equipment by reference to legislative documents and brochures provided by suppliers of safety equipment. Underpinning Knowledge The candidate will be able to 1. state how to identify types, applications, and advantages of specific lifting equipment a wire rope slings b flat belt slings including woven nylon/terylene wire mesh plastics covered, plaited, nylon wound c the main types of lifting equipment i chain slings ii rope slings iii shackle iv swivel hook v plate clamp vi ring link/eye bolt d sling attachments including bow and dee shackles lugs, plain and collar eye bolts, pipe and plate clamps, dynamometer e the advantages of belt slings as providing breadth of bearing to a load, reducing risk of load damage f main types of fibre ropes as manilla, sisal, nylon, terylene, polypropylene 2. state the purpose of general erecting equipment a beam clamps b chain blocks c pull lift d sheave blocks e hand/power operated winches f Tirfors g spanners, including podger h drifts and wedges i hammers


3. state the preparatory requirements for site assembly including reference to site assembly drawings to identify suitable site for positioning steelwork, area to be cleared of structural materials, obstacles and debris 4. state the estimation of centre of gravity for components/assemblies 5. describe how to determine loadings and forces on lifting equipment a use of manufacturers’ tables to determine diameter of chain links, SWL and angle of slings for single and double chain slings b markings on load to be lifted c how to determine weights of plate, pipe and sections from manufacturers’ tables 6. state techniques required for lifting equipment including use of plate clamps 7. state techniques for loading crane hooks with slings 8. state procedures for lifting unbalanced loads in relation to positioning of crane hook with equal slings, positioning of crane with unequal length slings 9. state how to determine by estimating centre of gravity of simple and built up complex shapes in order to locate lifting positions a the main use of a range of lifting appliances in common use on engineering construction sites i winches ii mobile derrick iii tower crane iv truck mounted light duty mobile crane truck v crawler mounted heavy duty mobile crane vi skyhorse vii fly jib b the terminology applicable to lifting appliances i hoisting and lowering ii slewing iii derricking iv luffing


10. describe the potential health and safety hazards and appropriate actions in respect of construction lifting equipment regulations 1998 (LOLER) a the condition, suitability, inspection and identification of lifting chains, rope or lifting equipment b conditions relating to SWL of rope slings c type of faults in wire ropes which render them unserviceable in relation to worn, broken, fraying, kinked, or corroded strands d identify chain sling defects by visual examination i stretched links ii wear iii distortion e identify belt sling defects by visual examination i cuts ii fraying iii blistering f safety precautions to be taken when using flat belts, slings, in relation to i desired curvature ii care of hooks and eye bolts iii avoiding rough/sharp edges when using fibre ropes and slings iv need to avoid contact with heat or chemicals v storage in dry well ventilated areas vi observing maximum bite and slinging angles 11. state the particular health and safety hazards associated with pipe work assembly a safe lifting methods and use of lifting aids eg reasons for having a maximum included angle for a two leg sling b dangers when working at heights i use of staging and roping off to prevent personal falls ii use of warning signs and hard hats and other personal protective equipment to reduce risk of injury iii securing of ladders and ancillary equipment 12. state the rules for power lifting of loads with particular emphasis on a minimum and maximum safe working loads b stability of lifted loads during and immediately after lifting c avoidance of pushing/pulling loads d transporting loads over the heads of workers and others.


Outcome 3:Prepare join and inspect pipe work

Practical Activities 1. Write a risk assessment for workshop/site based hand cutting operations to include work area, tools, equipment and components being shaped. 2. Plan and undertake cutting and shaping operations safely. 3. Select and set up suitable shaping equipment to meet component specification. 4. Show the effect of different equipment settings on the quality of the cut edge. 5. Compare the products dimensional accuracy of different cutting methods with or without the use of templates/guides and stops. 6. Use standard cutting tools to give special purpose results and comparing for accuracy, finish and freedom from distortion. Underpinning Knowledge The candidate will be able to 1. state the sequence of operation to fabricate a pipe work structure in terms of a economy in the use of material b simplicity of construction c quantity required d full use of production aids /equipment e dimensional accuracy f accuracy g standard of finish 2. state the equipment used in oxy-fuel gas cutting a compressed gas cylinders owner colour, transport, storage b regulations c hose d blowpipes e safety equipment i flash back arrestors ii non-return valves 3. state the factors influencing the selection of thermal cutting processes (oxy-gas/arc plasma) a material to be cut: process applications for low-carbon steel, high- carbon steel, alloy steels, non ferrous metals and alloys in terms of the material’s i oxide melting point ii thermal conductivity iii electrical conductivity b limits on material thickness and/or size of product which can be cut c oxy-gas cutting high portability d relatively low cost for workshop/site operations


4. describe oxy-fuel gas cutting in terms of a exothermic chemical action b the influence of oxide combustion temperature c the functions of the pre-heat flame d the action of the cutting flame 5. state the set up of oxy-fuel gas cutting blowpipes, in terms of a control of blowpipe, oxygen and fuel gas pressure and flow rate b control of cutting oxygen flow rate c arrangements for mixing of oxygen and fuel gas for pre-heating d the construction and application of typical cutting nozzles e procedures for lighting, adjusting and extinguishing the cutting flame 6. state the factors influencing quality of the thermal cut edge a relationship between cutter nozzle size and thickness of material being cut b material to be cut and materials susceptible to hardening and cracking c cutting torch oxygen pressure d material condition: surface scale, internal defects e speed of cutting torch travel f distance of nozzle from the surface to be cut g consistency of angle of nozzle to surface during cutting h cutting path control for straight line and circles i methods of distortion control 7. describe arc plasma cutting process, in terms of a the use of pressurised high temperature plasma stream as the cutting medium i the generation of ionised plasma by an electric arc struck between a tungsten electrode and a copper torch nozzle ii focusing plasma gas at the cutting zone by arc transfer: distinction between main and pilot arc: arc transfer technique, devices for iii avoiding double arcing, action to be taken in the event of double arcing b gases used for plasma cutting and outline reasons for their selection i need for inert, non combustible gas ii gases used: argon/hydrogen/nitrogen combinations iii reasons for selection in terms of materials to be cut, material thickness gas cost 8. describe the safe method of dismantling steel structures 9. state the procedures to be adopted when working in confined spaces and safe exit routes 10. describe the noise and fumes produced by plasma cutting


11. state how to prepare powered tools for cutting and shaping operations a powered tools checked for correct operation of self centring chucks, position of holding handle and secure positioning of cutting tools b correct setting of speeds and feeds for the type and thickness of material to be cut c the work piece is securely clamped to i work tables for fixed cutting operations templates/guides for movable work pieces 12. state the safety precautions to be observed when using power tools a angle grinder b cutting discs 13. state the purpose and application of MMA, MIG and TIG welding a describe the processes in terms of i gases, electrodes and filler wires ii set up and use b the action of the flux constituents in terms of i protective gaseous shield ii stabilise the arc iii provide deoxidisers iv provide alloying elements 14. state the types of basic joints and positions a butt, fillet b flat, vertical, horizontal-vertical, overhead 15. state the procedure for tack welding pipe work a number, size and position of tacks b methods and reasons for maintaining root gap c methods of setting up, squaring and orientation of bolted flanges d setting weld neck, slip on, socket and stub flanges 16. state the importance of removal of protective coatings prior to thermal joining 17. state the relevant health and safety requirements and PPE equipment required for the joining methods listed in 13 18. state the causes of distortion in respect of a weld metal cooling from liquid to solid at room temperature b expansion of restrained metal when heated above plastic yield and subsequent contraction 19. describe the methods of controlling and acceptable methods of rectifying distortion of welded structures 20. state the appropriate process technology to carry out the following simple joining operations a tack welding b butt and fillet welds in a flat position 21. state procedures used for operational shut down of live plants prior to assembly operations including risk assessment and method statements


22. state the inspection of prefabricated pipe work as a continuous process to a list items to be checked and typical faults i material and general condition of pipe/pipe work ii NB of pipe iii position of fittings and equipment iv orientation of branches, tees, elbows and flanges v dimensions vi quality and accuracy of bends vii quality of pipe joints 23. state the purpose of inspection and method of checking the accuracy of dimensions, form and the fitness of the shaped component a the function of a datum surface and datum line b the function of standard measuring equipment c tolerances with regard to accuracy d standard tolerances for specific purposes e relate function to specific tolerances f the methods of checking the accuracy of shaped components in terms of i linear dimensions ii alignment iii squareness and freedom from twist iv circularity g batch to batch conformity, the condition for which i defects are critical and cannot be re-worked ii components can be brought back within specification through re-working h methods of non-destructive testing of joints i visual ii dye penetrant iii magnetic particle i the suitability of the tests named in h for a particular purpose.


Unit 10: Fabrication and installation of pipe work systems Rationale This optional unit is part of the occupational award or pipefitting. It covers the skills and knowledge associated with the fabrication, installation and commissioning of pipe work systems. The unit covers four performance outcomes. The candidate will be able to 1. apply safe working practices 2. fabricate products to specification 3. install pipe work systems 4. commission and test pipe work systems Connection with other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS IPS Pipe 2:3.12, IPS Pipe 3:4.02, IPS Pipe 5:6.02, IPS Pipe 6:2.11, IPS Pipe 7:2.12, IPS Pipe 8:2.13, IPS Pipe 9:2.15, IPS Pipe 11:6.02 CO2:7.06, CO3:7.04 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.



Practical Activities 1. Identify potential hazards on site. 2. Use models to identify potential hazards on site prior to installation operations. 3. Survey a work site to identify actual safety hazards and make recommendations for improvement. 4. Identify from site drawings and company documentation, safe shut down procedures for pipe systems. Underpinning Knowledge The candidate will be able to 1. state the sources of regulations related to piped services hazards including legal regulations applicable to piped systems a HSaW 1974 b Factories Act 1961 Regulations 2. state safe shut-down procedures for pipe systems a the safety requirements and procedures when shutting down an in-service pipeline i permit to work procedure ii certificate of clearance for work on hazardous chemical and flammable fluid pipelines iii arrangements for stand-by operation during maintenance b the safety precautions to be observed when dismantling a pipeline which has been isolated but is still under pressure i safe shut-off isolating valves ii controlled release of pressure iii cooling down allowance iv pressure checking before dismantling v blanking off as appropriate 3. state how to identify defects/potential safety hazards in the use and condition of hand tools a damaged equipment, repair or replace b use of non sparking tools when working in flammable and explosive environments c ensuring shaping tools are handled carefully 4. state requirements applicable to portable shaping equipment a use of low voltage portable electrical equipment b safety checks on electrical equipment: good insulation, appropriate guarding c working within the thickness range of the equipment 5. describe the potential safety hazards associated with sawing, drilling, and operations a correct use of work holding devices when drilling component parts b the need for personal protective clothing and eye protection to protect against hot metals and air born particles


6. state the potential safety hazards associated with grinding and sanding operations including the dangers of fire and explosion and the need for personal protective equipment 7. state the potential safety hazards associated with handling insulation in old and new situations.


Outcome 2: Fabricate products to specification

Practical Activities 1. Write a risk assessment for site based hand cutting operations to include work area, tools, equipment and components being shaped. 2. Plan and undertaking cutting operations safely. 3. Select and set up suitable shaping equipment to meet component specification. 4. Measure the accuracy of different cutting methods with or without the use of templates/guides/and stops. 5. Use standard cutting tools to give special purpose results and comparing for accuracy, finish and freedom from distortion. 6. Prepare tools for cutting and shaping operations. 7. Bend pipe using a range of techniques for a given task. Underpinning Knowledge The candidate will be able to 1. state how to select hand and powered cutting tools for specific shaping applications including a low cost high portability of hand tools b potential for higher production efficiency, greater accuracy and ability to cut thicker sections with power tools 2. state how to refer to manufacturers’ tables and charts to select hand tools capable of making cuts which conform to product specification requirements, factors to be considered include a the shape and dimensions of tools to meet dimensional requirements of the specification b design and dimensions of the tools cutting action i point angle of chisel/scraper ii teeth per centimetre (files and saw blades) iii helix angle of drills iv clearance angle/rake angle c equipment for general and specialist applications i twist drills in imperial and metric sizes for general purpose applications ii reamers for accurately finishing holes to an exact size and circular shape 3. state how to select mechanical and powered tools for specific applications; notching, straight cuts, external and internal circular shapes, irregular shapes 4. state that guide templates can be used as a production aid when cutting irregular shapes using powered tools 5. state why manually powered equipment with guides back stop and front stop production aids are suitable for batch production of uniform shaped components


6. state how to prepare hand tools for cutting threads and shaping operations a tools selected to meet specification requirements and checked for freedom from defects, degree of sharpness, loose parts, chips and cracks b trial tests on scrap materials to optimise cutting action and allow dimensional checks to confirm degree of accuracy 7. describe the difference and action of chip and non chip forming cutting processes 8. state hot and cold forming of pipe work a use of springs for forming 90° bends in copper up to 40 mm bore b cold bending steel pipe up to 20 mm bore c hot bending steel pipe over 20 mm bore using suitable bending blocks d use of expanding tools used without heat on copper tube ends and with heat for steel tube 9. state the factors to be considered in selecting hot or cold pipe bending methods a pipe dimensions b pipe material c mode of pipe manufacture d degree of accuracy required e type of equipment available 10. state how to prepare powered tools for thread cutting and shaping operations a powered tools checked for correct operation of self centring chucks, position of holding handle and secure positioning of cutting tools b correct setting of speeds and feeds for the type and thickness of material to be cut c the work piece is securely clamped to: i work tables for fixed cutting operations ii templates/guides for movable work pieces 11. state the purpose of inspection and method of checking the accuracy of dimensions, form and fitness of the shaped component a the function of a datum surface and datum line b the function of standard measuring equipment c tolerances with regard to accuracy d standard tolerances for specific purposes e relate function to specific tolerances the methods of checking the accuracy of shaped components in terms of i linear dimensions ii alignment iii squareness and freedom from twist iv circularity.


Outcome 3: Install pipe work systems

Practical Activities 1. Identify an operational pipe system conforming to BS1710 colour coding pipe contents/services including operating temperature, pressures and direction of flow. 2. Draw the system detailing operational features. 3. Identify from detail general arrangement and site drawings, the main components used in a pipe installation, operating principles and constructional features. 4. Produce an actual pipe system using a variety of components to be joined using lengths of tube fittings and pipe bracket supports. 5. Carry out suitable checks and commissioning the installation. Underpinning Knowledge The candidate will be able to 1. state the main uses of piped fluid systems a national: water, natural gas b factory services: steam, compressed air, vacuum c process installations: chemical, petrochemical, food d domestic: hot and cold water 2. describe how to identify pipe contents from technical data: BS 1710 Colour coding, and the limit to basic colours for water, steam, oils and combustible liquids, gases, acids, alkalis, air, other liquids and electrical services, identifying other details such as temperature, direction of flow 3. state that flow is proportional to the product of velocity and cross sectional area of the carrier system 4. state the application of, and pipe connections to, the main components used in pipe systems a pumps, fans/blowers, compressors b water tube and fire tube boilers c isolating valves, flow control valves, safety valves, drain valves, steam traps, bleeding and vent valves 5. describe the factors that determine the rate of heat transfer in heat exchangers a surface area b type of materials used c temperature difference d insulation e method of construction 6. state the application of filtration and filter systems a the purpose of filtration b filtration requirements of gas and liquid pipe systems c precautions necessary when assembling/dismantling filters


7. state pipeline protection systems a prevention of internal overloading b solidification, electrical/fire hazards and the main methods of achieving protection 8. state general considerations when installing pipe supports given in BS1552 (part 1) a methods of accommodating movement due to expansion gross weight b thermal/pressure cycling c hydrostatic testing d ability of building structure to withstand applied load e position of supports relative to plant equipment f vibration 9. state types of pipe supports in common use and their application 10. state factors to be considered when erecting and installing pipe work systems 11. describe methods of preparing pipe work for fabrication, the benefits and limitations of a cutting pipes to length by i hand and mechanical hacksaws ii hand and mechanical saws iii abrasive wheels iv tube cutters v thermal cutters b preparing pipe ends for welding by i hand grinding machines ii tube cutters iii thermal cutting c preparing pipes for branch attachment by i hand grinding machines ii thermal cutting 12. state the methods used for joint alignment including types of faces for flanged joints, spigots and butt weld clamping systems 13. describe the types of gaskets and sealing compounds in common use and their applications 14. state sequence of tightening bolts and methods of tensioning.


Outcome 4: Commission and test pipe work systems

Practical Activities 1. Obtain specification. 2. Select method and equipment required to check conformance. 3. Ensure equipment and methods are approved for checking. 4. Ensure all aspects checked for compliance to include a linear dimensions b angles c profiles d surface finish. 5. Assess compliance, defects and variations identified and dealt with. 6. Record checks made. 7. Observe appropriate safety precautions and carry out a pressure test at the recommended pressure and inspect for leaks. 8. Produce a check list of the tasks and tests to be undertaken to bring a pipe system on line following installation. 9. Commission a simple pipe system. Underpinning Knowledge The candidate will be able to 1. state the methods of cleaning pipe systems including special requirements: nuclear clean, grease free, bacteria free piping a mechanical and chemical descaling b detergents c pickling 2. Pre-test inspection and correction/final inspection as a means of checking for a compliance with drawings and specifications b adequate venting and drainage points in pipe work c valves and other equipment which may be damaged as a result of test pressure conditions which may render the test invalid 3. state the methods of carrying out pneumatic and hydraulic testing a lists equipment used b procedure for applying the test and safety precautions to be observed c states the limitations i upper pressure limit ii problems identifying faults d procedures for corrective action in the event of test failure 4. state the reasons for purge, slow warm-up and slow pressurisation to bringing pipe systems back on line


5. state the methods of decommissioning pipe systems prior to maintenance/repair a safe shutdown b safe isolation c controlled pressure release d safe cool down e checks before dismantling f isolation by freezing 6. state the checks required to bring piped systems on line following installation/maintenance work including a alignment and slope b electrical power supplies/insulation c safety switches/devices and interlocks d testing of pipes and pipelines e blowing through, purgised warm up, avoidance of thermal and hydraulic shock loading f operate the system and compare performance with production/ service requirements g complete reports and job sheets of i work carried out to restore system to operational condition ii complete maintenance schedule as appropriate iii report and recommendations on systems condition h report to head of user department 7. describe how and where to obtain specification and/or quality control documentation 8. state what typical fabrication defects and variations may arise 9. state how to identify typical fabricated defects 10. state how to identify typical checking defects 11. describe the procedures for dealing with defects and variations 12. state the factors taken into account to determine what action should be taken a relative costs of re-working b scrapping the defective item 13. state who to approach for assistance in applying inspection methods and techniques.


Unit 11: Preparing for and inspecting fitting operations

Rationale This optional unit is part of the occupational award for mechanical fitting. It covers the skills and knowledge associated with interpreting specifications and selecting materials prior to undertaking fitting. The unit covers three performance outcomes. The candidate will be able to 1. interpret drawings, specifications and data and procedures and apply to the required standard 2. prepare materials for fitting operations 3. carryout measurement, marking out and inspection Connections with other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS IPS Mech 1:3.03, IPS Mech 6:2.04, IPS Mech 9:2.11, IPS Mech 10:2.12, IPS Mech 11:2.13, IPS Mech 12:6.02 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Interpret drawings, specifications, data and procedures and apply to the required standard Practical Activities 1. Read and interpret specifications for fitting activities. 2. Identify limits, tolerances and finishes. 3. Identify component or material requirements. 4. Identify work constraints. 5. Identify component safety requirements. 6. Select the most effective method of fitting. 7. Sketch isometric and oblique views from orthographic drawings of simple components. Underpinning Knowledge The candidate will be able to 1. state the importance and purpose of a drawing or specification a determine shape and characteristics of a product b material, tools, equipment and machine requirements 2. describe how to obtain drawings, specifications and data 3. state the basic concept of standards for communication of technical information in terms of providing a universal language relevant to engineering 4. state the means of communicating technical information a technical drawings b data sheets and wall charts c manufacturers tables and servicing manuals d microfilm, microfiche, video tapes and VDUs 5. describe how to interpret drawings to BSEN ISO 1660(1996) a assembly and detail drawings b basic and additional information to be found on drawings i projection ii unit of measurement iii scale iv material and specification v heat and protective treatment vi general tolerance vi tool references viii warning notes c distinguish between i orthographic: first and third projections ii pictorial: isometric and oblique views iii single plane sectioned views d standard conventions: i types of line ii representation of common features e dimensioning techniques


6. state how to identify components from drawings, specifications and data a technical drawings, diagrams and exploded views b manufacturer’s servicing, repair and parts data c data sheets and wall charts d general arrangement drawings e setting out plans and site layouts 7. describe how to interpret standard/manufacturers’ tables and/or graphs to a select materials for a particular application b obtain specific information from graphs 8. state how to identify the link between colour coding and safety in an engineering workshop 9. state who can provide assistance in interpreting specifications 10. state how to interpret BS45000 A Limits and Fits.


Outcome 2: Prepare materials for fitting operation

Practical Activities 1. Identify materials, their uses and characteristics. 2. Select material of the required type, quality and quantity. 3. Check materials conform to specification. 4. Make materials ready for use and carry out pre-treatment if required. 5. Set out materials in required locations. Underpinning Knowledge The candidate will be able to 1. state materials used a ferrous metals b non-ferrous metals c non-metallic 2. state the constituent elements of materials 3. state material specifications, codes and conventions a company b manufacturer c national/international standard 4. state how to interpret specifications to determine material amounts 5. state workshop tests to identify materials a appearance b surface hardness c reaction to a magnet d by spark test 6. state properties of materials a ductility b hardness c strength (compressive, shear, tensile, torsional) d elasticity e toughness f brittleness g malleability h plasticity i thermal conductivity j electrical conductivity 7. describe characteristics of materials a temperature stability b heat resistance c corrosion and wear resistance d acoustic and shock absorption 8. state how to handle materials in a fitting activity 9. state the major hazards associated with handling materials


10. state the sources of commonly available materials 11. describe materials handling and treatment methods 12. state what equipment can be used to handle and treat materials 13. state the reasons for applying some treatment processes a annealing b normalising c pre and post heat treatments d surface heat treatment including case hardening 14. state which materials require special treatment e.g. cleaning and painting 15. state what procedures exist for pre-treatment of materials 16. describe how efficiency is affected by positioning of materials 17. describe methods of locating and setting up parts to be joined 18. describe forms of supply a ` pipe and tube b plate c sheet d sections e castings f extrusions.


Outcome 3: Carry out measurement, marking out and inspection

Practical activities 1. Select the appropriate tools for measuring, marking out and inspection tasks. 2. Measure, mark out accurately prescribed tolerances. 3. Store tools correctly. Underpinning Knowledge The candidate will be able to 1. state dimensional properties to be measured/checked 2. state application of standards to measurement and dimensional control a British and International agreements on standards b SI units and quantities 3. state types, applications, accuracy, operation and maintenance of tools and equipment for measuring and marking out lengths, circles, arcs and angles a rules b callipers c squares d protractors e micrometers i outside (imperial and metric) ii inside (imperial and metric) iii depth (imperial and metric) f verniers i callipers (imperial and metric) ii height gauge (imperial and metric) iii protractor g marking out from a reference position i use of XYZ axis ii from types of datum 4. state BSEN 45000 system of limits and fits a hole basis b shaft basis


5. state types of accuracy in terms of a limits and fits i clearance ii transition iii interference b accumulative errors c geometric tolerance in terms of i overall variation in form and or position of feature ii geometrical tolerancing, the symbols used on drawings, their indication and interpretation iii the definition of maximum material condition eg application to geometrical and dimensional tolerancing iv the significance of the letter ‘M’ when added to either a toleranced dimension or a datum letter, or both 6. state the types, applications, accuracy, operation and maintenance of tools/equipment used for checking position level and size a surface plates, tables and straight edges b vee-blocks c spirit levels (planes and graduated phials) d clinometers spirit and pendulum types i dumpy levels ii theodolite 7. state the application and care of measuring equipment a the methods of producing the following geometric shapes on components i datums, centre lines, cutting lines ii hole, positions iii circles iv angles v radii vi profiles b the use of gauge blocks as a reference standard for measuring length i classification of gauge blocks in terms of accuracy ii building up of gauge blocks combinations iii the use of ancillary equipment eg adjustable clamps, dovetail measuring accessories iv use of similar equipment for measuring length v care and maintenance of gauge blocks vi use of sine bars, angle blocks, rollers for use in angular measurement 8. state the main factors relating to surface texture a the significance of surface roughness b checking surface finish with standard blocks


9. describe the selection of inspection gauges a the use of gap, plug and ring gauges i distinguish between non-adjustable and adjustable gauges A. checking gauges used for checking during production B. gap gauges used for checking external dimensions C. plug gauges used for checking internal dimensions ii GO and NOT-GO features of gauges iii relate the accuracy of the gauges listed in i to the nominal dimension to be measured iv gauges used for checking internal and external threads b application in the use of the following gauges i dial ii radius iii pitch iv profile v feeler 10. describe inspecting mechanical products a the compliance checking methods and techniques used b what equipment is used during the compliance checking process c the reasons for applying some methods and not others d which defects can be rectified by levelling or re-shaping e how burrs can be removed on cut edges and trim excess material f when a poor surface finish is suitable for further treatment g the acceptable limits of dimensional tolerance h the acceptable limits of surface finishes i what defects are critical and non-critical j to visually inspect for surface and edge defects k to use rules for tape measures to check linear dimensions l to check shape and dimensions with straight edges, squares and gauges m to use surface plates to check flat surfaces n the importance of recording being able to trace information o the accuracy required by production and quality functions.


Unit 12: Fitting by filing and sawing Rationale This optional unit is part of the occupational award for mechanical fitting. It covers the skills and knowledge associated with fitting using the techniques of filing and sawing. The unit covers two performance outcomes. The candidate will be able to 1. identify techniques and procedures required to produce desired shapes 2. select appropriate tools for filing and sawing and carry out the operation Connections to other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS IPS Mech 1:3.03 Assessment Practical activities listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Identify techniques and procedures required to produce the desired shape Practical Activities 1. Identify types of file and saw. 2. Select tools for cutting work to shape. Underpinning Knowledge The candidate will be able to 1. state the classification of files in terms of a length b sectional form c cut of teeth 2. state the names of different cuts a rough b middle c bastard d second e smooth f dead smooth 3. state the angles to the centre line of single cut and double cut files 4. state the sectional forms of files and needle files a flat b hand c square d triangular (three square) e round f half round g knife edge 5. state the types of hacksaw holder a adjustable b fixed 6. state the types of saw blade a coarse b fine 7. state the profile of saw blade teeth 8. state the angles in the profile of saw blade teeth a wedge angle b clearance angle c rake angle i the applications of different types of file ii the applications of different types of saw.


Outcome 2: Select the appropriate tools for filing and sawing activities and carry out the operations Practical Activities 1. Select tools to carry out filing and sawing operations. 2. Check the condition of files and saws before use. 3. Secure appropriate work holding devices. 4. Shape components by filing and sawing. Underpinning Knowledge The candidate will be able to 1. describe the applications of different types of a files b saws 2. describe how to handle tools safely and effectively a files b hacksaws c mechanical saws 3. state the purpose of work holding in terms of location and restraint 4. state the appropriate work holding devices for filing and sawing 5. state what conditions make tools unsafe to use a hardness of the tool material relative to the work material b sharpness of the cutting tool c wedge form of the cutting tool d the function of angles in relation to the cutting action 6. describe how to use tools in accordance with manufacturer’s instructions 7. state how to carry out trial tests on scrap material.


Unit 13 : Fitting by drilling, reaming and threading Rationale This optional unit is part of the occupational award for mechanical fitting. It covers the skills and knowledge concerned with the techniques of drilling, reaming and threading within the context of fitting. The unit covers three performance outcomes. The candidate will be able to 1. identify correct methods of cutting and appropriate tools 2. identify appropriate work holding device and use correct techniques 3. apply general rules for efficiency in drilling, reaming, and threading processes Connections with other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS IPS Mech 1:3.03, IPS Mech 2:2.01, IPS Mech 3:2.02, IPS Mech 4:2.03 CO2:7.06, CO3:7.04 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Identify the correct methods of cutting and appropriate tool for the hole or thread required Practical Activities 1. Select the appropriate cutting methods from given specifications. Underpinning Knowledge The candidate will be able to 1. state the terms used to describe holes a through holes b blind holes c countersinking and counter boring d centring e accurate hole dimensions f surface finish 2. state applications of drilling and related operations a as a final operation i through holes for screw, bolts and rivets ii countersinking for screw and rivets iii counter boring for cap headed screws b as a preparatory operation for i tapping ii reaming iii countersinking, counter boring and trepanning iv cutting using chain-linked holes 3. describe the helical form of screw threads 4. describe the meaning of terms a major, minor and effective diameter b pitch c left/right hand thread d single or multi-start e thread form: standard specifications for different applications 5. state the applications of screw threads a as a fastening device: bolts, screws, studs and nuts b to transmit motion: vices, jacks and machine tool mechanisms 6. state the method used for drilling a hand drills b electrical and pneumatic portable drills c drilling machines


7. state the processes of hand reaming a hand reamers b hand taper-pin reamers c hand socket reamers 8. state manual methods used for threading a internal screw threads by taps b internal screw threads by special taps and thread inserts c external screw threads by dies d cleaning external screw threads by die nuts 9. describe the working principles of drills in terms of a rake angle b wedge angle c clearance 10. state geometry of a reamer and its effect on material removal in terms of a types of flute b taper lead c rotation of cutting d rake angle 11. describe the working principles of taps and dies a application of rake, clearance and cutting angle b cutting action.


Outcome 2: Identify the appropriate work holding device and use the correct technique to produce a hole or screw thread Practical Activities 1. Select the correct tap/die for a particular screw thread application. 2. Drill and thread holes to specification. 3. Drill and ream holes to specification. Underpinning Knowledge The candidate will be able to 1. describe the main features of drills and their terminology a flute length b drilling length c point d body and recess e shank f size (diameter) 2. describe different types of drill and their main features a parallel shank i jobber ii long series iii stub b morse taper shank c drills with more than two flutes 3. describe different materials from which drills are made 4. state different parts of taps a taper lead b flute c shank d thread length e head 5. state characteristics of taps in terms of a grouping into sets, ie taper, second and bottoming b serial taps for heavy duty work c flutes: type, number and application for different materials 6. state materials from which taps are made a tool steel for plain carbon steel, non-ferrous metals and cast iron b high speed steel for high tensile steel


7. state different types of die a circular split dies b rectangular loose dies c solid die nuts d pipe thread dies i parallel ii taper 8. state the concept of work holding in terms of the requirement to a locate the work piece b restrain the forces exerted when cutting and threading 9. state different work holding devices for drilling and threading a vices, clamps and blocks b chucks, tap wrenches and die-stocks.


Outcome 3: Apply the general rules for efficiency in the drilling, reaming and threading processes Practical Activities 1. Carry out drill and thread operation efficiently. 2. Carry out drill and ream operation efficiently. Underpinning Knowledge The candidate will be able to 1. state how to select the drill with the correct diameter, cutting angle and point angle 2. state how to use accurately ground drills 3. state how to consider when marking off whether required accuracy can be attained 4. state how to use a pilot drill to obtain accuracy when drilling large diameter holes 5. describe the importance of using correct drill size prior to reaming 6. describe how to use the appropriate cutting fluid 7. state to ensure the cutting fluid has full access 8. describe how to use alignment devices if possible 9. state advance turn and back off 10. describe how to check the thread with a thread gauge or mating nut/bolt 11. describe how to clean the tap/die after use and store correctly 12. state how to ensure initial diameter is correct prior to screw threading 13. describe the correct tap/die appropriate to the method/material to be threaded 14. state how to ensure the tap/die is in good condition 15. state the appropriate tool holding device 16. state the appropriate work piece holding device.


Unit 14: Fitting by machining and assembling components Rationale This optional unit is part of the occupational award for mechanical fitting. It covers the skills and knowledge related to machine tool operations and assembly techniques. This unit covers two performance outcomes. The candidate will be able to 1. carry out machine tool operations 2. assemble components Connections with other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS IPS Mech 2:2.01, IPS Mech 3:2.02, IPS Mech 4:2.03, IPS Mech 5:3.04 IPS Mech 7:3.12, IPS Mech 8:4.02 CO2:7.06, CO3:7.04 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Machine tool and grinding and scraping operations Practical activities

1. Read and interpret the machining specification/procedure to extract necessary information to prepare the work piece and machining process for the shaping operation. 2. Identify tolerances and surface finish. 3. Identify component or material requirements. 4. Identify work constraints. 5. Identify safety requirements. 6. Produce an operation sheet selecting the most effective and efficient process of manufacture. 7. Check speed, feed, and coolant systems operate correctly. 8. Use a range of machining operations that are basic and familiar (shape has a limited number of surfaces, angles and dimensions to be achieved and not more than two different stages). 9. Use a range of machining methods, single and multiple tool set up. 10. Monitor machine, grinding and scraping processes (cutting process, surface appearance and measurements). 11. Remedy problems relating to machining, grinding and scraping. Underpinning knowledge The candidate will be able to 1. describe common machine tools a identify common machine tools i centre lathe ii horizontal milling iii vertical milling iv drilling machine v shaping machine b methods of work holding for the machine tools listed in a i centre lathe: 3 and 4 jaw chucks, collet chuck ii horizontal and vertical milling: vices, clamps and rotary tables iii grinding machines: 3 and 4 jaw chuck iv drilling machine: vices and clamps v shaping machine: vices, clamps and rotary tables c apply the formula for calculating speeds and feeds for common machine tools


2. state common machine tool operations a centre lathe turning i the purpose of turning ii type and identification of lathe tools for A. turning and facing B. straight nose roughing C. knife/side cutting D. round nose E. parting off F. screw cutting G. knurling iii the methods of producing the following types of features A. external diameters B. shoulders C. faces D. chamfers F. radii b milling operations i the purpose of milling for producing A. flat, horizontal, vertical and angled surfaces B. slots C. grooves D. holes ii the types of cutter used in milling A. slot drills B. end mills C. face mills D. cylindrical E. tee slot F. wood ruff c shaping machine operations i methods of work holding A. machine vice B. clamping C. angle plates ii the purpose of shaping A. flat, horizontal and angled surfaces B. slots C. grooves 3. state the correct methods and purpose of grinding a the production of a flat, cylindrical surface b the removal of material from surfaces 4. state the principle of metal removal by grinding as a multi-point, self sharpening cutting tool 5. describe the construction of grinding wheel selection a abrasive materials b bonding materials


6. state the factors affecting wheel selection a material to be ground b amount of material to be removed c finish required d arc/area of contact 7. state that the parts of an off-hand grinder are a wheel guards b rotating wheels c work rest d safety glass visor 8. describe the concept of work holding in terms of the requirement to a locate the work piece b restrain the forces exerted by the tool 9. state what work pieces must be held on a correctly adjusted work rest for hand grinding 10. state what work pieces must be clamped when using portable power tools for hand grinding 11. describe the techniques used for scraping a vices, clamps and blocks are used for work holding when scraping b scrapers remove small amounts of metal c scraping applications i bearings can be scraped with a half-round scraper ii holes can be de-burred with a three-square scraper.


Outcome 2: Assemble components

Practical activities 1. Identify and select tools and equipment used in assembly. 2. Identify materials and consumables required for assembly operations. 3. Plan sequences of operations for assembly activities. 4. Carry out appropriate safety checks on tools equipment and processes. 5. Assemble mechanical components. 6. Assemble by thermal methods. 7. Inspect the assembled product for compliance to specification. Underpinning knowledge The candidate will be able to 1. state the mechanical joining systems for fitting operations a joining and locking systems in terms of i threaded fasteners ii bolts, nuts, screws washers iii thread inserts iv studs v internal and external circlips, spring washers, tab washers b pins and keys i parallel key and pins ii taper key and pins iii split pin c rivets i round ii flat iii counter sunk iv hollow 2. describe mechanical joining systems for fabrication operations a different types of bolts, washers, nuts/devices and simple applications i bolts A. black and turned B. high strength friction grip ii washers A. taper B. plane iii nuts and locking devices A. locknuts B. castellated nuts C. spring washers D. tab washers iv simple applications related to fabrication eg joining structural sections, columns to base plates


3. describe thermal joining using fusion welding: the purpose and application of MMA and TIG welding a process operations in terms of i set-up and use of MMA equipment (AC/DC) ii flux covered consumable electrodes iii the action of the flux constituents to provide a A. protective gaseous shield B. stabilise the arc C. provide deoxidisers D. provide alloying elements b safety, relating to MMA and TIG welding i routing of cables ii protective clothing/head screens etc iii fume extraction iv screening to protect from arc c types of basic joints and positions i butt, fillet ii flat, vertical, horizontal, vertical, overhead d process operations for hard and soft soldering in terms of i set up of the equipment and cleaning the joint ii selection of filler wires and fluxes iii techniques of applying filler wire iv removal of flux residues


Unit 15: Preparing and quality controlling the welding operation

Rationale This optional unit covers the preparations needed to carry out effectively any welding operation. It includes the interpretation of specifications, selection of the process, ancillary equipment and consumables and related quality assurance systems. The unit has two performance outcomes. The candidate will be able to 1. interpret welding specifications to BSEN ISO standards 2. inspect and control welding operations Connections with other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS W1:2.11, W3:2.13, W4:2.15, W6:1.12 CO3:7.04 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Interpret welding specifications to BS EN ISO standards Practical activities 1. Identify terminology in BSEN ISO 9000 quality documents (quality manual, procedures manual and work instructions). 2. Interpret fabrication engineering drawings in relation to welding requirements (edge preparations, position of welds, symbols, specific treatments). 3. Carry out simple tests to identify materials eg cast number and material test certificate, spark tests, colour and density etc. 4. Use of temperature indicating equipment to identify pre-heat temperature.

Underpinning Knowledge The candidate will be able to 1. describe the terminology and documented procedures used in BS EN ISO 9000 2000 - quality assurance and quality control systems 2. state how to define a quality assurance b quality control 3. state quality requirements applied to welding a reasons for using weld procedures b purpose of qualifying a weld procedure c reasons for qualifying welding personnel d welder qualifications, responsibilities and limitations e reasons for carrying out NDT on welds f monitoring and measuring welding repair rate to determine i quality ii productivity 4. state how to interpret fabrication engineering drawings to BSEN ISO 1660 (1996) a weld location b sectional views showing joint preparations designed for partial or full fusion with access from one or both sides eg lap and ‘T’ fillet, square edge ‘V’, ‘J’, and ‘U’ profiles c weld dimensions d significance of notes on drawings eg relating to sequence of welding operations, material specification treatments and testing of welds 5. state how to interpret weld symbols to BS EN 22553


6. describe the type of edge preparation required in relation to a metal thickness b type of metal c partial and full fusion joints d welding process used e single or double sided access f efficiency of welding operations i optimum geometry for application and process ii edge symmetry iii dimensional accuracy and tolerance of profile and edge alignment iv uniformity of edge preparation g the effects of incorrect edge preparation eg increased volume of weld metal and welding time, greater risk of distortion and residual stress 7. state methods used to prepare edge preparations a oxy-fuel gas cutting b arc/air cutting c grinding d nibbling 8. state how to differentiate between common engineering materials a ferrous metals; low carbon steel, high carbon steel and 18/8 stainless steel, cast iron b non-ferrous; aluminium alloys, copper alloys, nickel alloys, titanium alloys 9. describe factors influencing weldability e.g. thickness of material, thermal expansion and contraction, resistance to oxidation, dilution 10. state requirements for pre-heating and slow cooling on thick sections, alloy steels, non-ferrous alloys 11. state the criteria used to determine welding procedures including material type and section/welding process, welding position, interpass temperature, pre and post heating, selection and care of electrodes, filler wires, inserts and ceramic backing.


Outcome 2: Inspect and control welding operations

Practical activities 1. Rectify possible causes of deficiency in welding operations. 2. Set up edge cutting equipment. 3. Use welding gauges. 4. Carry out preparation for post weld inspections. Underpinning knowledge The candidate will be able to 1. state the relevant British and European standards relating to weld quality assurance: EN, AP, ASME 2. state the range of welding tests required a welder approval qualification to EN 287, ASME IX and BS 4872 b weld procedure qualification to EN 288 3. state common types of weld defects and types of weld failure associated with each 4. describe how to prepare for post weld inspection and testing 5. describe how to use gauges to inspect profile of edge preparations and weld dimensions 6 state the difference between destructive (DT) and non-destructive (NDT) methods of testing.


Unit 16: Welding with the manual metal arc process Rationale This optional unit covers the skills and knowledge related to joining materials using manual metal arc welding (MMA). It includes preparation of equipment and materials, welding techniques and safe working practices. The unit covers four performance outcomes. The candidate will be able to 1. assemble and prepare manual metal arc welding equipment 2. identify materials and consumables 3. identify and apply different welding techniques 4. apply conditions and precautions Connections with other awards This unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS W1:2.11, W3:2.13, W6:1.12, W16-17:3.09, W23&25:3.09, W31-34:3.09, W40:3.09, W42:3.09, W43:3.03 CO2:7.06, CO3:7.04 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Assemble and prepare manual metal-arc welding equipment Practical Activities 1. Select and set up manual metal-arc welding equipment. 2. Check and commission the equipment. 3. Select ancillary equipment appropriate to the application. Underpinning Knowledge The candidate will be able to 1. state the range and types of welding set, operating features of the equipment and safety procedures 2. state essential welding connections a welding lead b return c earth 3. state the range of ancillary equipment a electrode holders b welding leads c return clamp d remote control devices 4. describe essential operator and bystander safety requirements a protective clothing and equipment b anti flash screens c isolators 5. describe the factors influencing the selection of welding set and ancillary equipment a type and range of current required b operating parameters c location i workshop ii site iii at height 6. state the operation of AC and DC power sources a transformers b rectifiers c inverters d engine driven sets 7. describe electrical principles applied to power sources a open circuit and arc voltage/welding current relationship for drooping characteristics b equipment current and voltage control devices.


Outcome 2: Identify materials and consumables

Practical Activities 1. Identify materials from job specification or by applying tests. 2. Identify and select welding consumables appropriate to the material and application. 3. Prepare consumables in accordance with weld procedure or manufacturer’s recommendations. 4. Prepare and set up material/component for welding a jigs b positioners c tack welding. 5. Clean joint area and position/secure work accordingly. Underpinning Knowledge The candidate will be able to 1. state procedures for identifying type of material a drawing specification b spark and magnetic test 2. state the range of electrodes used with the manual metal-arc process a consumable electrodes (composition and flux coating) b deposition rate and quality c penetration d positional capabilities 3. state electrode sizes, correct diameter for material thickness and positional requirements 4. state electrode classification system to BSEN 499:1995 5. state the function of flux coatings a protection of weld metal b slag formation c addition of alloying elements to weld metal d stabilising the arc 6. describe the care and correct handling of welding electrodes a drying ovens b portable heating quivers c maintaining flux integrity i vacuum packing systems and procedures ii electrode storage 7. state the range of joint configurations used for manual metal-arc welding applications a ‘open square butt’ b lap and ‘T’ fillets c ‘V’ and bevel butt joints 8. state cleaning methods used for different materials a manual b portable power tools.


Outcome 3: Identify and apply different welding techniques Practical Activities 1. Use a range of different welding parameters. 2. Use different welding techniques. 3. Make joints in different materials. 4. Manipulate work piece as required. Underpinning Knowledge The candidate will be able to 1. describe appropriate current settings and conditions a AC b DC c amperage range d electrode polarity 2. state electrode types and sizes a diameter b basic and rutile coatings c powder coatings 3. state electrode manipulation and angles a positional considerations b deposition rates 4. describe different welding techniques a stop and start procedures b number and sequence of runs c weaving d blocking sequence e buttering f key holing 5. describe joint design and welding sequence a weld strength b distortion control c weld economics d weld procedures e heat input control using BS 5135 formula/run-out lengths 6. state requirements for positional welding a consumables b welding techniques 7. describe jigs, positioners and manipulators for a rigidity b distortion control and gravity assisted deposits c productivity.


Outcome 4: Apply conditions and precautions

Practical Activities 1. Prepare and monitor a safe welding operation. 2. Position and secure work piece correctly. 3. Interpret and apply correct weld procedure. 4. Use correct welding sequence for given application. 5. Clean and dress joint as required. Underpinning Knowledge The candidate will be able to 1. describe safe working practices and the range of personal protective equipment applicable to the process 2. describe the setting up and securing of a joints b tack welding c jigs d manipulators 3. describe the design and operation of fixing and manipulating devices a position b speed c safety 4. state the principles underlying the preparation and use of weld procedures a consumables specification b welding parameters c welding technique d pre and post weld care 5. state the factors influencing distortion and methods of control a material conductivity b joint design c heat input and distribution (process and speed) d number and sequence of runs 6. state the correct start and finish procedures a drawn arc b ‘run on’ c ‘run off’ d taper dressing to assist re-starts e advantages of using hot starting on power sources 7. state the factors affecting weld quality a use of correct welding parameters b consumables and procedure c cleanliness of joint and consumables


8. describe post weld treatment and cleaning procedures a portable hand and power tools b machining c heat treatment (stress relief) 9. describe the implications for personal safety and co-workers when working

a at height b on site c in inclement weather.


Unit 17: Welding with the tungsten inert gas/tungsten arc gas shielded welding process Rationale This optional unit covers the skills and knowledge related to joining materials using tungsten inert gas/tungsten arc gas shielded welding (TIG). It includes preparation of equipment and materials, welding techniques and safe working practices. The unit covers four performance outcomes. The candidate will be able to 1. assemble and prepare tungsten inert gas/tungsten-arc gas shielded equipment 2. identify materials and consumables 3. identify and apply different welding techniques 4. apply conditions and precautions Connections with other awards The unit combines and extends the underpinning knowledge contained in ECITB units and equivalent ECS W1:2.1, W3:2.13, W6:1.12, W10-15:3.09, W27-32:3.09, W34:3.09 CO2:7.06, CO3:7.04 Assessment Practical activities are listed for each outcome, assessment will be by means of an assignment for the occupational units. The underpinning knowledge requirements will be assessed by means of a short answer written test covering the occupational units.


Outcome 1: Assemble and prepare tungsten inert gas/tungsten arc gas-shielded equipment Practical Activities 1. Select and set up tungsten inert gas/tungsten-arc gas-shielded welding equipment. 2. Check and commission the equipment. 3. Select ancillary equipment appropriate to the application. Underpinning Knowledge The candidate will be able to 1. state the range and types of welding set and the operating features of the equipment a transformer/rectifier b wave forms c HF scratch start devices d remote control switches 2. state essential welding connections and services a welding return and earth b harnesses for hoses and cables i welding torch (light and heavy duty) ii selection of torch design including collets, bodies and gas lenses c gas supply and flow control d coolants i water ii air e remote control contactor 3. describe safe handling and care of gas cylinders a storage b portability c correct operation 4. state essential operator and bystander safety requirements a protective clothing b screens 5. state the factors influencing the selection of power source and ancillary equipment a material type and thickness b joint location c single or dual process eg suitability for TIG root and MMA fill and cap.


Outcome 2: Identify materials and consumables

Practical Activities 1. Identify materials from job specification or by applying tests. 2. Identify and select welding consumables appropriate to the material and application. 3. Prepare consumables in accordance with weld procedure or manufacturer’s recommendations. 4. Prepare and set up material/component for welding in accordance with weld procedure. 5. Clean joint area and position/secure work accordingly. Underpinning Knowledge The candidate will be able to 1. state procedures for identifying type of material a drawing specification b spark and magnetic test 2. describe the range of electrodes used with the tungsten-arc gas- shielded process a non-consumable b colour coding c pure d alloyed (thoriated, ceriated and lanthinated) 3. state electrode sizes a 1.6 mm b 2.4 mm c 3.2 mm 4. describe the care and correct preparation of tungsten electrodes; end profile appropriate to AC and DC welding applications a conical b frustrum 5. state the range of filler materials used with the tungsten-arc gas- shielded process a size and chemical composition to fulfil the requirements of the material and weld specification b classification of filler wires to BS2901 6. state the range of joint configurations used for tungsten arc gas- shielded welding applications a outside corners b lap and ‘T’ fillet c square edge d ‘V’, ‘U’ and ’J’ butt e inserts


7. state set up procedures for special joint configurations a machine profiled bevel b back purging methods and use of parts for root protection for welding alloys prone to oxidation 8. state the cleaning methods used for different materials and consumables a chemical b mechanical c abrasives.


Outcome 3: Identify and apply different welding techniques Practical Activities 1. Use a range of different welding equipment. 2. Use a range of different welding parameters. 3. Use different welding techniques. 4. Make joints in different materials. 5. Manipulate work piece as required. Underpinning Knowledge The candidate will be able to 1. state electrode types, current range, polarity, sizes and applications a profile considerations b type of material c joint design d penetration requirements 2. describe Inert gas flow settings a inert nature of shielding gas used to protect the weld b types and applications of gases c types of ceramic nozzles d flow meters in litres/hr in accordance with weld specification e types and application of gas lenses f gas purging purpose and techniques 3. state appropriate current settings and operating conditions a reasons for selecting AC (SWF) current for aluminium alloys b reasons for selecting DC electrode negative ferrite, austenite and nickel alloys 4. state electrode and filler rod manipulation and angles a leftward technique b included angle variations 5. state joint and insert design a profiles b fit-up and securing c purging systems for full and local requirements 6. state different welding techniques a multi run b dual process c manual d automated e spot f continuous hot wire


7. state joint design considerations a purging b welding sequence material type and thickness c distortion control d accessibility e weld quality 8. state requirements for positional welding a jigs b positioners c rotators 9. describe techniques for welding carbon steel and stainless butt welded pipe joints a rotated with and without backing rings or inserts b fixed position with and without backing rings or inserts c pipe to flange joints and branch joints in the rotated and fixed position.


Outcome 4: Apply conditions and precautions

Practical Activities 1. Prepare and monitor a safe welding operation. 2. Position and secure work piece correctly. 3. Interpret and apply correct weld procedure. 4. Use correct weld sequence and conditions for given application. 5. Clean and dress joint as required. Underpinning Knowledge The candidate will be able to 1. describe safe working practices and the range of personal protective clothing and equipment applicable to the process 2. describe the setting up and securing of joints a jigs tacking b presetting 3. describe purging techniques a local and full methods 4. state design and operation of fixing and manipulating devices a position b speed c safety 5. state the principles underlying the preparation and use of weld procedures a consumables specification b joint design c welding parameters d technique e pre and post weld care 6. describe the factors influencing distortion and methods of control a type of material b joint design c heat input and distribution (process and speed) d number and sequence of runs 7. state the correct start and finish procedures a variable current (slope-up and slope-down) b taper dressing to assist re-starts c post gas flow 8. describe the factors affecting weld quality a use of correct welding parameters b consumables and procedure c cleanliness of joint and consumables


9. state post weld treatment and cleaning procedures a portable hand and power tools b machining c heat treatment (stress relief) 10. state the implications for personal safety and co-workers when working a at height b on site c in inclement weather.

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Centre-devised assignment submission report Part A – To be completed by the centre

BOX 1

Centre details Date sent to City & Guilds (dd/mm/yyyy)

Centre number Sub centre Centre name

Name of Examinations Office contact Telephone number Fax number E-mail Name of author of question paper Telephone number

Assignment Details

BOX 2

Assignment component number Component title 2 4 5 6 -

Please complete the following checklist

The assignment submitted Yes No

Covers all practical activities from the Assignment template

Will take a minimum of TEN hours to complete

Can be marked according to the grading criteria provided

Please attach a copy of the proposed assignment to this Assignment Submission Form BOX 3

The centre confirms that the assignment contains

1. Assessor guidance notes including

A health and safety statement

The location of where the assignment will take place

The requirements for tools, equipment, materials and data

Notes on the content of the assignment

Notes on preparatory work required by the assessor

Details of evidence and recording requirements

Time considerations

2. Candidate instructions includes

An assignment brief setting the scene or giving a scenario

General guidance notes advising candidates to check they understand requirements

Time consideration

The importance of Health and Safety

Clearly defined tasks – covering all practical activities from the Assignment Template

Recording/reporting sheets to record progress through the tasks

Notes advising candidates on how their evidence should be stored

Any required engineering drawings provided to current standards

Note the centre should allow 6 weeks from the date of submission by e-mail for City and Guilds to agree the assignment

Name (block capitals)

Date

Signed

Please e-mail to [email protected]

Centres which are unable to submit via e-mail must post THREE copies of the proposed assignment to City & Guilds, Centre Devised, 1 Giltspur Street, London, EC1A 9DD. This must be sent EIGHT weeks before intended use.

SP-03-2456

Documents

Level 3 Certificate in Engineering Construction · 4 Level 3 Certificate in Engineering Construction Level 3 Certificate in Engineering Construction (2456-21 to 2456-25) Introduction