POWER PLANT HIGH PRESSURE WELDER · • Perform welding on pressure vessels, boilers and high pressure equipment in a power plant: Perform welding of ferrous and non-ferrous pressure

Power Plant High Pressure Welder i

Model Curriculum

POWER PLANT HIGH PRESSURE

WELDER

SECTOR:

SUB-SECTOR:

OCCUPATION:

REF ID:

NSQF LEVEL:

POWER

GENERATION

WELDING & CUTTING

PSS/Q0401, V1.0

4

Power Plant High Pressure Welder ii

Power Plant High Pressure Welder iii

TABLE OF CONTENTS

1. Curriculum 01

2. Trainer Prerequisites 08

3. Annexure: Assessment Criteria 09

Power Plant High Pressure Welder 1

Power Plant High Pressure Welder CURRICULUM / SYLLABUS

This program is aimed at training candidates for the job of a “Power Plant High Pressure

Welder”, in the “Power” Sector/Industry and aims at building the following key competencies

amongst the learner

Program Name Power Plant High Pressure Welder

Qualification Pack Name

& Reference ID. ID Power Plant High Pressure Welder PSS/Q0401

Version No. 1.0 Version Update Date 13-09-2021

Pre-requisites to Training ITI (Fitter/ Mechanical)

Training Outcomes After completing this programme, participants will be able to:

• Gain familiarity with Power system: overview especially

Generation Sector. Understand basics of electricity terms used

while carrying activities related to testing, repair and

maintenance

• Perform welding on pressure vessels, boilers and high

pressure equipment in a power plant: Perform welding of

ferrous and non-ferrous pressure products such as structures,

frames, plate and sheet assemblies, pipe-work and vessels used

for producing pressure vessels, boilers and high pressure

pipework, as per given specifications

• Manually weld carbon steel/ low alloy steel and austenitic

stainless steel using Metal Arc Welding / Shielded Metal Arc

Welding: Perform manual metal arc welding (MMAW) welding

also known as Shielded Metal Arc Welding (SMAW) for a range

of standard welding job requirements. This is for a skilled welder

who can weld different materials (mild or low carbon steel and

austenitic stainless steel) in 1G/1F, 2G/2F, 3G/3F, 4G/4F, 5G/5F

and 6G positions

• Perform basic manual Tungsten Inert Gas (TIG) Welding

also known as Gas Tungsten Arc Welding (GTAW) welding:

Perform basic manual TIG (GTAW) welding for a range of

standard welding job requirements. This involves welding

different materials (carbon steel, low alloy steel) in various

positions. The welder can prepare various joints including

corner, fillet and tee.

• Weld stud joints using stud welding equipment/machines:

Perform stud welding to secure studs and pins to metal surfaces

to attach materials such as boilers, surfaces, insulation and

refractories. This can be done through manual processes or with

machines in downward position. This involves setting-up and

preparing for operations interpreting the right information from


the WPS, obtaining the right consumables and raw materials,

etc.

• Use basic health and safety practices for power related

work: Understand procedure & practices to follow to maintain

healthy, safe & secure work environment covering safety of self,

others, assets, and the environment

• Work Effectively with others: Understand basic etiquette and

competencies to demonstrate in their behaviour and interaction

with others at workplace


This course encompasses 6 out of 6 National Occupational Standards (NOS) of “Power Plant High

Pressure Welder” Qualification Pack issued by “Power Sector Skill Council”.

Sr.

No. Module Key Learning Outcomes

Equipment

Required

1 Introduction Theory Duration

(hh:mm)

04:00

Practical Duration

(hh:mm)

00:00

Corresponding NOS Code

PSS/N0401

• Explain about Power sector

scenario including generation,

transmission, and distribution

scenario of India.

• Discuss elements of power

systems, transmission,

distribution and generations

• Discuss functions of Power

Generation Companies

• Discuss about generation from

generator to switchyard

2 Organizational context Theory Duration (hh:mm) 06:00 Practical Duration (hh:mm) 00:00 Corresponding NOS Code PSS/N0401

• Explain organization structure

and reporting levels in

Generation Company

• Discuss duties and

responsibilities of Power Plant

High Pressure Welder

• Discuss relevant Legislation,

Electricity act 2003, CERC,SERC

• Interpret CEA Regulations 2010

3 Basics Of Electricity Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 15:00


PSS/N0401

• Explain basic fundamentals of

Electricity, Mechanics and C & I

• Explain the basic key

concepts of Voltage,

Current, Capacitance,

Resistance, KVA, KWh.

• Discuss Circuit connections,

voltage and current

relationship in star & delta

configuration

• Explain 3 phase and 1 phase

supply

Voltmeter,

Ammeter,

Wattmeter, basic

components,

Energy Meter (

single phase and

three phase),

Register,

Inductor,

Capacitor etc.

4 Perform welding on pressure vessels, boilers and high pressure equipment in a power plant Theory Duration (hh:mm) 24:00 Practical Duration (hh:mm) 50:00

• Discuss the general layout of a

power plant

• Discuss the importance of a

code of construction for a

pressure vessel

• Explain the various aspects in

the selection of a material for a

pressure vessel

• Describe the various pressure

vessel components like water

wall panels, tubular panels,

pipes, headers etc


Sr.


Equipment

Required


PSS/N0401 • Discuss the qualification

requirement for a welder as

per codes

• Learn about the code

requirement for the fit up of

welded assemblies

• Discuss about the preheat

requirements for various

materials as per codes

• Describe the post weld heat

treatment requirements for

various materials as per codes

• Explain the testing and

inspection requirement for

weld elements as per codes

5 Manually weld carbon steel/ low alloy steel and austenitic stainless steel using Metal Arc Welding / Shielded Metal Arc Welding Theory Duration (hh:mm) 24:00 Practical Duration (hh:mm) 50:00


CSC/N0208

• Discuss the basics of shielded

metal arc welding process

• Discuss about the type of

power source, the type of

current and their

characteristics

• Describe about the various

types of electrodes and their

special characteristics

• Discuss about the weld joints,

edge preparation styles for

various applications

• Explain the welding positions

• Discuss the various welding

process parameters and their

effect on bead shape

• Discuss the typical defects

which are encountered and

their causes

• Describe various tests to

determine the weld quality

• Explain the advantages and

limitations of the process

• Discuss about the thermal

cycles in welding and their

metallurgical effects

• Discuss about the issues faced

during welding of carbon steel

material


during welding of alloy steel

material


Sr.


Equipment

Required


during welding of austenitic

stainless steel material

6 Perform basic manual Tungsten Inert Gas (TIG) Welding also known as Gas Tungsten Arc Welding (GTAW) welding Theory Duration (hh:mm) 12:00 Practical Duration (hh:mm) 50:00


CSC/N0212

• Describe the tungsten inert gas

welding process basics

• Discuss the type of power

source, the type of current and

their characteristics required

for welding

• Discuss the construction of

welding torch

• Explain the characteristics of

the shielding gases

• Discuss the various weld

controls which are required for

the process

• Discuss various welding

process parameters and their

effect on bead shape

• Describe the typical defects

which are encountered and

their causes

• Discuss the advantages and

limitations of the process


during welding of carbon and

low alloy steel


during welding of stainless

steels and nickel alloys


during welding of aluminium

alloys


during welding of titanium

alloys

7 Weld stud joints using stud welding equipment /machines Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm)

• Discuss the stud designs

• Discuss the stud welding

process basics

• Describe the consumables

used in the process

• Describe the features of arc

stud welding process

• Explain the features of

capacitor discharge stud

welding process


Sr.


Equipment

Required

41:00 Corresponding NOS Code CSC/N0210

• Describe the flux employed in

the process

8 Use basic Health & Safety practices for power related work Theory Duration

(hh:mm)

24:00

Practical Duration

(hh:mm)

16:00


PSS/N 2001

• Discuss general health issues

and precautions at workplace

• Discuss the clauses of CEA

Gazette Notification

• Explain legislature, provision,

rules and guidelines for

ensuring safety in power sector

• Mention the hazards

associated with erection and

commissioning of power plant

equipment

• Mention hazards associated

with operation and

maintenance of power plant

equipment

• Differentiate between hazards

and risk and their prevention

at worksite

• Describe factors causing

accidents and prevention of

accidents at workplace

• Explain causes of Electric

shocks

• Mention the effects of current

on human body

• Discuss the procedure to be

followed for reporting

accidents

• Describe the importance of

work permit system and

creation of safety zone

• Discuss best practices for

working safely in power

transmission network

• Explain the importance of

using PPE

• Name safety equipment used

at heights

• Discuss safety measures to be

taken while working with

electrical equipment

• Discuss electric and fire safety

at workplace

Helmet, Gloves,

rubber mat,

ladder, neon

tester, Personal

Protective

Equipment


Sr.


Equipment

Required

• Mention various types of fire

extinguisher

• Execute correct selection and

use of fire extinguisher

• Describe Basic Rules of First

Aid

• Discuss first aid and its impact

for saving lives in case of

Electrocution

• Discuss handling and storage

of oils, greases and paints

• Discuss ways to store material

and equipment

9 Work effectively with others Theory Duration

(hh:mm)

08:00

Practical Duration

(hh:mm)

08:00

Corresponding NOS Code PSS/N1336

• Working effectively in a team.

• Demonstrate good

interpersonal

relation, discipline

behaviour, developing a

positive attitude and building

self-confidence.

• Receiving information and

instruction from supervisor and

fellow workers, pass on

information

• Assist others to maximize

effectiveness

• Problem escalation

• Demonstrate responsible,

disciplined behaviour at

workplace

• Display appropriate

communication etiquette while

working

• Communication And Writing

Skills and their importance

• Basic Computer application

Total Duration

Theory Duration

120:00

Practical Duration

230:00

Unique Equipment Required:

First aid kit etc.

Grand Total Course Duration: 350Hours, 0 Minutes

(This syllabus/ curriculum has been approved by POWER SECTOR SKILL COUNCIL)


Trainer Prerequisites for Job role: “Power Plant High Pressure Welder” mapped to Qualification

Pack: “PSS/Q0401, v1.0”

Sr.

No. Area Details

1 Description To deliver accredited training service, mapping to the curriculum detailed

above, in accordance with the Qualification Pack “PSS/Q0401”

2 Personal

Attributes

Aptitude for conducting training, with relevant work experience. So, that

competent candidate is produced at end of the training who are employable.

Strong communication skills, interpersonal skills, ability to work as part of a

team, a passion for quality and for developing others; well-organised and

focused, eager to learn and keep oneself updated with the latest in the

mentioned field.

3 Minimum

Educational

Qualifications

ITI in Fitter trade ;

Preferably B.Tech (Mechanical) or 3 year Diploma in Mechanical Engineering,

4a Domain

Certification

Certified for Job Role: “Power Plant High Pressure Welder” mapped to QP:

“PSS/Q0401 v1.0”., Minimum accepted score as per PSSC guidelines- 80% for

Trainer and 90% for Master Trainer

4b Platform

Certification

Recommended that the Trainer is certified for the Job Role: “Trainer”,

mapped to the Qualification Pack: “MEP/Q2601”. Minimum accepted score

as per PSSC guidelines – 80% for Trainer and 90% for Master Trainer

5 Experience Engineer B.Tech. (Mechanical) with at least 1-year relevant experience in

power generation either in the Power Generation utility or with the

turnkey /EPC contractors of the power generation companies.

3 years Diploma in Mechanical Engineering with at least 2-3 years’ relevant

experience in power generation either in the Power Generation utility or with

the


ITI in Fitter Trade with at least five-year relevant experience in

power generation either in the Power Generation utility or with the



Annexure: Assessment Criteria

Assessment Criteria

Job Role Power Plant High Pressure Welder

Qualification Pack PSS/Q0401, v1.0

Sector Skill Council Power

Guidelines for Assessment 1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC. 2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC. 3. Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS. 4. Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below). 5. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criterion. 6. To pass the Qualification Pack, every trainee should score a minimum of 70% of aggregate marks to successfully clear the assessment. 7. In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.


Compulsory NOS Total Marks: 600

Marks Allocation

Assessment outcomes Assessment criteria for outcomes Total

Marks Out Of Theory

Skill Practical

1. PSS/ N 0401

Perform welding

for pressure

vessels, boilers

and high

pressure pipes in

power plants

PC1. comply with health and safety, environmental and other relevant regulations and guidelines at work

100

5 2 3

PC2. adhere to procedures and guidelines for personal protective equipment (PPE) and other relevant safety regulations while performing broaching operations 5 2 3

PC3. ensure work area is clean and safe from hazards 2 0 2

PC4. ensure that all tools, equipment, power sources, power tool cables, extension leads are in a safe and usable condition 2 0 2

PC5. ensure that all machines and machine tools are secured at all times 2 0 2

PC6. determine job requirement from job specification documents or WPS obtained from valid sources 3 1 2

PC7. recognize physically , the different equipment installed within the plant premises and identify function of the individual equipment 3 1 2

PC8. interpret weld procedure data sheets specifications 3 1 2

PC9. select welding machines e.g. transformer, inverters (AC/DC), rectifiers and generators, according to the materials and task 3 1 2

PC10. identify and evaluate properties and limitations of various thermal welding and mechanical jointing systems for the job 4 2 2

PC11. establish the type of welding to be done and procedures to complete the pipe fitting or assembling operations 3 1 2

PC12. perform trail weld and confirm that specifications are achieved by selected welding procedure 5 2 3

PC13. plan the sequence of activities and resources required 3 0 3


PC14. identify and obtain materials or components to be welded and the applicable parent metal group in accordance with applicable data 3 1 2

PC15. identify and obtain welding equipment as per the weld type established 3 1 2

PC16. inspect the equipment for serviceability and correctly set up in accordance with standard operating procedures 5 1 4

PC17. prepare the material for welding 2 0 2

PC18. prepare/determine suitable datums from which to mark out (e.g. choosing a machine face or filing a flat face as a datum) 2 0 2

PC19. apply a marking medium to enhance clarity of the marking out 3 0 3

PC20. use an appropriate method of marking out 3 1 2

PC21. use a range of marking out equipment (e.g. rules, squares, scribers, vernier instruments) 2 0 2

PC22. mark out a range of features required to perform the welding 2 0 2

PC23. perform various types of welding of cutting as per requirements 5 2 3

PC24. produce joints from various materials in different forms 4 1 3

PC25. perform groove and fillet weld in various positions 4 1 3

PC26. ensure welds are deposited correctly as per specifications. 3 1 2

PC27. select and apply appropriate distortion prevention measures for the weld type and material to ensure that distortions are rectified as required 4 1 3

PC28. achieve joint quality, tolerances and acceptance levels that clears the following tests as laid out in ASME Pressure Vessel Code Sections I – XI, BS EN ISO5817 3 1 2

PC29. co-ordinate with the fitter while performing the weld 2 0 2

PC30. prepare the welded assembly and welded surface for quality tests to be conducted 3 1 2


PC31. shut down and make safe the welding equipment on completion of the welding activities 2 0 2

PC32. make sure that the work area is maintained and left in a safe and tidy condition 2 0 2

Total 100 25 75

2. CSC/ N 0208:

Manually weld

carbon steel/

low alloy steel

and austenitic

stainless

steel in all

positions using

Metal Arc

Welding /

Shielded Metal

Arc Welding

PC1. work safely at all times, complying with health and safety legislation, regulations and other relevant guidelines

100

3 1 2

PC2. adhere to procedures or systems in place for health and safety, personal protective equipment (PPE) and other relevant safety regulations 4 1 3

PC3. check the condition of, and correctly connect, welding leads, earthing arrangements and electrode holder 2 0 2

PC4. deal with any faults or differential as per laid procedures 2 0 2

PC5. follow fume extraction safety procedures 3 1 2

PC6. read and interpret routine information on written job instructions, welding procedure specifications (WPS) and standard operating procedures 3 1 2

PC7. select welding machines (e.g. transformers, rectifiers, inverters and generators, etc.) according to the task 2 0 2

PC8. select type and size of electrodes according to classification and specifications 3 1 2

PC9. re-dry electrodes as per electrode classification requirement

3 1 2

PC10. prepare the work area for the welding activities

2 0 2

PC11. perform measurements for joint preparation and routine MMAW

3 0 3

PC12. prepare the materials and joint in readiness for welding

2 0 2

PC13. tack weld the joint at appropriate intervals, and check the joint for accuracy before final welding 3 1 2


PC14. use manual metal-arc welding and related equipment to include a. alternating current (AC) equipment b. direct current (DC) equipment 3 0 3

PC15. connect equipment to power source 3 0 3

PC16. connect cables, electrode holders, return leads and ground clamps to appropriate terminal 2 0 2

PC17. set, read and adjust amperage controls 3 1 2

PC18. verify setup by running test and appropriately handle weld specimen/scrap-plate 3 1 2

PC19. strike and maintain a stable arc 2 0 2

PC20. stop and properly re-start arc to avoid welding defects (scratch start, tapping techniques) 2 0 2

PC21. manipulate electrode angle using various methods as per WPS

3 1 2

PC22. maintain constant puddle by using appropriate travel speed

2 0 2

PC23. remove slag in an appropriate manner (e.g. wire brush, hammer, etc.)

2 0 2

PC24. weld the joint to the specified quality, dimensions and profile applicable to range of material from 1.5 mm – 24 mm 5 1 4

PC25. produce range of welded joints to within the mentioned standard using single or multi-run welds (as appropriate) 5 1 4

PC26. produce joints of the required quality and of specified dimensional accuracy which achieve a weld quality equivalent to Level C of ISO 5817 4 1 3

PC27. produce range of welded joints in various positions as per the WPS specified 3 0 3

PC28. shut down and make safe the welding equipment on completion of the welding activities 2 0 2

PC29. identify various weld defects, use appropriate methods and equipment to check the quality, and that all 4 1 3


dimensional and geometrical aspects of the weld are to the specification

PC30. check that the welded joint conforms to the specification, by checking various quality parameters by visual inspection 4 1 3

PC31. detect surface imperfections and deal with them appropriately

2 0 2

PC32. carry out DPT tests to assess fine defect open to the surface not detected by visual inspection (VT) 3 1 2

PC33. assist in preparation for non-destructive testing of the welds, for a range of tests

3 1 2

PC34. prepare for destructive tests on weld specimens for fillet, butt and corner

2 0 2

PC35. deal promptly and effectively with problems within their control, and seek help and guidance from the relevant people if they have problems that they cannot resolve 3 0 3

Total 100 17 83

3. CSC/ N 0212

Perform basic

manual

Tungsten Inert

Gas (TIG)

Welding also

known as Gas

Tungsten Arc

Welding (GTAW)

welding

PC1. work safely at all times, complying with health and safety legislation, regulations and other relevant guidelines

100

3 1 2

PC2. take necessary safety precautions for TIG welding operations 2 0 2

PC3. interpret weld procedure data sheets specifications 3 1 2

PC4. check that all measuring equipment is within calibration date

2 0 2

PC5. check if welding machines e.g. transformer, inverters (AC/DC), rectifiers and generators have been made available by the authorized person 2 1 1

PC6. check if welding torch, tungsten electrode and filler wire have been made available by the authorized person 2 1 1

PC7. prepare for the TIG welding process 2 1 1


PC8. prepare the materials and joint in readiness for welding 2 0 2

PC9. fit the welding shielding gases given by the authorised person, for a range of given applications

2 0 2

PC10. plan the welding activities before they start them effectively and efficiently for achieving specifications as per WPS 2 0 2

PC11. connect torches and the components 2 0 2

PC12. connect and adjust regulators and flow meters to cylinders 3 1 2

PC13. read, set and adjust current (amperage) as required 3 1 2

PC14. set pre-purge with shielding gas as required 2 1 1

PC15. prepare tungsten by sharpening or balling it to desired tip shape

3 1 2

PC16. set and verify gas flow rates 2 1 1

PC17. prepare and support the joint, using the appropriate methods

3 1 2

PC18. tack weld the joint at appropriate intervals, and check the joint for accuracy before final welding 2 0 2

PC19. match feed and travel speed as required 2 0 2

PC20. perform TIG welding operations using appropriate welding techniques to meet welding procedure specification requirements 5 1 4

PC21. use correct technique for starting the arc (using HF (high frequency) unit, scratching the electrode on the job material, lifting the electrode immediately after touching the job material) 4 2 2

PC22. use correct angle of torch and filler wire

4 1 3

PC23. weld the joint to the specified quality, dimensions and profile

4 1 3


PC24. use manual welding and related equipment, to carry out TIG welding processes 4 1 3

PC25. produce joints of the required quality and of specified dimensional accuracy which achieve a weld quality equivalent to Level B of ISO 5817 4 1 3

PC26. use both methods to produce the various joints a) with filler wire b) without filler wire (autogenously) 4 2 2

PC27. produce joints from various materials in different forms 2 0 2

PC28. weld joints in good access situations, in select positions 3 1 2

PC29. make sure that the work area is maintained and left in a safe and tidy condition 2 0 2

PC30. use appropriate methods and equipment to check the quality, and that all dimensional and geometrical aspects of the weld are to the specification 4 2 2

PC31. check that the welded joint conforms to the specification, by checking various quality parameters using visual inspection 3 1 2

PC32. identify various weld defects 3 1 2

PC33. detect surface imperfections and deal with them appropriately

2 1 1

PC34. report any defect or imperfection identified to the authorised person

2 0 2

PC35. shut down and make safe the welding equipment on completion of the welding activities

2 0 2

PC36. detect equipment malfunctions and deal with them appropriately

2 0 2

PC37. deal promptly and effectively with problems within their control, and seek help and guidance from the relevant people if they have problems that they cannot resolve 2 0 2

Total 100 26 74


4. CSC/ N 0210: Weld

stud joints using

stud welding

equipment/

machines

PC1. work safely at all times, complying with health and safety and other relevant regulations and guidelines

100

3 1 2

PC2. stop machine/equipment in case of emergencies and start when safe using correct procedure

3 1 2

PC3. operate machine/equipment safety devices in line with set procedures

3 1 2

PC4. stop the machine/equipment in a timely and safe manner during an emergency

2 0 2

PC5. interpret stud welding information from welding procedure data sheets specifications

2 1 1

PC6. set up stud welding machine/equipment for operations as per requirement

3 1 2

PC7. ensure portable equipment power leads are undamaged and securely connected

2 0 2

PC8. check if all machinery and equipment is calibrated and approved for use

2 0 2

PC9. check if base metal plates are approved for stud welding process

2 0 2

PC10. check if all equipment mechanical and electrical systems operate correctly

2 0 2

PC11. identify maintenance requirements for various equipment/machine parts

1 0 1

PC12. ensure welding material surface is appropriately prepared with required surface pre-treatment

2 0 2

PC13. match consumables to welding process

1 0 1

PC14. identify different types and sizes of common fasteners and ferrules

1 0 1

PC15. remove damaged and defective materials, equipment and consumables from operations

2 0 2

PC16. select required amount of materials

1 0 1

PC17. set up, check, adjust and operate stud welding machines

3 0 3


PC18. set up the equipment parameters in accordance with instructions and the welding procedure specifications

4 1 3

PC19. check supplies of components and consumables are adequate and correctly prepared

2 0 2

PC20. check that the parent material, components, consumables and joint preparation comply with specifications

4 1 3

PC21. produce test specimen by welding stud to approved specimen plates

3 0 3

PC22. weld position, nature of base metal and stud surfaces, current, and time shall be recorded during specimen testing

2 0 2

PC23. test specimen through approved tests and record results

3 0 3

PC24. adjust parameters as per test results to achieve desired output including plunge, lift, time and current

3 0 3

PC25. confirm that the machine is set up and operating correctly, ready for the joining operations to be carried out

2 0 2

PC26. follow the relevant joining procedure and work instructions

3 1 2

PC27. carry out and monitor the machine/equipment operations in accordance with specifications and job instructions

4 1 3

PC28. select positions of stud placement by looking at specifications, marked layout, drawing layout or provided templates

3 0 3

PC29. monitor the process operation and make adjustments to parameters, in order to produce welded components covering different components and different material thicknesses

3 0 3

PC30. level and square gun to base metal before starting the weld

3 0 3

PC31. stud weld threaded and unthreaded fasteners accurately

3 0 3

PC32. stud weld fasteners of different diameters in downward position

3 0 3


PC33. produce welded components which meet all the required quality parameters

4 1 3

PC34. ensure stud welds are correctly pitched out and located

2 0 2

PC35. meet the required dimensional accuracy within specified tolerances

4 1 3

PC36. achieve the rate of output as specified

2 0 2

PC37. support carrying out of destructive and non-destructive tests

2 0 2

PC38. detect equipment malfunctions and deal with them appropriately

2 0 2

PC39. deal promptly and effectively with problems within own control and seek timely and appropriate assistance from relevant personnel as per organizational procedure

3 0 3

PC40. shut down the equipment to a safe condition on conclusion of welding activities

1 0 1

Total 100 11 89

5. PSS/ N 2001

(Use basic health

and safety for

Power Related

Work)

PC1. use protective clothing/equipment for specific tasks and work conditions

100

3 0 3

PC2. state the name and location of people responsible for health and safety in the workplace 2 0 2

PC3. state the names and location of documents that refer to health and safety in the workplace 2 0 2

PC4. identify job-site hazardous work and state possible causes of risk or accident in the workplace 3 1 2

PC5. follow electrical safe working procedures such as Tag out/Lock out, PTW (Permit To Work),

3 1 2

PC6. follow warning signs (danger, out of service, etc.) while working with electrical systems 3 1 2

PC7. use standard safe working practices when working at heights, confined areas and trenches 3 1 2


PC8. test any electrical equipment and system using insulated testing devices before touching them 3 1 2

PC9. ensure positive isolation of electrical equipment & system as per given standards 3 1 2

PC10. recognize any abnormalities in electrical equipment or system installed alarm annunciation and/or noticing parameters from gauge/ indicator installed 3 1 2

PC11. carry out safe working practices while dealing with hazards to ensure the safety of self and others 3 1 2

PC12. state methods of accident prevention in the work environment of the job role 2 0 2

PC13. state location of general health and safety equipment in the workplace 2 0 2

PC14. inspect for faults, set up and safely use of scaffolds and elevated platforms and ladders 2 0 2

PC15. lift, carry and transport heavy objects & tools safely using correct procedures from storage to workplace and vice versa 3 1 2

PC16. inspect power plant and its equipment routinely for any signs of oil, water and/or steam leakage

3 0 3

PC17. store flammable materials and machine lubricating oil safely and correctly 2 0 2

PC18. check that the emission and pollution control devices are working properly in line with environmental policy standards 5 2 3

PC19. apply good housekeeping practices at all times 3 1 2

PC20. identify common hazard signs displayed in various areas 2 0 2

PC21. retrieve and/or point out documents that refer to health and safety in the workplace 2 0 2

PC22. inform relevant authorities about any abnormal situation/behavior of any equipment/system promptly 3 0 3


PC23. use the various appropriate fire extinguishers on different types of fires correctly 4 1 3

PC25. demonstrate good housekeeping in order to prevent fire hazards 3 1 2

PC26. demonstrate the correct use of a fire extinguisher 3 1 2

PC27. demonstrate how to free a person from electrocution 3 1 2

PC28. administer appropriate first aid to victims where required e.g. in case of bleeding, burns, choking, electric shock, poisoning etc. 3 0 3

PC29. demonstrate basic techniques of bandaging 3 1 2

PC30. respond promptly and appropriately to an accident situation or medical emergency in real or simulated environments

3 1 2

PC31. perform and organize loss minimization or rescue activity during an accident in real or simulated environments 3 1 2

PC32. administer first aid to victims in case of a heart attack or cardiac arrest due to electric shock, before the arrival of emergency services in real or simulated cases 3 1 2

PC33. demonstrate the artificial respiration and the CPR Process 3 1 2

PC34. participate in emergency procedures 3 1 2

PC35. complete a written accident/incident report or dictate a report to another person, and send report to person responsible 3 1 2

PC36. demonstrate correct method to move injured people and others during an emergency 3 1 2

Total 100 24 76

6. PSS/ N 1336

(Work

effectively with

others)

PC1. accurately receive information and instructions from the supervisor and fellow workers, getting clarification where required 100 10 3 7

PC2. accurately pass on information to authorized persons who require it and 10 3 7


within agreed timescale and confirm its receipt

PC3. give information to others clearly, at a pace and in a manner that helps them to understand 10 3 7

PC4. display helpful behavior by assisting others in performing tasks in a positive manner, where required and possible

10 3 7

PC5. consult with and assist others to maximize effectiveness and efficiency in carrying out tasks 10 3 7

PC6. display appropriate communication etiquette while working 10 3 7

PC7. display active listening skills while interacting with others at work 10 3 7

PC8. use appropriate tone, pitch and language to convey politeness, assertiveness, care and professionalism 10 3 7

PC9. demonstrate responsible and disciplined behaviors at the workplace 10 3 7

PC10. escalate grievances and problems to appropriate authority as per procedure to resolve them and avoid conflict 10 3 7

Total 100 30 70

Documents

POWER PLANT HIGH PRESSURE WELDER · • Perform welding on pressure vessels, boilers and high pressure equipment in a power plant: Perform welding of ferrous and non-ferrous pressure