WorldSkills - Technical Descriptionskill.irantvto.ir/uploads/91_252_TD10_39JP_EN.pdf · 2008. 10. 19. · ©WorldSkills - Technical Description Version: 1.0 Approved by: TC 10 –

© WorldSkills - Technical Description Version: 1.0 Approved by: TC

10 – Welding TD10_39JP_EN

Page 1 of 27 Date: 10.05.06

INTRODUCTION WorldSkills, by a resolution of the Technical Committee and in accordance with the Constitution, the Standing Orders and the Competition Rules, has adopted the following minimum requirements for this skill for the WorldSkills Competition. The Technical Description consists of the following:

• Section 1 – Technical/Competition Description (TD) • Section 2 – Project Design Criteria (PD) • Section 3 – Skill Management Procedures (SM) • Section 4 – Workshop Setup (WS) • Section 5 – Infrastructure List (IL) • Section 6 – Appendices

Effective 10.05.06

Liam Corcoran (LC) Chairman, Technical Committee 10.05.06



Page 2 of 27 Date: 10.05.06

1. SECTION 1 - TECHNICAL/COMPETITION DESCRIPTION (TD) 1.1 Name and description of skill

1.1.1 The name of the skill is Welding

1.1.2 Terms and definitions: Standard reference terms and definitions for welding processes, welding positions and weld testing shall be to International Standard Organisation (ISO) and American Welding Society (AWS) standards. Where conflict arises ISO standards shall have precedence. If no ISO standard is applicable then the relevant AWS standard shall be used. The word "shall" used throughout this Technical Description means mandatory compliance with that instruction.

1.1.3 The skill covers the welding of components, structures, plates, pipes and tanks. The following

welding processes shall be applied depending on the material and its application: • 111 - Shielded Metal Arc Welding, SMAW; Manual Metal Arc Welding, MMAW • 131 - Metal Inert Gas Welding, MIG. • 135 - Gas Metal Arc Welding, GMAW (MAG). • 136 - Flux Cored Arc Welding, FCAW and Metal Cored Arc Welding, MCAW. • 141 - Gas Tungsten Arc Welding, GTAW; Tungsten Inert Gas Welding, TIG. Materials to be welded are low carbon steel, austenitic stainless steels (300 series), as well as aluminium (1000, 4000, 5000, 6000 series) in the form of plates, pipes and rolled metal sections.

1.1.4 Every expert and competitor must know this Technical Description.

1.1.5 In the event of any conflict within the Technical Descriptions, the English version will take

precedence.

1.1.6 Words implying male gender shall also automatically imply female gender. 1.2 Scope of work at WorldSkills Competitions

1.2.1 The Test Project consists of practical welding and skill related competency knowledge.

1.2.2 The Test Project will consist of the following tasks: Task 1: Test plates/pipes Task 2: Pressure vessel Task 3: Aluminium structure Task 4: Stainless steel structure Task 5: Assembly according to prints and compliance with instructions Task 6: Competency interpretation

1.2.3 The total working time for the project is 22 hours.

1.2.4 The theoretical knowledge is limited to that necessary to carry out the practical and diagnostic

work. 1.3 Practical work



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1.3.1 The competitor has to be able to carry out, unaided, the following tasks: Butt and fillet welding of plates, pipes and rolled metal sections, in all working positions and with seams of different angles of inclination and rotation. Welding positions terminology shall be to both ISO2553 and AWS A3.0/A2.4

Plate or pipe Welding position Test position AWS ISO and EN Plate Flat 1G PA Plate Horizontal 2G, 2F PC, PB Plate Vertical up 3G, 3F uphill PF Plate Overhead 4G, 4F PE, PD Pipe Axis vertical, fixed 2G PC Pipe Axis horizontal, fixed 5G PF Pipe Axis @ 45º, fixed 6G uphill H-L045

1.3.2 The appropriate minimum technical skills are as per paragraphs 1.3.3 – 1.3.6.

1.3.3 General • Starting and using the welding equipment as supplied by the organiser, following the

appropriate safety regulations • Checking that the dimensions of the materials are in accordance with the material list and

the prints/drawings • Preparing the materials by filing and grinding • Assembling the materials in accordance with the drawings

1.3.4 111 - Shielded Metal Arc Welding, SMAW; Manual Metal Arc Welding, MMAW

• Selecting the most suitable size and type of electrode • Adjusting the correct current and polarity for welding.

1.3.5 131 - Metal Inert Gas Welding, MIG,

1.3.6 135 Gas Metal Arc Welding, GMAW, MAG,

1.3.7 136 Flux Cored Arc Welding, FCAW,

1.3.8 136 Metal Cored Arc Welding, MCAW.

• Using the appropriate shielding gas, current type (DC), amperage and voltage • Adjusting gas pressure and rate of flow • Adjusting and welding with different modes of transfer i.e. spray arc, globular arc, short arc

(dip), pulsed arc, etc. • Selecting the gas nozzles for wire electrodes • Adjusting the wire feed speed, welding with the appropriate contact tip, stick-out distance

and electrode-positioning angle

1.3.9 141 - Gas Tungsten Arc Welding, GTAW; Tungsten Inert Gas Welding, TIG • Using the most suitable welding power unit, current type, electrodes, gas nozzles, purging

devices and remote controls • Adjusting the appropriate amperage and polarity.

1.3.10 Paragraphs 1.3.11 – 1.3.18 are rules for the Welding Competition.

1.3.11 Welding machines, tools and equipment usage

• It is a requirement that the host country supplies welding machines that can be used in basic modes of operation.



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• Welding machines may be used to their full technical potential. • It is a requirement that the host country provides detailed operation manuals to all attending

countries at least six (6) months prior to the competition • The welding machines provided shall have the capability to be operated using both

standard amperage control and remote amperage control. Remote devices shall be made available and include hand-held and foot controls.

1.3.12 Grinding and the use of abrasive materials and equipment

• Material removal is not permitted on any of the root penetration or cap weld surfaces. A “cap passes” shall be defined as the final layer of the weld that meets the weld size, grooves and fillets. Restarts may be prepared before welding over them.

1.3.13 Wire brushing

• Wire brushing, manual or powered, may be used on all weld surfaces of the test plates/pipes (Task 1) and pressure vessel (Task 2). However, wire brushing is not permitted on any of the cap welds of aluminium project (Task 3) and the stainless steel project (Task 4).

1.3.14 Backing bars / plates and restraining devices

• No copper (Cu) chill plates or ceramic backing tapes/bars are to be used in the competition. • Purging equipment may only be used with the Gas Tungsten Arc Welding process on the

stainless steel project. • Restraining devices shall not be used during welding of the test plates. Such devices

include: clamps, jigs, fixtures or steel plates, tack welded to the test plates. • Welding of the test plates is to be carried out without the aid of restraining devices; this is

so the experts can assess the control of distortion.

1.3.15 Weld cleaning of GTAW (TIG) projects • The weld faces on the aluminium and stainless steel GTAW (TIG) projects are to be

presented in the “as welded” condition. Cleaning, grinding, steel wool, wire brushing or chemical cleaning is NOT permitted on any of the cap welds.

1.3.16 Tack welds

• Tack welds shall be maximum 15mm in length. • When assembling the pressure vessel, the competitor may use any of the welding

processes listed on that drawing for tack welding in any position. • No tack welds shall be made on the inside of the pressure vessel project. • HOLD POINT: A jury member must inspect the inside of the vessel to ensure the lack of

tacks before enclosing the vessel . This is to be confirmed by stamping.

1.3.17 Welding of test plates/pipes. • Once welding has commenced, the test plates may not be separated and then re-tacked.

Re-tacking may only take place, if root welding has not commenced. Competitors shall receive information on Task 1 (plates/pipes) regarding the material types and thickness six (6) months prior to the competition.

• At the competition, the experts shall select the position and process for root pass, fill and cap passes from a list of options (see Appendix 6.2) to be used for each test. This change to the project shall provide 25% of the 30% project design change as required by WorldSkills. The remaining 5% changes will be decided at the Competition by the experts on the remaining three tasks. This may include process/weld position changes but no changes to the material to be supplied by the host country shall be made.

1.3.18 Competitors hand pieces / torches

• Competitors may use their own SMAW, (MMAW), GTAW (TIG), GMAW (MIG/MAG) and FCAW hand pieces/torches, provided the competitor does not damage the host country's equipment. The competitor’s equipment must comply with safety regulations.



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1.4 Theoretical knowledge

1.4.1 The theoretical knowledge is limited to that necessary to carry out the practical work, welding procedures and the competency test.

1.4.2 Preparation and execution of welding exercises must be to ISO standards and welding

instructions.

1.4.3 The competitor must have an appropriate level of knowledge and understanding of the competition safety regulations.

1.4.4 The competitor must have the knowledge to select the appropriate materials and consumables

during the competition. 1.5 Materials

1.5.1 Refer Section 4. 1.6 Workshop installations

1.6.1 Refer Section 4 and Section 5. 1.7 Test Project marking

1.7.1 All documentation used must be available in digital form.

1.7.2 There is to be a majority agreement (minimum = 50 % + 1) from experts on the accepted Competition marking scale.

1.7.3 Selection of appropriate project/s is based on paragraph 1.7.2. The expert team may make

modifications to the proposed project.

1.7.4 The experts will provide workable marking criteria that are compatible with the presented projects and shall be on Forms 5 and 6.

1.7.5 Only Objective marking is to be used on all projects. (Form 5)

1.7.6 Please see sample marking sheets attached from Helsinki 2005.

• The test projects shall consist of the welding processes listed in Section 1.1.3.

1.7.7 Approximate percentage break down of welding processes by weld time: • SMAW - MMAW 25% • GMAW - MIG/MAG 25% • GTAW - TIG 25% • FCAW 25%

1.7.8 Weld sizes shall conform to the marking criteria and are to be assessed objectively, utilising

measuring equipment.

1.7.9 Form 6 is used to calculate total marks and ranking.



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1.7.10 Conversion from the 0 – 100 scale to the 400 - 600 scale will be performed by the WorldSkills Competition Information System (CIS).

1.7.11 All marking will be objective in accordance with the marking scale. • Only Form 6 will be required for the submission of marks. • Marking is to be entered after each section has been completed, and a program has been

developed for computer calculation after time and task data has been entered.

1.7.12 Experts are to complete a score sheet for each section completed, for each team.

1.7.13 Marks will vary according to the marking scale defined for the Competition, but will align to the following ranges as defined in paragraph 1.7.8.

1.7.14 Assessment criteria, objective:

Criterion ID

Criterion description Max. marks

A

Visual assessment of weld seams: Test pipe/plate, 7.1 marks Pressure vessel, 17.8 marks Aluminium structure, 7.3 marks Stainless structure, 7.8 marks

40

B Pressure test 15

C Destructive tests (bend tests) 15

D Non-destructive test (x-ray) 15

E Assembly according to prints 10

F Competency interpretation 5



Page 7 of 27 Date: 10.05.06

2. SECTION 2 - PROJECT DESIGN CRITERIA (PD) 2.1 General requirements

2.1.1 Overall, the Test Project must: • Be modular • Be in accordance with the current Technical Description • Comply with WorldSkills requirements and numbering standard • Be accompanied by proof of function/ proof of construction/ completion in the set time etc –

as appropriate to this skill category. – For example, a photograph of a project done according to the Test Project within material, equipment, knowledge and time constraints.

2.2 Design requirements

2.2.1 Refer Subsection 2.3.

2.2.2 Task 1: Day 1 - Test plates/pipes. • Time: 5 or 6 hours approximately. • Quantity: 3 or 4 specimens, either Single V-groove butt joint welds or fillet welds. • Processes: as per Section 1.1.3. • Positions: as per Section 1.3.1 • Materials: as per “Basic materials” in Subsection 4.1 • The competitor shall submit the test plates/pipes to the jury for stamping prior to welding. • One test plate shall consist of two (2) pieces, each 10mm in thickness, 100mm wide and

250mm in length. • The size of the second test plate shall consist of two (2) pieces, each 16mm x 150mm x

350mm, and either GMAW (MIG), FCAW or MCAW (136) process shall be used. The test plates welded with GMAW (MIG), FCAW or MCAW shall contain a stop/restart in the centre 75mm of the cap pass. When GMAW (MIG), FCAW or MCAW (136) is used as a fill and cap pass only, the stop and restart shall take place only at the cap pass. A weave or the last pass on a multi-pass weld is considered for the stop and restart. GMAW (MIG) is also qualified to be used for a root pass and a stop and restart as above shall be applied. FCAW or MCAW (136) shall not be used for making root passes.

• A third test piece shall be a pipe welding test, consisting of two (2) pieces of 114.3 dia x 8.56 wall (4” SCH 40) carbon steel pipe.

• HOLD POINT: All stops must be inspected by a jury and stamped before restarting. • For all test plates, 20mm at the start and finish shall be discarded for all aspects of

inspection and marking. • All butt weld test plates/pipes shall be milled or turned at 30º to a featheredge. • Assessment: Objective Visual Inspection, radiographic and bend testing. • At least two test plates must contain a set of bend test specimen. • SEE APPENDIX FOR DRAWINGS: TASK 1-A – DAY 1- GENERIC DRAWING.DWG and

TASK 1-E-DAY 1-GENERIC DRAWING.DWG.

2.2.3 Task 2: Day 2 and Day 3 - Pressure vessel • Time: 12 hours approximately. • Description: A completely enclosed plate/pipe structure, which shall encompass a minimum

of four of the process types as described in Section 1.1.3 and all weld positions as described in Section 1. 3.1.

• Size: Overall dimensional space, approximately 350mm x 350mmx 400mm. The pressure vessel shall not weigh more than 35kg in the welded condition.

• Plate thickness: 6, 8 and 10mm • Pipe wall thickness 3 to 10mm



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• Assessment: Objective visual inspection and hydrostatic pressure test • Pressure test minimum 1000psi • The pressure for the pressure test shall be set by the project designer and must be at the

highest test pressure possible. The experts reserve the right to amend the design test pressure of any pressure vessel prior to the contest.

(See Appendix #6.3 for Procedure of Pressure Testing)

2.2.4 Task 3: Day 4 - Aluminium structure

• Time: 2 or 3 hours approximately. • Description: A partially enclosed structure of aluminium plate/pipe material thickness 1.5 to

3mm, which shall be welded with TIG (141). • Size: Overall dimensional space approximately 200mm x 200mm x 250mm • This project shall be sawed in half, if necessary, to enable weld penetration inspection and

marking. • Assessment: Objective visual inspection

2.2.5 Task 4: DAY 4 - Stainless steel structure

• Time: 2 or 3 hours approximately. • Description: A partially enclosed structure of stainless steel plate/pipe material thickness

1.5 to 3mm, which shall be welded with TIG (141). • All root passes of butt joints and corner joints shall be purged with Argon. • Size: Overall dimensional space approximately 150mm x 150mm x 200mm • This project shall be sawed in half, if necessary, to enable weld penetration inspection and

marking. • Assessment: Objective visual inspection

2.2.6 Task 5 - Assembly according to prints and compliance with instructions

• Description: The competitor will be judged on the dimensional location, orientation, etc. of components on the test projects, according to prints and instructions. The competitor will also be expected to follow instructions to complete all operations successfully. These instructions will be on the drawing and in addition extra instructions may be given separately.

• Assessment: Objective

2.2.7 Task 6 - Competency and Interpretation • The competitor’s work shall be assessed for competency and shall be based upon correct

process selection and correct welding position and progression. • Assessment: Objective

2.3 Project development and implementation procedure

2.3.1 Experts, Technical Delegates, Jury Presidents, Shopmasters and other associated or invited people will use the WorldSkills Discussion Forums to communicate, collaborate and co-ordinate the development of the Test Project and the overall development of this skill category for the WorldSkills Competition. The address for the forum for this skill category is http://www.worldskills.org/members/forums/forum_10/index.php. The Chief Expert (or an expert nominated by the Chief Expert) will be moderator for this forum.

2.3.2 The completed projects shall include A3-size drawings in ISO A and ISO E, and each project

shall have a list of required materials. This list shall also show the material grades.

2.3.3 Welding symbols shall conform to ISO 2533 on ISO E drawings and to AWS Standard on ISO A drawings.



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2.3.4 All fillet welds shall be given and measured by the leg length.

2.3.5 A separate cutting list for all the required materials for the projects shall be included to assist the competition organisers.

2.3.6 A photograph of the welded stainless steel and aluminium structures.

2.3.7 A photograph of the pressure vessel under pressure test with the pressure attained visible,

1000psi (69 bar), minimum.

2.3.8 Additional instructions for competitors to aid in the completion of the project.

2.3.9 All projects shall comply with the Technical Description and project checklist. Project submission is optional for first-time experts. Any expert who fails to submit a test project for proposal shall not be eligible to vote on the project selection.

2.3.10 The final parts of the project including appropriate changes will be provided to participating

countries at least six (6) months prior to the WorldSkills Competition.



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3. SECTION 3 - SKILL MANAGEMENT PROCEDURES (SM) 3.1 Documents required

3.1.1 The Chief Expert will have available a current copy of all documents associated with this skill for the Competition.

3.1.2 The documents required are:

• Technical Description – Skill 10 Welding • (WorldSkills) Competition Rules • Health and Safety documents • QAMS – all documents • Any other documents referred to in the documents listed above.

3.1.3 While it is understood that the Chief Expert will have a copy of these documents in his/her own

language, there shall also be a complete set in the language identified as that taking precedence.

3.1.4 The Chief Expert is expected to have a sound knowledge of the requirements and procedures

specified in the documentation.

3.1.5 The Jury President is expected to have a thorough knowledge and understanding of the requirements and procedures specified in the documentation.

3.2 Pre-Competition responsibilities

3.2.1 In the period between one WorldSkills Competition and the next, the elected Chief Expert is responsible to ensure that the requirements of Section 2 – Project Design Criteria are complied with.

3.3 Skill Management procedures for the Chief Experts prior to and during the Competition

3.3.1 The procedures specified below must be adhered to.

3.3.2 On arrival at the Competition site for the first time, the Chief Expert must: • Welcome the experts and ensure introductions are made • Inform them of their duties and responsibilities in terms of the Competition Rules and

Standing Orders • Ensure that the project is endorsed by all the experts and that a copy is signed by all the

experts

3.3.3 The Chief Expert will then divide the experts into teams for the following activities: • Verify that the material on site is appropriate and sufficient • Verify again that the quantities of material as specified on the material list is accurate • Develop a program for the competitors to complete the modules • Develop timetables for activities • Set up equipment • Confirm that the layout, work areas and equipment are in accordance with the workshop

setup requirements • Confirm that all machinery/equipment is in a safe working order • Confirm that all workstations/machinery/equipment are in accordance with the plan, and

that they are numbered



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• Confirm that there is sufficient illumination • Confirm that there is sufficient space for the competitors to work efficiently • Confirm that the barriers are far enough removed from the competitors to ensure that there

will be no interference, and if they are not, set up a roster among the experts to police the area during the Competition

• If necessary, set up duty rosters for activities during the Competition – e.g. keeping watch during lunch, preventing access of unauthorised persons, etc

3.3.4 The Chief Expert will then divide the experts into teams for purpose of marking and setting up

marking schedules in accordance with the requirements of Subsection 1.7.

3.3.5 Suggestions and comments for the revision and improvement of the Technical Description are to be provided to the Deputy Chief Expert in writing. The Deputy Chief Expert will reduce the information to a single typed document ready for discussion by all experts. Prior to leaving the Competition site, the Chief Expert, the Deputy Chief Expert and the Jury President will facilitate the discussion and revision of the Technical Description. Also refer paragraph 3.3.12.

3.3.6 At any time that a unanimous decision is not achieved within a reasonable time, the Chief

Expert will put the matter under discussion to the vote. A majority will be 50% of the experts present plus one. This decision will be final. In the event that an expert is absent at the time that the vote takes place, he/she has the right to be informed of the decision but the matter will not be raised again or voted upon again. The exception to this majority rule will be in the case of approval of the changes to the Technical Description, where the majority of 80% is required.

3.3.7 In the event that an extension of time is requested for the Competition to exceed 22 hours, the

matter must be discussed with the Jury President. All possible alternative solutions must be investigated before approval of an extension of time is requested, or will be approved.

3.3.8 Prior to the end of the Competition, the Jury President will facilitate the selection of the Chief

Expert and Deputy Chief Expert for the next WorldSkills Competition.

3.3.9 Experts are eligible for selection as a Chief Expert if they: • Can speak English • Have attended the WorldSkills Competition at least twice before (if less than 4 experts have

been to the WorldSkills Competition before, this criteria may be relaxed at the discretion of the Jury President)

• Demonstrate a high degree of expertise in the skill • Demonstrate leadership qualities. • Are competent using a computer and the Internet – specifically to facilitate the Discussion

Forum for their skill category.

3.3.10 The process by which selection will take place is by secret ballot and is as follows: • Each expert present will list their choice of three experts in order of preference • The Jury President will allocate a score of three (3) points to each experts first preference,

two (2) points to the second preference and one (1) point to the third preference • The Jury President will then calculate total scores and announce the three highest scoring

experts • The expert with the highest score will be appointed Chief Expert for the next WorldSkills

Competition • If the first choice cannot attend, then the second choice will be Chief Expert • If the first and second choice cannot attend, then the third choice will attend • If none of the choices can attend, then the jury president will appoint, or facilitate the

appointment of a Chief Expert • The names of the selected experts will be entered into the provided documentation and

signed by the Jury President and returned to the WorldSkills Secretariat.



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3.3.11 Changes to the method of Competition design or suggestions offered for the next Competition design process or tasks must be written down and signed by 80% of the experts and included in Subsection 2.3.

3.3.12 The Deputy Chief Expert’s primary role is to ensure that the Technical Description is updated

to reflect the technological advances of the skill category and include overall improvements for the preparation and running of the Competition. He/she will ensure that all changes to the Technical Description are entered, that at least 80% of the experts sign it, and that it is delivered to the WorldSkills Secretariat as a hard copy and digitally.

3.3.13 The Deputy Chief Expert also assists in the distribution and collection of the QAMS Audit

Questionnaires and assists the Chief Expert where necessary. 3.4 Competition procedures

3.4.1 The project will be worked on over all four days of the Competition (project organised by tasks, sections or modules).

3.4.2 Each module/task/section will be completed on the assigned day so that progressive marking

can take place. Progressive results are to be available each day via a PowerPoint presentation or similar.

3.4.3 Prior to the start of the Competition, each competitor will receive a detailed timetable reflecting

the timing for completion of the project tasks or modules.

3.4.4 Competitors will have a maximum of 8 hours to become familiar with material, equipment and processes. Where processes are particularly difficult, a subject matter expert will be available to demonstrate the process and the competitors will be given the opportunity to practice.

3.4.5 The competitors will be given all Competition documents including the marking criteria 1 hour

prior to the commencement of the Competition so that they may study the requirements.

3.4.6 At no time during the Competition may the expert from the same country of origin as the competitor be involved in any discussion without another expert present or without permission from the Chief Expert.

3.4.7 Experts and competitors who continually fail to abide by the Technical Description and

Competition Rules may be temporarily or permanently removed from the Competition. 3.5 Competition safety requirements

3.5.1 Policies and procedures specified within the following documentation will be adhered to or followed at all times. • Health and Safety Policy – General Requirements • Health and Safety Policy – Skill Specific • Procedure for Safety Training • Safety Training Development Flowchart • Host Country Health and Safety Requirements • Medical Assistance Request Procedure • Accident Report Form

3.5.2 After having received training and briefing, the Chief Expert will provide the experts,

competitors and personnel for whom he has responsibility with the information and training required to ensure a safe Competition in accordance with the requirements of the



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documentation specified in paragraph 3.5.1 above, and taking into account any of the specified requirements identified in Subsection 3.6 below.

3.5.3 The Chief Expert will ensure that all experts, competitors and personnel for whom he has

responsibility complete and sign the Confirmation of Receipt of Training Form (refer Appendices) on completion of the training session.

3.5.4 The Chief Expert will countersign these forms, and keep them secure until the end of the

Competition at which time they will be returned to the Quality Auditor for the Competition.

3.5.5 The Chief Expert will additionally task the experts with the responsibility of ensuring that all experts, competitors, and other personnel comply with the safety requirements for the skill category and Competition site.

3.5.6 The Chief Expert will receive nominations and appoint a safety officer whose responsibility will

be to carry out the tasks specified in the Safety Checklist (refer Appendices).

3.5.7 Work clothes must comply with relevant codes. If the host country has any specific codes that are to be in place during the Competition, then these must be made known to the competitors at least 6 months prior.

3.5.8 All machinery and/or equipment must comply with the safety requirements of the host country.

3.5.9 Competitors must keep their work area clear of obstacles and their floor area clean of any

material, equipment or items likely to cause someone to trip, slip or fall.

3.5.10 Failure by the competitor to comply with safety directions or instructions may incur loss of marks for safety. Continuous unsafe practice may result in competitors being temporarily or permanently removed from the Competition.

3.6 Skill specific safety requirements

3.6.1 All competitors must wear safety glasses when in the workshop area.

3.6.2 A first-aid kit must be available throughout the Competition.

3.6.3 Experts will use the appropriate personal safety equipment when inspecting, checking or working with a competitor's project.

3.7 Judging procedural requirements

3.7.1 The experts will be divided into marking groups • in accordance to Expert Grouping • to deal with each section of the marking criteria.

3.7.2 Every completed module/task/section will be marked on the same day in which it was

completed.

3.7.3 To ensure transparency, each competitor is provided the same evaluation sheet as used by the experts.

3.7.4 The experts agree that a majority vote is needed to:

• Change scoring system (within limits specified in the Technical Description) • Change Competition sequence or content



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• Agree on a solution for disputes concerning points awarded etc. 3.8 Honesty, fairness and transparency

3.8.1 The competitors that attend the WorldSkills Competition have the right to expect fair and honest treatment during the Competition in terms of the following: • Instructions that are clear and unambiguous • Marking schedules that provide no advantage to an opposing competitor • All necessary equipment and material specified within the skill documentation that are

required to complete the Competition • The assistance necessary from judges and officials to ensure that he is able to complete

the project. (The assistance deemed necessary will be provided equally and at the same time to all competitors present)

• No undue interference by officials or spectators that may hinder them in the completion of their project

3.8.2 Every competitor has the right to expect and demand that no opposing competitors will receive

undue or unfair assistance or intervention that may provide that opposing competitor with an unfair advantage.

3.8.3 All officials and judges present on the Competition site are expected to ensure that paragraphs

3.8.1 and 3.8.2 above are complied with and maintained.

3.8.4 It is the responsibility of the Chief Expert or his Deputy to ensure that all competitors, interpreters, officials and judges comply with and maintain the integrity of the Competition, and additionally ensure that all necessary steps are taken to ensure that: • Translations and any interpretation to a particular competitor does not advantage that

competitor • Outside influences do not unduly improve or decrease competitors’ abilities to provide a

worthy performance.

3.8.5 A briefing will be provided to all experts and competitors on the requirements for integrity during the Competition.

3.8.6 Additionally, the Chief Expert is expected to identify these and any other factors that may exist

on the Competition site that may results in the contravention of paragraphs 3.8.1 and 3.8.2 above, and reduce them to a checklist for continuous reference.

3.8.7 In the event that any competitor, judge, official, observer or competitor compatriot is found to

be attempting to gain or provide assistance in any form that may result in an unfair advantage, the Chief Expert is to immediately refer the matter to the Jury President.

3.8.8 The Chief Expert will receive nominations and appoint a Security Officer whose responsibility it

will be to ensure that these requirements are carried out.

3.8.9 It will be explained to all experts and competitors that nothing is to come in or out of the site unless specified by the Chief Expert as being allowed after being briefed on this topic.

3.8.10 Security checks will be carried out each day on experts and competitors (by experts and

competitors) upon entry and exit to the site. 3.9 Information policy



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Information on the Competition contents is distributed based on the following two principles: • “Need to know” – Information is given only to those that need it to perform a task. • “Just in time” – Information is given to those that need it just before they need it to perform

a task.

3.9.2 This information covers everything to do with types of stations, components, assemblies and other equipment and on the tasks to be completed during the Competition.

3.9.3 Any persons involved in the development of the tasks, testing and shipping of the hardware

(as few as possible) are required to sign a Declaration of Confidentiality (refer Appendices) before being entrusted with information concerning the Competition.



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4. SECTION 4 – WORKSHOP SETUP (WS) 4.1 Materials & equipment

4.1.1 Welding power sources: 111 SMAW, MMAW, 141 GTAW, TIG: • AC/DC, 300 Amps Inverter-Type with Hi-Frequency and AC-Frequency (Hz) and Pulse

controls 135 GMAW, MAG, 136 FCAW: • DC, 300 Amps with Pulse control

4.1.2 Welding accessories:

• 111 SMAW, MMAW Welding cable and electrode holder • 141 GTAW, TIG gun and accessories, contact tips, diffusers, shielding gas accessories,

regulator, hoses, remote controls, foot- and hand-operated, hose for purging • 135 GMAW, MIG gun and accessories, contact tips, diffusers, shielding gas accessories,

regulator, hoses, etc. • 136 FCAW gun and accessories, contact tips, diffusers, shielding gas accessories,

regulator, hoses, etc.

4.1.3 During the competition only materials provided by the host country may be used.

4.1.4 Practice plates for the competition: The host country shall provide 10 practice plates of each different type of material and thickness used in the competition projects. These plates shall be made available to the competitor for practice on the day set aside for testing the installations, before the competition and for adjusting the welding parameters during the competition.

4.1.5 Dimensions of practice plates:

The practice plates shall be the same width and thickness as the actual project pieces, but they shall each be shorter by 20mm in length.

4.1.6 Basic materials:

• Steel groups according to CR ISO/TR 15608 (1999), Group 1, 2 or 3 for low carbon steel; Group 8 for stainless steel (300 series), and aluminium in the 1000, 4000, 5000 and 6000 series.

Plates: • Quality low carbon steel, 2mm to 20mm thick to ISO 10038. • For pressure vessel, plates are to have through-thickness tested certification. • Austenitic stainless steel, 1.5mm to 10mm thick e.g. 18/8 types X5CrNi 18 • Aluminium, 1.5mm to 10mm thick e.g. 1000, 4000, 5000 or 6000 series.

Pipes: • Quality low carbon steel pipes to ISO 10038, dia. 25mm to 250mm, wall thickness 1.6mm

to 10mm • Stainless steel and aluminium, dia. 25mm to 250mm, wall thickness 1.6mm to 6mm.

4.1.7 All material with weld bevel surfaces shall be milled or turned, so that they are smooth and

parallel.

4.1.8 Welding consumables For 111, Shielded Metal Arc Welding SMAW, Manual Metal Arc Welding MMAW



Page 17 of 27 Date: 10.05.06

• Hermetically sealed only, in small packages of 10-20 pieces each • SMAW electrodes, (basic type), AWS A5.1, E7016 and E7018 dia. 2.5, 3.2, and 4.0mm

For 136, Flux Cored Arc Welding FCAW • Rutile, flux cored wire, Grade 3, shipping society approvals (e.g.: L.R.S., A.B.S., D.N.V.

etc.), AWS A5.20 E71T-1/1M dia. 1.2mm

For 136, Metal Cored Arc Welding MCAW • AWS A 5.18, E70C-6, dia. 1.2mm

For 135, Gas Metal Arc Welding GMAW, MIG / MAG Welding • Low carbon steel wire electrodes, dia. 0.9mm, 1.0mm and 1.2mm AWS A5.18 ER70S-6

For 141, Gas Tungsten Arc Welding GTAW • AWS A5.18 R70S-2, Carbon steel, filler rods, dia. 1.6, 2.4 and 3.2mm • AWS A5.10 R5356 or R4043, Aluminium, filler rods, dia. 2.4 and 3.2mm • AWS A5.9 R308L or R316L, stainless steel filler rods, dia. 1.6, 2.4 and 3.2mm • Ceramic gas lenses of various diameters and lengths • Tungsten electrodes and collets of 2.4mm, 3.2mm diameters.

• The consumables used shall match and be suitable for the welding of the base materials

supplied.

4.1.9 Shielding gases and purging gas • Pure Argon, Ar 4.5 (99.995%) • Carbon dioxide, CO2 • Gas mixtures as required for GMAW, FCAW, MCAW welding. • Purging gas, pure Argon, Ar 4.5 (99.995%)

4.1.10 When GMAW, FCAW or MCAW welding, the competitor shall have the choice of shielding gas

between CO2 and the gas mixture supplied,.

4.1.11 Notification of welding consumables & gases • Welding consumables (filler metals) and shielding gas combinations, chemical

compositions and classifications must be provided to the competing countries at least six (6) months prior to the competition.

4.1.12 Tools

The competitor shall bring tools and equipment in a toolbox and is encouraged to bring other new tools and devices that are being used in today's industry: • Welding safety glasses • Grinding goggles • Welders helmet, speed lenses are permitted • Safety boots with steel toes • Ear protection • Hand angle grinder with guard, maximum 125mm (5inch) • Wire brush wheels to suit grinder • Fire retardant clothing • Chipping hammer (slag hammer) • Inter-weld run cleaning, blade scrapers • Chisels • Scriber • Files • Wire brushes • Hammer



Page 18 of 27 Date: 10.05.06

• Weld gauge (fillet gauge) • Metric steel ruler (tape measure) • Square • Chalk/soapstone • Dividers • G-clamps and/or c-clamps and quick gripping devices • Power transformer (if required) and extension leads • Other personal hand tools • Working clothes and all tools must comply with safety regulations.

4.1.13 Alignment aids for setting up test samples may be used, provided they are removed prior to

welding.

4.1.14 No material that may be used to assemble a project or part of a project is allowed to be brought to the Competition.

4.2 Workshop installation

4.2.1 Pressure test pump complete with water and drain hook-ups and compressed air supply for drying.

4.2.2 Basic SMAW, MMAW electrodes shall be stored in a drying oven or be hermetically sealed in

small packages until used. 4.3 Sample layout See Appendix 6.1 for a sample floor layout. 5.



Page 19 of 27 Date: 10.05.06

SECTION 5 – INFRASTRUCTURE LIST (IL) 5.1 See separate document IL10_39JP_EN.doc



Page 20 of 27 Date: 10.05.06

6. SECTION 6 – APPENDICES 6.1 Workshop layout in Helsinki, 2005

6.2 List of positions and processes for selection on Task 1, Day 1.

Selecting the test plate and pipe projects for Skill 10 Welding

SELE

CTE

D F

OR

200

7

Test Pipe 1A Positions Root Pass Fill and Cap

GTAW 141 SMAW 111 GTAW 141 GMAW 135 FI

SMAW 111 SMAW 111 NO

2 PC

GMAW 135 GMAW 135 GTAW 141 SMAW 111 UK GTAW 141 GMAW 135 JP

SMAW 111 SMAW 111

5 UPHILL PF

GMAW 135 GMAW 135 GTAW 141 SMAW 111 IR GTAW 141 GMAW 135 HK

SMAW 111 SMAW 111 AT

6 UPHILL H-LO45

GMAW 135 GMAW 135 ZA Test Plate 1B 10mm Positions Root Pass Fill and Cap

SMAW 111 GTAW 141 GMAW 135 SMAW 111 SMAW 111 FCAW 136 GMAW 135

1 PA

GMAW 135 FCAW 136

2 GTAW 141 SMAW 111



Page 21 of 27 Date: 10.05.06

GMAW 135 SMAW 111 KR SMAW 111 FCAW 136 GMAW 135 PT

PC

GMAW 135 FCAW 136 SMAW 111 NL GTAW 141 GMAW 135 CH SMAW 111 BR SMAW 111 FCAW 136 CA GMAW 135

3 UPHILL PF

GMAW 135 FCAW 136 SMAW 111 FR GTAW 141 GMAW 135 SMAW 111 MY SMAW 111 GMAW 135 NZ

4 PE

GMAW 135

Test Plate 1C 16mm Positions Root Pass Fill and Cap

GMAW 135 GTAW 141 FCAW 136 TW GMAW 135 GMAW 135 FCAW 136 AE GMAW 135

1 PA

SMAW 111 FCAW 136 GMAW 135 SW GTAW 141 FCAW 136 GMAW 135 GMAW 135 FCAW 136 AU GMAW 135

2 PC

SMAW 111 FCAW 136 GMAW 135 GTAW 141 FCAW 136 IE GMAW 135 GMAW 135 FCAW 136 TH GMAW 135

3 UPHILL PF

SMAW 111 FCAW 136 US GMAW 135 GTAW 141 GMAW 135 GMAW 135 GMAW 135

4 PE

SMAW 111



Page 22 of 27 Date: 10.05.06

6.3 Procedure for the hydrostatic pressure test. 1. The expert, whose competitor’s vessel is being tested, is allowed to witness the test. 2. Fill the vessel with water and ensure that all air is allowed to escape. 3. Plug vessel and pressurize to 2 bar (30psi). 4. Ensure vessel is fully dry on outside. 5. If vessel exhibits a leak – Score 1 point and test is complete. (see # 9) 6. If vessel exhibits no leak, continue to pressurize to 35 bar (500psi). Allow 10 seconds to stabilize. 7. Hold for 60 seconds. If a leak is observed – Score 1 point and test is complete. (see # 9) If no leak is

detected, pressurize to 69 bar (1000psi). Allow 10 seconds to stabilize. 8. Hold for a 60 seconds. If a leak is observed – Score 7.5 points. If no leak is observed – Score 15

points and test is complete. 9. Drain all water from the vessel. Note: If a leak is detected, it shall be highlighted with a metal marker.



Page 23 of 27 Date: 10.05.06

6.4 Task 1, Day 1 - ISO A



Page 24 of 27 Date: 10.05.06

6.5 Task 1, Day 1 – ISO E

WorldSkills

Text Box

Note: This drawing is not to scale. Please contact WorldSkills Secretariat for original AutoCAD file.

WorldSkills Competition Berufsweltmeisterschaft Concours Mondial des Mètiers

Shizuoka, Japan 14 – 21 November, 2007

© WorldSkills 2007 – Technical Description Version 1.0 10 - WELDING Page 1 of 5 Approved by: TC IL10_39JP Date: 10.05.06

5. INFRASTRUCTURE LIST WELDER SCHWEISSER SOUDAGE

Description (EN)

Beschreibung (DE) Description (FR) TD Qty

OC JP Qty

Qty per competiitor

Dimensions Masse Mesures mm

Comments

General installations Allgemeine Einrichtung Installations générales Tables Tische Tables 10 Chairs Stühle Sièges 36 Set office material Büromaterial-Set Fourniture de bureau 1 Tape, Marker,

Pens, etc.

Desk lamp (adjustable) Tischlampe (verstellbar) Lampe de bureau 3 Computer with Internet connection Computer mit Internet Anschluss Ordinateur plus Internet 2 Printer b / w Drucker s/w Imprimante N/ B 1 Office table Schreibtisch Bureau 2 Chair Stuhl Siège 4 Flipchart / Writer Flipchart / Schreiber Flipchart / Stylo-feutre 1 First Aid Kit Erste Hilfe Koffer Pharmacie de premier

secour 1

Fire extinguisher Feuerlöscher Extincteur 6 Flashlight Handlampe Torche manuel à pile 6 Locker Competitors Garderoben Kandidaten Casier pour candidats 1 TD

Qty OC JP Qty

Qty per competiitor

Dimensions Masse Mesures mm

Comments

Locker Experts Garderoben Experten Casier pour experts 30 Cloakroom Garderobe Vestiaire 1 Cupboard lockable Schrank abschliessbar Armoire fermant à clé 1 Clock Wanduhr Pendule 1 Refrigerator Kühlschrank Réfrigérateur 1 Coffee machine Kaffeeemaschine Cafetière électrique 1 Broom and dust pan Reinigungssets Nécessaire de ménage 12 Wash basin with soap/towels Waschgelegenheit Lavabos 1 Pressure test pump Druckprüfpumpe Pompe hydraulique pour

essai de pression 1 Minimum test

pressure of 80 bar

Trolley for material handling Handwagen für Materialtransport Chariot de manutention 1 Capacity: 100kg Floor concrete Fussboden aus Beton Sol en béton Cleaning rags Putzlappen Chiffons 50




Protractor Transporteur Rapporteur d’angle 2 Measuring ruler Messlineal Mètre à ruban 6 500mm minimum Scriber Reissnadel Pointe à tracer 6 Universal electric adaptors Universaler elektrischer Adapter Adapteur électrique

universel 12

Electrical extension cord Verlängerungskabel Rallonge électrique 12 Marker for metal Markierstift für Metal Marqueur pour métal 12 Pump cart Hubwagen Transpalette 1 Data Projector with screen Beamer und Leinwand Video projecteur avec écran 1 Water buckets for cleaning and cooling of work pieces

Wasserkübel zur Reinigung und Abkühlung der Werkstücke

Seau d’eau pour nettoyage et refroidissement des pièces

6

Technical Descriptions Technische Beschreibungen Descriptions techniques TD

Qty OC JP Qty

Qty per competitor

Work station Arbeitsbereich Poste de travail 1 3000x3500x2250 Chipboard, untreated on both sides Spanplatten, roh Panneaux de bois

agglomérés , bruts sur trois côtés

1

Safety curtains (yellow) Schweissvorhang (gelb) Rideau antiéblouissant sur cadre ( )

1 H=2000, 0.4

Lighting fluorescent, at the top of the wall

FL-Leuchten oben an Wand Eclairage en haut sur paroie 1

Welding bench with adjustable arm, clamping fixture that can be moved up and down, rotated and locked

Schweisstisch mit verstellbarem Arm / Klemmvorrichtung mit Auf- / Abwärtsbewegung / Drehung

Table de soudage avec bras réglable / dispositif de blocage déplacement ascendant / descendant et en rotation

1 900x800x100

Circular stool, vertically adjustable, swivelling and lockable

Rundhocker, klemmbar, höhenverstellbar, drehbar

Tabouret rond pivotant, réglable en hauteur

1

Electrical connections (for grinders) 3 receptacles, protected by time-lag fuses

Elektrizität,(fuer Schleifmaschinen), 3er-Steckerleiste, träge abgesichert

3 prises électrique, avec raccordement, protégés par fusibles à action retardé

1

Smoke extraction system with illumination

Rauchabzug mit Beleuchtung Système d’extraction des fumées de soudage avec éclairage

1

Workbench with vice Arbeitstisch mit Schraubstock Etablit avec étau à mors 1




parallèle Beltsander Bandschleifmaschine Ponceuse Fixe à bande 2 Tungsten electrode grinding machine

Schleifgerät für Wolframelektroden Affûteuse pour électrode de tungstène

2

Weld gauges Schweissnahtlehre Jauge à soudure 6 Weld bead inspection tools Schweissnahtprüfwerkzeuge Jauge de mesure de largeur

et hauteur de cordon 3

Set of stamping numerals and numbers and hammer

Satz Schlagzahlen mit Hammer Jeux à frapper de lettres et numéro, plus marteau

5 Minimum size 10mm high

Pliers Zangen Pinces de manutention 6 Work gloves, fabric and leather Arbeitshandschuhe, Baumwolle und

Leder Gants de travail en tissu ou cuir

30

Hearing protection, disposable Gehörschutz Protection anti-bruit à disposition ( bouchon )

100

Masking tape, Abdeckband Masque de protection 20 50mm wide Welding Power Sources, etc.: Schweissanlagen, etc.: Equipement de Soudage,

etc.:

111 SMAW, MMAW and 141 GTAW

111 Lichtbogenhand-schweissen und 141 Wolframinertgas-schweissen

111 pour soudage à l'arc avec électrode enrobée et 141 pour le soudage sous gaz inerte avec électrode non fusible

1 111 SMAW, 141 GTAW, AC/DC, 300Amp, Inverter-Type with Hi-Frequency and AC-Frequency (Hz) and Pulse controls

Welding cable and electrode holder Schweisskabel mit Zange Câble de soudage et pince de masse

1

GTAW gun and accessories, contact tips, diffusers

GTAW Brenner, Spannhülse, Spannmutter, Gasdüse

Torche de soudage TIG et accessoires diffuseur et pince électrode

1 Dia. 1.6, 2.4, 3.2 electrodes and collets

Shielding gas accessories: regulator, hoses, etc.

Schutzgaszubehör, Druckminderer Accessoire pour la protection gazeuse : Détendeur –débilitre, tuyaux, etc

1

Pulse facilities with accessories Pulseinrichtung mit Zubehör installation pour l’utilisation de courant pulsé

1

Remote controls: foot- and hand-operated

Fuss- und Handfernbedienung commande à distance pour contrôle manuel ou au pied

1

Hose for purging Schlauch für Formiergas Tuyau pour purge de gaz 1 Dia. 10 x 3m




135 GMAW, MAG, 136 FCAW

135 GMAW, 136 FCAW

135 GMAW, MAG, 136 FCAW, FFAG

1 135 GMAW, 136 FCAW, DC, 300Amps with Pulse control

GMAW gun and accessories, contact tips, diffusers

GMAW Brenner, Kontaktrohre und Gasdüsen

Torche pour le soudage MAG et accessoires

1 Dia. 0.8, 1.0, 1.2mm

FCAW gun and accessories, contact tips, diffusers

FCAW Brenner, Kontaktrohre und Gasdüsen

Torche pour le soudage FFAG et accessoires

1 Dia. 1.2mm

Shielding gas accessories: regulator, hoses, etc.

Schutzgaszubehör, Druckverminderer

Accessoire pour la protection gazeuse : Détendeur –débilitre, tuyaux, etc

1

Pulse facilities with accessories Pulseinrichtung mit Zubehör installation pour l’utilisation de courant pulse

1

Welding consumables for: Zusatz-Werkstoffe für: Métaux d'apport pour : 111 SMAW,MMAW, Electrodes, basic

111 SMAW, MMAW, Basisch umhüllte Stabelectroden

111 SMAW, MMAW,AEE électrodes à enrobage basique

2kg, each AWS: 5.1 E7016 and E7018, dia. 2.6, 3.2, 4.0mm

141 GTAW, TIG, tungsten electrodes,

141 GTAW, TIG, Wolframelektroden 141 GTAW, TIG,électrode de Tungstène

10 each Tungsten electrodes, dia. 2.4, 3.2 and collets

141 GTAW, TIG, filler metal 141 GTAW, TIG, Schweisstäbe 141 GTAW, TIG, Baguette de métal d’apport

1kg, each Carbon steel filler rod, dia. 1.6, 2.4, 3.2 Stainless steel, dia. 1.6, 2.4, 3.2 Aluminum, dia. 2.4, 3.2

135 GMAW, MAG, filler solid wire 135 GMAW, MAG, Massivdrahtelectrode

Fil plein de métal d’apport 15kg spool AWS 5.18 ER70S-6, dia. 0.8, 1.0, 1.2mm

136 FCAW, filler flux cored wire 136 FCAW, Fülldrahtelectrode 136 FCAW, fil fourré de métal d’apport

15kg spool AWS 5.20 E71T-1, dia. 1.2

Shielding gases: Schutzgase: Gaz de protection: 141 GTAW, Argon, Ar 4.5 (99.995%)

141 GTAW Ar 4.5 (99,99%) 141 GTAW Ar 4.5 (99,99%) 1 Ar 4.5 (99,99%)

135 GMAW, MAG, ArCO2 82/18 135 GMAW, MAG, ArCO2 80/20 135 GMAW, MAG, ArCO2

80/20 1 ArCO2 80/20




136 FCAW, ArCO2 82/18 136 FCAW, ArCO2 80/20 136 FCAW, ArCO2 80/20 1 ArCO2 80/20, CO2 Materials Verbrauchsmaterial Consommables TD

Qty OC JP Qty

Qty per competitor

Low carbon steel plate Unlegierte Stähle Tôle en acier bas carbone 1 set Quality low carbon steel plate, 2-20 thick

Low carbon steel pipe Unlegierte Stahlrohre Tube en acier bas carbone 1 set Quality low carbon steel pipe, dia. 25-250, wall 1.6-10 thick

Austenitic nickel chromium steels, plate and pipe

Austenitische Chrom-Nickelstähle, Bleche und Rohre

Aciers inoxydable austénitiques pour Tôle et Tube

1 set Austenitic 18/8 stainless plate, 1.5-10 thick and pipe

Aluminium, 1000, 4000, 5000 or 6000 series, plate and pipe

Aluminium, Serie 1000, 4000, 5000 oder Bleche und Rohre

Aluminium,séries 1000, 4000, 5000 ou 6000 pour Tôle et Tube

1 set Aluminum, 1000, 4000, 5000 or 6000 series plate, 1.5-10 thick and pipe

Practice material of all types 1 set Steel, Stainless steel, aluminum as above

All practice material to be the same type and thickness, but 20mm shorter than the project pieces.