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Unit QPEO2/027NPreparing and using manual metal arc  welding equipment

Name: Mitch Small Tutor: Steven Smith

Jobs

  • Jobs
  • MMA Welding
  • Evidence
Knowledge Criteria
  • Unit QPEO2/027N Referencing
  • Knowledge Quiz
  • Toolbox Talks
  • Assessor's Feedback
  • Witness Testimony

Contents

Toolbox talk

Jobs

Assessors feedback

Annotated evidence for jobs

Witness testimony

Referencing

Jobs

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  • I put on appropriate PPE (gloves, overalls, safety boots, safety glasses and my welding visor and gauntlets for later) and ensured the workspace was clean and tidy to prevent slips, trips, and falls. I retrieved the necessary equipment from stores, performing a visual inspection for damage or faults.
  • Using a steel rule and set square, I measured and marked out 150mm x 50mm lines on a sheet of carbon steel with chalk. I switched on the guillotine, placed the sheet metal on a free support, and carefully aligned the chalk marks with the shadow cast behind the guard.
  • I anchored myself by resting my arm on an unused support and applied pressure to the pedal bar with my foot, clamping the sheet metal and lowering the guillotine blade. I cut along the desired line, repeating the process to create enough 5mm plates for welding.
  • After cutting, I turned off the power and collected the newly cut plates from the gated pen at the back of the guillotine. Using proper manual handling techniques, I transported the plates to the welding bays.
  • In the welding bays, I switched on the extractor fan and welding equipment. I placed the electrode in the holder, bending it to a 45° angle, and set up the plates for welding on a properly earthed workbench.
  • In this job I used an electrode to bond two pieces of steel plate (this is known as MMA, or Manual Metal Arc welding).
  • I gathered and inspected my equipment and machinery. This included an electrode, MMA welding machine, shielding curtains, workbench (earthed), ventilation, chipping hammer, wire brush, 5mm carbon steel sheet, steel rule, French chalk, set square, and guillotine (or plate cutter).

MMA Welding

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repeated the process for various weld types (bead, corner, lap, and T-fillet) as needed.

  • After welding, I switched off the machine, removed slag with a chipping hammer, and inspected the weld quality. I repeated the process for various weld types (bead, corner, lap, and T-fillet) as needed.
  • Once finished, I disposed of remaining rod lengths, hung up my visor and welding handle, and stored welded joints in a metal bin. I cleaned the workstation with a brush and pan, returning unused plates to the centre table.
  • For non-destructive testing, I used a penetrant dye method in a well-lit, ventilated area. I cleaned the welded area with solvent, applied red penetrant dye, allowed it to soak for 30 minutes, then removed excess dye with a clean cloth.
  • I applied white developer spray, creating a thin film over the tested area. I visually inspected for red indications or "bleed-out" from the white developer, which would indicate surface flaws or cracks.
  • After inspection, I thoroughly cleaned the weld and work area, returning all equipment and materials to their correct stores.

  • I pulled down the welding curtains, turned on the welding machine, and set the amps to approximately 108. Wearing my welding visor (Darkness Setting: 11), I struck the rod to begin welding, maintaining a consistent angle and speed for a strong weld.
  • After welding, I switched off the machine, removed slag with a chipping hammer, and inspected the weld quality. I

MMA Welding (cont.)

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Right: Here is a photo of me performing a lap weld using MMA welding techniques. I wore a welding visor and gauntlets for protection from the splatter created in the welding process, as well as any risk of eye damage from the intense light produced by the metal arc.

Left: Here are some photos of me demonstrating various MMA welding techniques, including a lap weld, corner weld, and T-fillet weld. I had to be careful when performing these welds as there was a potential hazard of burns from the hot metal and arc flash if proper PPE wasn't used. The metal plates needed to be properly secured on the welding bench to prevent inadequate welding, as well as any slips, trips or falls as a result of them shifting during the welding process.

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Right: Here is a photo of me using a clean cloth to wipe off the surface layer of red penetrant dye, after letting it develop for an appropriate length of time (in preparation for applying the white developer). I had to be careful when wiping off the penetrant dye, as there was a potential hazard of getting the chemicals on my skin or in my eyes. The welded joint needed to be properly cleaned with the cloth to prevent inadequate testing results, as well as any false indications or missed defects as a result of improper removal of excess dye.

Left: Here is a photo of me and my team performing a NDT penetrant dye test on a T-fillet joint created with MMA welding techniques. I had to be careful when applying the penetrant and developer as there was a potential hazard of getting the chemicals on my skin or in my eyes. The welded joint needed to be properly cleaned and prepared to prevent inadequate testing results, as well as any false indications or missed defects as a result of improper application.

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Knowledge Criteria

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All criteria covered in Knowledge Quiz

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Referencing Unit QPEO2/027N: Preparing and using manual metal arc welding equipment

  • P1 1.1, 1.2
  • Jobs: Job 1 - Hydrostatic Pressure Testing, Job 2 - Grinding / Pipe Cutting
  • P2
  • Jobs: Job 3 - Pipe Bending, Job 4 - Pipe Threading
  • P3
  • Jobs: Job 5 - Sheet Metal Fabrication, Job 6 - Flange Installation
  • P4
  • Jobs: Job 7 - Self-Soldering Copper Elbow Fitting, Job 10 - Welding
  • P5
  • Jobs: Job 8 - Expansion Loop Manufacturing / Expansion Loop Installation, Job 9 - Mechanical Fitting (Centrifugal Pump / Helical Bevel Gearbox)

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    Job 10: MMA Welding (with Plate Cutting & NDT) Materials Needed:

    • Plate cutter (guillotine)
    • 5mm steel plate
    • MMA welding equipment
    • Welding electrodes
    • Steel rule and set square
    • Chalk
    • Chipping hammer
    • Welding curtains
    • Welding visor (Darkness Setting: 11)
    • NDT testing materials - surface cleaning spray, red penetrant dye, white developer spray, clean cloth
    • Personal protective equipment (PPE) - safety glasses, gloves, overalls, safety boots, hearing protection, welding visor and gauntlets
    Steps: Information Gathering and Documentation [P1, S1] 
    • Collected required data, documents, and specifications from authorised sources 
    • Validated document accuracy and currentness prior to work initiation 
    • Implemented stringent document management throughout the project 
    • Meticulously extracted all essential data for plate cutting, welding, and NDT testing 

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    • Actively pursued supplementary information to fill knowledge gaps 
    • Notified supervisors of any data discrepancies or issues 
    • Made informed decisions based on comprehensive engineering data review 
    • Ensured proper document storage upon task completion 
    • Promptly and accurately completed all necessary production records
    Interpreting Engineering Specifications [P2, S2, S3, S4]
    • Analysed detailed component blueprints and digital displays for relevant information 
    • Utilised job guidelines, material requirements, and quality assurance protocols to inform cutting, welding, and testing procedures 
    • Precisely gathered data on measurements, weld types, and inspection standards 
    • Determined required materials, components, and welding locations 
    Reporting Discrepancies [P3]
    • Immediately alerted project management to any inconsistencies in drawings or specifications 
    Defining Operational Parameters [P4]
    • Applied gathered and interpreted data to establish specific plate cutting, welding, and NDT testing criteria 
    Documentation and Communication [P5, S5]
    • Created detailed illustrations of welding configurations for clarity 
    • Thoroughly prepared work planning documents 
    • Precisely recorded welding data, including amperage settings and NDT results 
    • Generated and submitted comprehensive technical reports 
    • Completed necessary requisition forms for materials and tools

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    • Itemised any required replacement components for welding equipment 
    Issue Management [P6]
    • Efficiently resolved problems within our jurisdiction 
    • Consulted appropriate personnel for guidance on complex issues beyond our immediate expertise
    Preparation and Safety [P7]
    • Donned appropriate PPE (gloves, overalls, safety boots, safety glasses)
    • Ensured workspace was clean and tidy to prevent slips, trips, and falls
    • Retrieved necessary equipment from stores, performing visual inspection for damage or faults
    Plate Cutting [P8]
    • Measured and marked out 150mm x 50mm lines on steel sheet with chalk using steel rule and set square
    • Switched on guillotine and placed sheet metal on free support
    • Aligned chalk marks with shadow cast behind guard
    • Applied pressure to pedal bar, clamping sheet metal and lowering guillotine blade
    • Cut along desired line, repeating process to create enough 5mm plates for welding
    • Turned off power and collected newly cut plates from gated pen
    • Transported plates to welding bays using proper manual handling techniques
    MMA Welding [P9]
    • Switched on extractor fan and welding equipment in welding bays
    • Placed electrode in holder, bending to 45° angle
    • Set up plates for welding on properly earthed workbench

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    • Pulled down welding curtains and turned on welding machine
    • Set amps to approximately 108
    • Wearing welding visor, struck rod to begin welding, maintaining consistent angle and speed
    • Completed various weld types: bead, corner, lap, and T-fillet
    • After each weld, switched off machine, removed slag with chipping hammer, and inspected weld quality
    Non-Destructive Testing (NDT) [P10]
    • Conducted penetrant dye testing in well-lit, ventilated area
    • Cleaned welded area with solvent
    • Applied red penetrant dye and allowed 30-minute soak time
    • Removed excess dye with clean cloth
    • Applied thin film of white developer spray
    • Visually inspected for red indications or "bleed-out" from white developer
    Post-Welding and Testing Procedures [P11]
    • Disposed of remaining rod lengths
    • Stored welded joints in metal bin
    • Cleaned workstation with brush and pan
    • Returned unused plates to center table
    • Thoroughly cleaned weld and work area
    • Returned all equipment and materials to correct stores

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    Knowledge quiz 2

    Knowledge Quiz

    Question 1: What documents and resources must you refer to before starting a welding job? A) Safety protocols B) Method statement, technical information, and data sheets C) Company handbook D) Employee contracts Question 2: Why is effective communication important in welding operations? A) To communicate different types of instructions and information depending on the job B) To ensure all team members are paid on time C) To manage company finances D) To maintain inventory levels Question 3: Which of the following is NOT essential personal protective equipment (PPE) required for welding? A) Safety glasses B) Overalls C) Sandals D) Ear defenders Question 4: What is the primary purpose of wearing gloves during welding? A) To protect your hands from sharp edges and chemicals B) To keep your hands warm C) To improve grip strength D) To follow dress code Question 5: What is one way to ensure proper planning and safety before starting a welding job? A) Method statement, toolbox talk, correct planning with paperwork B) Asking a colleague C) Guessing the procedure D) Starting the job without preparation Question 6: What should you do first when preparing for a welding job? A) Collect relevant documentation B) Start welding immediately C) Call a meeting D) Take a break Question 7: How do you determine the tools required for a welding task? A) Read any documentation to establish the tools needed B) Guess based on previous jobs C) Use any available tools D) Ask a friend Question 8: Which tool is used to ensure accuracy in your welding work by checking that your work is square? A) Engineer's square B) Hammer C) Pliers D) Screwdriver Question 9: How do you ensure you have all necessary materials for a welding job? A) Check any relevant paperwork to see what materials are needed B) Ask a colleague C) Use leftover materials D) Start the job and get materials as needed Question 10: What should you do if you encounter a problem or incomplete items while preparing for a welding job? A) Double-check everything, re-read instructions, check all tools B) Ignore the problem and continue C) Blame someone else D) Abandon the job

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    Knowledge Quiz (cont.)

    Question 11: Which of the following is NOT a way to access and interpret relevant work instructions and information? A) Referring to the organization's policies and procedures  B) Reading technical manuals and job aids  C) Consulting with supervisors or subject matter experts  D) Ignoring the information and proceeding with the job   Question 12: What should you do if you encounter issues beyond your competence, responsibilities, and accountability? A) Report the issue to your immediate supervisor or manager  B) Try to solve it yourself  C) Ignore the issue  D) Blame a colleague   Question 13: Why is personal hygiene important in the workplace? A) To maintain a clean appearance  B) To prevent the spread of illnesses and maintain a safe work environment  C) To impress colleagues  D) To comply with company dress code   Question 14: How can you prepare and maintain a safe working environment? A) Follow all relevant safety protocols and conduct risk assessments  B) Work as quickly as possible  C) Avoid using personal protective equipment  D) Ignore safety procedures

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    • Today we'll be cutting steel plates and performing MMA welding, followed by non-destructive testing. The main hazards include cuts from sharp metal edges, burns from welding, and exposure to welding fumes and testing chemicals. Wear appropriate PPE including gloves, overalls, safety boots, and safety glasses.
    • When using the guillotine, be aware of the blade and keep hands clear of the cutting area. Anchor yourself properly and use the pedal bar to control the blade. For welding, ensure proper ventilation by using the extractor fan and pull welding curtains down to protect others from arc flash.
    • Set the welding machine to approximately 108 amps and use a welding visor with Darkness Setting 11. Maintain a consistent angle and speed while welding for strong joints. After welding, use caution when removing slag with a chipping hammer.
    • For non-destructive testing, work in a well-lit, ventilated area. Be careful when applying penetrant dye and developer spray, avoiding inhalation. Allow proper soak time for accurate results.
    • Maintain a clean workspace throughout the process to prevent trips and falls. Inspect all equipment before use and report any damages or malfunctions immediately. After completing all your tasks, clean up thoroughly and return all equipment and materials to their proper storage locations.

    MMA Welding (with Plate Cutting & NDT)

    • Today we'll be using an angle grinder to prep a section of pipe. Remember, the main hazards are flying sparks and debris, so ensure protective curtains and screens are in place, and wear all necessary PPE including safety glasses, boots, overalls, and gloves.

    Toolbox Talks

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    Steve Smith Assessor Assessor's Feedback for Mitchell Small Unit QPEO2/027N: Preparing and Using Manual Metal Arc Welding Equipment Mitchell, I am pleased to provide this positive feedback on your performance in the Manual Metal Arc Welding unit. Your work has been exemplary, demonstrating a high level of skill and professionalism throughout. Strengths: Safety Awareness: Your consistent adherence to safety protocols, including proper use of PPE, was outstanding. Technical Proficiency: You demonstrated excellent skills in preparing materials, setting up equipment, and executing various weld types with precision. Quality Control: Your attention to detail in post-weld inspections and use of NDT methods was commendable. Problem-Solving: You showed initiative in addressing challenges and seeking clarification when needed. Documentation: Your record-keeping was thorough and accurate, reflecting a strong understanding of industry standards. Areas for Continued Growth: While your performance was strong overall, I encourage you to: Further explore advanced welding techniques to broaden your skill set. Consider pursuing additional certifications to enhance your professional profile. Overall Assessment: Your work in this unit has been of an exceptionally high standard. You have not only met but exceeded the criteria for this unit, demonstrating both theoretical understanding and practical mastery of MMA welding techniques. It's been a pleasure to assess your work, Mitchell. Your dedication and skill set you up for a promising career in welding. Keep up the excellent work!

    Assessor's  Feedback

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    Mitchell has exhibited exceptional skills and knowledge throughout the unit. He demonstrated a thorough understanding of MMA welding processes, consistently adhering to safety protocols by wearing appropriate personal protective equipment (PPE) and maintaining a clean workspace. In his practical work, Mitchell effectively prepared materials by measuring and marking carbon steel plates, cutting them accurately using a guillotine, and setting up welding equipment. He maintained a consistent welding technique across various weld types, including bead, corner, lap, and T-fillet welds, achieving high-quality results. Mitchell also conducted post-welding inspections, removing slag and assessing weld integrity. His use of non-destructive testing (NDT) methods, specifically the penetrant dye test, showcased his attention to detail and commitment to quality assurance. Throughout the unit, Mitchell displayed strong problem-solving abilities, proactively seeking guidance when necessary and effectively communicating with his team. His professionalism and dedication to safety and quality make him a competent technician in the field of MMA welding. In conclusion, I confidently attest to Mitchell Small's mastery of the skills and knowledge required for this unit, reflecting his readiness for further challenges in the welding profession.

    Witness Testimony

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