This standard identifies the competencies you need for cutting and shaping plate (3mm thickness and above), rolled sections, pipe and tube for fabrications, using portable thermal cutting equipment, in accordance with approved procedures. The equipment to be used will include hand held oxy/fuel gas cutting equipment, plasma cutting equipment and simple portable machines running on tracks.

You will be required to assist in assembling and setting up the appropriate equipment to be used, for the material and thickness to be cut, the type of operation to be carried out and the accuracy to be achieved. Materials to be cut and shaped may include mild steel, stainless steel, special steels and other appropriate materials, and will include guided cuts, external curved contours, round and square holes and demolition work, as appropriate. This will call for care in the use of the equipment and tools, so as to avoid damage to the material and tools, and danger to oneself.

Your responsibilities will require you to comply with organisational policy and procedures for the cutting operations undertaken, and to report any problems with the equipment, materials, consumables or cutting activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will provide an informed approach to applying thermal cutting procedures. You will have an understanding of the processes, and will know about the equipment and its application, the materials and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when working with the thermal cutting equipment, especially those with regard to fire and potential explosion, and the safeguards necessary for undertaking the activities safely and correctly. You will be expected to demonstrate safe working practices throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. confirm that the machine is set up and ready for the machining activities to be carried out
3. manipulate the machine tool controls safely and correctly in line with operational procedures
4. produce components to the required quality and within the specified dimensional accuracy
5. carry out quality sampling checks at suitable intervals
6. deal promptly and effectively with problems within your control and report those that cannot be solved
7. shut down the equipment to a safe condition on conclusion of the machining activities

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1. the specific safety precautions to be taken when working with thermal cutting equipment in a fabrication environment (general workshop and site safety, appropriate personal protective equipment (PPE), fire and explosion prevention, protecting other workers, safety in enclosed/confined spaces; fume control; accident procedure; statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials)
2. the personal protective clothing and equipment that needs to be worn when working with fabrications and thermal cutting equipment (such as leather aprons and gloves, eye/ear protection, safety helmets)
3. the correct methods of moving or lifting plate materials and components
4. the hazards associated with thermal cutting (naked flames, fumes and gases, explosive gas mixtures, oxygen enrichment, spatter, hot metal, elevated working, enclosed spaces), and how they can be minimised
5. safe working practices and procedures for using thermal equipment in line with British Compressed Gas Association (BCGA) codes of practice, to include setting up procedures, permit-to-work procedures and emergency shutdown procedures
6. how to obtain the necessary drawings and thermal cutting specifications
7. how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate British, European or relevant International standards in relation to work undertaken)
8. the thermal cutting process (basic principles of thermal cutting and related equipment; the various techniques and their limitation; care of the equipment to ensure that it is safe and ready to use)
9. the various types of thermal cutting equipment available, and typical applications of each type
10. the accessories that can be used with hand held thermal cutting equipment to aid cutting operations (such as guides, trammels, templates); arrangements for attaching cutting aids to the equipment
11. the gases used in thermal cutting; gas identification and colour codes; their particular characteristics and safety procedures
12. how to set up the thermal cutting equipment (connection of hoses, regulators and flashback arrestors, selection of cutting torch and nozzle size in relationship to material thickness and operations performed)
13. preparations prior to cutting (checking connections for leaks, setting gas pressures, setting up the material/workpiece, checking cleanliness of materials used)
14. the holding methods that are used to aid thermal cutting, and the equipment that can be used
15. setting of operating conditions (flame control and the effects of mixtures and pressures associated with thermal cutting)
16. the correct procedure for lighting and extinguishing the flame, and the importance of following the procedure
17. procedures to be followed for cutting specific materials, and why these procedures must always be adhered to
18. material thermal cutting characteristics and material preparation requirements
19. the terminology used in thermal cutting in relation to the operations being performed
20. the problems that can occur with thermal cutting, and how they can be avoided; causes of distortion during thermal cutting and methods of controlling distortion
21. the effects of oil, grease, scale or dirt on the cutting process
22. the causes of cutting defects, how to recognise them, and methods of correction and prevention
23. quality requirements of the type of work being undertaken
24. the extent of your own authority and whom you should report to if you have problems that you cannot resolve
25. reporting lines and procedures, line supervision and technical experts

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1. Confirm that the equipment is safe and fit for purpose by carrying out all of the following checks:

   1. regulators, hoses and valves are securely connected and free from leaks and damage
   2. the correct gas nozzle is fitted to the cutting torch
   3. that a flashback arrestor is fitted to gas equipment
   4. gas pressures are set and maintained as instructed
   5. the correct procedure is used for lighting, adjusting and extinguishing the cutting flame
   6. hoses are safely routed and protected at all times
   7. gas cylinders are handled and stored safely and correctly

2. Use one of the following thermal cutting methods:

   1. hand held oxy/fuel gas cutting equipment
   2. hand held plasma gas cutting equipment
   3. simple portable track driven cutting equipment (electrical or mechanical)

3. Perform thermal cutting operations to produce four of the following features:

   1. down-hand straight cuts (freehand)
   2. irregular shapes         
   3. square holes
   4. down-hand straight cuts (track guided)  
   5. angled cuts                  
   6. rough cutting (demolition)   
   7. external curved contours
   8. weld preparations
   9. vertical cuts                         
   10. round holes
   11. square/rectangular shapes

4. Produce thermal cuts in two of the following forms of material (metal of 3mm and above, and two different thickness):

   1. plate           
   2. rolled sections   
   3. structures
   4. bar              
   5. pipe/tube

5. Produce cut profiles for one type of material from the following:

   1. mild steel                 
   2. special steels
   3. stainless steel          
   4. other appropriate material

6. Produce thermally cut components which meet all of the following quality and accuracy standards:

   1. dimensional accuracy is within the tolerances specified on the drawing/specification or within +/- 3 mm
   2. angled cuts are within specification requirements (perpendicular/angularity)
   3. cuts are clean and smooth and free from flutes

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​​Additional Information

You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:

• strong work ethic
• positive attitude
• team player
• dependability
• responsibility
• honesty
• integrity
• motivation
• commitment

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3

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31 Mar 2020

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Current

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Original

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Semta

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SEMFWE233

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Engineering, Engineering and Manufacturing Technologies, Metal Forming, Welding and Related Trades

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5213

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engineering; welding; fabrication; machining; cutting; shaping; thermal cutters; oxy/fuel gas equipment; plasma equipment

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