This standard identifies the competencies you need for cutting and shaping plate (3mm thickness and above), rolled sections, pipe and tube for fabrications using gas cutting machines, in accordance with approved procedures. You will be required to assist in the assembling and setting up of 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 straight cuts, external curved contours, round and square holes and internal curved contours. This will call for care in the use of the equipment and tools so as to avoid damage to the material, tools and danger to oneself.

Your responsibilities will require you to comply with organisational policy and procedures for the thermal 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 personal responsibilities, to the relevant authority. 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 machine gas cutting procedures. You will have an understanding of the gas cutting processes, and their application, and will know about the equipment, 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 gas 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 gas cutting machines in a fabrication environment (general workshop and site safety, appropriate personal protective equipment, fire and explosion prevention, protecting other workers, safety in enclosed/confined spaces; fume control; accident procedure; statutory regulations)
2. the personal protective clothing and equipment (PPE) that needs to be worn when working with fabrication materials and gas 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 using gas cutting machines (such as naked flames, fumes and gases, explosive gas mixtures, oxygen enrichment, spatter, hot metal), and how they can be minimised
5. safe working practices and procedures for using gas cutting machines 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 gas 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 interpretation of the drawings or sketches in first or third angle projection
9. the gas cutting process (basic principles of gas cutting and related equipment, the various techniques and their limitation, care of the equipment to ensure that it is safe and ready to use)
10. the gases used in thermal cutting; gas identification and colour codes; their particular characteristics and safety procedures
11. preparations prior to cutting (checking connections for leaks, setting gas pressures, setting up the material/workpiece, checking cleanliness of materials used)
12. the holding methods that are used to aid gas cutting, and the equipment that can be used
13. setting of operating conditions; flame control and the effects of mixtures and pressures associated with gas cutting machines
14. the correct procedure for lighting and extinguishing the flame, and the importance of following the procedure
15. procedures for cutting specific materials, and why these procedures must always be adhered to
16. the terminology used in gas cutting, in relation to the operations being performed
17. the problems that can occur with gas cutting, and how they can be avoided; causes of distortion during gas cutting, and methods of controlling distortion
18. the effects of oil, grease, scale or dirt on the cutting process
19. the causes of cutting defects, how to recognise them, and methods of prevention and correction
20. quality requirements for the type of work being undertaken
21. the extent of your own authority and whom you should report to if you have problems that you cannot resolve

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

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

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

   1. straight cuts                                 
   2. round holes
   3. square/rectangular shapes        
   4. square holes
   5. irregular shapes                          
   6. internal curved contours
   7. angled cuts                                  
   8. weld preparations
   9. external curved contours

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

   1. plate
   2. bar
   3. rolled sections
   4. pipe/tube
   5. other specific form

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

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

5. Produce 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 +/- 2 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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SEMFWE234

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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; manual machining; thermal cutting; gas cutting; oxy/fuel gas cutter; profile cut

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