Cutting and shaping marine steelwork using gas cutting machines
Overview
This standard identifies the competences you need for cutting and shaping marine steelwork, such as plate (3mm thickness and above), rolled sections, pipe and tube for fabrications, using fixed or portable 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.
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 sound basis for your work and will provide an informed approach to applying machine gas-cutting procedures. You will have an understanding of the gas cutting process, and its 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 necessary safeguards 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.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- confirm that the machine is set up and ready for the cutting activities to be carried out
- operate the machine tool controls safely and correctly in line with operational procedures
- produce cut and shaped steelwork components to the required quality and within the specified dimensional accuracy
- carry out quality sampling checks at suitable intervals
- deal promptly and effectively with problems within your control and report those that cannot be solved
- shut down the equipment to a safe condition on conclusion of the machining activities
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken when working with gas cutting machines in a fabrication environment (to include general workshop and site safety, fire and explosion prevention, protecting other workers, safety in enclosed/confined spaces; fume control; accident procedures; statutory regulations)
- the personal protective clothing and equipment (PPE) to be worn when working with marine steelwork and gas-cutting equipment (such as leather aprons and gloves, eye/ear protection, safety helmets)
- the correct methods of moving or lifting plate materials and components
- 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
- 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)
- how to obtain and interpret information form job instructions, drawings and thermal cutting specifications, in relation to the work undertaken
- 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
- preparations prior to cutting (checking connections for leaks, setting gas pressures, setting up the material/workpiece, checking cleanliness of materials used)
- the holding methods that are used to aid gas cutting and the equipment that can be used
- setting of operating conditions; flame control and the effects of mixtures and pressures associated with gas cutting machines
- the correct procedure for lighting and extinguishing the flame and the importance of following the procedure
- procedures for cutting specific materials and why these procedures must always be adhered to
- the terminology used in gas cutting, in relation to the operations being performed
- why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
- 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
- the effects of oil, grease, scale or dirt on the cutting process
- the causes of cutting defects, how to recognise them and methods of prevention and correction
- the extent of your own authority and whom you should report to if you have problems that you cannot resolve
Scope/range
Scope Performance
Confirm that the machine is safe and fit for purpose, by carrying out all of the following checks:
- hoses and equipment are securely connected and are free from leaks and damage
- the correct gas nozzle is fitted to the cutting torch
- appropriate gas pressures are set and maintained, as instructed
- the correct procedure is used for lighting, adjusting and extinguishing the cutting flame
- hoses are safely routed and protected at all times
- where appropriate, gas cylinders are handled and stored, safely and correctly
Use one of the following types of gas cutting machine:
- fixed bench or gantry type machine
- portable track-driven cutting machine
Perform thermal cutting operations to produce four of the following features:
- straight cuts
- round holes
- square/rectangular shapes
- square holes
- irregular shapes
- internal curved contours
- angled cuts
- weld preparations
- external curved contours
Produce thermal cuts in two of the following forms of material:
- plate
- bar
- rolled sections
- pipe/tube
Produce cut profiles for one type of material from the following:
- mild steel
- high tensile steel
stainless steel
special steels
- other specific material
Produce cut components which meet all of the following quality and accuracy standards:
- dimensional accuracy is within the tolerances specified on the drawing/specification, or within +/- 2 mm
- angled/radial cuts are within specification requirements (perpendicular/angularity/elliptical/parabolic)
- cuts are clean and smooth, with minimal drag lines
Scope Knowledge
Values
Behaviours
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