Producing socket and flange fillet welded joints in pipe using a manual welding process

This standard identifies the competences you need to produce socket and flange fillet welded joints in pipe, using a manual welding process such as manual metal arc (MMA), MIG, MAG, TIG, flux cored wire, plasma or oxy/fuel gas welding equipment, in accordance with instructions and/or approved welding procedures. You will be required to check that all the workholding equipment and manipulating devices required are available and are in a usable condition. You will be expected to check the welding equipment to ensure that all the leads/cables, hoses and wire feed mechanisms are securely connected and are free from damage. 

In preparing to weld, you will need to set and adjust the welding conditions, in line with the instructions or welding procedure specification. You must operate the equipment safely and correctly, and make any necessary adjustments to settings, in line with your permitted authority, in order to produce the welded joints to the required specification. You will be required to demonstrate your capability to produce the fillet welds to the required quality, and this could be through tests according to BS 4872 or EN 287-1 or EN9606-1.

Your responsibilities will require you to comply with organisational policy and procedures for the welding activities undertaken and to report any problems with the welding activities or equipment that you cannot resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.   

Your underpinning knowledge will be sufficient to provide a sound basis for your work and will provide an understanding of how the particular welding process works. You will know about the equipment, materials and consumables, in adequate depth to provide a sound background for the welding operations to be performed and for ensuring that the work output is produced to the required specification. 

You will understand the safety precautions required when working with the welding equipment. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.

1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines

2. follow the relevant joining procedure and job instructions

3. confirm that the joint preparation complies with the specification
4. confirm that joining and related equipment and consumables are as specified and fit for purpose
5. make the joints as specified using the appropriate thermal joining technique
6. produce joints of the required quality and of specified dimensional accuracy
7. shut down the equipment to a safe condition on completion of joining activities
8. deal promptly with excess and waste materials and temporary attachments, in line with approved and agreed procedures
9. deal promptly and effectively with problems within your control and report those that cannot be solved
10. complete relevant documentation in line with organisational procedures

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1. Prepare for the pipe welding process, to include carrying out all of the following:

   1. obtaining the appropriate equipment for the welding activities to be carried out
   2. checking the condition of, and correctly connecting, welding leads, earthing arrangements and electrode holder (where appropriate)
   3. connecting all required hoses, regulators and/or flow meters and safety devices (where appropriate)
   4. setting and adjusting welding conditions/parameters, in accordance with welding procedure specification
   5. preparing the work area for the welding activities (such as placing welding screens, positioning fume extraction equipment)
   6. ensuring that the components are correctly set up with regard to specified joint preparation and is secure
   7. obtaining and wearing appropriate personal protective equipment

2. Set up, check, adjust and use welding and related equipment for one of the following welding processes:

   1. manual metal arc
   2. MIG/MAG
   3. TIG
   4. cored wire
   5. plasma
   6. oxy/fuel gas welding

3. Use consumables appropriate to the material and application, to include:

either two types of electrode from:

1.  rutile
2.  basic
3.  cellulosic 
4.  nickel alloy
5.  aluminium
6.  stainless
7.  other specific type  

or
8. two types of filler wire from different material groups

4. Produce socket and flange fillet welded joints in one of the following:

   1. small bore pipe (50mm outside diameter or less)
   2. large bore pipe (above 50mm outside diameter)

5. Weld joints according to BS EN ISO 6947, in good access situations, in four of the following positions:

   1. flat (PA) rotating
   2. horizontal vertical (PB) fixed
   3. horizontal vertical (PB) rotating
   4. vertical upwards (PF) fixed
   5. vertical down (PG) fixed
   6. horizontal overhead (PD) fixed

6. Produce marine socket and flange fillet welded joints in pipe, which comply with all of the following:

   1. achieve minimum weld quality requirements applicable to fillet welds equivalent to those given in the relevant European/International Standards (such as BS EN ISO 5817 and EN 30042/ISO 10042) as required by the application standard or specification
   2. meet the required dimensional accuracy within specified tolerance

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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