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This training opportunity will allow applicants to learn a trade and ...

By Ruby Riley,2014-12-03 02:40
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This training opportunity will allow applicants to learn a trade and ...

    United Association of Journeymen and Apprentices of

    the Plumbing and Pipefitting

    Industry

“VETERANS IN PIPING”

    Wisconsin

    Accelerated

    Welding Program

    Candidate and Support Services

    Assessment Packet

    Version 1 2010

    Name: _____________________________Phone:________________________ Address: _________________________________________________________

UA Veterans In Piping Training Expectations

    The United Association (UA) VIP Welder Training Program is strictly a voluntary educational program. Students will be invited to participate in the training program on a voluntary basis. Training will be provided to the students at no cost. However, no payment or remuneration of any kind will be paid to students participating in the welder training program.

    The United Association or the UA Training Instructor may rescind any student’s invitation to participate in the training program at any time, without advance notice. A student will be dismissed upon his or her third absence or third tardy.

    The training program will be approximately 20 weeks in duration, consisting of 40-hour weeks and 8 hour days. Classes are administered by UA Instructors and are held daily Monday thru Friday at a designated UA Training Facility.

    The UA VIP welder training program is competency based; students may progress at their own rate of speed, in accordance with UA standards. If, for any reason an applicant believes they may not be able to complete the training course, admission into the program may be denied.

    Student applicants to the training program must be 18 years old or older, with a high school diploma or a General Education Development (GED) certificate and must hold a current drivers license.

    Students must have good eyesight, using corrective lenses if necessary. Student must provide a copy of a recent eye exam (within the last six-months) showing acceptable near distance vision.

    Student applicants must pass a urinalysis drug test to be accepted into the welder training program.

    Each student must provide their own personal protective clothing and work boots. The UA Welder Training Program will provide students with a welding hood, safety glasses, face shield, ear plugs, and other necessary tools and welding equipment.

    In addition to the subjects covered in different sections of this program document, the students should receive instruction in basic math skills, such as fractions, decimals, angles, tolerances; and piping and equipment terminology used on the job.

    Prior to the completion of the training program students must attend and satisfactorily complete an OSHA 30 course, a Heritage class and a class on the UA Standard for Excellence.

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UA Veterans In Piping Program - Data Sharing

    SECTION I: WELDING SAFETY AND CARE & USE OF TOOLS

Objective: Each student must have completed class room instruction and hands on practical

    exercises on Welding Safety and the Care & Use of Tools.

1. Personal Protective Equipment

    a) Eye Protection

    b) Hand Protection

    c) Foot Protection

    d) Ear Protection

    e) Face and Head Protection

    f) Proper Clothing

    g) Shaded Lenses Requirements (discuss brighter arc with no slag shielding)

2. Welding Safety

    a) Fume Hazards and Ventilation during welding b) Work Area Safety

    c) Compress Gas Cylinder Storage and Handling d) Material handling

    e) Tool Safety

    - Bench and grinder safety (incorporate tungsten grinding)

    - Hand Tool and Power equipment safety

    3. Use and Care of Hand Tools

    a) Identify layout and measuring tools and their uses

    - Folding rulers

    - Levels

    - 25 & 100 foot tape rules

    - 2 foot and combination squares

    - Bevel protractors

    b) Identify clamping tools and their uses

    - Vice Grips

    - C clamps

    - Channel Locks

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    UA Veterans In Piping Program - Data Sharing

    c) Identify cutting/finishing tools and their uses

    - Bastard files

    - Chisels

    - Wire brushes (stainless/carbon)

    - Small fine mill file

    - Flapper wheels for GTAW pipe end preparation d) Identify other hand tools used by welders and their uses

    - Ball peen and sledge hammers

    - Scribes, picks and other special cleaning tools

    - Side cutters (Klein’s)

    - Hi low gauges

    - Fitter wedge

    e) Power Tools

    - Safe operation of bench and pedestal grinders

    - Safe operation of angle and straight grinders

    - Use and safe operation of metal forming and shaping tools

    - Identify procedures for cutting metals using power cut-off saws, and metal cutting band saws

    f) Safe practice of sharpening tungsten on pedestal grinders (discuss options for holding and turning

    tungsten during sharpening)

    4. Hands on Exercises using Tools

    a) Hand Tools

    - Practice with layout and measuring tools

    - Practice with clamping tools

    - Practice with cutting/finishing tools

    b) Power Tools

    - Practice with power tools

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UA Veterans In Piping Program - Data Sharing

    SECTION II: OXY-FUEL SAFETY AND OXY-FUEL CUTTING EQUIPMENT

    Objective: Each student must be able to demonstrate safe handling and set-up of oxy-fuel equipment,

    practical applications of preheating and cutting on plate and pipe, correct selection of tip sizes.

    1. Introduction to Oxy-Fuel Process

    a) Oxy-fuel Safety Summary

    - Protective Clothing and Equipment

    - Fire/Explosion Prevention

    - Work Area Ventilation

    b) Oxy-fuel Cutting Equipment

    - Oxygen

    - Acetylene

    - Liquefied Fuel Gases

    - Regulators

    - Hoses

    c) Cutting Torches

    d) Cutting Torch Tips

    e) Tip Cleaners and Tip Drills

    f) Friction Lighters

    g) Cylinder Cart

    h) Soapstone Markers

    2. Setting up Oxy-fuel Equipment

    a) Transporting and Securing Cylinders

    b) Cracking Cylinder Valves

    c) Attaching Regulators

    d) Installing Flashback Arrestors or Check Valves e) Connecting Hoses to Regulators

    f) Attaching Hoses to the Torch

    g) Connecting Cutting Attachments (Combination Torch Only) h) Installing Cutting Tips

    i) Closing Torch Valves and Loosening Regulator Adjusting Screws j) Opening Cylinder Valves

    k) Purging the Torch and Setting the Working Pressures

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UA Veterans In Piping Program - Data Sharing

    l) Testing for Leaks

    3. Controlling the Oxy-fuel Torch Flame

    a) Oxy-fuel Flame Types (i.e. Neutral, Carbonizing) b) Backfires and Flashbacks

    c) Igniting the Torch and Adjusting the Flame d) Shutting Off the Torch

    4. Shutting Down and Disassembling Oxy-fuel Equipment

    a) Shutting Down Oxy-fuel Cutting Equipment b) Disassembling Oxy-fuel Cutting Equipment c) Changing Empty Cylinders

    d) Practice Setting-up, igniting, adjusting, shutting down and disassembling oxy-fuel equipment as

    well as changing empty cylinders

    5. Performing Cutting Operations

    a) Oxy-fuel Cutting Equipment Operation

    b) Torch Adjustment

    c) Straight Line Cutting

    d) Bevel Cutting on Plate

    e) Bevel Cutting on Pipe

    f) Performing Cutting

    - Preparing for Oxy-fuel Cutting and Hand Cutting Torch - Cutting thick Steel

    - Piercing Plate & Pipe When Cutting Bevels - Inspecting the Cut Edges

    6. Hands on Practical Exercises

    a) Perform a square cut on a 1/2” mild steel plate

    b) Cut a 37? bevel on a 6” Sch. 80 mild steel pipe for preparation of a weld joint

    SECTION III: BASE METAL PREPARATION & JOINT DESIGNS

Objective: Each student must have completed class room instruction and hands on practical

    exercises on material preparation and weld joint configurations.

1. Base Metal Cleaning

    a) Surface Corrosion

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UA Veterans In Piping Program - Data Sharing

    b) Defects caused by Surface Contamination c) Mechanical Cleaning

    d) Hand Tool Use

    e) Power Tool Use

    f) Inspecting the Prepared Areas

2. Joint Configurations

    a) V-Groove

    b) Fillet

    c) Socket

3. Fittings

    a) Flanges

    b) Sockets

    c) Weld-O-Lets

4. Welding Positions

    a) Flat

    b) Vertical

    c) Horizontal

    d) Over Head

5. Thermal Joint Preparation

    a) Preheat Temperatures

    b) Interpass Temperatures

    c) Tempsticks

    6. Mechanical Joint Preparation

    a) Grinders

    b) Pipe Beveling Machines

    7. Hands on Practical Exercises

    c) Prepare plate joints mechanically d) Prepare plate joints thermally e) Prepare pipe coupons for a single bevel open V-groove manually

    f) Prepare pipe coupons for a single bevel open V-groove by machine.

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UA Veterans In Piping Program - Data Sharing

    SECTION IV: SHIELDED METAL ARC WELDING (SMAW)

Objective: Each student must have completed class room instruction and hands on practical

    exercises on the basics of shielded metal arc welding.

    1. Set-up and Equipment Preparation for SMAW Process

    a) Types of Welding Current

    - DC Welding Current

    - Polarity

    b) Characteristics of Welding Current

    - Amperage

    - Voltage

    c) Welding Machine Types

    - Transformer Welding Machines

    - Inverter Power Sources

    d) Welding Cable

    - Welding Cable End Connections

    - Lugs and Quick Disconnects

    - Work Piece Clamps

    - Electrode Holder

    e) Equipment Setup

    - Selecting the Proper SMAW Equipment

    - Locating the Work Piece Clamp

    - Energizing Electrically Powered Welding Machines f) Tools for Cleaning Welds

    - Hand Tools

    - Pneumatic Cleaning and Slag Removal Tools

    - Power Tools

2. SMAW Electrodes

    a) AWS Filler Metal Specification System

    - Classification System

    - Manufacturer’s Identification

    - Electrode Sizes

    b) Electrode Types

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UA Veterans In Piping Program - Data Sharing

    - Fast-Freeze Electrodes

    - Fast-Fill Electrodes

    - Fill-Freeze Electrodes

    - Low-Hydrogen Electrodes

    c) Electrode Selection Considerations

    - Welding Procedure Specification

    - Base Metal Type

    - Base Metal Thickness

    - Base Metal Surface Condition

    - Welding Position

    - Joint Design

    - Welding Current

    d) Filler Metal Control and Storage

    - Filler Metal Traceability Requirements

    - Code requirements

    - Receiving Filler Metal

    - Storing Filler Metal

    - Storage Ovens

    - Exposure Times

    - Drying Electrodes

    3. Pad Welding

    a) Beginning Welding Exercises

    - Practice setting up welding equipment,

    - Practice striking and extinguishing an arc b) Stringer, Weave and Overlapping Beads

    - Practice stringer & weave beads with E6010 and E7018

    - Practice overlapping beads with E6010 and E7018 c) Position Welds on Plate

    - Practice flat, horizontal, vertical an overhead welds with E6010 and E7018

    d) Performance Evaluation

    - Each student must be able to satisfactorily complete stringer, weave and overlapping bead

    placement welds on pad weld coupons using (1/2" x 4" x 6") plate, in the flat, vertical, horizontal,

    and overhead positions, using E6010 & E7018 (3/32” & 1/8”). Visual inspections of the coupons

    will be performed by the UA Welding Instructor.

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UA Veterans In Piping Program - Data Sharing

    - Failure to pass the evaluation will result in the student being remanded to the UA Welding

    Instructor for evaluation and determination as to future training of the individual. 4. Plate Welding

    a) Welding Plate Groove Weld Coupons

    - Practice flat, horizontal, vertical an overhead welds on open-root V-groove joints using (1/2” x 4”

    x 6”) plate coupons with E6010 root with E7018 fill (3/32” & 1/8”).

    b) Performance Evaluation

    - Each student must be able to satisfactorily complete open butt groove welds using (1/2” x 4” x 6”)

    plate coupons, with E6010 root with E7018 fill (3/32” & 1/8”), in the flat, horizontal, vertical and

    overhead test positions. Visual inspections and bend tests of the plate coupons will be performed

    by the UA Welding Instructor

    - Failure to pass the evaluation will result in the student being remanded to the UA Welding

    Instructor for evaluation and determination as to future training of the individual 5. Pipe Welding

    a) Bead on Pipe Welds

    - Practice stringer & weave beads on 6 inch Sch. 80 pipe coupons in the 2G & 5G positions using

    E6010 & E7018 (3/32” & 1/8”)

    b) Instruction in Preparing V-Groove Pipe Welds

    - Pipe groove weld configurations & positions

    - Open butt root pass welding

    - Electrode selection for different weld passes

    - Acceptable and unacceptable groove weld profiles

    c) Practice welding multiple open root v-groove pipe welds in the 2G & 5G positions using both 6 inch Sch. 40 and 3 inch Sch.40 pipe coupons, with E6010 root with E7018 fill (3/32” & 1/8”).

    d) Performance Evaluation

    - Each student must be able to consistently complete open butt groove welds on three 2 inch Sch.

    80 pipe coupons in both the 2G and 5G test positions, with E6010 root with E7018 fill (3/32”).

    Visual inspections and bend tests of the pipe coupons will be performed by the UA Welding

    Instructor

    - Failure to pass the tests will result in the student being remanded to the UA Welding Instructor

    for evaluation and determination as to future training of the individual.

    e) If the student satisfactorily completes all the practice and evaluation welds specified above, they will be required to pass the UA-76 weld test. Radiographic examinations of the test coupon will be performed by a local independent test lab. Failure to pass the test will result in the student being

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