Competency-Based Learning Material: Kabankalan Training Center (KTC)

COMPETENCY-BASED LEARNING MATERIAL
Sector: Metals and Engineering
Qualification Title: Shielded Metal Arc Welding NC II
Unit of Competency: Weld Carbon Steel Plates
Module Title: Performing Groove Welding on Carbon Steel Plates
Kabankalan Training Center (KTC)

Kabankalan Training Center/Provincial Training Center – Kabankalan
FZO Subd., Brgy 1‚ Kabankalan City‚ Negros Occidental
MODULE IN SHIELDED Date Developed: Document No.

KABANKALAN METAL ARC WELDING August 2012 Page 1 of 55
Issued by:
TRAINING CENTER SMAW NCII
KTC
Weld Carbon Steel Plates Developed by:
Revision # 00
QA using SMAW
Plan
Training
Session
Date Developed: Document No.
MODULE IN SHIELDED
KABANKALAN August 2012
METAL ARC WELDING Issued by:
TRAINING CENTER
SMAW NCII Page 2 of 55
KTC
Developed by:
Weld Carbon Steel Plates
QA
using SMAW Revision # 00
SYSTEM
How to Use This Competency Based Learning Materials
Welcome to the module in Performing Groove Welding on Carbon

Steel Plates. This module contains training materials and activities
for you to comply.
The unit of competency “Weld Carbon Steel Plates” contains

knowledge, skills and attitudes essential for Shielded Metal Arc
Welding NC II.
You are required to go through a series of learning activities in

order to complete each learning outcome in the module. In each
learning outcome are information sheets, self-checks, operation sheets
and job sheets. Follow these activities on your own. If you have
questions, don’t hesitate to ask your facilitator for assistance.
This module was prepared to help achieve the required competency

in Shielded Metal Arc Welding NC II.
When you have completed this module and feel confident that you
have had sufficient practice, tell your trainer that you are ready for
assessment. He will arrange an appointment with a registered
assessor to assess you. The results of your assessment will be
recorded in your competency Achievement Record.
Issued by:
KTC
Revision # 00
QA using SMAW
Data Gathering Instrument for Trainee's Characteristics
ANDAN, CLYDE
Name of Trainee: ANTHONY
Qualification Title: SHIELDED METAL ARC WELDING NC II
Instructions: Please answer the following instrument according

to the characteristics described below. Encircle the letter of your
choice that best describes you as a learner. Blank spaces are
provided for some data that need your response.
Characteristics of Learners
Average grade in:
English Math
Language, literacy
a. 95 and
and numeracy
a. 95 and above above
(LL&N)
b. 90 to 94 b. 90 to 94
c. 85 to 89 c. 85 to 89
d. 80 to 84 d. 80 to 84
e. 75 to 79 e. 75 to 79
Cultural and Ethnicity/culture:
language
background a. Ifugao
b. Igorot
c. Ibanag
d. Gaddang
e. Muslim
f. Ibaloy
g. Others( please
specify)____Hiligaynon_________

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Highest Educational Attainment:
h. High School Level

i. High School
Graduate
Education & general j. College Level
knowledge k. College Graduate
l. with units in Master's degree
m. Masteral Graduate
n. With units in Doctoral Level
o. Doctoral Graduate
a. Male
Sex
b. Female
Age Your age: _19
1. Disabilities(if any)_____________________
2. Existing Health Conditions (Existing

illness if
any)
a. None
b. Asthma
Physical ability
c. Heart disease
d. Anemia
e. Hypertension
f. Diabetes
g. Others(please specify)
___________________
Certificates
Previous experience
Shielded Metal Arc Welding SMAW NCI
with the topic
______
Previous learning List down trainings related to Shielded
experience Metal Arc Welding
Training Level Shielded Metal Arc Welding SMAW NCI

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Special courses Other courses related to Shielded Metal
Arc Welding
a. Visual - The visual learner takes

mental pictures of information given, so
in order for this kind of learner to
retain information, oral or written,
presentations of new information
must contain diagrams and drawings,
preferably in color. The visual learner
can't concentrate with a lot of
activity around him and will focus
better and learn faster in a quiet study
environment.
b. Kinesthetic - described as the

students in the classroom, who have
problems sitting still and who often
Learning style
bounce their legs while tapping their
fingers on the desks. They are often
referred to as hyperactive students
with concentration issues.
c. Auditory- a learner who has

the ability to remember speeches
and lectures in detail but has a hard
time with written text. Having to read
long texts is pointless and will not be
retained by the auditory learner unless it
is read aloud.
Other needs a. Financially

challenged
b. Working student
c. Solo parent
d. Others(please specify)
________________________

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FORM 1.1 SELF-ASSESSMENT CHECK
INSTRUCTIONS: This Self-Check Instrument will give the trainer

necessary data or information which is essential in planning training
sessions. Please check the appropriate box of your answer to the
questions below.
Name of Trainee : _____________________________ Date :

__________________
Training Duration :
_____________________________
CAN I ?...
YES NO
CORE COMPETENCIES
1. Weld carbon steel plates using SMAW
Can I deposit weld beads on plate?

Can I weld plates in single pass fillet joints in
all positions?
Can I weld plates in multiple pass fillet joints in
all positions?
Can I weld plates in single pass groove joints in
flat, horizontal and vertical positions?
Can I weld plates in multiple pass groove joints

in flat, horizontal and vertical positions?
2. Weld carbon steel plates and pipes using

SMAW

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Can I weld plates in single pass groove joints in
overhead position?
Can I weld plates in multiple pass groove joints

in overhead position?
Can I weld pipe in 1G, 2G, 5G and 6G

positions?
Prepared By : ERIC D. EINOSAS, C.E.
Evidences/Proof of Current Competencies
Form 1.2: Evidence of Current Competencies acquired related to

Job/Occupation
Name of ANDAN, CLYDE ANTHONY
Trainee:
Qualification SHIELDED METAL ARC WELDING NC II

Title:
Current
Proof/Evidence Means of Validating
Competencies
Check authenticity
of certificate of
achievement
Weld Carbon
certificate of Performed tasks
Steel Plates
achievement correctly according to
Using SMAW
standard operating
procedure through
Institutional evaluation
Weld Carbon
Steel Pipes

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Using SMAW
Identifying Training Gaps
From the accomplished Self-Assessment Check (Form 1.1) and the

evidences of current competencies (Form 1.2), the Trainer will be able to
identify what the training needs of the prospective trainee are.
Form 1.3 Summary of Current Competencies Versus Required

Competencies (Sample)
Name of Trainee: ANDAN, CLYDE ANTHONY
SHIELDED METAL ARC WELDING NC

Qualification Title:
II

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Required Units of
Competency / Current Training Gaps/
Learning Outcomes Competencies Requirements
based on CBC
1. Welding
1. Weld Carbon Steel Carbon Steel
Plates Using SMAW Plates Using
SMAW
1.1 Perform Root
1.1 Perform Root pass
pass
1.2. Clean Root
1.2. Clean Root Pass
Pass
1.3 Weld 1.3. Weld
Subsequent/Filling Subsequent/Fillin
passes g passes
1.4. Perform
1.4 Perform capping
capping
2. Weld Carbon
2. Weld Carbon Steel
Steel Pipes Using
Pipes Using SMAW
SMAW
2.1 Perform Root
2.1 Perform Root pass
pass
2.2. Clean root

2.2. Clean root pass
pass
2.3 Weld 2.3 Weld

subsequent/Filling subsequent/Fillin
passes g passes
2.4. Perform
2.4. Perform capping
capping
Qualification Title:
Name of Trainee: Andan, Clyde
Shielded Metal Arc
Anthony
Welding NCII
Module Title /
Training Needs ( Learning
Module of
Outcomes)
Instruction

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L.O.1 Weld carbon steel plates in flat
position (1G)
L.O.2 Weld carbon steel plates in horizontal
position (2G) 2. Weld Carbon Steel
L.O.3 Weld carbon steel plates in vertical Pipes Using SMAW
position (3G)
L.O.4 Weld carbon steel plates in overhead
position (4G)
L.O.1 Weld Carbon Steel Pipes In
Horizontal Position (2G) 2. Weld Carbon Steel
L.O.2 Weld Carbon Steel Pipe In Fixed Pipe, Pipes Using SMAW
Horizontal Position (5G)
L.O.3 Weld carbon steel pipes in fixed pipe,
inclined at 45º position (6G)

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LIST OF COMPETENCY
Unit of Module
No. Code
Competency Title
Performing
groove
Weld Carbon welding on
1 MEE721306
Steel Plates carbon
steel
plates
Performing
groove
Weld Carbon
2 welding on MEE721306
Steel Pipes
carbon steel
plates

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MODULE CONTENT
QUALIFICATION : Shielded Metal Arc Welding NC II
UNIT OF COMPETENCY : Weld Carbon Steel Plates
MODULE TITLE : Preparing Groove Welding on Carbon Steel

Plates
NOMINAL DURATION:
INTRODUCTION:
This module covers the skills, knowledge and attitude required
in welding carbon steel plates in different positions such as 1G, 2G,
3G, & 4G using SMAW process.
LEARNING OUTCOMES:
1. Weld carbon steel plates in flat position (1G)
2. Weld carbon steel plates in horizontal position (2G)
3. Weld carbon steel plates in vertical position (3G)
4. Weld carbon steel pates in overhead position (4G)
ASSESSMENT CRITERIA:
1. Instructions for the preparation of the work activity are communicated
and confirmed to ensure clear understanding.

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2. Tools, and equipments needed to perform SMAW process are
identified, checked to ensure they work correctly as intended and are
safe to use in accordance with established procedures
3. Materials needed for work are obtained in accordance with established
procedures
4. Protective gears and body coverings should be used to avoid accidents
and injuries. Safety should always be observed.
5. SMAW process is performed in accordance to the latest edition of
Training Regulations (TR), Competency Based Curriculum and other
related articles obtained from the Technical Education and Skills
Development Authority.
Learning Outcome # 1: WELD CARBON STEEL

PLATES IN FLAT POSITION
(1G)
CONTENTS:
1. Preparation of base plate
2. Welding carbon steel plate in Flat position
1. Root penetration not exceeding allowable tolerances specified by
welding codes/standards on; concavity, convexity, undercut, excess
penetration, lack of fusion, burn-through and cracks.
2. Weld capping/final pass not exceeding allowable tolerances specified
by welding codes/standards on; height of reinforcement, under fill,
porosities, undercut, cracks and cold laps.
3. Uniformity of bead ripples must be in accordance with welding
standards.
4. Stringer or layered beads deposited in accordance with welding
standards.
5. Finish weldment visually acceptable in accordance with welding
standards on; spatters, arc strikes; slag; uniformity of beads.

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CONDITIONS:
Students/trainees must be provided with the following:
1. WORKPLACE
2. TOOLS, ACCESSORIES AND SUPPLIES
Welding mask, electrodes, steel brush, clear and dark glass, chipping
hammer, mechanical pliers.
3. EQUIPMENT
Welding machine (AC or AC/DC), welding table, portable grinder,
Welding booth, portable oven
4. TRAINING MATERIALS
Competency Based Learning Material on SMAW NCII
ASSESSMENT METHODS:
Direct observation
Visual examination of plates
Learning Experiences
Learning Activities Specific Instruction

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After reading INFORMATION
1. READ INFORMATION
SHEET NO. 1.1-1 proceed to
SHEET NO. 1.1-1 on AWS
Task Sheet 1.1-1
Code
After performing Weld Carbon

2. Perform Task Sheet 1.1-1
Steel Plates In Flat Position,
Weld Carbon Steel Plates In
Let the trainer evaluate your
Flat Position
work.
After the trainer’s evaluation

and approval of the plate, you
can proceed to the next LO.

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Information Sheet No. 1.1-1
Weld Carbon Steel Plates In Flat Position (1G)
Preparation of Base Plate

The bevels are to be flame cut on the edges of the plate before the
parts are assembled. The bevel face must be smooth and free of
notches.
The groove face and inside and outside plate surface with in 1”
(25mm) of the joint must be mechanically cleaned of slag, rust and
mill scale. Cleaning must be done with a wire brush or grinder down
to bright metal.
Flat Position (1G)
1G is a plate in the flat position that is beveled. This position is the

most basic and only covers the welder in that position

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TASK SHEET 1.1-1
Title: Weld Carbon Steel Plates In Flat Position (1G)
Performance Objective: Should be able to perform penetration,

filling and capping to plates in flat position
Supplies/Materials : Electrode, welding mask, clear and

dark glass, chipping hammer, steel brush, mechanical pliers
Equipment: Welding machine (AC or AC/DC), welding table,
portable grinder, welding booth, portable oven
Steps/Procedure:
1. Wear PPE
2. Prepare the base metal.
3. Place the base metal in a flat position
4. Turn on the welding machine
5. Perform welding of carbon steel plates in flat position
6. turn off the welding machine
Assessment Method:
1. Observation
2. Examination of plates

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Performance Criteria Checklist 1.1-1
CRITERIA
YES NO
1. Deposit weld beads on plate?

2. weld plates in single pass groove joints in flat
positions
3. weld plates in multiple pass groove joints in
flat position

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SELF-CHECK NO. 1.1-1
Is your response
is satisfactory?
Direction: Answer the following questions
briefly. Compare your response to the model
Sati Not
answer provided. Tick on the box to indicate
sfac Satisf
whether your response is satisfactory or not
tory actor
satisfactory based on your own judgment. y
1. Performed lecture and demonstration
2. Trainees comprehension on the subject
3. Trainees performance on Weld carbon steel

plates in flat position
As an overall result, is your response satisfactory?

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Satisfactory Not Satisfactory

PLATES IN HORIZONTAL
POSITION (2G)
CONTENTS:
2. Welding carbon steel plate in Horizontal position

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standards.
standards.
CONDITIONS:
1. WORKPLACE
3. EQUIPMENT
ASSESSMENT METHODS:
Direct observation
LEARNING ACTIVITIES

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1. READ INFORMATION After reading INFORMATION
SHEET NO. 1.2-1 on WELD SHEET NO. 1.2-1 proceed to
CARBON STEEL PLATES Task Sheet 1.2-1
IN HORIZONTAL POSITION
(2G)
2. Perform Weld Carbon Steel After performing Weld Carbon

Plates In Horizontal Position Steel Plates In Horizontal
Position, Let the trainer
evaluate your work.


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INFORMATION SHEET NO. 1.2-1
Horizontal Welding
When welding in the 2G or 2F position it is necessary to control the

weld puddle and travel speed to produce a strong weld. The horizontal
position is used widely in agricultural sectors to make repairs.
The steps necessary to perform welds in the 2G or 2F position are:

-Secure the plate in a position for running beads in a straight line
from left to right. Use adjustable locking piers or C-clamps to secure
the metal firmly.
-When performing this type of weld, the electrode and the plate
sides should form a 90º angle. Lean the electrode slightly in the
direction of the weld area.
-Adjust the amperage, travel speed, and arc length to prevent the
weld puddle from running or sagging.
-Metal that is over 1/8 inch thick should be beveled prior to
welding in the horizontal position. If welding thicker metal, or metal
that has been beveled, it is necessary to make more than one weld
pass to enhance the strength of the weld.
-A root, filler, and cap pass will be necessary.

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SYSTEM Revision # 00
TASK SHEET 1.2-1
Title: Weld Carbon Steel Plates In Horizontal Position (2G)

Supplies/Materials: Electrode, welding mask, clear and dark

glass, chipping hammer, steel brush, mechanical pliers
Equipment: Welding machine (AC or AC/DC), welding table,
portable grinder, welding booth, portable oven
Steps/Procedure:
1. Wear PPE
Assessment Method:
1. demonstration
2. observation

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CRITERIA
YES NO
1. deposit weld beads on plate?

2. weld plates in single pass groove joints in
horizontal positions
horizontal position

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Is your response
is satisfactory?
Sati Not
sfac Satisf
tory actor


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PLATES IN VERTICAL
POSITION (3G)
CONTENTS:
2. Welding carbon steel plate in Vertical position
standards.
standards.

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CONDITIONS:
1. WORKPLACE
EQUIPMENT
4. 4. TRAINING MATERIALS
ASSESSMENT METHODS:
Direct observation
LEARNING ACTIVITIES

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IN VERTICAL POSITION
(3G)

Plates In Vertical Position Steel Plates In Vertical
evaluate your work.


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INFORMATION SHEET NO. 1.3-1
Vertical Welding
There are two basic techniques for performing welds in the vertical
position. These two techniques are commonly referred to as “vertical
up” and “vertical down.” These two techniques can be used to perform
welds in the 3G and 3F positions.
The following is a set of instructions for performing “vertical up”
and “vertical down” welds. For most welders, light metal is easier to
weld than heavy metal because it requires less penetration.
Be certain that the metal plate is secured in a vertical position. The
use of adjustable locking pliers or C-clamps is recommended to aid in
securing the metal in position.
Position the electrode at an angle of 60º to the plate and in the
path of the weld. The electrode should be perpendicular to the sides of
the plate.
For “vertical down” welding, begin at the top of the plate with a
short arc. If the electrode sticks, stop and increase the amperage. If
the electrode burns through the metal, lower the amperage. If the
electrode continues to burn through the metal, increase the speed of
the electrode movement downward.

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When welding “vertical up”, position the electrode 85º to the plate
in the path of the weld. Begin at the bottom of the plate and work up.
Use the same procedures if the electrode sticks or burns through the
metal.
As you become better at welding in the 3G and 3F positions, begin

work on thicker metals. Experiment and increase the amperage
accordingly. When welding thick plate, use one or more side-to-side
electrode movements.
As with fillet welds, “vertical up” and “vertical down” welds will
need more than one pass. A root pass should be made, along with a
filler and cap pass.

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TASK SHEET 1.3-1
Title: Weld Carbon Steel Plates In Vertical Position (3G)

es/Materials :Electrode, welding mask, clear and dark glass, chipping hammer,
steel brush, mechanical pliers
welding booth, portable oven
Steps/Procedure:
1. Wear PPE
Assessment Method:
1. demonstration
2. observation

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CRITERIA
YES NO

vertical positions
vertical position

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Is your response
is satisfactory?
Sati Not
sfac Satisf
tory actor


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PLATES IN OVERHEAD
POSITION (4G)
CONTENTS:
2. Welding carbon steel plate in Vertical position
standards.
standards.

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CONDITIONS:
1. WORKPLACE
3. 3. EQUIPMENT
4. 4. TRAINING MATERIALS
ASSESSMENT METHODS:
Direct observation
LEARNING ACTIVITIES

IN OVERHEAD POSITION
(4G)

Plates In Overhead Position Steel Plates In Overhead
evaluate your work.

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INFORMATION SHEET NO. 1.4
Overhead Welding
Welding in the 4G or 4F position is the most difficult of the out-of-

position welds. The major challenge in this type of welding is
controlling the weld puddle. The procedures for performing overhead
welds are very similar to the flat position, except that they are far

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more difficult. It is necessary to pay special attention to the weld
puddle and travel speed. You must maintain a short arc as well.
The steps in overhead welding are:
Secure the metal overhead with the use of an adjustable locking
pliers or C-clamps.
Find a position that is comfortable for you before starting to weld.
Welding in the 4G or 4F position is much more difficult if the welder is
uncomfortable from the start.
Adjust the amperage setting and travel speed. The amperage should
be set at approximately the same setting as needed during vertical
welding (3). Be certain to maintain a very short arc length throughout
the entire process.
Weld with a short arc and use a moderately fast rate of travel to
prevent sagging and undercutting.
A weaving pattern is recommended for use on heavier metals. This

motion must be faster than weaves used for other position welds.
Three passes will be needed to complete this weld properly.

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TASK SHEET 1.4-1
Title: Weld Carbon Steel Plates In Overhead Position (4G)

Supplies/Materials: Electrode, welding mask, clear and dark

glass, chipping hammer, steel brush, mechanical pliers
Steps/Procedure:
1. Wear PPE
Assessment Method:
1. demonstration
2. observation

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CRITERIA
YES NO

overhead positions
overhead position

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Is your response
is satisfactory?
Sati Not
sfac Satisf
tory actor


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Learning Outcome # 5: WELD CARBON STEEL PIPES
IN HORIZONTAL POSITION
(2G)
CONTENTS:
2. Welding carbon steel pipe in horizontal position
standards.
standards.

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CONDITIONS:
1. WORKPLACE
3. EQUIPMENT
ASSESSMENT METHODS:
Direct observation
LEARNING ACTIVITIES

CARBON STEEL PIPES IN Task Sheet 1.5-1
HORIZONTAL POSITION
(2G)

Pipes in Horizontal Position Steel Pipes in Horizontal
evaluate your work.

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INFORMATION SHEET NO. 1.5
Horizontal Position

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The 1G pipe welding position is a pipe in the horizontal position and the pipe
is rolled when welding. This is basically welding in the flat position. The 1G
pipe welding certification is rarely used.

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TASK SHEET 1.5-1
Title: Weld Carbon Steel pipes In Horizontal Position (2G)
Performance Objective:
Should be able to perform penetration, filling and capping to plates
in flat position
Supplies/Materials :
Electrode, welding mask, clear and dark glass, chipping hammer,
steel brush, mechanical pliers
Equipment:
Steps/Procedure:
1. Wear PPE
Assessment Method:
1. demonstration
2. observation

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CRITERIA
YES NO
1. deposit weld beads on pipe?

horizontal position
3. weld plates in multiple pass groove joints
horizontal position

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Is your response
is satisfactory?
Sati Not
sfac Satisf
tory actor


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MODULE IN SHIELDED
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Competency-Based Learning Material: Kabankalan Training Center (KTC)

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COMPETENCY-BASED LEARNING MATERIAL

Sector: Metals and Engineering

Qualification Title: Shielded Metal Arc Welding NC II

Unit of Competency: Weld Carbon Steel Plates

Module Title: Performing Groove Welding on Carbon Steel Plates

Kabankalan Training Center (KTC)

MODULE IN SHIELDED Date Developed: Document No.

How to Use This Competency Based Learning Materials

Welcome to the module in Performing Groove Welding on Carbon

The unit of competency “Weld Carbon Steel Plates” contains

You are required to go through a series of learning activities in

This module was prepared to help achieve the required competency

Qualification Title: SHIELDED METAL ARC WELDING NC II

Instructions: Please answer the following instrument according

Average grade in:

Date Developed: Document No.

h. High School Level

2. Existing Health Conditions (Existing

Training Level Shielded Metal Arc Welding SMAW NCI

Date Developed: Document No.

a. Visual - The visual learner takes

b. Kinesthetic - described as the

c. Auditory- a learner who has

Other needs a. Financially

Date Developed: Document No.

INSTRUCTIONS: This Self-Check Instrument will give the trainer

Name of Trainee : _____________________________ Date :

1. Weld carbon steel plates using SMAW

Can I deposit weld beads on plate?

Can I weld plates in multiple pass groove joints

2. Weld carbon steel plates and pipes using

Date Developed: Document No.

Can I weld plates in multiple pass groove joints

Can I weld pipe in 1G, 2G, 5G and 6G

Prepared By : ERIC D. EINOSAS, C.E.

Evidences/Proof of Current Competencies

Form 1.2: Evidence of Current Competencies acquired related to

Qualification SHIELDED METAL ARC WELDING NC II

Date Developed: Document No.

Identifying Training Gaps

From the accomplished Self-Assessment Check (Form 1.1) and the

Form 1.3 Summary of Current Competencies Versus Required

Name of Trainee: ANDAN, CLYDE ANTHONY

SHIELDED METAL ARC WELDING NC

Date Developed: Document No.

2.2. Clean root

2.3 Weld 2.3 Weld

Date Developed: Document No.

inclined at 45º position (6G)

Date Developed: Document No.

Date Developed: Document No.

QUALIFICATION : Shielded Metal Arc Welding NC II

UNIT OF COMPETENCY : Weld Carbon Steel Plates

MODULE TITLE : Preparing Groove Welding on Carbon Steel

Date Developed: Document No.

Learning Outcome # 1: WELD CARBON STEEL

Date Developed: Document No.

Learning Activities Specific Instruction

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After performing Weld Carbon

After the trainer’s evaluation

Date Developed: Document No.

Weld Carbon Steel Plates In Flat Position (1G)