COMPETENCY-BASED LEARNING MATERIAL

METALS AND ENGINEERING SECTOR

Sector
SHIELDED METAL ARC WELDING SMAW NCI
Qualification
Weld Carbon Steel Plates Using SMAW
Unit of Competency
Welding Carbon Steel Plates Using SMAW
Module Title

Page 1 of 36
 HOW TO USE THIS
COMPETENCY-BASED LEARNING MATERIAL (CBLM)

Welcome to the competency-based learning material for the module: Welding

Carbon Steel Plates Using SMAW. This module contains training materials and activities
for you to accomplish.
The unit of competency “Weld Carbon Steel Plates Using SMAW. ” contains the
knowledge, skills and attitudes required for SMAW NCI
You are required to go through a series of learning activities in order to complete
each learning outcomes of the module. In each learning outcome, there are instructional
sheets (information sheets, operation sheets, job sheets, task sheets) for further reading
to help you better understands the required activities. Follow the activities at your own
pace and answer the self-check at the end of each learning outcome. If you have
questions, please feel free to ask for the assistance of your trainer/facilitator.
This module was prepared to help you achieve the required competency: Obey
and Observe Traffic Rules and Regulations. This will be the source of information for
you to acquire the knowledge and skills in this particular module with minimum
supervision or help from your trainer. With the aid of this material, you will acquire the
competency independently and at your own pace.
Remember to:
Work through all the information and complete the activities in each section. Do
what is asked in the INSTRUCTIONAL SHEET (TASK SHEET, OPERATION SHEET, and
JOB SHEET) and complete the SELF-CHECK. Suggested references are included to
supplement the materials provided in this module.
Most probably, your trainer will also be your supervisor or manager. He/ she are
there to support you and show you the correct way to do things. Ask for help.
You will be given plenty of opportunities to ask questions and practice on the job.
Make sure you practice your new skills during regular work shifts. This way, you will
improve both your speed and memory and also your confidence.
Use the self-check questions at the end of each section to test your own progress.
When you feel confident that you have had sufficient practice, ask your trainer to
evaluate you. The result of your assessment/evaluation will be recorded in the
ACHIEVEMENT CHART AND PROGRESS CHART.
You need to be competent in this module before you can move to the next
competency. A CERTIFICATE OF ACHIEVEMENT will be awarded to you after passing
the Institutional Competency Evaluation.

Page 2 of 36
TABLE OF CONTENTS

Page 3 of 36
 This competency-based learning material covers the following
competencies for shielded metal arc welding NC I as Follows:
CORE COMPETENCY:
• Weld Carbon Steel Plate Using SMAW

In this module, you are required to complete a series of learning activities to

achieve each learning outcome. Each outcome includes Information Sheets, Self-
Checks, Operation Sheets, and Task/Job Sheets. Follow and perform the
activities independently. If you have questions, do not hesitate to seek assistance
from your facilitator.

Guidelines to Follow:

 Work through all the information and complete the activities in each
section.
 Read the Information Sheets and Complete the Self-Checks. Suggested
references are provided to supplement the materials in this module.
 Your trainer will most likely also be your supervisor or manager. They
are there to support you and demonstrate the correct procedures.
 You will have many opportunities to ask questions and practice on the
job. Practice your new skills during regular work shifts to enhance your
speed, memory, and confidence.
 Use the Self-Checks, Operation Sheets, or Task/Job Sheets at the end
of each section to test your progress. Compare your performance against
the Performance Criteria Checklist or Procedural Checklist provided after
each sheet.
 When you feel confident that you have practiced sufficiently, ask your
trainer to evaluate you. The results of your assessment will be recorded in
your Progress Chart and Accomplishment Chart.
 Complete this module before proceeding to the Institutional
Assessment.

Page 4 of 36
 INFORMATION SHEET 1
Welding Positions for Steel Plate Fillet Welds Using WPS

Introduction
Welding Procedure Specifications (WPS) are standardized documents that outline
the methods and parameters required to produce a sound weld. Understanding
how WPS defines different welding positions for steel plate fillet welds is crucial
for ensuring consistent weld quality and adherence to standards.

Learning Objective:
After reading of the information sheet, learners are capable to perform different
Welding Procedure Specification (WPS) for steel plate fillet welds

1. Flat Position (1F)

WPS Code: 1F
Description: The welding is
performed on the top surface
of a horizontally positioned
plate.

WPS Parameters
Electrode Angle: 45°

2. Horizontal Position (2F)

WPS Code: 2F
Description: Performed on
the upper side of a
horizontal fillet weld.

WPS Parameters
Electrode Angle: 45° to the
plate.

Page 5 of 36
 3. Vertical Position (3F)
WPS Code: 3F
Description: Weld on a
vertical surface. Welding can
be performed using either an
upward or downward
progression.

WPS Parameters
Electrode Angle: 10° to 15°
from vertical.

4. Overhead Position (4F)

WPS Code: 4F
Description: Performed
underneath the joint.

WPS Parameters:
Electrode Angle: 10° to 20°
from horizontal.

SELF-CHECK 1

Page 6 of 36
 DIFFERENT WELDING PROCEDURE SPECIFICATION (WPS) FOR STEEL
PLATE FILLET WELDS

IDENTIFICATION: Identify the following welding positions.

1. Weld on a vertical surface. Welding can be performed using either an
upward or downward progression.
2. Performed underneath the joint.
3. Performed on the upper side of a horizontal fillet weld.
4. The welding is performed on the top surface of a horizontally positioned
plate. Electrode Angle: 45°

Page 7 of 36
ANSWER KEY 1

DIFFERENT WELDING POSITION IN STEEL PLATE FILLET

IDENTIFICATION:

1) Vertical Position (3F)

2) Overhead Position (4F)
3) Horizontal Position (2F)
4) Flat Position (1F)

Page 8 of 36
TASK SHEET 1: WELDING TWO STEEL PLATES IN 1F POSITION
Objectives:
Fit up two steel plates, apply the 1F welding position, and adhere to the
specified welding procedure.

Task Overview
1. Fit-Up: Align and secure the two steel plates.
2. Welding: Perform welding in the 1F position (flat).
3. Documentation: Record the welding parameters and specifications.

MATERIALS AND EQUIPMENTS

Steel Plates:
E6O11, 3.2mm ø electrode – 6 pcs
E6013, 3.2mm ø electrode – 10 pcs
Dimensions: 2” x 3/8” x 6” MSP – 2 pcs
Welding Machine:
Type: [Specify, e.g., SMAW Machine]
Model:________

Electrodes:
Type: E7018
Diameter: 3.2 mm (1/8 inch)
Other Tools:
Measuring Tape
Clamps
Angle Grinder
Welding Helmet
Gloves
Wire Brush

Parameter Specification
Welding Process SMAW
Base Metal Steel (A36)
Filler Material E7018 electrode
Preheat Temperature 100°C (212°F)
Interpass Temperature Maintain below 200°C (392°F)
Welding Position 1F (Flat)
Weld Passes Single pass
Current 120-150 amps
Voltage 20-25 volts
Travel Speed 100-150 mm/min

Page 9 of 36
PROCEDURE
Step 1: Preparation

1. Clean Plates: Remove rust, oil, and other

contaminants.
2. Check Alignment: Ensure plates are
aligned as per design requirements.
3. Gap Setting: Maintain a root gap of
[specify gap, e.g., 2-3 mm].

Step 2: Fit-Up

1. Align Plates: Position plates for welding.

2. Clamp Plates: Use clamps to secure
plates in position.
3. Check Fit-Up: Verify alignment and gap
using measuring tools.

Step 3: Welding in 1F Position

1. Preheat: Preheat plates to 100°C (212°F) if

required.
2. Set Parameters:
o Current: 120-150 amps
o Voltage: 20-25 volts
o Travel Speed: 100-150 mm/min
3. Weld: Perform welding in the 1F position.
o Passes: Single pass
o Electrode Angle: 20° to 30° from
vertical
4. Check Weld: Inspect the weld bead for
consistency.

Step 4: Post-Weld

1. Clean Weld: Use a wire brush to remove

slag.
2. Inspect: Verify weld quality (check for
defects such as cracks, porosity).
3. Documentation: Record welding
parameters and observations.

Page 10 of 36
 PERFORMANCE CRITERIA CHECKLIST
TASK SHEET 1

Trainees name:_____________________________ Date:_____________________

Please tick (✓) the column that best describes your evaluation of each of each identified
evidence.
CRITERIA Yes No
1. Fit-Up
Plates are cleaned of rust, oil, and contaminants.
Alignment of plates meets design specifications.
Root gap is maintained at [specify gap, e.g., 2-3 mm].
Plates are securely clamped and do not move during welding.
Fit-up is inspected and approved before welding begins.
2. Welding Parameters
Preheat temperature is achieved and uniform (if required).
Current is set between 120-150 amps.
Voltage is set between 20-25 volts.
Voltage is set between 20-25 volts.
Electrode angle is maintained at 20° to 30° from vertical.
3. Welding Process
Weld performed in the 1F (flat) position.
Weld pass is consistent and continuous.
Proper arc length maintained throughout welding.
Slag is removed between passes (if multiple).
Weld bead appearance is uniform without significant undercut or
excessive reinforcement.
4. Weld Quality
No visible cracks or porosity in the weld.
Weld has appropriate penetration and fusion.
No visible weld spatter outside acceptable limits.
Weld bead profile meets specified dimensions.
Completed weld is free of defects as per standard inspection criteria.
5. Post-Weld
Weld area cleaned with wire brush after welding.
Weld inspected and any defects documented.
All welding parameters and results recorded accurately.
Post-weld heat treatment applied if specified.
6. Safety and Compliance
Welder wore appropriate personal protective equipment (PPE).
Area around the welding site was safe and free from hazards.
Compliance with welding safety standards and guidelines observed.
Fire extinguishing equipment available at the site.
Safety briefing provided before the task.

_________________________
Name and Signature of the trainer

Page 11 of 36
TASK 2: WELDING TWO STEEL PLATES IN 2F POSITION

Objectives:
Fit up two steel plates, apply the 2F welding position, and follow the correct
welding procedure specifications.

Task Overview
1. Fit-Up: Align and secure the two steel plates.
2. Welding: Perform welding in the 2F position (horizontal fillet weld).
3. Documentation: Record the welding parameters and specifications.

MATERIALS AND EQUIPMENTS

Steel Plates:
Type: [Specify Grade, e.g., A36]
Dimensions: [Specify, e.g., 300 mm x 150 mm x 10 mm]
Welding Machine:
Type: [Specify, e.g., SMAW Machine]
Model:________
Electrodes:
Type: E7018
Diameter: 3.2 mm (1/8 inch)
Other Tools:
Measuring Tape
Clamps
Angle Grinder
Welding Helmet
Gloves
Wire Brush

Parameter Specification
Welding Process SMAW
Base Metal Steel (A36)
Filler Material E7018 electrode
Preheat Temperature 100°C (212°F)
Interpass Temperature Maintain below 200°C (392°F)
Welding Position 1F (Flat)
Weld Passes Single pass
Current 120-150 amps
Voltage 20-25 volts
Travel Speed 100-150 mm/min

Page 12 of 36
PROCEDURE
Step 1: Preparation

1. Clean Plates: Remove rust, oil,

and other contaminants.
2. Check Alignment: Ensure plates
are aligned as per design
requirements.
3. Gap Setting: Maintain a root gap
of [specify gap, e.g., 2-3 mm].

Step 2: Fit-Up

1. Align Plates: Position plates for

welding.
2. Clamp Plates: Use clamps to
secure plates in position.
3. Check Fit-Up: Verify alignment
and gap using measuring tools.

Step 3: Welding in 2F Position

1. Preheat: Preheat plates to 100°C

(212°F) if required.
2. Set Parameters:
a. Current: 120-150 amps
b. Voltage: 20-25 volts
c. Travel Speed: 100-150
mm/min
3. Weld: Perform welding in the 2F
position (horizontal fillet weld).
a. Passes: Single pass
b. Electrode Angle: 45° to 50°
from horizontal
4. Check Weld: Inspect the weld bead
for consistency.

Step 4: Post-Weld

1. Clean Weld: Use a wire brush to

remove slag.
2. Inspect: Verify weld quality
(check for defects such as cracks,
porosity).
3. Documentation: Record welding
parameters and observations.

Page 13 of 36
 PERFORMANCE CRITERIA CHECKLIST
TASK SHEET 2

Trainees name:_____________________________ Date:_____________________

Please tick (✓) the column that best describes your evaluation of each of each identified
evidence.
CRITERIA Yes No
1. Fit-Up
Plates are cleaned of rust, oil, and contaminants.
Alignment of plates meets design specifications.
Root gap is maintained at [specify gap, e.g., 2-3 mm].
Plates are securely clamped and do not move during welding.
Fit-up is inspected and approved before welding begins.
2. Welding Parameters
Preheat temperature is achieved and uniform (if required).
Current is set between 120-150 amps.
Voltage is set between 20-25 volts.
Voltage is set between 20-25 volts.
Electrode angle is maintained at 20° to 30° from vertical.
3. Welding Process
Weld performed in the 2F (flat) position.
Weld pass is consistent and continuous.
Proper arc length maintained throughout welding.
Slag is removed between passes (if multiple).
Weld bead appearance is uniform without significant undercut or
excessive reinforcement.
4. Weld Quality
No visible cracks or porosity in the weld.
Weld has appropriate penetration and fusion.
No visible weld spatter outside acceptable limits.
Weld bead profile meets specified dimensions.
Completed weld is free of defects as per standard inspection criteria.
5. Post-Weld
Weld area cleaned with wire brush after welding.
Weld inspected and any defects documented.
All welding parameters and results recorded accurately.
Post-weld heat treatment applied if specified.
6. Safety and Compliance
Welder wore appropriate personal protective equipment (PPE).
Area around the welding site was safe and free from hazards.
Compliance with welding safety standards and guidelines observed.
Fire extinguishing equipment available at the site.
Safety briefing provided before the task.

_________________________
Name and Signature of the trainer

Page 14 of 36
TASK SHEET 3: WELDING TWO STEEL PLATES IN 3F POSITION

Objectives:
Fit up two steel plates and apply the 3F welding position (vertical fillet weld)
following the correct weld procedure specifications.
Task Overview
1. Fit-Up: Align and secure the two steel plates.
2. Welding: Perform welding in the 3F position (horizontal fillet weld).
3. Documentation: Record the welding parameters and specifications.

MATERIALS AND EQUIPMENTS

Steel Plates:
Type: [Specify Grade, e.g., A36]
Dimensions: [Specify, e.g., 300 mm x 150 mm x 10 mm]
Welding Machine:
Type: [Specify, e.g., SMAW Machine]
Model:________
Electrodes:
Type: E7018
Diameter: 3.2 mm (1/8 inch)
Other Tools:
Measuring Tape
Clamps
Angle Grinder
Welding Helmet
Gloves
Wire Brush

Parameter Specification
Welding Process SMAW
Base Metal Steel (A36)
Filler Material E7018 electrode
Preheat Temperature 100°C (212°F)
Interpass Temperature Maintain below 200°C (392°F)
Welding Position 1F (Flat)
Weld Passes Single pass
Current 120-150 amps
Voltage 20-25 volts
Travel Speed 100-150 mm/min

Page 15 of 36
PROCEDURE
Step 1: Preparation

1. Clean Plates: Remove rust, oil,

and other contaminants.
2. Check Alignment: Ensure plates
are aligned as per design
requirements.
3. Gap Setting: Maintain a root gap
of [specify gap, e.g., 2-3 mm].

Step 2: Fit-Up

1. Align Plates: Position plates for

welding.
2. Clamp Plates: Use clamps to
secure plates in position.
3. Check Fit-Up: Verify alignment
and gap using measuring tools.

Step 3: Welding in 3F Position

1. Preheat: Preheat plates to 100°C

(212°F) if required.
2. Set Parameters:
a. Current: 120-150 amps
b. Voltage: 20-25 volts
c. Travel Speed: 100-150
mm/min
3. Weld: Perform welding in the 3F
position (horizontal fillet weld).
a. Passes: Single pass
b. Electrode Angle: 80° to 90°
from horizontal
4. Check Weld: Inspect the weld bead
for consistency.

Step 4: Post-Weld

1. Clean Weld: Use a wire brush to

remove slag.
2. Inspect: Verify weld quality
(check for defects such as cracks,
porosity).
3. Documentation: Record welding
parameters and observations.

Page 16 of 36
 PERFORMANCE CRITERIA CHECKLIST
TASK SHEET 3

Trainees name:_____________________________ Date:_____________________

Please tick (✓) the column that best describes your evaluation of each of each identified
evidence.
CRITERIA Yes No
1. Fit-Up
Plates are cleaned of rust, oil, and contaminants.
Alignment of plates meets design specifications.
Root gap is maintained at [specify gap, e.g., 2-3 mm].
Plates are securely clamped and do not move during welding.
Fit-up is inspected and approved before welding begins.
2. Welding Parameters
Preheat temperature is achieved and uniform (if required).
Current is set between 120-150 amps.
Voltage is set between 20-25 volts.
Voltage is set between 20-25 volts.
Electrode angle is maintained at 20° to 30° from vertical.
3. Welding Process
Weld performed in the 2F (flat) position.
Weld pass is consistent and continuous.
Proper arc length maintained throughout welding.
Slag is removed between passes (if multiple).
Weld bead appearance is uniform without significant undercut or
excessive reinforcement.
4. Weld Quality
No visible cracks or porosity in the weld.
Weld has appropriate penetration and fusion.
No visible weld spatter outside acceptable limits.
Weld bead profile meets specified dimensions.
Completed weld is free of defects as per standard inspection criteria.
5. Post-Weld
Weld area cleaned with wire brush after welding.
Weld inspected and any defects documented.
All welding parameters and results recorded accurately.
Post-weld heat treatment applied if specified.
6. Safety and Compliance
Welder wore appropriate personal protective equipment (PPE).
Area around the welding site was safe and free from hazards.
Compliance with welding safety standards and guidelines observed.
Fire extinguishing equipment available at the site.
Safety briefing provided before the task.

_________________________
Name and Signature of the trainer

Page 17 of 36
TASK SHEET 4: WELDING TWO STEEL PLATES IN 4F POSITION

Objectives:
Fit up two steel plates and apply the 4F welding position (overhead fillet weld)
following the correct weld procedure specifications..

Task Overview
1. Fit-Up: Align and secure the two steel plates.
2. Welding: Perform welding in the 4F position (overhead fillet weld).
3. Documentation: Record the welding parameters and specifications.

MATERIALS AND EQUIPMENTS

Steel Plates:
Type: [Specify Grade, e.g., A36]
Dimensions: [Specify, e.g., 300 mm x 150 mm x 10 mm]
Welding Machine:
Type: [Specify, e.g., SMAW Machine]
Model:________
Electrodes:
Type: E7018
Diameter: 3.2 mm (1/8 inch)
Other Tools:
Measuring Tape
Clamps
Angle Grinder
Welding Helmet
Gloves
Wire Brush

Parameter Specification
Welding Process SMAW
Base Metal Steel (A36)
Filler Material E7018 electrode
Preheat Temperature 100°C (212°F)
Interpass Temperature Maintain below 200°C (392°F)
Welding Position 1F (Flat)
Weld Passes Single pass
Current 120-150 amps
Voltage 20-25 volts
Travel Speed 100-150 mm/min

Page 18 of 36
PROCEDURE
Step 1: Preparation

4. Clean Plates: Remove rust, oil,

and other contaminants.
5. Check Alignment: Ensure plates
are aligned as per design
requirements.
6. Gap Setting: Maintain a root gap
of [specify gap, e.g., 2-3 mm].

Step 2: Fit-Up

4. Align Plates: Position plates for

welding.
5. Clamp Plates: Use clamps to
secure plates in position.
6. Check Fit-Up: Verify alignment
and gap using measuring tools.

Step 3: Welding in 4F Position

5. Preheat: Preheat plates to 100°C

(212°F) if required.
6. Set Parameters:
a. Current: 120-150 amps
b. Voltage: 20-25 volts
c. Travel Speed: 100-150
mm/min
7. Weld: Perform welding in the 4F
position (overhead fillet weld).
a. Passes: Single pass
b. Electrode Angle: 90° from
horizontal
8. Check Weld: Inspect the weld bead
for consistency.

Step 4: Post-Weld

4. Clean Weld: Use a wire brush to

remove slag.
5. Inspect: Verify weld quality
(check for defects such as cracks,
porosity).
6. Documentation: Record welding
parameters and observations.

Page 19 of 36
 PERFORMANCE CRITERIA CHECKLIST
TASK SHEET 4

Trainees name:_____________________________ Date:_____________________

Please tick (✓) the column that best describes your evaluation of each of each identified
evidence.
CRITERIA Yes No
1. Fit-Up
Plates are cleaned of rust, oil, and contaminants.
Alignment of plates meets design specifications.
Root gap is maintained at [specify gap, e.g., 2-3 mm].
Plates are securely clamped and do not move during welding.
Fit-up is inspected and approved before welding begins.
2. Welding Parameters
Preheat temperature is achieved and uniform (if required).
Current is set between 120-150 amps.
Voltage is set between 20-25 volts.
Voltage is set between 20-25 volts.
Electrode angle is maintained at 20° to 30° from vertical.
3. Welding Process
Weld performed in the 4F position.
Weld pass is consistent and continuous.
Proper arc length maintained throughout welding.
Slag is removed between passes (if multiple).
Weld bead appearance is uniform without significant undercut or
excessive reinforcement.
4. Weld Quality
No visible cracks or porosity in the weld.
Weld has appropriate penetration and fusion.
No visible weld spatter outside acceptable limits.
Weld bead profile meets specified dimensions.
Completed weld is free of defects as per standard inspection criteria.
5. Post-Weld
Weld area cleaned with wire brush after welding.
Weld inspected and any defects documented.
All welding parameters and results recorded accurately.
Post-weld heat treatment applied if specified.
6. Safety and Compliance
Welder wore appropriate personal protective equipment (PPE).
Area around the welding site was safe and free from hazards.
Compliance with welding safety standards and guidelines observed.
Fire extinguishing equipment available at the site.
Safety briefing provided before the task.

_________________________
Name and Signature of the trainer

Page 20 of 36
 INFORMATION SHEET 2
DIFFERENT WELDING POSITION IN STEEL PLATE GROOVE
FROM 1G TO 3G

Introduction
Welding positions for steel plate groove welds are defined based on the orientation of the plates
and the welding line. Mastery of each position is crucial for achieving high-quality welds in
various applications.

Objective
After reading the INFORMATION SHEET, learner must be able to perform
the different welding position in steel plate groove

1. Flat Groove Position (1G)

The workpieces are positioned
horizontally, and the weld is
performed on the top surface,
joining the edges of the plates
to form a groove weld.

Welding Parameters:

 Electrode Angle: Typically 15° to

25° from vertical.
 Travel Speed: 6-12 inches per
minute (ipm).
 Heat Input: 20-30 kJ/in.

Page 21 of 36
2. Horizontal Groove Position (2G)
The workpieces are vertical, and the
welding is performed horizontally,
joining the edges of the plates.

Welding Parameters:

 Electrode Angle: Typically 45° to

the plate.
 Travel Speed: 5-10 ipm.
 Heat Input: 20-30 kJ/in.

3. Vertical Groove Position (3G)

The workpieces are vertical, and the
welding is performed vertically,
joining the edges of the plates.

Welding Parameters:

 Electrode Angle: 10° to 15° from

vertical.
 Travel Speed: 3-6 ipm.
 Heat Input: 15-25 kJ/in.

Page 22 of 36
 SELF-CHECK 1
DIFFERENT WELDING POSITION IN STEEL PLATE GROOVE

IDENTIFICATION: identify the following.

1. The workpieces are positioned horizontally, and the weld is performed
on the top surface, joining the edges of the plates to form a groove weld.
2. The workpieces are vertical, and the welding is performed vertically, joining
the edges of the plates.
3. The workpieces are vertical, and the welding is performed horizontally,
joining the edges of the plates.

Page 23 of 36
 ANSWER KEY 1
DIFFERENT WELDING POSITION IN STEEL PLATE GROOVE

IDENTIFICATION

1. Groove Vertical Position (1G)

2. Groove Flat Position (3G)
3. Groove Horizontal Position (2G)

Page 24 of 36
TASK SHEET 1: FIT-UP OF STEEL PLATE IN GROOVE FLAT POSITION
(1G)

Task Objective

Fit up a steel plate in a groove in the flat position (1G) according to specified
dimensions and tolerances.

Tools and Equipment

 Measuring tape
 Level
 Square
 C-clamps
 Welding clamps
 Spacer bars
 Chalk or marker
 Cleaning brush or grinder
 PPE: Safety glasses, gloves, welding helmet, protective clothing

Materials

 Steel plates as per specifications

 Alignment tools (e.g., straightedges)
 Filler material (if required)

Safety Precautions

 Ensure proper ventilation in the workspace.

 Wear appropriate PPE at all times.
 Inspect tools and equipment for damage before use.
 Follow proper lifting techniques for heavy materials.
 Keep the work area clean and free of obstructions.

Procedure
5.1 Preparation

1. Inspect the Work Area: Ensure the area is clean and free of hazards.
Check for proper lighting.
2. Check Materials: Verify that steel plates match the required specifications
(grade, thickness, dimensions).
3. Prepare Steel Plates: Clean the edges of the steel plates to remove rust, oil,
and other contaminants using a cleaning brush or grinder.
4. Layout Marking: Use chalk or a marker to draw reference lines on the
plates as per the drawing.

Page 25 of 36
 5.2 Alignment

1. Positioning: Place the steel plates in the groove, ensuring they are in the
flat position (1G).
2. Spacing: Insert spacer bars between the plates to maintain the required gap
as per the welding procedure specification (WPS).
3. Alignment: Align the plates using a level and square. Ensure the edges are
parallel and the top surfaces are flush.

5.3 Clamping

1. Secure Plates: Use C-clamps or welding clamps to hold the plates in place.
Ensure they are tight enough to prevent movement but do not distort the
plates.
2. Double-Check Alignment: Re-check the alignment and spacing after
clamping.

5.4 Tack Welding

1. Apply Tack Welds: Apply tack welds at regular intervals (typically every 6-
12 inches) along the seam to hold the plates together.
2. Verify Position: After each tack, verify the alignment and make
adjustments if necessary.

5.5 Final Adjustments

1. Check for Warpage: Inspect the plates for any warping or misalignment due
to the tack welding.
2. Make Adjustments: If necessary, adjust the clamps and re-tack to correct
any issues.

Quality Checks

1. Visual Inspection: Check for proper fit-up, alignment, and spacing.

2. Dimensional Verification: Measure critical dimensions (gap, alignment) to
ensure they meet the specified tolerances.
3. Cleanliness: Ensure the fit-up area is free from contaminants that could
affect the welding quality.

Documentation

 Record the dimensions, tolerances, and any deviations observed during fit-
up.
 Note the batch numbers of steel plates used.
 Document any issues encountered and the corrective actions taken.

Page 26 of 36
 PERFORMANCE CRITERIA CHECKLIST
TASK SHEET 1

Trainees name: Date:

Please tick (✓) the column that best describes your evaluation of each
of each identified evidences.

CRITERIA YES NO
1. Preparation
2. Alignment
3. Clamping
4. Tack Welding
5. Final Adjustments
6. Quality Checks
7. Documentation
For satisfactory achievement, all items should receive a YES response.

Comment:

Name and Signature of the trainer

Page 27 of 36
Task Sheet 2: Fit-Up of Steel Plate in Groove Horizontal Position (2G)

Task Objective

Fit up a steel plate in a groove in the horizontal position (2G) according to

specified dimensions and tolerances.

Tools and Equipment

 Measuring tape
 Level
 Square
 C-clamps
 Welding clamps
 Spacer bars
 Chalk or marker
 Cleaning brush or grinder
 PPE: Safety glasses, gloves, welding helmet, protective clothing

Materials

 Steel plates as per specifications

 Alignment tools (e.g., straightedges)
 Filler material (if required)

Safety Precautions

 Ensure proper ventilation in the workspace.

 Wear appropriate PPE at all times.
 Inspect tools and equipment for damage before use.
 Follow proper lifting techniques for heavy materials.
 Keep the work area clean and free of obstructions.

Procedure
5.1 Preparation

1. Inspect the Work Area: Ensure the area is clean and free of hazards.
Check for proper lighting.
2. Check Materials: Verify that steel plates match the required specifications
(grade, thickness, dimensions).
3. Prepare Steel Plates: Clean the edges of the steel plates to remove rust, oil,
and other contaminants using a cleaning brush or grinder.
4. Layout Marking: Use chalk or a marker to draw reference lines on the
plates as per the drawing.

Page 28 of 36
5.2 Alignment

1. Positioning: Place the steel plates in the groove, ensuring they are in the
horizontal position (2G).
2. Spacing: Insert spacer bars between the plates to maintain the required gap
as per the welding procedure specification (WPS).
3. Alignment: Align the plates using a level and square. Ensure the vertical
edges are parallel and the front surfaces are flush.

5.3 Clamping

1. Secure Plates: Use C-clamps or welding clamps to hold the plates in place.
Ensure they are tight enough to prevent movement but do not distort the
plates.
2. Double-Check Alignment: Re-check the alignment and spacing after
clamping.

5.4 Tack Welding

1. Apply Tack Welds: Apply tack welds at regular intervals (typically every 6-
12 inches) along the seam to hold the plates together.
2. Verify Position: After each tack, verify the alignment and make
adjustments if necessary.

5.5 Final Adjustments

1. Check for Warpage: Inspect the plates for any warping or misalignment due
to the tack welding.
2. Make Adjustments: If necessary, adjust the clamps and re-tack to correct
any issues.

Quality Checks

1. Visual Inspection: Check for proper fit-up, alignment, and spacing.

2. Dimensional Verification: Measure critical dimensions (gap, alignment) to
ensure they meet the specified tolerances.
3. Cleanliness: Ensure the fit-up area is free from contaminants that could
affect the welding quality.

Documentation

 Record the dimensions, tolerances, and any deviations observed during fit-
up.
 Note the batch numbers of steel plates used.
 Document any issues encountered and the corrective actions taken.

Page 29 of 36
 PERFORMANCE CRITERIA CHECKLIST
TASK SHEET 2

Trainees name: Date:

Please tick (✓) the column that best describes your evaluation of each
of each identified evidences.

CRITERIA YES NO
1. Preparation
2. Alignment
3. Clamping
4. Tack Welding
5. Final Adjustments
6. Quality Checks
7. Documentation
For satisfactory achievement, all items should receive a YES response.

Comment:

Name and Signature of the trainer

Page 30 of 36
Task Sheet 3: Fit-Up of Steel Plate in Groove Vertical Position (3G)

Task Objective

Fit up a steel plate in a groove in the vertical position (3G) according to specified
dimensions and tolerances.

Tools and Equipment

 Measuring tape
 Level
 Square
 C-clamps
 Welding clamps
 Spacer bars
 Chalk or marker
 Cleaning brush or grinder
 PPE: Safety glasses, gloves, welding helmet, protective clothing

Materials

 Steel plates as per specifications

 Alignment tools (e.g., straightedges)
 Filler material (if required)

Safety Precautions

 Ensure proper ventilation in the workspace.

 Wear appropriate PPE at all times.
 Inspect tools and equipment for damage before use.
 Follow proper lifting techniques for heavy materials.
 Keep the work area clean and free of obstructions.

Procedure
5.1 Preparation

1. Inspect the Work Area: Ensure the area is clean and free of hazards.
Check for proper lighting.
2. Check Materials: Verify that steel plates match the required specifications
(grade, thickness, dimensions).
3. Prepare Steel Plates: Clean the edges of the steel plates to remove rust, oil,
and other contaminants using a cleaning brush or grinder.
4. Layout Marking: Use chalk or a marker to draw reference lines on the
plates as per the drawing.

Page 31 of 36
5.2 Alignment

1. Positioning: Place the steel plates in the groove, ensuring they are in the
vertical position (3G).
2. Spacing: Insert spacer bars between the plates to maintain the required gap
as per the welding procedure specification (WPS).
3. Alignment: Align the plates using a level and square. Ensure the vertical
edges are parallel and the front surfaces are flush.

5.3 Clamping

1. Secure Plates: Use C-clamps or welding clamps to hold the plates in place.
Ensure they are tight enough to prevent movement but do not distort the
plates.
2. Double-Check Alignment: Re-check the alignment and spacing after
clamping.

5.4 Tack Welding

1. Apply Tack Welds: Apply tack welds at regular intervals (typically every 6-
12 inches) along the seam to hold the plates together.
2. Verify Position: After each tack, verify the alignment and make
adjustments if necessary.

5.5 Final Adjustments

1. Check for Warpage: Inspect the plates for any warping or misalignment due
to the tack welding.
2. Make Adjustments: If necessary, adjust the clamps and re-tack to correct
any issues.

Quality Checks

1. Visual Inspection: Check for proper fit-up, alignment, and spacing.

2. Dimensional Verification: Measure critical dimensions (gap, alignment) to
ensure they meet the specified tolerances.
3. Cleanliness: Ensure the fit-up area is free from contaminants that could
affect the welding quality.

Page 32 of 36
 PERFORMANCE CRITERIA CHECKLIST
TASK SHEET 3

Trainees name: Date:

Please tick (✓) the column that best describes your evaluation of each
of each identified evidences.

CRITERIA YES NO
1. Preparation
2. Alignment
3. Clamping
4. Tack Welding
5. Final Adjustments
6. Quality Checks
7. Documentation
For satisfactory achievement, all items should receive a YES response.

Comment:

Name and Signature of the trainer

Page 33 of 36
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