Danau CoCu Welding Operation Level 4

CURRICULUM OF COMPETENCY UNIT (CoCU)
Sub Sector WELDING TECHNOLOGY AND FABRICATION

Job Area WELDING TECHNOLOGY
Competency Unit Title WELDING DOCUMENT PREPARATION
The person who is competent in this CU shall be able to prepare welding document required, compiled and made
available to all parties in accordance with quality manual
Upon completion of this unit, trainee will be able to:
Learning Outcome Determine various welding forms and documents required

Obtain welding documents requirement
Prepare welding documents
Check completeness of welding documentation
Training Credit
Competency Unit ID CU01 Level 4 144 Hours 15
Duration Values
Attitude / Safety / Training Delivery Assessment
Work Activities Related Knowledge Related Skills
Environmental Hours Mode Criteria
1. Determine i. Quality manual 12 Lecture, i. Quality manual

various welding ii. Types of welding forms Discussion & reviewed
forms and and documents Presentation ii. Welding forms and
documents Welding Procedure documents
required Specification (WPS) selected.
Fit-up Report iii. Welding documents
Visual Inspection required
(VI) Report confirmed as
per the quality
Weld Map
manual
Positive Material
Identification (PMI)
Report
10
Post Weld Heat iv.Required welding
Treatment (PWHT) forms selected
Chart and applied
Hardness Test v.Code and Standard
Report Identified
NDT Request Form
Mill certificate
Code and standard
i. Interpret quality manual 18 Observation

ii. Distinguish the required & Group
welding forms and discussion
documents (WPS, fit-up
& VI, Weld map, PMI,
PWHT, Hardness test
report, NDT and Mill
certificate).
iii. Confirm the welding
documents required
iv. Apply required welding
forms and documents
v. Identify Code and
Standard
Attitude:
i. Cautious in
selecting WPS
ii. Meticulous in
analysing report
iii. Cautious in
applying forms
11
3. Obtain welding i. Document filing and 12 Lecture & i. Welding document,

documents storage system Presentation Code and
requirement ii. Fabrication Drawing Standard
iii. Welding Procedure retrieved.
Specification (WPS) ii. Welding
iv. Fit-up Report documentation
v. Visual Inspection (VI) requirement
Report determined and
vi. Weld Map explained
vii. Positive Material iii. Welding
Identification (PMI) documentation
Report reviewed and
viii. Post Weld Heat selected
Treatment (PWHT)
Chart
ix. Hardness Test Report
x. NDT Request Form
xi. Mill certificate
xii. Code and standard
i. Locate required 18 Observation

welding documents, & Group
Code and Standard discussion
ii. Distinguish the
required welding
documents (WPS, fit-
up, VI, PMI, PWHT,
Hardness test, weld
map and NDT).
iii. Review welding
documents
requirement.
12
Attitude:
i. Meticulous in
selecting WPS
ii. Knowledgeable
in reviewing fit-
up and Visual
Inspection (VI)
reports
iii. Knowledgeable
in interpreting
weld map
iv. Resourceful in
obtaining
documents
5. Prepare welding i. Types of welding 18 Lecture & i.Welding documents

documents documents Presentation reviewed and
ii. Fabrication Drawing compiled
iii. Welding Procedure i.Code and Standard
Specification (WPS) compiled
iv. Fit-up Report ii.Required welding
v. Visual Inspection (VI) documents
Report verified against
vi. Weld Map quality manual
vii. Positive Material iii.Welding documents
Identification (PMI) required
Report reviewed and
viii. Post Weld Heat compiled
Treatment (PWHT)
Chart
ix. Hardness Test Report
x. NDT Request Form
13
xi. Mill certificate
xii. Code and standard
i. Compile welding 24 Observation

documents ((WPS, fit- group &
up, VI,PMI, PWHT, discussion
Hardness test, weld
map and NDT), Code
and Standard
ii.Confirm welding document
compliance to quality
manual
iii.Review welding document
required
Attitude:
i. Conversant with
understanding of
welding
documents
ii. Meticulous in
collating welding
documents
14
7. Check i. Quality manual 18 Lecture & i. Welding documents

completeness ii. Welding Procedure presentation checked
of welding Specification (WPS) ii. Sufficiency of
documentation iii. Fabrication drawing welding
iv.Welding Inspection report documents
Fit-up Report verified
Visual Inspection(VI) iii. Welding report
Report analysed and
Weld Map identified
iv. Welding documents
Positive Material
compliance
verified against
Report
quality manual
v. Post Weld Heat
v. Welding documents
Treatment (PWHT)
validated and
Chart
approved
vi. Hardness Test Report
vii. NDT Request Form
viii. Mill certificate
ix. Code and standard
i.Verify welding documents 24 Observation

used group &
ii.Review sufficiency of discussion
welding documents
iii.Analyse welding report
Compliance
Non-conformance
Adherence
iv.Determine quality manual
requirement on welding
documentation
v.Confirm completeness of
15
welding documents
Attitude:
i.Conversant
understanding of
welding
documents
requirement
ii.Meticulous in
reviewing welding
documents
iii.Knowledgeable in
analysing chart
and report
16
Employability Skills
Core Abilities Social Skills

1. Communication skills
04.08 Develop and negotiate staffing plan 2. Interpersonal skills
04.09 Prepare project /work plans 3. Conceptual skill
04.10 Utilize science and technology to achieve goals 4. Learning skill
05.04 Delegate responsibilities and/or authorities
5. Multitasking and prioritizing
05.05 Coordinate contract and tender activities
6. Self-discipline
7. Teamwork
8. Leadership skills
Tools, Equipment and Materials (TEM)
ITEMS RATIO (TEM : Trainees)

1. Quality manual 1:5
2. Fabrication Drawing 1:1
3. Welding Procedure Specification (WPS) 1:1
4. Fit-up & VI report 1:1
1:1
5. PMI report
1:1
6. PWHT chart
1:1
7. Hardness test report 1:1
8. NDT Request form 1:1
9. Welding Inspection report 1:1
10. Mill certificate 1:1
11. Code and standard 1:5
References
17
REFERENCES
1. N.T.Burgess: Quality Assurance of Welded Construction, 2nd Edition, ISBN 0-203-97580-4

2. Roger Timing, Fabrication and Welding Engineering, ISBN: 978-0-7506-6691-6
3. American Institute of Steel Construction Inc, 2nd Edition, Designing with Structural Steel (A Guide for Architect). ISBN 1-56424-052-5
4. American Institute of Steel Construction Inc, A Teaching Guide for Structural Steel Connections
5. AWS D1.1, Structural Welding Code Steel, 2nd Edition (2010)
6. ANSI Z49.1 Safety in Welding & Cutting Published by AWS & Occupational Safety & Health Standard. US Department of Labour
7. Dale H. Besterfield : Quality Control, 7th Edition Published by Pearson Prentice Hall. ISBN 0-13-191135-X
18
Competency Unit Title WELDING MATERIAL AND CONSUMABLE PROCUREMENT ARRANGEMENT
The person who is competent in Welding Material and Consumable Procurement Arrangement process shall be able
to prepare procurement activities for welding material and consumables in accordance with project specifications.
Upon completion of this competency unit, trainee will be able to:-

Identify welding material and consumable requirement
Learning Outcome Plan Welding material and consumable procurement arrangement activities
Define welding material and consumable items required
Carry out material take off (MTO)
Evaluate and compile welding material and consumable procurement arrangement activities
Training Credit
Duration Values
1. Identify welding i. Type of welding material 16 Lecture i. Welding

material and and consumable material and
consumable ii. Project specification consumable
requirement iii. Vendor list. type and usage
listed.
ii. Project
i. Gather welding material and 24 Group specification
consumable type and discussion identified.
usage iii. Vendor list
ii. Determine project confirmed
specification
iii. Determine vendor list
Attitude
19
Meticulo
us in determining
welding material
and consumable
requirement
Knowled
geable in
interpreting
project
specification
iii. Resourc
eful in obtaining
vendor
information
3. Plan welding Welding material and 16 Lecture Welding material

material and consumable and
consumable procurement consumable
procurement resources procurement
arrangement ii. Procurement procedure resources listed
activities iii. Project specification ii. Procurement
iv. Vendor list procedure
implemented
iii. Project
i. Prepare welding material and 24 Group specification
consumable procurement discussion complied
resources iv. Vendor list
ii. Apply procurement procedure confirmed
for welding material and
consumable
iii. Adhere to project
specification
iv. Select vendor list
20
Attitude
i. Meticulo
us in
determining
welding material
and
consumable
requirement
ii. Resourc
eful in
obtaining
vendor
information
iii. Judgmen
tal in selecting
vendor
5. Define welding i. Project specification 16 Lecture Project

material and ii. Welding material and specification for
consumable consumable welding material
items required specification and
iii. Type of welding material consumable
and consumable identified
iv. Welding material and ii. Welding material
consumable storage and
requirement consumable
specification
confirmed
Verify project specification for 24 Group iii. Type of welding
welding material and discussion material and
consumable consumable
21
ii. Verify welding material and listed
consumable specification iv. Welding material
iii. Select type of welding and
material and consumable consumable
iv. Verify welding material and storage
consumable storage requirement
requirement confirmed
Attitude
i. Meticulo
us in
determining
welding material
and
consumable
requirement
ii. Judgmen
tal in
determining
type of welding
material and
consumable in
accordance with
project
specification
7. Carry out Fabrication drawing 16 Lecture Joint detail for

ii.
material take off Material to be welded welding
(MTO) Type documented
Specification ii. Material to be
welded
Dimensions identified.
Quantity iii. Consumable
22
iii. Type of consumable selection
iv. Material take off (MTO) confirmed.
format iv. MTO format utilised
i. Interpret joint to be welded 24 Group

from the fabrication discussion
drawing
ii. Determine material to be
welded
iii. Classify consumable
selection
iv. Apply MTO
Attitude
Meticulo
us in determining
project
requirement
Judgmen
tal in determining
welded material
and welding
consumable
matching
iii. Resourc
eful in obtaining
material and
consumable
information
23
8. Evaluate and Project specification for 16 Lecture Project

compile welding welding material and specification
material and consumable confirmed
consumable ii. Welding material and ii. Procurement
procurement consumable procedure
arrangement procurement implemented
activities procedure
iii. Welding material and iii. Project
consumable procurement
procurement activities activities check
check list list verified
iv. Filing system iv. Filing system
implemented
Verify project specification for 24 Group

welding material and discussion
consumable
ii. Verify the implementation of
welding material and
consumable procurement
procedure
iii. Utilise project procurement
activities check list
iv. Apply filing system Attitude
Meticulo
us in determining
material data
Meticulo
us in interpreting
project
specification
iii. Resourc
24
eful in obtaining
material
reference
Environment
i. Recycle usable
paper

04.09 Prepare project /work plans 1. Communication skills
04.10 Utilize science and technology to achieve goals 2. Interpersonal skills
05.03 Allocate record and usage of financial and physical resources 3. Conceptual skill
05.04 Delegate responsibilities and/or authorities 4. Learning skill
05.05 Coordinate contract and tender activities 5. Multitasking and prioritizing
06.08 Identify and analyse effect of technology on the environment 6. Self-discipline
7. Teamwork
1. Computer set 1:1

2. Printer 1:5
4. Welding consumable catalogue 1:5
1:1
5. Project schedule
1:5
6. Vendor list
25
References
REFERENCES
1. N.T.Burgess, Quality Assurance of Welded Construction, 2nd Edition, Procurement and Material Control, ISBN 0-203-97580-4
2. Roger Timing, Fabrication and Welding Engineering, Chapter 2, Using and Communicating Technical Information, ISBN: 978-0-7506-669
3. Dale H. Besterfield : Quality Control, 7th Edition Published by Pearson Prentice Hall. ISBN 0-13-191135-X
26
Competency Unit Title WELDING ACTIVITY PLANNING
The person who is competent in this CU shall be able to plan and organize resources required before implementing a
welding project in accordance with project requirement.
Upon the completion of this competency unit, trainee will be able to:
Learning Outcome Identify budgeting / costing required for welding project

Identify shop floor arrangement for welding activity.
Develop man hour loading / planning required for welding project
Plan material, consumable and welding equipment for welding activity
Check welding planning activity.
Training Credit
Competency Unit ID CU03 Level 4
Duration
280
Values
28
1. Identify i. Project schedule 16 Lecture, i. Project

budgeting/ ii. Project budget Presentation & schedule
costing required iii. Manpower allocation Group briefed
for welding iv. Welding tools and discussion ii. Manpower
project equipment allocation
v. Project material listed
vi.Material delivery iii. Welding tools
schedule and
equipment
listed
24 Demonstration iv. Project
i. Determine project
& Observation material listed
schedule
27
ii.Determine manpower v. Material
allocation delivery
iii. Determine welding schedule
tools and equipment briefed
iv. Determine Project vi.Project budget
material estimated
v.Determine Material
delivery schedule
vi.Determine project
budget
Attitude:
i. Knowledgeable and
meticulous in
identifying
budgeting
required for
welding project
ii. Knowledgeable and
meticulous in
identifying costing
required for
welding project
28
2. Identify shop i. Location plan 24 Lecture, i. Location plan

floor Equipment Presentation & marked
arrangement for arrangement Group ii. Project size
welding activity. discussion listed
Material storage
Consumable v. Manpower
requirement
storage
listed
Office iii. Lay out plan
ii. Project size marked
Equipment
Material
Consumables
iii. Manpower requirement
iv. Lay out plan
i. Determine location plan 32 Demonstration

ii. Determine Project size & Observation
Equipment
Material
Consumabl
es
iii. Determine manpower
requirement
iv. Determine lay out plan
Equipment
arrangement
Material storage
Consumable storage
Office
29
Attitude
Knowledgeable and
meticulous in
identifying QA/QC
activities and
requirement
4. Develop man i. Project schedule 24 Lecture, i. Project

hour loading / ii. Project budget Presentation & schedule
planning iii. Manpower allocation Group verified
required for iv. Welding tools and discussion ii. Project budget
welding project equipment allocation confirmed
v. Material delivery iii. Manpower
schedule allocation
confirmed
iv. Welding tools
i. Study project schedule 32 Demonstration and
& Observation equipment
ii. Review project budget
allocation
iii. Check manpower summarised
allocation
v. Material
iv. Check welding tools delivery
and equipment schedule
allocation confirmed
v. Study material delivery
schedule
Attitude
i. Knowledgeable
and meticulous in
developing man
hour loading /
planning required
for welding project
30
6. Plan material, i. Project schedule 24 Lecture, i. Project

consumable and ii. Fabrication Presentation & schedule
welding schedule Group confirmed
equipment for iii. Welding tools and discussion ii. Fabricati
welding activity equipment on schedule
iv. Welding material confirmed
and consumable iii. Welding
v. Material delivery tools and
schedule equipment
listed
iv. Welding
i. Review project 48 Demonstration material and
schedule & Observation consumable
listed
ii. Review
fabrication v. Material
schedule delivery
schedule
iii. Prepare welding
confirmed
tools and
equipment
iv. Prepare welding
material and
consumable
v. Determine
material delivery
schedule
Attitude
i. Knowledgeable and
meticulous in
planning material,
consumable &
welding
equipment for
31
welding activity
8. Check welding i. Budgeting/ costing 24 Lecture, i. Budgeting/

planning activity required for welding Presentation & costing
project Group required for
ii. Shop floor discussion welding
arrangement for project
welding activity evaluated
iii. Man hour loading / ii. Shop floor
planning required for arrangement
welding project for welding
iv. Material, activity
consumable & welding confirmed
equipment required for iii. Man hour
welding activity loading /
planning
required for
i. Review budgeting/ 32 Demonstration welding
costing required for & observation project
welding project confirmed
ii. Review shop floor iv. Material,
arrangement for consumable &
welding activity welding
equipment
iii. Evaluate man hour
required for
loading / planning
welding
required for welding
activity
project
confirmed
iv. Evaluate material,
consumable &
welding equipment
required for welding
activity Attitude
i. Knowledgeable
32
and meticulous in
checking welding
planning activity

04.09 Prepare project /work plans 1. Communication skills
04.10 Utilize science and technology to achieve goals 2. Interpersonal skills
05.03 Allocate record and usage of financial and physical resources 3. Conceptual skill
05.04 Delegate responsibilities and/or authorities 4. Learning skill
05.05 Coordinate contract and tender activities 5. Multitasking and prioritizing
06.08 Identify and analyse effect of technology on the environment 6. Self-discipline
7. Teamwork
1. Computer set 1:1

2. Printer 1:5
4. Lay out plan 1:1
1:1
5. Fabrication schedule
References
REFERENCES
33
N.T.Burgess, Quality Assurance of Welded Construction, 2nd Edition, ISBN 0-203-97580-4

Competency Unit Title WELDING ACTIVITIES SUPERVISION
The person who is competent in this CU shall be able to ensure that utilizing of resources and the work progress in
accordance with project schedule
Learning Outcome Identify welding projects scope of works

Develop welding supervision activities schedule
Carry out supervision of welding activities
Liaise with project and engineering management team, customer and other inspection authority.
Compile welding supervision activities report
Training Credit
Competency Unit ID CU04 Level 4 312 31
Duration Values
34
1. Identify welding i. Fabrication drawing 24 Lecture & i. Fabrication drawing

projects scope ii. Type of welding process Presentation defined
of works iii. Type of welding material ii. Type of welding
Pipe process
confirmed
Plate
iii. Type of welding
Structure material
iv.Manpower requirement confirmed
Welder iv.Manpower
Fitter requirement
General worker confirmed
Supervisor
v. Welding facilities v. Welding
requirement facilities
Type of welding requirement
machine confirmed
Working area
vi. Tools and equipment
i. Interpret fabrication 40 Group

drawing discussion
ii. Determine type of welding
process
iii. Determine type of welding
material
iv.Determine manpower
requirement
v.Determine welding
facilities requirement
Attitude
35
i. Meticulous in
identifying
welding project
scope
ii. Resourceful in
obtaining
reference
Safety
i. Awareness on
safe working area
ii. Monitor
housekeeping
3. Develop i. Welding activities 24 Lecture & i. Welding activities

welding planning Presentation planning
supervision Fabrication work established
activities schedule ii. Welding activities
schedule Inspection Test Plan monitoring
(ITP) established
ii. Welding activities
monitoring
Welding progress
Welding material
delivery and receiving
schedule
Manpower, machine,
equipment capacity
and allocation
i. Prepare welding 32 Group
36
activities planning discussion
ii. Prepare welding
activities monitoring
Attitude
i. Meticulous in
developing
supervision
activities
schedule
ii. Resourceful in
obtaining
reference
37
5. Carry out i. Welding activities 32 Lecture & i. Fabrication work

supervision of planning Presentation complied
welding Fabrication work according to
activities schedule work schedule
Inspection Test Plan ii. Welding inspection
(ITP) work carried out
according to ITP
ii. Welding activities
monitoring iii. Welding work
progress
Welding activities
determined
schedule progress
iv. Quality of welding
QC inspection work maintained
activities v. Material stock
Material maintained
delivery/receiving vi. Usage of
schedule manpower,
Manpower, machine, machine and
equipment capacity equipment
and allocation optimized
iii. Welding work problem vii. Welding work
solving techniques problem resolved
i. Ensure fabrication 48 Group

work carry out discussion
accordingly
ii. Ensure welding
inspection work
carried out
accordingly
iii. Check welding work
progress
iv. Carry out QC
38
Inspection
v. Ensure welding
material delivery and
receiving according to
schedule
vi. Ensure optimum
usage of manpower,
machine and
equipment
vii. Carry out welding
work problem solving
Attitude
Rational
in handling
personnel issue
Decisive
in making decision
iii. Firm in
carrying out
supervision of
welding activities
Safety
Awareness on
safe working area
ii. Awareness on
Personnel
Protective
Equipment (PPE)
requirement
39
7. Liaise with i. Statutory requirement 24 Lecture & i. Statutory

project and on welding activities Presentation requirement on
engineering ii. Welding activities welding
management planning and activities
team, customer monitoring defined
and other Welding activities ii. Welding activities
inspection schedule planning and
authority monitoring
Work In Progress
complied
(WIP)
according to
iii. Fabrication drawing schedule
and technical
iii. Fabrication drawing
specification
and technical
specification
complied
i. Determine statutory 32 Group iv. Work delivery
requirement on discussion issues resolved
welding activities v. Welding Inspection
ii. Ensure welding activity issues
activities planning and related to
monitoring carried out authority
iii. Determine fabrication requirement
drawing and technical resolved
specification
requirements
iv. Communicate with the
customer on delivery
schedule
v. Coordinate welding
inspection activities
with authority
40
Attitude
i. Cooperative in
dealing with
project &
engineering
management
team, customer
and other
inspection
authority
ii. Openness in
resolving any
issues
9. Compile i. Documentation system 24 Lecture & i. Documentation

welding ii. Types of document Presentation system utilised
supervision iii. Types of supervision ii. Various types of
activities report activities reports documents
iv. Types of records classified
v. Document storage iii. Various types of
system reports
classified
iv. Various types of
i. Apply documentation 32 Group records
system discussion classified
ii. Differentiate various v. Storage system
types of documents implemented
iii. Differentiate various
types of reports
iv. Differentiate various
types of records
41
v. Utilize storage
system
Attitude
Meticulou
s in compiling
welding
inspection
activities records
42
04.08 Develop and negotiate staffing plan 1. Communication skills

04.09 Prepare project /work plans 2. Interpersonal skills
04.10 Utilize science and technology to achieve goals 3. Conceptual skill
05.03 Allocate record and usage of financial and physical resources 4. Learning skill
05.04 Delegate responsibilities and/or authorities 5. Multitasking and prioritizing
05.05 Coordinate contract and tender activities 6. Self-discipline
7. Teamwork

1. Fabrication drawing 1:1
2. Computer set 1:1
3. Printer 1:25
4. Fabrication work schedule 1:1
1:1
5. Inspection Test Plan (ITP)
1:1
6. Delivery schedule
1:1
7. Welding inspection report format
References
REFERENCES
1. N.T.Burgess, Quality Assurance of Welded Construction, 2nd Edition, ISBN 0-203-97580-4

3. American Institute of Steel Construction Inc, A Teaching Guide for Structural Steel Connections.
43
4. AWS D1.1, (2010), 2nd Edition, Structural Welding Code Steel.
5. ASME Section IX, (Latest Edition), Welding and Brazing Qualification.
6. ISO 9000:2008 Quality System Management Requirements
7. Meri William ; The Principles of Project Management , Published by Site Point Pty. Ltd. 2008 ISBN 978-0-9802858-6-4
Job Area WELDING OPERATION
Competency Unit Title WELDING INSPECTION ACTIVITY COORDINATION
The person who is competent in Welding Inspection Activity Coordination shall be able to schedule and carry out
monitoring of welding inspection activities and compile records in accordance with welding project requirement. to

Determine various type of welding inspection activities requirement
Plan and arrange welding inspection activities before, during and after completion of welding work
Learning Outcome Confirm welding inspection activities to be performed before, during and after completion of welding work
Request for welding inspection activities
Arrange for Non-Destructive Testing (NDT) and Destructive Testing (DT).
Determine weldment status based on NDT or DT result.
Compile welding inspection coordination activities records
Training Credit
Duration Values
44
1. Determine Inspection Test Plan (ITP) 40 Lecture Inspection Test

various type of requirement Plan (ITP)
welding ii. Code and Standard requirement
inspection Specification (MS, listed
activities AWS, ANSI, API, Code and
requirement ASME, ASTM, ISO Standard
etc.) Specification
iii. Project specification (MS, AWS,
iv. Inspection before welding ANSI, API,
ASME, ASTM,
ISO etc.) listed
45
Material inspection Project
Consumable specification
inspection listed
Edge preparation iii. Inspection
activities
Fit-up inspection before welding
Preheat inspection listed
Welding equipment iv. Inspection
set-up activities
Current setting during welding
listed
v. Inspection during welding
Inspection
Interpass cleaning activities after
Interpass visual welding listed
check vi. Post Weld Heat
Interpass Treatment
temperature (PWHT)
vi. Inspection after welding requirement
Weldment cleaning confirmed
Visual inspection
Non Destructive
Test
Dimensional
inspection
vii. Post Weld Heat Treatment
(PWHT) requirement
46
Identify Inspection Test Plan 40 Group

(ITP) requirement discussion &
ii. Identify Code and Standards Presentation
Specification welding
inspection requirement
iii. Identify project specification
iv. Identify inspection activities
before welding
v. Identify inspection activities
during welding
vi. Identify inspection activities
after welding
vii. Identify Post Weld Heat
Treatment (PWHT)
requirement
Attitude
Observant in
determining
inspection and
testing
requirement
Knowledg
eable in welding
inspection
iii. Resourcef
ul in obtaining
references
47
2. Plan and Work 24 Lecture Work

arrange arrangement schedule arrangement
welding ii. Inspection schedule
inspection activities before applied
activities before, welding Inspec
during and afteriii. Inspection tion activities
completion of activities during before welding
welding work welding scheduled
iv. Inspection iii. Inspec
activities after welding tion activities
v. Welding during welding
inspection tools and scheduled
equipment iv. Inspec
tion activities
48
after welding
Determine work 24 Group scheduled
arrangement schedule discussion & Weldin
ii. Determine presentation g inspection
inspection activities tools and
before welding equipment
iii. Determine selected and
inspection activities arranged
during welding
iv. Determine
inspection activities after
Attitude
welding
Rational on
v. Determine
preparing
welding inspection tools
inspection
and equipment
planning
Knowledg
eable in welding
inspection
iii. Resourcef
ul in obtaining
references
3. Confirm welding Inspection Test Plan (ITP) 32 Lecture Inspection Test

inspection requirement Plan (ITP)
activities to be ii. Work arrangement requirement
performed schedule defined
before, during iii. Welding Inspection activity ii. Work
and after schedule arrangement
completion of iv. Inspection activities before schedule
welding work welding utilised
Material inspection iii. Welding
inspection
Consumable
49
inspection activity
Edge preparation schedule
Fit-up inspection utilised
iv. Inspection
Preheat inspection
activities
Welding equipment before welding
set-up verified
Current setting v. Inspection
v. Inspection activities during activities
welding during welding
Interpass cleaning verified
Interpass visual vi. Inspection
activities after
check
welding
Interpass verified
temperature
vi. Inspection activities after
welding
Weldment cleaning
Visual inspection
Non Destructive
Test
Dimensional
inspection
Determine Inspection Test 32 Group

Plan (ITP) requirement discussion &
ii. Apply welding work Presentation
arrangement schedule
iii. Apply welding inspection
activity schedule
iv. Check inspection activities
before welding
v. Check inspection activities
50
during welding
vi. Check inspection activities
after welding
Attitude
Observant during
performing
welding
inspection.
Resourcef
ul in obtaining
reference
Safety
Awareness on
safe working area
Monitor
housekeeping
4. Request for i. Inspection Test Plan 16 Lecture i. ITP

welding (ITP) requirement requirement
inspection ii. Welding inspection adhered
activities activity schedule ii. Welding
iii. Welding inspection inspection
request form activity
iv. Welding inspection schedule
coordination procedure adhered
iii. Welding
inspection
i. Adhere to ITP requirement 16 Group request form
discussion & utilised
51
ii. Apply welding inspection Presentation iv. Welding
activity schedule inspection
iii. Use welding inspection coordination
request form procedure
iv. Apply welding inspection utilised
coordination procedure
Attitude
Proactive
in arranging
inspection
Resourcef
ul in obtaining
reference
Safety
Awarenes
s on safe working
area
Environment
Minimise material
wastage
Monitor
housekeeping
52
5. Arrange for i. Inspection activity 16 Lecture i. Inspection

Non-Destructive schedule activity
Testing (NDT) ii. Code and Standards schedule
and Destructive Specification testing adhered
Testing (DT) requirement ii. Code and
iii. NDT requirement Standards
Type of NDT Specification
testing
NDT procedure
requirement
Joint detail adhered
iv. DT requirement iii. NDT
Type of DT requirement
DT method confirmed
v. Testing coordination iv. DT
NDT inspection requirement
confirmed
company
v. Testing
Inspection request coordination
form organised
i. Adhere to inspection 16 Group

activity schedule discussion
ii. Apply Code and
Standards Specification
testing requirement
iii. Determine NDT
requirement
53
iv. Determine DT
requirement
v. Coordinate testing
activities
Attitude
Proactive in
arranging NDT/DT
inspection
Resourceful in
obtaining
references
Safety
Complianc
e to radiation
safety regulation
6. Determine i. Code and Standards 24 Lecture i. Code and

weldment status Specification Standards
based on NDT ii. NDT inspection report Specification
and/or DT result iii. DT inspection report confirmed
iv. Weldment acceptance ii. NDT
and rejection criteria inspection
report
54
evaluated
i. Determine Code and 24 Group iii. DT inspection
Standards Specification discussion & report
ii. Review NDT inspection Demonstration evaluated
report iv. Acceptance
iii. Review DT inspection and rejection
report criteria applied
iv. Determine acceptance
and rejection criteria Attitude
Judgment
al in assessing
NDT/DT reports
Resourcef
ul in obtaining
reference
7. Compile Welding inspection 8 Lecture Welding

welding records inspection
inspection ii. NDT reports records
coordination iii. DT reports confirmed
activities iv. Filing system NDT reports filed
records iii. DT reports filed
iv. Filing system
i. Verify welding inspection 8 Group implemented
records discussion &
ii. Verify NDT reports demonstration
iii. Verify DT reports
iv. Apply filing system Attitude
Proactive
in obtaining
inspection reports
55

5. Multitasking and prioritizing
05.03 Allocate record and usage of financial and physical resources
6. Self-discipline
05.04 Delegate responsibilities and/or authorities 7. Teamwork
05.05 Coordinate contract and tender activities 8. Leadership skills
1. Inspection Test Plan (ITP) 1:1

2. Code and Standards Specification 1:5
(MS, AWS, ANSI, API, ASME, ASTM, ISO) 1:5
3. Project specification 1:1
4. Non-Destructive Testing (NDT) & Destructive Testing (DT) Reports
5. Computer set 1:1
6. Printer 1:25
56
References
REFERENCES

3. American Institute of Steel Construction Inc, A Teaching Guide for Structural Steel Connections.
4. AWS D1.1, (2010), 2nd Edition, Structural Welding Code Steel.
5. ASME Section IX, (Latest Edition), Welding and Brazing Qualification.
6. ISO 9000:2008 Quality System Management
57
Competency Unit Title WELDING RECORDS AND REPORT DOCUMENTATION
The person who is competent in this CU shall be able to document and compile welding records and reports to
ensure that records and reports are maintained in accordance with contract requirement and quality manual
Learning Outcome Identify welding records and reports

Check types of records and reports
Categorize and classify records and reports
Compile and file records and reports
Training Credit
Duration Values
1. Identify welding i. Quality manual 24 Lecture, Quality manual

records and ii. Types of welding records Presentation & requirement
reports and reports Group identified
iii. Fabrication Drawing discussion ii. Welding records
iv. Welding Procedure and reports
Specification (WPS) obtained and
v. Inspection report explained
Fit-up Report iii. Welding records
selected
Visual Report
Welding Records
58
Positive Material iv. Welding records
Identification (PMI) selected and
Report applied
Weld Map
Hardness Test
Report
NDT Report
vi. Post Weld Heat Treatment
(PWHT) Chart
vii. Mill Certificate
viii. Material list
i. Conversant with 16 Demonstration

quality manual & Observation
ii. Obtain various type of
welding records and
reports
iii. Distinguish types of
welding records and
reports
iv. Confirm types of
welding records and
reports
Attitude:
i. Meticulous in
determining type
of records
ii. Knowledgeable in
identifying
various type of
report
iii. Knowledgeable in
59
NDT requirement
listed in quality
manual
2.Check types of i. Quality manual 16 Lecture, i. Welding records

records and ii. Types of welding records Presentation & and reports
reports and reports Group acquired
iii. Fabrication Drawing discussion ii. Authentication of
iv. Welding Procedure welding
Specification (WPS) records and
v. Inspection report reports
Fit-up Report confirmed
iii. Welding records
Visual Report and reports
Welding Records validated
Positive Material
Report
Weld Map
Hardness Test
Report
NDT Report
(PWHT) Chart
viii. Material list
i. Obtain welding records 24 Demonstration

and reports & observation
ii. Verify authenticity types of
welding records and
60
reports
iii. Confirm types of welding
records and reports
Attitude:
i. Meticulous in
determining type
of records
ii. Conversant in
identifying various
type of report
iii. Resourceful in
obtaining records
and reports
3.Categorize and i. Quality manual 16 Lecture, i. Welding records

classify records ii. Types of welding records Presentation & and reports
and reports and reports Group listed
iii. Fabrication Drawing discussion ii. Types of records
iv. Welding Procedure and reports
Specification (WPS) categorized
v. Inspection report and classified
Fit-up Report as per quality
manual
Visual Report iii. Records and
Welding Records reports
Positive Material confirmed in
Identification (PMI) accordance
Report with quality
Weld Map manual
Hardness Test
Report
61
NDT Report iv. Records and
vi. Post Weld Heat Treatment reports are
(PWHT) Chart documented
vii. Mill Certificate as per
viii. Material list contract
requirement
and quality
manual
i. Familiarize with 24 Demonstration
Welding records and & Observation
reports as listed in
accordance with
quality manual
ii. Determine types of
records and reports
iii. Verify types of records
and reports
iv. Confirm records and
reports are
documented
Attitude:
i. Meticulous in
determining type
of records
ii. Conversant in
identifying various
type of report
62
4.Compile and file i. Quality manual 16 Lecture, i. Records and

records and ii. Types of welding records Presentation & reports
reports and reports Group acquired
iii. Fabrication Drawing discussion ii. Records and
iv. Welding Procedure reports
Specification (WPS) verified
v. Inspection report iii. Records and
Fit-up Report reports
compiled
Visual Report
Welding Records
Positive Material
Report
Weld Map
Hardness Test Report
NDT Report
(PWHT) Chart
viii. Material list
i. Obtain records and 24 Demonstration

reports & Observation
ii. Review records and
reports
iii. Gather records and
reports
63
Attitude:
i. Profound
understanding of
welding
documents
ii.Meticulous in
collating welding
documents
iii.Resourceful in
obtaining records
and reports

05.03 Allocate record and usage of financial and physical resources 5. Multitasking and prioritizing
05.04 Delegate responsibilities and/or authorities 6. Self-discipline
05.05 Coordinate contract and tender activities 7. Teamwork
64

1. Quality Manual 1:1
3. Welding Procedure Specification (WPS) 1:1
4. Fit-up & VI report 1:1
1:1
5. PMI report
1:1
6. PWHT chart
1:1
7. Hardness test report 1:1
8. NDT form 1:1
9. Mill certificate
References
REFERENCES

65
66
Competency Unit Title WELDING SAFETY ACTIVITIES IMPLEMENTATION
The person who is competent in this CU shall be able to ensure safety practices is adhered and provide overall safe
working environment at the work site in accordance with company procedure and project requirement
Learning Outcome Identify welding safety activities implementation requirements.

Plan welding safety activities implementation
Carry out welding safety briefing.
Carry out welding safety audit.
Evaluate welding safety activities implementation
Training Credit
Competency Unit ID CU07 Level 4
Duration
220 Hours
Values
22
1. Identify welding i. Company safety policy 28 Lecture, i. Company

safety activities ii. Welding safety presentation & safety policy
implementation requirement group related to
requirement iii. Safety act and discussion welding work
regulation explained
iv. Welding risk and ii. Welding
hazard safety
requirements
defined
i. Interpret company 16 Demonstration iii. Safety act
safety policy related to observation & and
welding work role play regulation
67
ii. Apply welding safety related to
requirements welding work
iii. Interpret safety act explained
and regulation related iv. Welding risk
to welding work and hazard
iv. Determine welding defined
risk and hazard
Attitude:
i. Observant in
identifying safety
infringement
ii. Alert in safety
behavioural
violation
iii. Cautious towards
work surrounding
2. Plan welding i. Company safety policy 16 Lecture, i. Company safety

safety activities ii. Welding safety Presentation & policy related
implementation requirements Group to welding
iii. Safety act and discussion work
regulation explained
iv. Welding risk and ii. Welding safety
hazard requirements
v. Welding safety elaborated
programs iii. Safety act and
Welding safety regulation
schedule related to
welding work
Permit To Work assessed
(PTW)
68
Confine space iv. Welding risk and
Working at height hazard
identified and
Welding safety
defined
training
v. Welding safety
Toolbox meeting program
First aid developed
Job Safety Analysis
(JSA)/ Job Hazard
Analysis (JHA)
i. Interpret company 28 Demonstration

safety policy related to & Observation
welding work
ii. Determine welding
safety requirements
iii. Interpret safety act
and regulation related
to welding work
iv. Determine welding risk
and hazard
v. Conversant in
development of
welding safety
program Attitude
i. Firm in imposing
safety penalty
ii. Rational in planning
safety activities
iii. Positive in
championing
safety rules and
regulation
69
4. Carry out i. Safety Standard 12 Lecture, i. Safety

welding safety Operating Procedure Presentation & Standard
briefing (SOP) Group Operating
ii. Regulatory body discussion Procedure
Department of (SOP)
Occupational Safety implemented
and Health (DOSH) ii. Regula
National Institute of tory body
determined
Occupational Safety
and Health (NIOSH) iii. Staff
safety
Suruhanjaya Tenaga briefing
(ST) implemented
Fire Department iv. Toolbo
(BOMBA) x meeting
iii. Staff safety implemented
briefing v. Safety
iv. Toolbox meeting awareness
v. Safety campaign
awareness campaign implemented
vi. First Aid Training vi. First
vii. Safety risk Aid Training
assessment implemented
viii. Emergency vii. Safety
response program risk
(ERP) assessment
ix. HSE audit implemented
viii. emerg
ency
i. Apply Safety 32 Demonstration response
Standard Operating & observation program
Procedure (SOP) (ERP)
ii. Identify implemented
70
regulatory body ix. HSE
iii. Conduct staff audit
safety briefing implemented
iv. Conduct
toolbox meeting
v. Conduct safety
awareness campaign
vi. Conduct First
Aid Training
vii. Conduct safety
risk assessment
viii. Conduct
Emergency Response
Program (ERP)
Attitude:
ix. Conduct HSE
audit i. Firm in imposing
safety penalty
ii. Rational in planning
safety activities
iii. Positive in
championing
safety rules and
regulation
6. Carry out i. Safety document and 12 Lecture, i. Safety

welding safety procedures presentation & document and
audit ii. Safety practices group procedures
iii. Non-compliance on discussion verified
welding safety ii. Compliance of
safety Prentice
i. Review related 32 Demonstration verified
document in safety & observation iii. Non-
compliance on
71
procedures welding safety
ii. Check compliance of verified
safety practice
iii. Observe non-
compliance on welding
safety
Attitude:
i. Rational in carrying
out safety audit
8. Evaluate welding i. Welding safety activities 12 Lecture, Weldin

safety activities schedule presentation & g safety
implementation ii. Safety Standard group activities
Operating Procedure discussion schedule
(SOP) checked
iii. Welding safety ii. Safety
programme record Standard
iv. Welding safety reports Operating
Procedure
(SOP) adopted
i. Review welding safety 32 iii.
Demonstration Weldin
activities schedule & observation g safety
programme
ii. Observe Safety
record
Standard Operating
confirmed
Procedure (SOP)
iv. Weldin
iii. Review welding
g safety
safety programme
reports
record
confirmed
iv. Review welding
safety reports
Attitude:
i. Rational in evaluating
safety activities
implementation
72

04.08 Develop and negotiate staffing plans 1 Communication skills
04.09 Prepare project/work plans 2 Interpersonal skills
04.10 Utilize science and technology to achieve goals 3 Conceptual skill
05.03 Allocate and record usage of financial and physical resources 4 Leaning skill
05.04 Delegate responsibilities and/or authority 5 Multitasking and prioritizing
05.05 Coordinate contract and tender activities 6 Self-discipline
06.08 Identify and analyse effect of technology on the environment 7 Teamwork
8 Leadership skills

1. Safety policy 1:1
2. Safety act and regulation 1:1
3. Computer set 1:1
4. Printer 1:25
1:1
5. Health Safety and Environment (HSE) program
1:1
6. Health Safety and Environment (HSE) record
References
REFERENCES

6. ANSI Z49.1 Safety in Welding & Cutting Published by AWS & Occupational Safety & Health Standard. US Department of Labour
73
Competency Unit Title WELDING SOFTWARE APPLICATION
The person who is competent in this CU shall be able to provide good simulation in welding software in accordance
with standard requirement of companys policy, rules and regulation.

Learning Outcome Identify welding software for simulation and usage.
Familiarize with welding software application
Create welding software instruction
Validate welding software instruction.
Training Credit
Competency Unit ID E01 Level 4 126 Hours 13
Duration Values
1. Identify welding i. Welding software 8 Lecture & i. Welding

software for information Group software
simulation and Software brand discussion information
usage. (Cigweld ABB , OTC , listed
ProWrite, WeldDocs ii. Suppliers
Weld Toolbox, etc.) listed
Specification
Price
ii. Welding software suppliers
Local
International
74
i. Gather types of 16 Observation
welding software
information
Software brand
(Cigweld ABB ,
OTC , ProWrite,
WeldDocs Weld
Toolbox, etc)
Specification
Price
Attitude
Meticulou
s in identifying
welding software
information
2. Familiarize with i. Welding software 8 Lecture & i. Welding software

welding specification Group specification
software ii. Welding software discussion explained
application principle operation and ii. Welding software
application principle
operation and
application
1. Describe welding software 16 Demonstration demonstrated
specification &
2. Apply welding software Observation
principle operation
Attitude
Meticulous in
identifying welding
software
75
information
Resourceful in
identifying the
welding software
vendor
3. Create welding i. Welding software 12 Lecture & i. Welding software

software principle operation and Group principle
instruction application discussion operation and
ii. Welding software code application
instruction demonstrated
ii. Welding software
code instruction
i. Identify welding 30 Demonstration utilized
software principle and iii. Welding software
operation and Observation application
application demonstrated
ii. Apply welding iv. Welding software
software code instruction
instruction confirmed
iii. Run (debug) welding
software instruction
iv. Simulate welding
Attitude
i. Meticulou
s in identifying
welding software
information
76
5. Validate welding i. Welding software 12 Lecture & i. Welding software
software principle operation and Group principle
instruction. application discussion operation and
ii. Welding software code application
instruction demonstrated
ii. Welding software
code
i. Apply welding 24 Demonstration instruction
software principle & demonstrated
operation and Observation confirmed
application iii. Welding software
ii. Verify welding instruction
software code updated
instruction
iii. Update welding
Attitude
i. Meticulous in
identifying
welding software
information
77

04.08 Identify welding software 2. Interpersonal skills
04.09 Determine Welding software principle operation and application 3. Conceptual skill
04.10 Utilize Welding software to achieve goals 4. Learning skill
05.04 Delegate welding software instruction 5. Multitasking and prioritizing
6. Self-discipline
7. Teamwork
1. Computer 1:1
2. Welding software 1:1
3. Printer 1:25
4. Standard Operating Procedure (SOP) 1:1
References
REFERENCES
1. Engineering and welding software (2010) on 16 September 2012,

2. http://www.computereng.com/products/welding_documentation_software.aspx
3. SysWELD software for computer simulation heat treatment and welding (2012) http://www.tc-liv.eu2.
4. ABB Robot studio overview (2012),http://www.abb.com/product/
5. OTC Daihen, Advanced Welding & Robotic Systems (2012), http://www.daihen-usa.com/
6. WeldToolbox software (2012), http://www.thinkcei.com/utilities/overview
78

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CURRICULUM OF COMPETENCY UNIT (CoCU)

Sub Sector WELDING TECHNOLOGY AND FABRICATION

Upon completion of this unit, trainee will be able to:

Learning Outcome Determine various welding forms and documents required

1. Determine i. Quality manual 12 Lecture, i. Quality manual

i. Interpret quality manual 18 Observation

3. Obtain welding i. Document filing and 12 Lecture & i. Welding document,

i. Locate required 18 Observation

5. Prepare welding i. Types of welding 18 Lecture & i.Welding documents

i. Compile welding 24 Observation

7. Check i. Quality manual 18 Lecture & i. Welding documents

i.Verify welding documents 24 Observation

Core Abilities Social Skills

Tools, Equipment and Materials (TEM)

ITEMS RATIO (TEM : Trainees)

1. N.T.Burgess: Quality Assurance of Welded Construction, 2nd Edition, ISBN 0-203-97580-4

Upon completion of this competency unit, trainee will be able to:-

1. Identify welding i. Type of welding material 16 Lecture i. Welding

3. Plan welding Welding material and 16 Lecture Welding material

5. Define welding i. Project specification 16 Lecture Project

7. Carry out Fabrication drawing 16 Lecture Joint detail for

i. Interpret joint to be welded 24 Group

8. Evaluate and Project specification for 16 Lecture Project

Verify project specification for 24 Group

Core Abilities Social Skills

Tools, Equipment and Materials (TEM)

ITEMS RATIO (TEM : Trainees)

1. Computer set 1:1

Learning Outcome Identify budgeting / costing required for welding project

1. Identify i. Project schedule 16 Lecture, i. Project

2. Identify shop i. Location plan 24 Lecture, i. Location plan

i. Determine location plan 32 Demonstration

4. Develop man i. Project schedule 24 Lecture, i. Project

6. Plan material, i. Project schedule 24 Lecture, i. Project

8. Check welding i. Budgeting/ costing 24 Lecture, i. Budgeting/

Core Abilities Social Skills

Tools, Equipment and Materials (TEM)

ITEMS RATIO (TEM : Trainees)

1. Computer set 1:1

CURRICULUM OF COMPETENCY UNIT (CoCU)

Learning Outcome Identify welding projects scope of works

1. Identify welding i. Fabrication drawing 24 Lecture & i. Fabrication drawing

i. Interpret fabrication 40 Group

3. Develop i. Welding activities 24 Lecture & i. Welding activities

i. Prepare welding 32 Group

5. Carry out i. Welding activities 32 Lecture & i. Fabrication work

i. Ensure fabrication 48 Group

7. Liaise with i. Statutory requirement 24 Lecture & i. Statutory

9. Compile i. Documentation system 24 Lecture & i. Documentation

Core Abilities Social Skills

04.08 Develop and negotiate staffing plan 1. Communication skills

Tools, Equipment and Materials (TEM)

ITEMS RATIO (TEM : Trainees)

1. N.T.Burgess, Quality Assurance of Welded Construction, 2nd Edition, ISBN 0-203-97580-4

Upon completion of this competency unit, trainee will be able to:-

1. Determine Inspection Test Plan (ITP) 40 Lecture Inspection Test

Identify Inspection Test Plan 40 Group

2. Plan and Work 24 Lecture Work

3. Confirm welding Inspection Test Plan (ITP) 32 Lecture Inspection Test

Determine Inspection Test 32 Group

4. Request for i. Inspection Test Plan 16 Lecture i. ITP

5. Arrange for i. Inspection activity 16 Lecture i. Inspection

i. Adhere to inspection 16 Group