EUROSKILLS TECHNICAL DESCRIPTION · welding and laser welding, A welder can work in a unit or...

EUROSKILLS TECHNICAL DESCRIPTION

WELDING (10)

ES2016_TD_WELDING_10_V1.2 2

WorldSkills Europe, by a resolution of the Competition Development Committee (CDC) and in

accordance with the Constitution, the Standing Orders and the Competition Rules, has adopted the

following minimum requirements for this skill for the EuroSkills Competition.

THE TECHNICAL DESCRIPTION CONSISTS OF THE FOLLOWING:

INDEX:

1 INTRODUCTION .................................................................................................................................................................. 3

2 THE WORLDSKILLS EUROPE STANDARDS SPECIFICATION ....................................................................................... 5

3 THE ASSESSMENT STRATEGY AND SPECIFICATION ................................................................................................. 10

4 THE MARKING SCHEME .................................................................................................................................................. 11

5 THE TEST PROJECTS ...................................................................................................................................................... 15

6 SKILL MANAGEMENT AND COMMUNICATION ............................................................................................................. 24

7 SKILL SPECIFIC SAFETY REQUIREMENTS ................................................................................................................... 26

8 MATERIALS AND EQUIPMENT ........................................................................................................................................ 27

9 VISITOR AND MEDIA ENGAGEMENT ............................................................................................................................. 29

10 SUSTAINABILITY .............................................................................................................................................................. 30

Effective 04.11.15

Mr Guillaume Suteau Chair - CDC

Ms Szofia Csiszar Vice Chair - CDC

© WorldSkills Europe (WSE) reserves all rights in documents developed for or on behalf of WSE,

including translation and electronic distribution. This material may be reproduced for non-commercial

vocational and educational purposes provided that the WorldSkills Europe logo and copyright notice

are left in place.


1. INTRODUCTION

1.1 NAME AND DESCRIPTION OF THE SKILL COMPETITION

1.1.1 THE NAME OF THE SKILLS COMPETITION IS

Welding

1.1.2 DESCRIPTION OF THE ASSOCIATED WORK ROLE(S) OR OCCUPATION(S)

A welder prepares and joins a range of metals of various gauges using electrical and electrical/gas

shielded processes. A welder needs to be able to interpret engineering working drawings, standards

and symbols and correctly translate these requirements into accurate structures and products.

Welders need to have a thorough knowledge and understanding of safe working procedures and

personal protection equipment. They need to gain specific knowledge of a wide range of welding

equipment and processes as well as a good working knowledge of metallurgy. They need to be

familiar with electricity and electrical processes.

Welders join sections, pipe and plate and fabricate large and small pressure vessels. A welder

prepares, assembles and joins a wide range of metals and metal alloys using various welding

processes including MMAW (manual metal arc welding), MAGSW (metal arc gas shielded welding),

TAGSW (Tungsten arc gas shielded welding) gas welding and cutting. They use gas, electrical, and

gas shielded electrical processes to join and cut a wide range of materials. They must be able to

choose and operate the correct equipment, process and methodology depending upon the material

being joined.

Welders may be engaged in using thermal cutting processes and should be able to identify and follow

the correct preparation for joining as applied to the type, thickness and intended use of the joint. They

use grinding and cutting equipment to prepare and finish welded joints. Modern methods of joining, as

well as those noted above, include mechanised processes such as submerged arc, plasma arc, stud

welding and laser welding,

A welder can work in a unit or factory which produces fabrications and/or structures for industries as

diverse as civil engineering, mechanical engineering, transport, marine engineering, and construction,

service and leisure industries. Welders also work on site preparation, construction, and the repair and

maintenance of structures within the areas described above. A welder can work in many locations and

situations, ranging from a bench in a factory, to shipyards, power stations and off-shore structures in

order to inspect and repair gas or oil rig terminals. Welders also work in engineering, construction,

power generating and petro-chemical plants. The working environment may include hazardous

settings such as the open sea.

The modern welder may specialize in one or a number of welding processes and environments. He or

she may also be asked to work in exotic alloys such as duplex stainless steels and cupronickels. The

quality of the welding will vary according to cost and function, with the most skilled welders depended

upon to carry out the finest work where faults and failure may have the most serious consequences in

terms of cost, safety and environmental damage.

1.2 THE CONTENT, RELEVANCE AND SIGNIFICANCE OF THIS DOCUMENT

This document incorporates a Role Description and Standards Specification which follow the principles

and some or all of the content of the WorldSkills Standards Specifications. In doing so WSE

acknowledges WorldSkills International’s (WSI’s) copyright. WSE also acknowledges WSI’s

intellectual property rights regarding the assessment principles, methods and procedures that govern

the competition.


Every Expert and Competitor must know and understand this Technical Description.

In the event of any conflict within the different languages of the Technical Descriptions, the English

version takes precedence.

1.3 ASSOCIATED DOCUMENTS

Since this Technical Description contains only skill-specific information it must be used in association

with the following:

o WSE –Competition Rules

o WSI – WorldSkills Standard Specification framework

o WSE – WorldSkills Europe Assessment Strategy

o WSE – Online resources as referenced in this document

o Host Country – Health and Safety regulations


2. THE STANDARDS SPECIFICATION

2.1 GENERAL NOTES REGARDING WSSS / WSESS

Where appropriate WSE has utilised some or all of the WorldSkills International Standards

Specifications (WSSS) for those skills competitions that naturally align between the two international

Competitions. Where the skill is exclusive to the EuroSkills Competition, WorldSkills Europe has

developed its own Standards Specification (WSESS) using the same principles and framework to that

used for the development of the WSSS. For the purposes of this document the use of the words

“Standards Specification” will refer to both WSSS and WSESS.

The Standards Specification specifies the knowledge, understanding and specific skills that underpin

international best practice in technical and vocational performance. It should reflect a shared global

understanding of what the associated work role(s) or occupation(s) represent for industry and

business. (www.worldskills.org/WSSS) (TBA for WorldSkills Europe) Helpfully, for the global

consultation on the WSSS in 2014, around 50 per cent of responses came from European industry

and business.

Each skill competition is intended to reflect international best practice as described by the Standards

Specification, and to the extent that it is able to. The Standards Specification is therefore a guide to

the required training and preparation for the skill competition.

In the skill competition the assessment of knowledge and understanding will take place through the

assessment of performance. There will not be separate tests of knowledge and understanding.

The Standards Specification is divided into distinct sections with headings and reference numbers

added.

Each section is assigned a percentage of the total marks to indicate its relative importance within the

Standards Specification. The sum of all the percentage marks is 100.

The Marking Scheme and Test Project will assess only those skills that are set out in the Standards

Specification. They will reflect the Standards Specification as comprehensively as possible within the

constraints of the skill competition.

The Marking Scheme and Test Project will follow the allocation of marks within the Standards

Specification to the extent practically possible. A variation of five percent is allowed, provided that this

does not distort the weightings assigned by the Standards Specification.

2.2 STANDARDS SPECIFICATION

SECTION RELATIVE IMPORTANCE %

1 Work organization and self-management 25

The individual needs to know and understand: o the standards and laws relating to the health, safety, security and

hygiene in the welding industry o the standards and regulations relating to safe working practices,

accident procedures, evacuation procedures and escape routes o the range, use and maintenance of personal protective

equipment used in the industry for any given circumstances

http://www.worldskills.org/WSSS


o the selection and use of safety equipment related to specific or dangerous tasks

o the safety recommendations and regulations relating to the welding of materials in all conditions including wet/damp areas, confined spaces and situations where oxygen levels are likely to be below those required for safe working.

o the recommendations, regulations and procedures required to prevent explosion, fire or combustion in all circumstances

o terminology and safety data supplied by manufacturers o the dangers of slips, trips and falls while engaged in welding

operations o primary electrical supply circuit terminology and its operation o secondary electrical / welding circuit terminology and operation o the requirements and effects of welding production for the

environment and sustainability issues o basic mathematical manipulation and unit conversion o geometrical principles, techniques and calculations

The individual shall be able to: o work safely with regard to themselves and others in all

circumstances o select, wear and maintain PPE to high standards as appropriate o select, maintain and wear specialist safety PPE as appropriate to

tasks o recognize hazardous situations and take appropriate actions with

regard to their own and others safety o follow correct procedural processes when working in dangerous

and semi-dangerous environments o demonstrate the adherence to manufacturers safety data sheets o maintain a clean working environment o store used materials in relevant containers for recycling and

sustainability o complete work within agreed timescales o calculate material requirements, consumables and costs of

welding o calculate areas and volumes using geometric formulae o recognise and inspect the main components of primary and

secondary electrical/welding circuits o make essential connections for specific welding procedures being

undertaken

2 Preparation for welding 5

The individual needs to know and understand: o the interpretation of welding / engineering drawings and weld

symbols o correct alignment of process with material being used o the classification and specific uses of welding consumables

including: o colour coding of gas cylinders o coding and designation of welding rods o diameters and specific use of welding wire o choice and preparation of welding electrodes o forms of edge preparation process available


o how surface contamination can influence the finished weld characteristics

o the correct machine settings to be aligned to: o welding polarity o welding position o material o material thickness o filler material and feed speed

o any fine adjustments needed to machine hardware, TIG electrode shape, wire type and diameter etc.

o the characteristics and properties of filler materials o the methods of edge preparation to align with joint profile,

strength, material and drawing specification o welding parameters/variables for specific tasks o effects of changes in welding variables/ parameters of completed

weld

The individual shall be able to: o prepare material edges as per drawing specification o select welding consumables by use, size, positional characteristic

and material being welded o remove surface contamination prior to welding o select correct filler material and size to suit materials being

welded o adjust welding equipment with consideration to welding

parameters/variables o set up welding equipment to manufacturers specification

including (but not limited to) o welding polarity o welding amperage o welding voltage o wire feed speed o travel speed o travel/electrode angles o mode of metal transfer

o prepare material edges in line with specification and drawing requirements

3 Welding materials 10

The individual needs to know and understand: o the mechanical and engineering properties of carbon steels o the mechanical and engineering properties of (5000 and 6000

series) aluminium and its alloys o the mechanical and engineering properties of stainless steel

(austenitic 300 series) o selection, and storage of welding consumables o correct storage and handling of welding consumables o selection and safe use of electrical power tools o the influence of time taken on the outcome cost of services o the supply costs of metals and consumables used for specific

tasks o the control of material and welding operations in environmental

protection


The individual shall be able to: o use materials with consideration to their mechanical and

engineering properties o store welding consumables correctly with reference to type, use

and safety considerations o select and prepare materials with reference to drawing material

list and welding symbols o prepare materials according to their properties and surface

characteristics o use electrical power tools safely to cut, grind and prepare / finish

welds o work efficiently within time limits set o use material efficiently with a view to supply and replacement

costs o carry out work effectively and efficiently with regard to

environmental protection

4 Welding Processes 60

The individual needs to know and understand: o the international specifications for the control of weld quality o specific terminology used in the welding industry o the precautions necessary for the safe use of power tools o and welding equipment o terminology, characteristics and safe use of welding and purging

gasses o recognition and selection of welding consumables o the selection, use and techniques of the various welding process

used o the specific methods used in shielding the weld area from

contamination o the selection of gasses used for shielding and purging o weld positions, weld angles and electrode travel speeds o faults / inclusions that may occur during welding o methods of distortion control in steels, alloys and aluminium o appropriate methods of finishing completed welds o range of destructive and non-destructive weld testing o the techniques for efficient stop / starts o the selection, adjustment and safe operation of electrical power

tools o the methods used to control heat input o methods and processes used in transfer of weld metal to the weld

area o the benefits of alloying to improve the properties of welding

material o the benefits and limitations of specific welding processes o weld defects and their appropriate rectification o the importance of weld metal cleanliness in weld quality

The individual shall be able to: o make welded joints in relation to international specifications o interpret welding terminology to complete task to specification o maintain welding equipment to deliver quality results


o select and use appropriate method of shielding the weld area from contamination

o select and adjust welding equipment to provide appropriate methods of weld metal transfer to the weld area

o select correct welding consumable to suit process and conditions o perform welding in all positions on pipe and plate for all

nominated welding processes as detailed in EN ISO 2553 and EN ISO 6947

o weld steel plate and sections using the manual metal arc welding process (111)

o weld steel plate and sections using the gas metal arc welding process (135)

o weld steel plate and sections using the flux cored welding process (136)

o weld stainless steel plate and sections using the Gas tungsten arc welding process (141)

o weld aluminium plate and sections using the gas tungsten arc welding process (141)

o dress welds using wire brushes, scrapers, chisels etc. o perform stop / starts to weld processes o dress completed welds o work accurately to drawing specification o produce welds to meet drawing and legislative specifications o correct weld faults and inclusions to maintain quality o check completed work against drawing requirements to reflect

accuracy, square and flatness where necessary o set up and operate appropriate controls to minimise and correct

distortion o perform non-destructive weld testing o demonstrate the preparation and safe use of electrical power

tools and equipment o carry out appropriate procedures to control heat input o recognise weld defects and take appropriate action to rectify

them o take appropriate actions to ensure that weld metal cleanliness is

maintained

The individual needs to know and understand: o mechanical systems and their functionality o how a component is assembled o how to demonstrate the working of an image

The individual shall be able to: o create functions relative to the operation of the system being

designed using industry programmes o create animations that demonstrate how different parts work or

are assembled o save work for future access

Total 100%


3. THE ASSESSMENT APPROACH & PRINCIPLES

3.1 GENERAL GUIDANCE

Note: this Section and Section 4 summarize a great deal of new information and guidance regarding assessment. Please refer to the Competition Rules for greater detail.

The Competition Development Committee (CDC) establishes the principles and techniques to which

assessment at the EuroSkills Competition must conform.

Expert assessment practice lies at the heart of the EuroSkills Competition. For this reason it is the

subject of continuing professional development and scrutiny. The growth of expertise in assessment

will inform the future use and direction of the main assessment instruments used by the EuroSkills

Competition: the Marking Scheme, Test Project, and Competition Information System (CIS).

Assessment at the EuroSkills Competition falls into two broad types: measurement and judgement.

Where the earlier terms “objective” and “subjective” still occur, these must be understood to mean

measurement and judgement for all procedural and practical purposes. All assessment will be

governed by explicit benchmarks, referenced to best practice in industry and business.

The Marking Scheme must include these benchmarks and follow the weightings within the Standards

Specification. The Test Project is the assessment vehicle for the skill competition, and also follows the

Standards Specification. The CIS enables the timely and accurate recording of marks, and has

expanding supportive capacity.

The Marking Scheme, in outline, will lead the process of Test Project design. After this, the Marking

Scheme and Test Project will be designed and developed through an iterative process, to ensure that

both together optimize their relationship with the Technical Description and the principles for

assessment as set out in the WSE Assessment Strategy. They will be agreed by the Experts and

submitted to WSE for approval together, in order to demonstrate their quality and conformity with the

Standard Specification.

Prior to submission for approval to WSE, the Marking Scheme and Test Project will be reviewed by the

WSE Skill Advisors in order to benefit from the capabilities of the CIS.


4. THE MARKING SCHEME

4.1 GENERAL GUIDANCE

This Section describes the role and place of the Marking Scheme, how the Experts will assess

Competitors’ work as demonstrated through the Test Project, and the procedures and requirements for

marking.

The Marking Scheme is the pivotal instrument of the EuroSkills Competition, in that it ties assessment

to the standards that represent the skills to be tested. It is designed to allocate marks for each

assessed aspect of performance in accordance with the weightings in the Standards Specification.

By reflecting the weightings in the Standards Specification, the Marking Scheme establishes the

parameters for the design of the Test Project. Depending on the nature of the skill and its assessment

needs, it may initially be appropriate to develop the Marking Scheme in more detail as a guide for Test

Project design. Alternatively, initial Test Project design can be based on the outline Marking Scheme.

From this point onwards the Marking Scheme and Test Project should be developed together.

Section 2.1 above indicates the extent to which the Marking Scheme and Test Project may diverge

from the weightings given in the Standards Specification, if there is no practicable alternative.

The Marking Scheme and Test Project may be developed by one person, or several, or by all Experts.

The detailed and final Marking Scheme and Test Project must be approved by the whole Expert Jury

prior to submission for independent quality assurance. The exception to this process is for those skill

competitions which use an external designer for the development of the Marking Scheme and Test

Project.

In addition, Experts are encouraged to submit their Marking Schemes and Test Projects for comment

and provisional approval well in advance of completion, in order to avoid disappointment or setbacks

at a late stage. They are also advised to work with the CIS Team at this intermediate stage, in order to

take full advantage of the possibilities of the CIS.

In all cases the complete and approved Marking Scheme must be entered into the CIS at least eight

weeks prior to the Competition using the CIS standard spreadsheet or other agreed methods.

4.2 ASSESSMENT CRITERIA

The main headings of the Marking Scheme are the Assessment Criteria. These headings are derived

in conjunction with the Test Project. In some skill competitions the Assessment Criteria may be similar

to the section headings in the Standards Specification; in others they may be totally different. There

will normally be between five and nine Assessment Criteria. Whether or not the headings match, the

Marking Scheme must reflect the weightings in the Standard Specification.

Assessment Criteria are created by the person(s) developing the Marking Scheme, who are free to

define criteria that they consider most suited to the assessment and marking of the Test Project. Each

Assessment Criterion is defined by a letter (A-I).

The Mark Summary Form generated by the CIS will comprise a list of the Assessment Criteria.

The marks allocated to each criterion will be calculated by the CIS. These will be the cumulative sum

of marks given to each aspect of assessment within that Assessment Criterion.


4.3 SUB CRITERIA

Each Assessment Criterion is divided into one or more Sub Criteria. Each Sub Criterion becomes the

heading for a EuroSkills marking form.

Each marking form (Sub Criterion) has a specified day on which it will be marked.

Each marking form (Sub Criterion) contains Aspects to be assessed and marked by measurement or

judgement. Some Sub Criteria have assessment by both measurement and judgement, in which case

there is a separate marking form for each method

4.4 ASPECTS

Each Aspect defines, in detail, a single item to be assessed and marked together with the marks, or

instructions for how the marks are to be awarded. Aspects are assessed either by measurement or

judgement and appear on the appropriate marking form.

The marking form lists, in detail, every Aspect to be marked together with the mark allocated to it, the

benchmarks, and a reference to the section of the Standards Specification.

The sum of the marks allocated to each Aspect must fall within the range of marks specified for that

section of the Standards Specification. This will be displayed in the Mark Allocation Table of the CIS,

in the following format, when the Marking Scheme is reviewed from C-8 weeks. (Section 0).

CRITERIA

TOTAL MARKS PER SECTION

A B C D E F G H I

ST

AN

DA

RD

SP

EC

IFIC

AT

ION

SE

CT

ION

S 1

2

3

4

5

6

7

8

9

TO

TA

L M

AR

KS

PE

R C

RIT

ER

ION

100


4.5 ASSESSMENT AND MARKING BY JUDGEMENT

In addition to measurement, Experts are expected to make professional judgements. These are

normally judgements about quality. Benchmarks will be designed, agreed and recorded during the

design and finalization of the Marking Scheme and Test Project in order to steer and support these

judgements.

Marking through judgement uses the following scale:

o 0: performance below industry standard to any extent, including a non-attempt

o 1: performance that meets industry standard

o 2: performance that both meets industry standard and surpasses that standard to some extent

o 3: excellent or outstanding performance relative to industry standards and expectations.

4.6 ASSESSMENT AND MARKING BY MEASUREMENT

Unless otherwise stated, only the maximum mark or zero will be awarded. Where they are used,

partial marks will be clearly defined within the Aspect.

4.7 ASSESSMENT OVERVIEW

For both measurement and judgement there will be three Experts in the assessment team.

Good practice in assessment comprises measurement and judgement applied both specifically and

broadly. The final proportions of measurement and judgement, whether specific or broad, will be

determined by the standards, their weightings and the nature of the Test Project.

4.8 COMPLETION OF SKILL ASSESSMENT SPECIFICATION

The skill assessment criteria are clear concise Aspect specifications which explain exactly how and

why a particular mark is awarded. The following table is a guide to the visual assessment of weld

seams.

Imperfection Description

Explanation Limits for Imperfections

1. Cracks Is the weld free of all cracks? Not permitted

2. Weld starts and craters

Are weld bead craters and starts completely filled? (From crown to crater bottom, or crown of stop and crown of restart)

Task 2 (PV) - ≤1.5mm Task 3 (AL) - ≤1.0mm Task 4 (SS) - ≤1.0mm

3. Stray Arc Strikes

Are stray arc strikes absent? Not permitted

4. Slag and Spatter removed

Is all surface slag and spatter removed from the joint and surrounding area?

Greater than 99% of all slag and spatter to be removed


5. Grinding Marks

other metal removal on the cap pass (es) and penetration, for the purpose of enhancing the finished weld?

No metal removal permitted from the finished weld

6. Visual Inclusions

Is the weld metal free of short, solid imperfections? (slag, flux, oxide or metallic inclusions)

Task 2 (PV) Incremental marking Max. 2 defects

7. Worm Holes

Is the weld metal free of visual wormholes or cavities? (elongated cavities)

Task 1 (Coupon) - See International Standard IS0 5817

8. Surface or internal Porosity and Gas pores

Is the weld metal free of porosity? Task 1 (Coupon) - See International Standard IS0 5817 Task 2 (PV) Incremental marking Max. 2 defects Task 3 (AL) - Incremental marking Max. 2 defects Task 4 (SS) - Incremental marking Max. 2 defects

9. Undercut Is the weld joint free from undercut? ≤ 0.5mm depth is allowed

10. Overlap (Overall)

Is the weld joint completely free of overlap (overall)?

Not permitted

11. Lack of Penetration

Is the joint free from lack of penetration or root fusion?

Task 1 (Coupon)- See International Standard IS0 5817 Task 3 (AL) – Incremental marking Task 4 (SS) - Incremental marking

12. Excessive root concavity (shrinkage groove)

Is the weld penetration free of excessive root concavity “suck back”?

Task 1 - See International Standard IS0 5817 Task 4 – Not permitted

13. Excessive Penetration

Is the joint free of excessive penetration?

Task 1 (Coupon)- ≤ 2.0mm Task 2 (PV)– N/A Task 3 (AL) - ≤ 3.0mm Task 4 (SS) - ≤ 2.5mm

14. Excessive Face Reinforcement (height)

Is the weld joint free of excessive face reinforcement?

Task 1 (Fillet)- ≤ 3.0mm Task 1 (Butt) - ≤ 2.5mm Task 2 (PV) – ≤ 2.5mm Task 3 (AL) - ≤ 1.5mm Task 4 (SS) - ≤ 1.5mm

15. Incompletely filled groove

Is the butt weld groove and corner completely filled?

Not Permitted Task 1 Task 2


16. Linear misalignment (high/low)

Is the joint free from linear (high/low) misalignment?

Task 1 - See International Standard IS0 5817 Task 2 (PV) - ≤ 1.0mm Task 3 (AL) - ≤ 1.0mm Task 4 (SS) - ≤ 1.0mm

17. Fillet Weld Sizes

Are fillet sizes in accordance with specifications? (Measurement leg length)

Task 1 (Coupon) -0/+2mm Task 2 (PV) -0/+2mm Task 3 (AL) -0/+2mm Task 4 (SS) -0/+1mm

18. Full Radius Contour

Does the joint exhibit a full radius contour = to plate thickness?

Task 2 Full radius contour (-0/+2 mm) Task 3 full radius contour (0/ +2mm) Task 4 Full radius contour (-0/ +1 mm)

19. Excessive Width of Butt Weld Face

Are bead widths uniform and regular? (Measure narrowest portion vs. widest portion)

Task 1 (Coupon) - ≤ 2.0mm Task 2 (PV) - ≤ 2.0mm Task 3 (AL) - ≤ 1.5mm Task 4 (SS) - ≤ 1.0mm

4.9 SKILL ASSESSMENT PROCEDURES

Procedure for performing visual assessment

The marking forms of the previous competition are a guide to the visual assessment of weld seams.

Procedure for performing non-destructive testing

o Specified procedures shall be used for all non destructive testing.

o The welded test coupons shall be radiographed in the as welded condition. (No removal of

any excess weld metal)

o Radiography of the test coupons shall be performed in accordance with EN ISO 10675-1 or

EN ISO 5817.

Procedure for performing fracture tests on the Fillet welded coupon

o Each test piece shall be positioned for breaking in accordance with ISO 9017

o Each coupon shall be visually assessed after breaking for lack of fusion and porosity.

Procedure for the hydrostatic pressure test

o The expert, whose competitor’s vessel is being tested, is allowed to witness the test.

o Fill the vessel with water and ensure that all air is allowed to escape.

o Plug vessel and pressurize to 2 bar (30psi).

o Ensure vessel is fully dry on outside.

o If vessel exhibits a leak – Score 1 point and test is complete.

o If vessel exhibits no leak, continue to pressurize to 35 bar (500psi). Allow 10 seconds to

stabilize.

o Hold for 60 seconds. If a leak is observed – Score 1 point and test is complete. If no leak is

detected increase pressure to 69 bar (1000psi). Hold for 10 seconds to stabilize.

o Hold for a 60 seconds. If a leak is observed – Score 7.5 points. If no leak is observed - Score

15 points and test is complete.

o Drain all water from the vessel.

Note: If a leak is detected, it shall be highlighted with a metal marker.


5. THE TEST PROJECT

5.1 GENERAL NOTES

Sections 3 and 4 govern the development of the Test Project. These notes are supplementary.

Whether it is a single entity, or a series of stand-alone or connected modules, the Test Project will

enable the assessment of the skills in each section of the Standards Specification.

The purpose of the Test Project is to provide full and balanced opportunities for assessment and

marking across the Standards Specification, in conjunction with the Marking Scheme. The relationship

between the Test Project, Marking Scheme and Standards Specification will be a key indicator of

quality.

The Test Project will not cover areas outside the Standards Specification, or affect the balance of

marks within the Standards Specification other than in the circumstances indicated by Section 0.1.

The Test Project will enable knowledge and understanding to be assessed solely through their

applications within practical work.

The Test Project will not assess knowledge of the EuroSkills Competition’s rules and regulations.

This Technical Description will note any issues that affect the Test Project’s capacity to support the full

range of assessment relative to the Standard Specification. Section 2.1 refers.

5.2 FORMAT/ STRUCTURE OF THE TEST PROJECT

[ ] Test Project assessed at end of Competition

[ ] Test Project with separately assessed modules

[ ] Test Project assessed in stages

[ X ] Series of standalone modules

[ ] Other

If other, please specify here:

5.3 TEST PROJECT DESIGN REQUIREMENTS

General Description: o Module 1: welding of test plates / pipes

o Module 2: welding of a pressure vessel

o Module 3: welding of an aluminium structure

o Module 4: welding of a stainless steel structure


Details:

o Module 1: welding of test plates / pipes (coupons)

o Time: 5 hours approximately

o Quantity: 4 specimens – 1 test plate coupon in fillet joint welds and 3 tests plate/pipe

coupon with single V-groove butt joint welds (see the previous competition drawings)

o Material: Carbon steel (group 1) ISO EN 15608.

o Description: (the sequence can be changed)

First (fillet) test plate coupon shall consist of two (2) pieces, each 12 mm in

thickness, one piece125 wide and the other 100 mm wide, and 250 mm in

length.

The welding processes to select are: 136 – FCAW; 135 – MAG and

MMAW – 111.

The welding positions to select are: PB, PF and PD

Second test plate coupon shall consist of two (2) pieces, each 10 mm in

thickness, 100 mm wide and 250 mm in length.

The welding processes to select are: 111 – MMAW; 135 – MAG.

The welding positions to select are: PC, PF and PE

Third test plate coupon shall consist of two (2) pieces, each 16 mm in

thickness, 100 mm wide and 350 mm in length.

The welding processes for the root pass to select are: 111 – MMAW;

135 – MAG

The welding processes for the fill and cap passes to select are: 136 –

FCAW; 135 - MAG

The welding positions to select are: PA, PC and PF

Fourth test coupon shall be a pipe welding test, consisting of two (2) pieces of

114.3 diam. x 8.56 wall (4” SCH 80) x 120 in length.

The welding processes to select for the root, fill and cap passes are:

111 – MMAW; 135 - MAG; 141 - TIG.

The welding positions to select are: PC, PF and H-L045

In the table below is a summary of the possibilities of selection for all tests this module. The position,

the process for the root pass and the process for the fill and cap passes for each one is listed and the

selection will be drawn at random just prior to the Competitor familiarization period (C-1). The

Competitors shall be informed of the selection at the earliest opportunity during the familiarization

period.

Fillet weld test 12mm

Positions Process

PB, PF or PD MMAW - 111


MAG - 135

FCAW - 136

Test Plate 10mm

Positions Root pass Fill and cap passes

PC, PF or PE

MMAW - 111 MMAW - 111

MAG - 135 MAG - 135

Test Plate 16mm

PA, PF or PC

MMAW - 111

MAG - 135

FCAW - 136

MAG - 135

MAG - 135

FCAW - 136

Test pipe

PC, PF or H-L045

TIG - 141

TIG - 141

MAG - 135

MMAW - 111

MAG - 135 MAG - 135

MMAW - 111 MMAW - 111


The Competitor shall submit the test coupons fully assembled to the jury for stamping prior to welding.

HOLD POINT: All directed stops shall be inspected by a jury and stamped before restarting.

All tests plates shall contain a stop start in the middle 75mm of the test coupon. It is located in the root

and in the capping run. A weave or the last pass on a multi-pass weld is considered for the stop and

restart.

This shall be verified by stamping.

For all test plates, 20mm at the start and finish shall be discarded for all aspects of inspection and

marking.

All butt weld test coupons shall be milled or turned at 30º to a featheredge.

o Module 2: welding of a pressure vessel (see the previous competition drawings)

o Time: 9 hours approximately.

o Description: A completely enclosed plate/pipe structure of low carbon steel (group 1)

o Size: Overall dimensional space, approximately 350 mm x 350 mm x 400 mm.

o Material: Carbon steel (group 1)

o Plate thickness: 6, 8 and 10 mm

o Pipe wall thickness 3 to 10 mm

o The welding processes required are: 111 – MMAW; 135 - MAG; 136 - FCAW; 141 -

TIG.

o The welding positions required are: all except vertical down.

o Pressure test 1000 psi (69 bar)

The pressure vessel shall not weigh more than 35kg in the welded condition.

o Module 3: Aluminium structure (see the previous competition drawings)


o Description: A partially enclosed structure of aluminium, which shall be welded in all

positions with TIG (141)

o Size: Overall dimensional space approximately 200 mm x 200 mm x 250 mm

o Material: 5000 and 6000 series aluminium plate/pipe thickness 3 mm

o Module 4: Stainless Steel structure (see the previous competition drawings)


o Description: A partially enclosed structure of stainless, which shall be welded in all

positions with TIG (141).

o Size: Overall dimensional space approximately 150 mm x 150 mm x 200 mm

o Material: 300 series austenitic stainless steel (group 8) plate/pipe thickness 2 mm

o All root passes of butt joints and corner joints shall be purged with Argon.

Competition Specific Instructions

Welding machines, tools and equipment usage:

o It is a requirement that the host country supplies welding machines that can be used in basic

modes of operation.

o Welding machines may be used to their full technical potential.

o The welding machines provided shall have the capability to be operated using both standard

amperage control and remote amperage control. Remote variable amperage devices shall be

made available and include hand-held and foot controls.


Grinding and the use of abrasive materials and equipment:

o Material removal is not permitted on any of the root penetration or cap weld surfaces. “Cap

pass” shall be defined as the final layer of the weld that meets the weld size, grooves and

fillets.

o Restarts may be prepared before welding over them.

o Grinding the surfaces of the fillet coupon material before welding is permitted but the

preparation angles shall not be changed.

Wire brushing:

o Wire brushing, manual or powered, may be used on all weld surfaces of the test plates/pipes

(Module 1) and pressure vessel (Module 2). However, wire brushing is not permitted on any of

the cap welds of aluminum project (Module 3) and the stainless steel project (Module 4).

Backing bars / plates and restraining devices:

o No copper (Cu) chill plates or ceramic backing tapes/bars are to be used in the Competition.

o Purging equipment may only be used with the Gas Tungsten Arc Welding process on the

stainless steel project.

o Restraining devices shall not be used during welding of the test plates. Such devices include:

o clamps, jigs, fixtures or steel plates, tack welded to the test plates.

o Welding of the test plates is to be carried out without the aid of restraining devices; this is so

the Experts can assess the control of distortion.

o Only standard manipulators (Positioners), supplied by the host country may be used for the

welding of the test coupons. The Pressure vessel, Aluminium structure and Stainless steel

projects shall at all times be welded on the workbench. The use of jigs, fixtures or standard

manipulators is not allowed.

Weld cleaning of TIG - 141 projects:

o The weld faces on the Aluminium and stainless steel TIG - 141 projects are to be presented in

the “as welded” condition. Cleaning, grinding, steel wool, wire brushing or chemical cleaning is

NOT permitted on any of the cap welds.

Tack welds:

o Tack welds shall be maximum 15mm in length.

o When assembling the pressure vessel, the Competitor may use any of the welding processes

listed on that drawing for tack welding, in any position. The Experts reserve the right to decide

if the tacks are permitted in the joints intersections or not, 3 month prior to the Competition.

o No tack welds shall be made on the inside of the pressure vessel project, aluminum and

stainless steel structure.

o All tasks are to be fully assembled prior to submission for stamping.

o HOLD POINT: A jury member shall inspect the inside of the vessel to ensure the lack of tacks

before enclosing the vessel. This is to be confirmed by stamping.

Welding of test plates/pipes:

o Once welding has commenced, the test plates may not be separated and then re-tacked. Re-

tacking may only take place, if root welding has not commenced.

o HOLD POINT: A jury member shall inspect the positioning of the test pipe coupon in the

coupon holder and mark the 12 o’clock position before welding commences. This is to be

confirmed by stamping.

o If any Competitor welds a coupon with the incorrect process or in the incorrect position, an

assessment shall not be carried out and no marks are awarded to that coupon. This will

include visual and either fillet break or radiograph.

o If any of the joint configurations on the pressure vessel i.e. Butt, Fillet or outside corners are

welded with the incorrect process or in the incorrect position, that joint configuration shall not


be visually assessed and no marks are awarded. The Experts reserve the right to amend this

penalty for the incorrect process prior to the Competition.

o If the Aluminum or stainless steel structures are welded in the incorrect position, visual

assessment shall not be carried out and no marks are awarded.

Equipment, materials and consumables:

Welding power sources:

o 11 SMAW, MMAW, 141 GTAW, TIG: AC/DC, 300 Amps Inverter-Type with Hi-Frequency, AC

Frequency (Hz) and Pulse controls

o 135 GMAW, MAG, and 136 FCAW: DC, ≈300 Amps with Pulse control

Welding accessories:

o 111 SMAW, MMAW Welding cable and electrode holder

o 141 GTAW, TIG gun and accessories, contact tips, diffusers, shielding gas accessories,

regulator, hoses, remote variable amperage controls, foot- and hand-operated, hose for

purging

o 135 GMAW, MAG gun and accessories, contact tips, diffusers, shielding gas accessories,

regulator, hoses, etc.

o 136 FCAW gun and accessories, contact tips, diffusers, shielding gas accessories, regulator,

hoses, etc.

During the Competition only materials provided by the host country may be used.

Practice plates for the Competition:

o The Host country shall provide 1 sets (2 pieces each) of material for each of the test coupons,

6 pieces (4 beveled to 30º) for pressure vessel and 10 pieces each (100x50mm) of Aluminium

and Stainless Steel material in the thickness of the tasks, to be used for practice plates. These

plates shall be made available to the Competitor for practice on the day set aside for testing

the installations before the Competition and for adjusting the welding parameters during the

Competition.

Dimensions of practice plates:

o The practice plates shall be the same width and thickness as the actual project pieces, but

they shall each be shorter by 20mm in length.

Basic materials:

o Steel groups according to CR ISO/TR 15608 (1999), group 1, 2 or 3 for carbon steel; group 8

for stainless steel (300 series), and aluminium in the 5000 and 6000 series.

Plates:

o High quality carbon steel, 5mm to 16mm thick to ISO 10038.

o For pressure vessel, plates are to have through-thickness tested certification.

o Austenitic stainless steel, 2mm to 3mm thick e.g. 18/8 types X5CrNi 18

o Aluminium, 3mm e.g. 5000 or 6000 series.

o Pipes:

o High quality carbon steel pipes to ISO 10038, dia. 25mm to 200mm, wall thickness

3mm to 10mm

o Stainless steel and aluminium, diameter 25mm to 80mm, wall thickness 2mm to 3mm.

All material with beveled weld surfaces shall be milled or turned, so that they are smooth and parallel

and all other prepared edges are to be smooth and square.


Consumables: (the following information is indicative – all the information about the consumables

should be on the Infrastructure List)

o MMAW Electrodes - EN ISO 2560-A: E 42 4 B 42 H5 / AWS A5.1: E 7018 Ø2.4,3.2, 4,0mm

o FCAW wire – EN 758: T 46 P M 1 H5 / AWS A5.20: E71T-1, Ø 1,2 mm

o MAG wire - EN 440: G3Si1 / AWS A5.18: ER70S-6, Ø 0,8 and 1,0 mm

o TIG Filler Wire – EN 440: G3 Si1 / AWS A5.18: ER70S-6, Ø 2, 2,4 mm

o TIG Filler Wire - EN 12072: W 19 9 L / AWS A5.9: ER308L Ø 1,6, 2 mm

o TIG Filler Wire – EN ISO 18273: AlMg5 / AWS 5.10: ER 5356 Ø 2, 2,4 mm

5.4 TEST PROJECT DEVELOPMENT

The Test Project MUST be submitted using the templates provided by WSE. Use the Word template

for text documents and DWG template for drawings. Please contact

[email protected] for guidance.

5.4.1 WHO DEVELOPS THE TEST PROJECTS OR MODULES

[ X ] All Experts

[ ] Some Experts

[ ] Nominated Experts

[ ] Equipment supplier

5.4.2 HOW AND WHERE IS THE TEST PROJECT OR MODULES DEVELOPED

The Test Project or modules are developed:

[ ] Jointly on the Discussion Forum

[ ] By an external enterprise

[ X ] Independently

The Test Project/modules are developed independently, however, discussion, collaboration and

communication is encouraged through the forum

5.4.3 WHEN IS THE TEST PROJECT DEVELOPED

The Test Project is developed according to the following timeline:

TIME ACTIVITY

At the previous Competition not applicable

XX months prior to the Competition Until 6 months before the current Competition

At the Competition not applicable

mailto:[email protected]


5.5 TEST PROJECT VALIDATION

All projects must comply with the Technical Outline. The Chief Expert and the Deputy Chief Expert will

validate each project submitted for selection prior to voting using the project checklist below.

Welding Project Selection Criteria

Submitted by: Name: ______________________ Country: ____________________

Pressure Vessel

Aluminium Structure

Stainless Steel Structure

Requirement Yes / No

Project Drawings ISO E Weld symbols as per ISO 2533 Electronic Format

Material/Cutting list

Photograph of completed tasks

Pressure Vessel weight N/A N/A

Project Major Dimensions

Additional instructions on drawings

5.6 TEST PROJECT SELECTION

[ ] By vote of Experts at the previous Competition

[ X ] By vote of Experts on the Discussion Forum

[ ] By vote of Experts at the current Competition

[ ] By random draw by Technical Director 3 months before the current Competition

[ ] Other

If other, please specify here


5.7 TEST PROJECT CIRCULATION

The Test Project is circulated via the website as follows:

[ X ] Submitted to Secretariat for circulation 3 months before the current Competition

[ ] Not circulated

[ ] Other

If other, please specify here

5.8 TEST PROJECT COORDINATION (PREPARATION FOR COMPETITION)

Coordination of the Test Project will be undertaken by:

[ ] Skill Management Team

[ ] Chief Expert

[ X ] Chief Expert and Deputy Chief Expert

[ ] Chief Expert and Workshop Manager

[ ] Chief Expert with selected Experts

[ ] Chief Expert with Competition Organizer

[ ] Experts

[ ] Other

If other, please specify here:

5.9 TEST PROJECT CHANGE AT THE COMPETITION

Not applicable

5.10 MATERIAL OR MANUFACTURER SPECIFICATIONS

Specific material and manufacturer specifications are located on the Infrastructure List which is online

(Worldskills Europe website).


6. SKILL MANAGEMENT AND COMMUNICATION

6.1 DISCUSSION FORUM

Prior to the EuroSkills Competition, all discussion, communication, collaboration, and decision making

regarding the skill competition must take place on the skill specific Discussion Forum, which can be

reached via www.euroskills.org. Skill related decisions and communication are only valid if they take

place on the forum. The Chief Expert (or an Expert nominated by the Chief Expert) will be the

moderator for this Forum. Refer to Competition Rules for the timeline of communication and

competition development requirements.

6.2 COMPETITOR INFORMATION

All information for registered Competitors is available from the WorldSkills Europe website

www.euroskills.org. Please contact [email protected] for guidance.

The information includes:

o Competition Rules

o Technical Outlines

o Marking Schemes

o Test Projects

o Infrastructure List

o Health and Safety documentation

o Other Competition-related information

6.3 TEST PROJECTS AND MARKING SCHEMES

Circulated Test Projects will be available at the WorldSkills Europe website from www.euroskills.org.

Please contact [email protected] for guidance.

6.4 DAY-TO-DAY MANAGEMENT

The day-to-day management of the skill competition during the EuroSkills Competition is defined in the

Skill Management Plan that is created by the Skill Management Team led by the Chief Expert. The

Skill Management Team comprises the Jury President, Chief Expert and Deputy Chief Expert. The

Skill Management Plan is progressively developed in the six months prior to the Competition and

finalized at the Competition by agreement of the Experts. The Skill Management Plan can be viewed

at www.euroskills.org. Please contact [email protected] for guidance.

http://www.euroskills.org/








7. SKILL SPECIFIC SAFETY REQUIREMENTS

Refer to Host Country/Region Health and Safety documentation for Host Country/Region regulations.

All Competitors at a minimum have to use during the competition the following personal protective

equipment:

o Safety Glasses

o Cotton drill long sleeve shirt

o Cotton drill trousers

o Steel toe cap work boots

o Hearing Protection

o When they are welding shall use the specific personal protective equipment (helmet,etc…)


8. MATERIALS AND EQUIPMENT

8.1 INFRASTRCUTURE LIST

The Infrastructure List details all equipment, materials and facilities provided by the Competition

Organizer.

The Infrastructure Lists will be available at the WorldSkills Europe website from www.euroskills.org.

Please contact [email protected] for guidance.

The Infrastructure List specifies the items and quantities requested by the Experts for the next

Competition. The Competition Organizer will progressively update the Infrastructure List specifying the

actual quantity, type, brand, and model of the items. Items supplied by the Competition Organizer are

shown in a separate column.

At each Competition, the Experts must review and update the Infrastructure List in preparation for the

next Competition. Experts must advise the Technical Director of any increases in space and/or

equipment.

At each Competition, the Technical Observer must audit the Infrastructure List that was used at that

Competition.

The Infrastructure List does not include items that Competitors and/or Experts are required to bring

and items that Competitors are not allowed to bring – they are specified below.

8.2 MATERIALS, EQUIPMENT AND TOOLS SUPPLIED BY COMPETITORS IN THEIR

TOOLBOX

The Competitor shall bring tools and equipment in a toolbox and is encouraged to bring other new

tools and devices that are being used in today's industry.

The following list as a minimum shall be supplied by the Competitor.

o Welding safety glasses o Grinding goggles o Welders helmet, speed lenses are permitted o Safety boots with protective toes o Ear protection o Hand angle grinder with guard, maximum 125mm (5inch) o Wire brush wheels to suit grinder o Fire retardant clothing o Chipping hammer (slag hammer) o Inter-weld run cleaning, blade scrapers o Chisels o Scriber o Files o Wire brushes o Hammer o Weld gauge (fillet gauge) o Metric steel ruler (tape measure) o Square o Chalk/soapstone o Dividers o G-clamps and/or c-clamps and quick gripping devices o Power transformer (if required) and extension leads o Other personal hand tools




All working clothes and all tools have to comply with host country safety regulations.

Alignment aids for setting up test samples may be used, provided they are removed prior to welding.

Competitors may use their own MMAW - 111, TIG - 141, MAG - 135 and FCAW - 136 hand

pieces/torches, provided the Competitor does not damage the Host Country equipment. The

Competitor’s equipment has to comply with safety regulations.

8.3 MATERIALS, EQUIPMENT AND TOOLS SUPPLIED BY EXPERTS

Not applicable

8.4 MATERIALS AND EQUIPMENT PROHIBITED IN THE SKILL AREA

o Any material that may be used to assemble a project or part of a project is not allowed to be

brought to the Competition.

o No additional consumables or practice materials are allowed to be brought to the Competition.

8.5 PROPOSED WORKSHOP AND WORKSTATION

Workshop layouts from previous competitions are available by contacting the Technical Coordinator

at: [email protected]

Proposed workshop layout:



9. VISITOR AND MEDIA ENGAGEMENT

o Try a trade

o Display screens

o Test Project descriptions

o Enhanced understanding of Competitor activity

o Competitor profiles

o Career opportunities

o Daily reporting of competition status

o Time based parts of the Test Project

o Welding simulator


10. SUSTAINABILITY

o Recycling

o Use of ‘green’ materials

o Use of completed Test Projects after Competition

EUROSKILLS TECHNICAL DESCRIPTION · welding and laser welding, A welder can work in a unit or...

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