PERFORMING ENGINEERING
OPERATIONS
NVQ LEVEL 1
OXY-ACETYLENE WELDING
AND
OXY-FUEL CUTTING
STUDENTS NAME: ………………………………………………………………….
D:\106761442.doc KIm
2251 NVQ IN Performing Engineering Operations
Section 1 - What’s it all about?
You are about to start a programme of workplace training and assessment leading
to a National Vocational Qualification. This candidate guide has been written in
order to provide you with information and support as you work through achieving
your qualification. As you make progress you will be able to demonstrate that you
have the necessary practical skills and the knowledge to do your work effectively
and efficiently.
What is a National Vocational Qualification?
National Vocational Qualification (NVQ’s) are fundamental to the drive to increase
the skills of people, just like you, working in a wide range of industries.
Developing the skills of each individual, wherever they work, and whatever they
do, fulfils a basic individual need for personal growth. Developing your individual
skills also fulfils the needs of your employer in the drive to be competitive and to
succeed. It is vital component for any business wishing for success, competing in
domestic and world markets.
NVQ’s have been and will continue to be developed for all industries, and are
supported by the government. They have been designed to provide valid and
relevant vocational qualifications for people at work.
Each NVQ is made up of a number of different units of competence.
Each unit describes the standards of a broad area of work that a competent
person should be able to perform.
Each unit is broken down into a number of elements. Taken together the
elements show what needs to be done to achieve the whole unit.
To gain your NVQ certificate you will be expected to show competence in the
appropriate mandatory and optional units dependent on where you work in the
industry. When you have successfully completed the relevant units, you will be
able to claim your NVQ. The certificate will be awarded by City & Guilds. Even if
you only complete some of the units, you will still be able to claim unit certification.
The NVQ’s in Performing Engineering Operations (PEO)
The NVQ’s in PEO are available at level 1 and 2. They are designed for those
who work in various sections of the engineering industry and provide for a basic
understanding of the skills and knowledge to undertake a variety or engineering
practices.
The units have been developed by the Engineering and Marine Training Authority
(EMTA).
There are two different types of units:
D:\106761442.doc KIm
Who will be involved in my NVQ?
Assessment for your NVQ is carried out at your centre which has been approved
by City & Guilds. Your centre may be your place of work, a college, training
agency or a combination of these.
The people involved in your assessment are as follows:
The Candidate
That’s you! You are the most important person of all because without you, NVQ’s
would not exist. Your responsibilities as a candidate are to:  Negotiate and agree an assessment programme with your assessor
 Negotiate and develop a personal action plan with dates for review and
assessment.
 Collect the evidence which proves your competence in your job.
 Organise and reference the evidence in a portfolio.
 Judge the evidence against the standards of competence to see whether it is
adequate to present for assessment.
 Present the evidence for assessment; this may include:Attending an assessment interview
Being available to discuss your evidence with the internal and/or external
verifier if requested.
Later in this guide we will explain how you can identify and collect evidence.
We will also explain what is meant by assessment and how you can prepare
for being assessed in your daily work.
The Assessor
 Will have experience in your area of work, must be occupationally competent
and is most likely to be your immediate supervisor or manager or trainer.
 Will themselves have achieved or be working towards an NVQ qualification to
allow them to act as an assessor.
 Will help you plan and organise your evidence.
 Is responsible for making the decision about your evidence and judging when
you are competent.
The Internal Verifier
 Is responsible for maintaining the quality of assessment within the centre by
checking and validating assessment decisions made by assessors.
 Will have experience in your area of work and must be technically competent.
 Will themselves have achieved or be working towards an NVQ qualification to
allow them to act as an internal verifier. In some circumstances the internal
verifier might also be an assessor.
The External Verifier
 Is employed by City & Guilds to ensure that all assessments undertaken in
your centre are fair, valid, consistent and that your centre meets the required
national standard.
 Will make regular visits to your centre to observe assessments and examine
portfolios of evidence.
 Will make regular reports to City & Guilds confirming what happens with
assessment practice in your centre.
D:\106761442.doc KIm
The Witness
There may be circumstances where you will undertake performance where the
assessor will not be present. Wherever possible, the evidence which you produce
should be witnessed. For example your line manager or colleagues may witness
an activity or authenticate a document as being your own work.
It is important to demonstrate that the evidence was produced by you under the
circumstances described. The witness is therefore able to observe and report on
your performance on tasks which produce evidence towards the NVQ.
How do you involve a witness?
The key to this is planning. In many cases someone, for example a colleague,
may naturally be involved with your work and so be able to witness and
authenticate evidence. However, if the work is usually unobserved, you might
arrange for someone to be present (where practical) to observe your performance.
What do they have to do?
After observing you work, the witness will need to write a short statement
describing what you actually did. The witness should be aware of performance
criteria for the activity and the evidence requirements which are explained in the
standards.
One person may witness many pieces of evidence and on each occasion, the
witness must sign and date the Witness Statement form. You must ensure that
each witness is recorded, with a signature in the Witness Status List.
A Witness Statement Form and Witness Statement List have been included for
you to photocopy and use in the section of this guide Documents provided for
inclusion in your portfolio.
Only the approved assessor is qualified to judge the candidate’s evidence.
The job of the witness is to report to the assessor their observations of the
candidate’s performance.
How will my competence be assessed?
Occupational competence can be described as the consistent demonstration of
skill, knowledge and understanding, to the standard specified by the performance
criteria for each unit of the NVQ. Each unit relates to competence in a different
area of activity within a job.
Assessment of your competence will be based upon realistic work place
situations, performing purposeful and recognisable tasks which will require a
combination of skills and related knowledge. For each unit of the NVQ the
evidence requirements are clearly stated and support the performance criteria.
Achieving your NVQ requires you to provide sufficient evidence which shows that
you can work to the National Occupational Standards contained within the
qualification.
Most assessment for your NVQ will be carried out by your assessor observing you
at work and by questioning you’re about what you are doing. There are three
basic sources of evidence and you may collect evidence from all of them:
D:\106761442.doc KIm
What is a Portfolio?
Most candidates working to achieve an NVQ find that the simplest way to collect
their evidence is in a loose-leaf lever arch file or binder.
This is called a Portfolio of evidence.
A portfolio can be any shape or size, depending on the type of evidence you want
to put forward for assessment. However, it is usual to use an A4 ring binder or
lever arch folder.
Your portfolio will need to be well organised, structured collection of all the
evidence you have collected, gathered together and reference to the National
Occupational Standards. In order to achieve this, it is recommended that dividers
are used between each unit and the evidence you have collected, so that the
portfolio is easy to work through.
You are required to present your evidence quite simply to show – what you can
do, and – what you know. It should be presented to demonstrate how it matches
the performance criteria, the evidence and the underpinning knowledge
requirements. You will discover that one piece of work might provide evidence for
more than one element or unit. It must be correctly cross referenced using the
evidence summary forms provided.
Types of evidence to be filed in your portfolio will include:  Assessment action plans
 Records of assessment
 Assessor Reports
 Witness Statements
 A record of products from your work
 Reports your manager or supervisor
 Details of questions you have been asked
 Historical Evidence (APL)
You must produce your portfolio when requested by the Internal Verifier and the
External Verifier will also need to inspect your portfolio during a visit.
Only assessors and internal verifiers can confirm that you have completed a
unit and complete your record of achievement.
The key of the evidence collection will be in using an effective index system and
the following is intended to assist you complete this.
Begin a simple 1, 2, 3, 4 etc numerical indexing system which will be used to
identify the appropriate piece(s) or evidence. Each individual piece of evidence
regardless of its type should be identified by its own number and placed in the file
in ascending numerical order (i.e. last number on top). The number quoted will be
identified as the Portfolio Reference Number (PPN) which you will see referred to
in the units. Where observations have taken place, the observation sheet will also
be indexed, by the assessor / verifier will also enter the appropriate PRN in the
envelopes on the page of the unit requires three observations. By using this
method, an individual action plan of assessment can be generated for you, as the
D:\106761442.doc KIm
tracking sheet will indicate clearly where there remains a requirement to provide
further evidence.
Ensure that you have your portfolio with you at all times. This will help to speed
up the process of assessment and could substantially reduce the time it takes you
to gain the full award.
Your assessor will regularly inspect your portfolio, providing support and guidance
as appropriate. As you begin to collect evidence you must index it using the
evidence summary, with cross references to the National Occupational Standards.
Your assessor will show you how to do this because it will identify what you must
do to complete the unit.
The table on the following page lists the order of all the information to be filed in
your portfolio. The list also makes reference to the documents we have produced
for you to photocopy for use in your portfolio. You will find copies of the
documents in the section in this guide entitled, Documents provided for inclusion
in your portfolio.
Supporting Information
The following categories of information are not regarded as Performance
Evidence, nor will they meet your requirements to demonstrate your knowledge
and Understanding.
They will however, provide valuable supporting information for you which should
be kept in a separate information file.
This information should not be included as part of the Portfolio of Evidence:
 Leaflets or booklets supporting legislative requirements.
 The session plans or overall content of training programmes
 Any notes or information handouts from training courses
 Booklets explaining company operating policy or work procedures
 Handbook describing eg how the company computer system works
 Technical information about specific products supplied by manufacturers
 Product catalogues
D:\106761442.doc KIm
JOB NUMBER
Work piece Inspection Record
Gas Welded Test pieces
1
Comments /
Feedback
The work piece is secure on the table.
Materials are cleaned of excessive contamination and edges to be welded are prepared
to specifications.
Joint is correctly set up and secure.
Tack welds are suitably positioned and are of an appropriate size and pitch for the
material thickness and size of component being welded.
Tack welds are adequately fused.
Assembled joints are secure and dimensionally accurate within the limits of the drawing
requirements.
Welds are adequately fused, regular in width, uniform in appearance with regular and
even ripple formation, undercut and overlap are minimal.
Welds are free from inclusions, porosity, cracks and surface contamination.
Stops and starts are smoothly blended in and weld finishes are built up to the full section
of the weld.
Tack welds are blended in to form part of the finished weld without excessive “hump”.
Fillet welds are equal in leg length, slightly convex in profile and equivalent to thickness
of the material being welded.
Corner joints have minimal burn through to the underside of the joint or where
appropriate penetration is present to a maximum depth of 3mm for at least 75% of the
joint.
Complete joints are free from stray arcing and excessive spatter.
Assessed By:
Assessor’s Signature
Date
Unit Element
Evidence
Apply safe working practices
Prepare and operate arc welding equipment
Set up and Tack Weld Joints
Produce Welded Joints
Restore Workplace
Location of relevant underpinning knowledge – written tests reference questionnaires.
Candidate Comments
Signature: ………………………………….
Assessor Feedback
Signature: ……………………………………….
D:\106761442.doc KIm
Assessment Task – 1
Title – Close Outside Corner Joint
Material
Main Tool &
Equipment
Assessment Method
Candidate
Signature
Low carbon mild steel 3mm x 50mm x 160mm
Gas Cylinders, regulators, pressure gauges, hoses, hose protection devices, torches, nozzles,
safety glasses, protective clothing.
O
Observation
W
Work piece Inspection
Assessment Points
Assessed By
Date
Damage to individuals and equipment is avoided by correct storage
Personal protection is assisted by the use of protective clothing, to include
eye protection with the correct shade of filter.
A suitable means of fume ventilation is used.
Hazards are fire risks are minimised by maintaining a clean and tidy working
area
All gas valves are turned off before leaving the workplace.
Workpiece Drawing
Procedure
1) Prepare two pieces of low carbon
steel to the dimensions shown.
Clearly and permanently identify
the pieces with your name.
2) Use a suitable arrangement
which may include special
fixtures, to hold the pieces in
correct alignment.
3) Produce an outside corner weld
as shown in a single run.
4) Once visually approved cut
through the weld 24mm from one
end, and carry out nick break
test.
Workpiece Inspection Record
Comments / Feedback
Regular in width with even and regular ripple formation.
Uniform in appearance.
Free from excessive undulations
Free from pronounced “hump” or “notching” resulting from stops and starts.
Showing minimal undercut or overlap
Showing adequate penetration on corner joints for at least 75% of joint
length
Showing weld finished which are built up.
Assessed by
Assessor’s Signature
D:\106761442.doc KIm
Date
Assembly Method
Safety Precautions Observed
Equipment List
Candidates Name
Safety Equipment
Competent Not yet
Assessors Signature
competent
Candidate Signature
D:\106761442.doc KIm
Date
JOB NUMBER
Work piece Inspection Record
2
Gas Welded Test pieces
Comments /
Feedback
The work piece is secure on the table.
Materials are cleaned of excessive contamination and edges to be welded are prepared
to specifications.
Joint is correctly set up and secure.
Tack welds are suitably positioned and are of an appropriate size and pitch for the
material thickness and size of component being welded.
Tack welds are adequately fused.
Assembled joints are secure and dimensionally accurate within the limits of the drawing
requirements.
Welds are adequately fused, regular in width, uniform in appearance with regular and
even ripple formation, undercut and overlap are minimal.
Welds are free from inclusions, porosity, cracks and surface contamination.
Stops and starts are smoothly blended in and weld finishes are built up to the full section
of the weld.
Tack welds are blended in to form part of the finished weld without excessive “hump”.
Fillet welds are equal in leg length, slightly convex in profile and equivalent to thickness
of the material being welded.
Corner joints have minimal burn through to the underside of the joint or where
appropriate penetration is present to a maximum depth of 3mm for at least 75% of the
joint.
Complete joints are free from stray arcing and excessive spatter.
Assessed By:
Assessor’s Signature
Date
Unit Element
Evidence
Apply safe working practices
Prepare and operate arc welding equipment
Set up and Tack Weld Joints
Produce Welded Joints
Restore Workplace
Location of relevant underpinning knowledge – written tests reference questionnaires.
Candidate Comments
Signature: ………………………………….
Assessor Feedback
Signature: ……………………………………….
D:\106761442.doc KIm
Assessment Task – 2
Title – Butt Joint
Material
Main Tool & Equipment
Assessment Method
Candidate
Signature
Low carbon mild steel 3mm x 50mm x 160mm
Gas Cylinders, regulators, pressure gauges, hoses, hose protection devices, torches,
nozzles, safety glasses, protective clothing.
O
Observation
W
Work piece Inspection
Assessment Points
Assessed
By
Date
Damage to individuals and equipment is avoided by correct storage
Personal protection is assisted by the use of protective clothing, to include eye
protection with the correct shade of filter.
A suitable means of fume ventilation is used.
Hazards are fire risks are minimised by maintaining a clean and tidy working area
All gas valves are turned off before leaving the workplace.
Workpiece Drawing
Procedure
1) Prepare two pieces of low
carbon steel to the
dimensions shown.
Clearly and permanently
identify the pieces with
your name.
2) Use a suitable
arrangement which may
include special fixtures, to
hold the pieces in correct
alignment.
3) Produce an outside corner
weld as shown in a single
run.
4) Once visually approved
cut through the weld
24mm from one end, and
carry out nick break test.
Workpiece Inspection Record
Comments / Feedback
Regular in width with even and regular ripple formation.
Uniform in appearance.
Free from excessive undulations
Free from pronounced “hump” or “notching” resulting from stops and starts.
Showing minimal undercut or overlap
Showing adequate penetration on corner joints for at least 75% of joint length
Showing weld finished which are built up.
Assessed by
Assessor’s Signature
D:\106761442.doc KIm
Date
Assembly Method
Safety Precautions Observed
Equipment List
Candidates Name
Safety Equipment
Competent Not yet
Assessors Signature
competent
Candidate Signature
D:\106761442.doc KIm
Date
JOB NUMBER 3
Work piece Inspection Record
Gas Welded Test pieces
Comments /
Feedback
The work piece is secure on the table.
Materials are cleaned of excessive contamination and edges to be welded are prepared
to specifications.
Joint is correctly set up and secure.
Tack welds are suitably positioned and are of an appropriate size and pitch for the
material thickness and size of component being welded.
Tack welds are adequately fused.
Assembled joints are secure and dimensionally accurate within the limits of the drawing
requirements.
Welds are adequately fused, regular in width, uniform in appearance with regular and
even ripple formation, undercut and overlap are minimal.
Welds are free from inclusions, porosity, cracks and surface contamination.
Stops and starts are smoothly blended in and weld finishes are built up to the full section
of the weld.
Tack welds are blended in to form part of the finished weld without excessive “hump”.
Fillet welds are equal in leg length, slightly convex in profile and equivalent to thickness
of the material being welded.
Corner joints have minimal burn through to the underside of the joint or where
appropriate penetration is present to a maximum depth of 3mm for at least 75% of the
joint.
Complete joints are free from stray arcing and excessive spatter.
Assessed By:
Assessor’s Signature
Date
Unit Element
Evidence
Apply safe working practices
Prepare and operate arc welding equipment
Set up and Tack Weld Joints
Produce Welded Joints
Restore Workplace
Location of relevant underpinning knowledge – written tests reference questionnaires.
Candidate Comments
Signature: ………………………………….
Assessor Feedback
Signature: ……………………………………….
D:\106761442.doc KIm
Assessment Task – 3
Title –
Material
Main Tool &
Equipment
Assessment Method
Candidate
Signature
Low carbon mild steel 1.6mm or 3mm x 50mm x 160mm
Gas Cylinders, regulators, pressure gauges, hoses, hose protection devices, torches, nozzles,
safety glasses, protective clothing.
O
Observation
W
Work piece Inspection
Assessment Points
Assessed By
Date
Damage to individuals and equipment is avoided by correct storage
Personal protection is assisted by the use of protective clothing, to include
eye protection with the correct shade of filter.
A suitable means of fume ventilation is used.
Hazards are fire risks are minimised by maintaining a clean and tidy working
area
All gas valves are turned off before leaving the workplace.
Workpiece Drawing – All dimensions in millimetres
Procedure
Workpiece Inspection Record
Comments / Feedback
Regular in width with even and regular ripple formation.
Uniform in appearance.
Free from excessive undulations
Free from pronounced “hump” or “notching” resulting from stops and starts.
Showing minimal undercut or overlap
Showing adequate penetration on corner joints for at least 75% of joint
length
Showing weld finished which are built up.
Assessed by
Assessor’s Signature
D:\106761442.doc KIm
Date
Assembly Method
Safety Precautions Observed
Equipment List
Candidates Name
Safety Equipment
Competent Not yet
Assessors Signature
competent
Candidate Signature
D:\106761442.doc KIm
Date
Assessor Checklist
Candidate Name
Date
Check List
Oxy/Acetylene Gas Welding
1) General
C
N/C
Assessor Comments
Observe Health & Safety Precautions at all times.
Check equipment was fit for purpose
Set up equipment correctly
Produce weld joints as per weld procedure
Restore workplace at the end of the task
Complete written report detailing process
2) Weld Appearance
All welds are linear
All welds are free from excessive undulations
The toes of the weld bend smoothly without overlap
All welds are of uniform profile
3) Undercut
Slight intermittent undercut is permitted
Depth of undercut does not exceed 1 mm in any weld
Surface Defects
All weld surfaces are free from cracks
All stop / starts merge without hump or crater
4) Fillet Welds
Weld leg lengths do not differ by more than 1.5 mm
All welds are generally free from concavity
5) Butt Welds
Surface re-enforcement is no more than 3mm
6) Result
Competent
Assessor Signature
Candidate Signature
D:\106761442.doc KIm
Not Competent
Date
Date
C&G 2251
Oxy-Fuel Gas Cutting
Task 1
Candidate Name:
Using Flat Bed Oxy-Fuel cutting equipment cut out the following to the dimensions
given by your tutor / assessor. Set the speed and angle of cut as per the
procedure sheet.
Activity
Set up of Equipment
Quality of cut
Safety
Closedown of Equipment
Candidate: Assessor: Date: -
D:\106761442.doc KIm
Competent
NYC
C&G 2251
Oxy-Fuel Gas Cutting
Task 2
Candidate Name:
Using Oxy-Fuel gas cutting equipment cut out the following dimensions given by
your tutor / assessor.
6 mm Low Carbon Steel Plate
Activity
Set up of Equipment
Quality of cut
Safety
Closedown of Equipment
Candidate: Assessor: Date: -
D:\106761442.doc KIm
Competent
NYC
Assembly Method
Safety Precautions Observed
Equipment List
Candidates Name
Safety Equipment
Competent Not yet
Assessors Signature
competent
Candidate Signature
D:\106761442.doc KIm
Date
C&G 2251
Oxy-Fuel Gas Cutting
Task 3
Candidate Name:
Using Oxy-fuel cutting equipment, cut out the following using the template given to
you by your tutor / assessor.
State one advantage of using a template (Valentines heart shape)
Activity
Set up of Equipment
Quality of cut
Safety
Closedown of Equipment
Advantage: Candidate: Assessor: Date: -
D:\106761442.doc KIm
Competent
NYC
Assembly Method
Safety Precautions Observed
Equipment List
Candidates Name
Safety Equipment
Competent Not yet
Assessors Signature
competent
Candidate Signature
D:\106761442.doc KIm
Date
Assessor Checklist – Oxy-Acetylene Cutting
Candidate Name
Date
Job Description
1) General
C
N/C
Assessor Comments
Observe Health & Safety Precautions at all times.
Check equipment was fit for purpose
Set up equipment correctly
Produce components to within tolerance
Restore workplace at the end of the task
Complete log book entry
2) Cut Appearance
All cuts are accurate to +/- 3mm
Edges have sharp top and bottom edges
Dross has been removed
Scale has been removed
Angles and cut edges are within 5.0 degrees
3) Restore Workplace
Shut down equipment correctly
Store equipment safely
Remove waste materials
Clean work area
4) Result
Competent
Assessor Signature
Candidate Signature
D:\106761442.doc KIm
Not Competent
Date
Date
1) What is COSHH?
COSHH stands for the Control of Substances Hazardous to Health Regulations
2002. Using hazardous substances can put people’s health at risk. COSHH
requires employers to control exposures to hazardous substances to protect both
employees and others who may be exposed from work activities.
2) What are hazardous substances?
Hazardous substances are anything that can harm your health when you work
with them if they are not properly controlled eg by using adequate ventilation.
They are found in nearly all work places eg factories, shops, mines, farms and
offices. They can include:
 Substances used directly in work activities eg glues, paint, cleaning agents.
 Substances generated during work activities eg fumes from soldering and
welding.
 Naturally occurring substances eg grain dust, blood, bacteria.
For the vast majority of commercial chemicals, the presence (or not) for a warning
label will indicate whether COSHH is relevant. For example, household washing
up liquid doesn’t have a warning label but bleach does so COSHH applies to
bleach but not washing up liquid when used at work.
Remember that asbestos and lead are covered by separate laws.
3) Following the 8 steps to COSHH
Employers must………
 Step 1
Work out what hazardous substances are used in your work place and find out
the risks from using these substances to people’s health.
 Step 2
Decide what precautions are needed before starting work with hazardous
substances.
 Step 3
Prevent people being exposed to hazardous substances, but where this is not
reasonably practicable, control the exposure.
 Step 4
Make sure control measures are used and maintained properly and that safety
procedures are followed.
 Step 5
If required, monitor exposure of employees to hazardous substances.
 Step 6
Carry out health surveillance where your assessment has shown that this is
necessary or COSHH makes specific requirements.
 Step 7
If required, prepare plans and procedures to deal with accidents, incidents and
emergencies.
 Step 8
Make sure employees are properly informed, trained and supervised.
D:\106761442.doc KIm
Oxy-Acetylene Welding
Safety
1) Important – Use no oil or grease around oxygen. When mixed with oil or
grease, oxygen can cause a violent explosion.
2) Do not use pipe fitting compounds on oxygen connections.
3) Only hoses which are made for welding should be used.
4) Do not force connections which do not fit.
5) If gas cylinders are not clearly marked as to the contents, do not use them.
6) Do not use oxygen under pressure without an oxygen regulator.
7) Be sure that the oxygen cylinder is securely fastened so it can not fall.
8) Stand to one side when opening a cylinder.
Acetylene Handling
1)
2)
3)
4)
5)
Do not use pipe fitting compounds on acetylene equipment.
Always use an acetylene pressure regulator.
Never force an acetylene pressure regulator.
Be sure the acetylene cylinder is securely fastened so it cannot fall.
Do not release acetylene into the atmosphere when welding is being done in
the area.
6) Leave the cylinder key on the acetylene cylinder.
General Rules
1) Never lay a lighted torch down.
2) Before lighting the torch be sure it is not pointing at another person.
3) Before lighting the torch be sure that the flame will not come in contact with
inflammable material.
4) Make it a habit to hold your hands close to a piece of metal to see if it’s hot
before picking it up.
5) Never operate equipment without instruction on its use.
6) Wear safety glasses or grinding shields when using a power grinder.
7) Be aware of the condition of the hoses on the torch. If a leak develops it
should be reported immediately, and the hoses taken out of service.
8) Report all burns.
9) Never work with defective equipment.
10)
Hammers, chisels and punches wear out. Do not use then if they are
defective.
11)
Never use any kind of fire oxygen and acetylene cylinders. Oxygen
supports combustion and acetylene will burn or explode.
12)
Galvanising on some sheets contains zinc. When zinc is heated it gives off
a toxic vapour. Do not breathe these fumes. Be sure the ventilation is
adequate.
13)
Avoid breathing the fumes when welding painted objects.
14)
Always wear goggles when cutting or welding.
15)
Always wear protection clothing when cutting or welding.
16)
Know the location of fire extinguishers, and how to use them.
17)
Some factors which contribute to accidents.
Poor lighting, poor maintenance or equipment, poor ventilation, machines without
guards, poor arrangement of equipment, horseplay, dirty floors, damaged
equipment and inadequate instruction.
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
Name: …………………………………………
Date: …………………………….
Health & Safety
Fire can occur from many sources. It is important that the different types of fire
are dealt with in the correct manner. Look at the list of different types of fire and
match up the correct method of extinguishing it.
Type of Fire
Wood
Flammable Liquids,
Oils, Fats, Spirits,
etc
Flammable Liquids
and Gases (i.e.
Butane)
Petrol
Electrical
Fabrics
Paper
D:\106761442.doc KIm
Type of Extinguisher
Colour Code
NVQ ENGINEERING MANUFACTURE LEVEL II
UNDERPINNING KNOWLEDGE ASSESSMENT T13
1)
State three items of protective clothing to be worn when gas welding?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
2)
What colour is an acetylene cylinder?
………………………………………………………………………
3)
What colour is an oxygen cylinder?
………………………………………………………………………
4)
5)
Oxygen hoses are ……………………… in colour.
Acetylene hoses are ……………………. In colour.
What gas cylinders have left hand threads?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
6)
When assembling gas-welding equipment how would leaks be detected?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
7)
What gas pressures would be used when using a number two-gas nozzle?
a)
b)
Oxygen: …………………………..
Acetylene: ………………………..
8)
What checks would be carried out before suing the gas welding equipment?
9)
Where is the flashback arrester fitted?
10) Why should oil or grease NOT be allowed to come in contact with oxygen /
acetylene gas welding equipment?
D:\106761442.doc KIm
Questionnaire Number 1
Health & Safety
1)
What does HASAW stand for?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
2)
Identify the warning signs for hazardous substances?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
3)
Who would you contact if you thought there were harmful substances
present?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
4)
Where would you find the colleges work practices and regulations?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
5)
Where are the warning signs for the workshop placed?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
6)
What must you do in case of an accident involving injury to yourself or
others?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
D:\106761442.doc KIm
7)
Where can you get first aid and who is your First Aider?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
8)
What is the correct procedure when hearing the emergency alarm and where
is your assemble point?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
9)
Why is it important to report all injuries?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
10) What is meant by dangerous occurrences and hazardous malfunction, and
why must they be reported?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
11) Can you name three different types of fire extinguisher with their colour
codes and what are the common causes of fire?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
12) What does COSHH stand for and what does it inform your about hazardous
substances?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
13) What hazards would be present in your working environment, including tools
and equipment and substances and working practices?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
D:\106761442.doc KIm
Question Paper 2
Working with Others
1)
What do you learn from your tutorials?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
2)
Who is responsible for your training and supervision?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
3)
Who do you report to for help and guidance in the workplace?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
4)
When in the workplace what communication systems are used and explain
the advantages and disadvantages of each?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
5)
What do you do when you have a disagreement?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
6)
Who are the main people involved in your course?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
D:\106761442.doc KIm
7)
What do the race relations act and the equal opportunities act in the college
state?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
8)
Why should you be polite and courteous in the workplace?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
Candidate Signature: - ………………………………
Date: - ……………………………….
Assessor Signature: - ……………………………….
Feedback: -
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
D:\106761442.doc KIm
Questionnaire 6
1)
Where would you find the information to complete your job?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
2)
What do you find out from a weld procedure sheet?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
3)
Where would you obtain permission to start you job?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
4)
Where do you return drawings at the end of the lesson?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
5)
Where do you place waste material at the end of the lesson?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
6)
What do you do if you need help in the workplace?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
7)
What is expected from your test piece and why must they be tested?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
8)
After achieving your level 1 qualification, what can you progress onto?
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
D:\106761442.doc KIm
Risk Assessment Test
For this test you must walk through the workshop and make a risk assessment on:
a)
b)
c)
Environment
Materials
Tools
Write down your findings for assessment: -
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
………………………………………………………………………
Assessors Signature: Candidate Signature: Date: -
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm
D:\106761442.doc KIm