2850 L3 Diploma Qualification Handbook IVQ v1

QU ALIF ICAT ION H AN D B OOK
Level 3 Diploma
Engineering (IVQ) (285085/86/87/88/89/90)
October 2012 Version 1.0
Qualification at a glance
Subject area
Engineering
City & Guilds number
2850
Age group approved
16+
Entry requirements
Level 3
Assessment
Online multiple choice

Assignment
Dated entry written exam
Fast track
Required
Support materials
Centre handbook
Assessment pack
Smartscreen
Registration and
certification
Consult the Walled Garden/Online

Catalogue for last dates
Title and level
City & Guilds

number
Accreditation
number
Level 3 Diploma in Engineering Welding
2850-85
600/0882/9
Level 3 Diploma in Engineering

Fabrication
2850-86
600/0882/9

Fabrication and Welding
2850-87
600/0882/9

Maintenance, Installation and
Commissioning
2850-88
600/0882/9

Mechanical Manufacturing
Engineering
2850-89
600/0882/9

Electrical and Electronic
Engineering
2850-90
600/0882/9
City & Guilds Level 3 Diploma Engineering (IVQ) (2850-85/86/87/88/89/90)
Contents
Introduction
Structure
Centre requirements
Approval
12
12
Resource requirements
12
Learner entry requirements

Delivering the qualification
Initial assessment and induction
15
16
16
Support materials
16
Recording documents
Assessment
Summary of assessment requirements
16
17
17
Assessment strategy
Units
24
25
Unit 301
Engineering health and safety
26
Unit 302
Engineering principles
32
Unit 310
Manual metal arc welding of materials
38
Unit 311
MIG welding of materials
43
Unit 312
TIG welding of materials
49
Unit 313
Platework fabrication of materials
55
Unit 314
Sheet metalwork fabrication of materials
60
Unit 315
Fabrication and erection of structural steelwork
64
Unit 316
Pattern development for fabrication
69
Unit 317
Maintenance of machine systems
73
Unit 318
Maintenance of utility systems
79
Unit 319
Maintenance of plant services
85
Unit 320
Maintenance of hydraulic systems
91
Unit 321
Maintenance of pneumatic systems
97
Unit 322
Power generation systems and ancillary equipment103
Unit 323
Machining materials by turning
109
Unit 324
Machining materials by milling
114
Unit 325
Machining materials by grinding
119
Unit 326
CNC machining of materials
124
Unit 327
Detailed fitting of materials
130
Unit 328
Maintenance of electrical equipment and systems136
Unit 329
Produce drawings using CAD
Unit 330
Organising and managing engineering operations145
141
Unit 332
Mechatronics systems principles and fault finding150
Unit 333
Computer automated and robotic systems principles

and control
155
Unit 334
Power supply, and analogue and digital circuit

principles and fault
165
Unit 335
Electronic power control principles and practice 170
Unit 336
MIG Welding of aluminium
174
Unit 337
TIG Welding of aluminium
180
Unit 338
Flux-cored Arc welding materials
186
Unit 351
Advanced mathematics and science
191
Unit 353
Principles of welding
198
Unit 354
Principles of fabrication
204
Unit 355
Principles of fabrication and Welding
208
Unit 356
Principles of engineering maintenance, installation

and commissioning
214
Unit 357
Principles of mechanical manufacturing engineering219
Unit 358
Principles of electrical & electronic engineering 224
Appendix 1
Sources of general information
227
Introduction
This document tells you what you need to do to deliver the qualification:
Area
Description
Who is the
qualification for?
This certificate is aimed at learners who:

intend to follow an Apprenticeship or Advanced
Modern Apprenticeship programmes
wish for career progression within engineering
wish to develop the skills learnt from other
qualifications
What does the

qualification cover?
It allows learners to learn, develop and practise the

basic introductory skills required for employment
and/or career progression in the engineering sector.
What opportunities
for progression are
there?
It allows learners to progress into employment or to

the following
City & Guilds qualifications:
Higher Level Engineering qualifications
This qualification
replaces
2565 -02 Level 3 IVQ Technician Diploma in

Engineering
8030-22 Level 3 IVQ Technician Diploma in Electrical
and Electronic Engineering
Structure
To achieve the Level 3 Diploma in Engineering - Welding, learners

must achieve 27 credits from (301, 302 ,352) plus a minimum of 27
credits from (310-312, 330,351,336-338) of which 9 credits must come
from (310-312).
Unit
reference
number
City &
Unit title
Guilds unit
number
Credit
value
GLH
Mandatory
Y/503/0334
301
80
D/503/0433
D/503/0335
302
353
Engineering health and

safety
9
9
80
80
Optional
F/503/0344
310
80
R/503/0347
D/503/0349
A/503/0424
311
312
330
Manual metal arc welding of

materials
9
9
9
80
80
80
H/503/0353
Y/503/0351
K/503/0354
336
337
338

9
9
9
80
80
80
K/503/0449
351
Advanced mathematics and

science
80
Organising and managing

engineering operations
Flux-cored arc welding

materials
To achieve the Level 3 Diploma in Engineering - Fabrication, learners

must achieve 27 credits from (301-302, 354) and a minimum of 27 credits
from (313-316, 330, 351) of which a minimum 9 credits must come from
(313 - 316)
Unit
reference
number
City &
Unit title
Guilds unit
number
Credit GLH
value
Mandatory
Y/503/0334
301
80
D/503/0433
H/503/0336
302
354

safety
9
9
80
80
Optional
F/503/0375
313
80
A/503/0374
314
Platework fabrication of
materials
Sheet metalwork fabrication
of materials
80
J/503/0376
315
80
Y/503/0379
316
Fabrication and erection of

structural steelwork
Pattern development for
fabrication
80
A/503/0424
330
80
K/503/0449
351

science
80
To achieve the Level 3 Diploma in Engineering Fabrication and

Welding, learners must achieve 27 credits from (301, 302, 355) plus a
minimum of 27 credits from (310-316, 330,351,336-338) 310-312) of
which a minimum of 9 credits must come from (310- 316)
Unit
reference
number
City &
Unit title
Guilds unit
number
Credit GLH
value
Mandatory
Y/503/0334
301
80
D/503/0433
K/503/0337
302
355
9
9
80
80
Optional
F/503/0344
310
80
R/503/0347
D/503/0349
F/503/0375
311
312
313
9
9
9
80
80
80
A/503/0374
314
80
J/503/0376
315
Y/503/0379
316
A/503/0424
330
H/503/0353
Y/503/0351
K/503/0354
336
337
338
K/503/0449
351
Sheet metalwork fabrication 9

of materials
9
9
fabrication
9
MIG welding of aluminium
9
TIG welding of aluminium
9
9
Flux-cored arc welding
materials
Advanced mathematics and 9
science

safety
Principles of fabrication and
welding
materials
materials
80
80
80
80
80
80
80
To achieve the Level 3 Diploma in Engineering - Maintenance,

Installation and Commissioning, learners must achieve 27 credits from
(301-302) and a minimum of 27 credits from (317-322, 330,332, 351) of
which a minimum of 9 credits must come from (317-322)
Unit
reference
number
City &
Unit title
Guilds unit
number
Credit GLH
value
Mandatory
Y/503/0334
301
80
D/503/0433
M/503/0338
302
356
9
9
80
80
Optional
R/503/0381
317
Maintenance of machine
systems
80
D/503/0383
318
80
H/503/0384
319
80
T/503/0390
320
80
R/503/0395
321
80
K/503/0435
322
80
A/503/0424
330
80
R/503/0428
332
80
K/503/0449
351
Maintenance of utility
systems
Maintenance of plant
services
Maintenance of hydraulic
Systems
Maintenance of pneumatic
systems
Power generation systems
and ancillary equipment
Mechatronics systems
principles and fault finding
science
80

safety
Principles of engineering
maintenance, installation
and commissioning
To achieve the Level 3 Diploma in Engineering - Mechanical

Manufacturing Engineering, learners must achieve 27 credits from
(301-302, 357) and a minimum of 27 credits from (323-330, 351) of which
a minimum of 9 credits must come from (323-327)
10
Unit
reference
number
City &
Unit title
Guilds unit
number
Credit GLH
value
Mandatory
Y/503/0334
301
80
D/503/0433
T/503/0339
302
357
9
9
80
80
Optional
T/503/0437
323
Machining materials by
turning
80
M/503/0436
324
milling
80
A/503/0438
325
80
D/503/0416
M/503/0419
H/503/0420
326
327
328
grinding
9
9
9
80
80
80
M/503/0422
329
80
A/503/0424
330
Produce drawings using

CAD
80
K/503/0449
351

science
80

safety
Principles of mechanical
manufacturing engineering
Maintenance of electrical
equipment and systems
To achieve the Level 3 Diploma in Engineering - Electrical and

Electronic Engineering, learners must achieve 27 credits from (301-302
358) the mandatory units and a minimum of 27 credits from (328, 330,
332-335, 351) of which a minimum 9 credits must come from (328, 332 335)
Unit
reference
number
City &
Unit title
Guilds unit
number
Credit GLH
value
Mandatory
Y/503/0334
301
80
D/503/0433
K/503/0340
302
358

safety
80
Principles of electrical &

electronic engineering
80
Optional
H/503/0420
328
80
A/503/0424
330
80
R/503/0428
332
80
R/503/0431
333
80
Y/503/0432
334
80
H/503/0434
335
Computer automated and
robotic systems principles
and control
Power supply, and analogue
and digital circuit principles
and fault
Electronic power control
principles and practice
80
K/503/0449
351

science
80
11
Centre requirements
Approval
Centres wishing to offer City & Guilds qualifications must be approved:
new centres must apply for centre and qualification approval. Please
refer to the Centre Manual Delivering International Qualifications for
further information. Centre staff should familiarise themselves with
the structure, content and assessment requirements of the
qualification before designing a course programme.
existing City & Guilds centres will need to get specific qualification
approval to run these awards and to submit a QAP form.
City & Guilds reserves the right to suspend an approved centre, or
withdraw its approval from an approved centre to conduct City & Guilds
qualifications for reasons of debt, malpractice or for any reason that
maybe detrimental to the maintenance of authentic, reliable and valid
qualifications or that may prejudice the name of City & Guilds.
Resource requirements
Centre staffing
Staff delivering this qualification must be able to demonstrate that they
meet the following occupational expertise requirements. They should:
be occupationally competent or technically knowledgeable in the
areas for which they are delivering training and/or have experience of
providing training. This knowledge must be at least to the same level
as the training being delivered
have recent relevant experience in the specific area they will be
assessing
have credible experience of providing training.
Centre staff may undertake more than one role, eg tutor and assessor or
internal verifier, but cannot internally verify their own assessments.
Physical Resources
Centres wishing to use this qualification must review this handbook and
ensure that they have the staff and access to sufficient equipment in the
centre or workplace so that learners have the opportunity to cover all of
the activities of the qualification. It is acceptable for a centre to use
specifically designated areas within a centre if the learner does not have a
work placement. Where facilities do not exist for realistic practical work, it
is strongly recommended that centres develop links with local
organisations to provide opportunities for hands on experience.
12
Internal quality assurance

Approved centres must have effective quality assurance systems to
ensure optimum delivery and assessment of qualifications. Full
information is provided in the Centre manual Delivering international
qualifications.
Centres are responsible for internal quality assurance, and City & Guilds is
responsible for external quality assurance.
International standards and rigorous quality assurance are maintained by
the use of:
City & Guilds externally set and externally marked examinations for
the mandatory unit.
City & Guilds activities, delivered and assessed by the centre
according to externally set evidence requirements
internal (centre) quality assurance
City & Guilds external verification.
To meet the quality assurance criteria for this qualification, the centre
must ensure that the following internal roles are undertaken:
Assessment Manager
Tutor/Assessor
Internal Verifier Co-ordinator (for larger centres)
Internal Verifier
Examinations Secretary
Invigilator
Full details and guidance on the internal and external quality assurance
requirements, procedures and roles, are provided in Centre manual
Delivering international qualifications together with full details of the
tasks, activities and responsibilities of quality assurance staff.
In order to fully support learners, centres are required to retain original
copies of learners assessment and internal verification records for three
years after certification.
13
The following is a summary of the key roles involved in the successful

implementation and assessment of the qualification. (Please refer to the
Centre manual Delivering international qualifications for further
information).
The role of the Internal Verifier (IV) is to ensure that:
they liaise with City & Guilds personnel
there are adequate resources, both staff and materials
the work of all personnel contributing to the delivery and assessment
of the programme is sampled by a range of methods which should
include sampling the observation checklist, learner training plans and
multiple choice quiz responses
records of all sampling activities are monitored and maintained
where several members of staff are involved in the
delivery/assessment of the qualification, that there is a consistent
interpretation of the requirements through standardisation activities
and that these are documented
all staff carrying out delivery and assessment are familiar with and
understand the qualification requirements
an appropriate referral policy is in place
an appropriate appeals procedure is in place
learner evidence is clearly organised and accessible to the Internal
and Qualification consultant
relevant records and pro formas are completed, maintained and
retained for the purposes of Internal and External Verification along
with the record of course delivery form.
The role of the Tutor/Assessor is to:
plan, manage, deliver and assess the qualification using the City and
Guilds materials provided
ensure availability of technical support for ICT equipment
ensure that each learner is aware of the assessment requirements
throughout their programme of learning
provide guidance and support to learners on the assessment and
evidence requirements for the qualification
ensure that the assessment and evidence requirements have been
met by the learner
observe learners delivered sessions
facilitate the multiple choice quiz and mark learner responses
complete relevant records and pro formas.
All staff should participate in appropriate Continuous Professional
Development (CPD), to keep up to date with the delivery of the
qualification and their role.
External quality assurance
External quality assurance for the qualifications will be provided by the
usual City & Guilds external verification process and reported on using
relevant documentation to provide a risk analysis of individual centre
assessment and verification practice.
14
Continuing professional development (CPD)

Centres must support their staff to ensure that they have current
knowledge of the occupational area, that delivery, mentoring, training,
assessment and verification is in line with best practice, and that it takes
account of any national or legislative developments. All teaching and
assessment must take place in the English language and centres must
support their staff in this.
Learner entry requirements

No specific prior qualifications, learning or experience are required for
learners undertaking the qualification. However, centres will need to
make an initial assessment of each learner to ensure that the level of the
scheme is appropriate. The nature of both the learning and assessment
required for the qualification is such that learners will need basic literacy
and numeracy skills: i.e. the ability to read and interpret written tasks and
to write answers in a legible and understandable form in the English
language. Learners will also need to be able to organise written
information clearly and coherently, although they will not be assessed for
spelling or grammatical accuracy unless this is part of the assessment
criteria.
There are no restrictions on entry for this award. City & Guilds
recommend that learners should not enter for a qualification of the same
level and the same content as that of a qualification they already hold.
Age restrictions
City & Guilds cannot accept any registrations for candidates under 16 as
these qualifications are not approved for under 16s.
15
Delivering the qualification
Initial assessment and induction

Centres will need to make an initial assessment of each learner prior to
the start of their programme to ensure they are entered for an
appropriate type and level of qualification.
The initial assessment should identify:
any specific training needs the learner has, and the support and
guidance they may require when working towards their qualification.
This is sometimes referred to as diagnostic testing.
any units the learner has already completed, or credit they have
accumulated which is relevant to the qualification they are about to
begin.
City & Guilds recommends that centres provide an induction programme
to ensure the learner fully understands the requirements of the
qualification they will work towards, their responsibilities as a learner, and
the responsibilities of the centre. It may be helpful to record the
information on a learning contract.
All teaching and assessment for this qualification must take place in the
English language.
Support materials
The following resources are available for this qualification:
Description
How to access
Assignment guide for centres
www.cityandguilds.com
Assignments (310 to 330 and

332-338)
www.cityandguilds.com (password
protected)
SmartScreen
www.smartscreen.co.uk
Recording documents
Learners and centres may decide to use a paper-based or electronic
method of recording evidence.
City & Guilds endorses several ePortfolio systems, including our own,
Learning Assistant, an easy-to-use and secure online tool to support
and evidence learners progress towards achieving qualifications. Further
details are available at: www.learningassistant.com.
16
Assessment
The mandatory core units 301 Engineering health and safety and 302
Engineering principles are assessed by a City & Guilds online multiplechoice assessment. The remaining Principles of units are assessed by a
dated entry written exam paper. All other units are assessed by
assignment which contains practical and knowledge tasks.
The practical aspect of the assignments are centre devised with guidance
provided by City & Guilds, confirmation that the centre devised practical
aspect is acceptable is required from the City & Guilds Qualification
consultant. The knowledge aspect of the assignments (short-answer
questions) is provided by City & Guilds. As assignments are designed to
sample practical activities, it is essential that the centres ensure that
candidates cover the content of the whole unit.
Assessment components are graded (Pass, Merit, Distinction). A pass is
the achievement level required for the knowledge and understanding in
an IVQ and generally represents the ability to follow instructions and
procedures. Merit and distinction represent increasing levels of ability to
adapt to changing circumstances and to independently resolve problems.
Summary of assessment requirements

For these qualifications, candidates will be required to complete the
following assessments:
one online test for each mandatory unit
one dated entry written exam for each Principles of unit
one assignment for each chosen optional unit
if choosing unit Advanced mathematics and science, one dated entry
written exam.
City & Guilds provides the following assessments:
Unit
Title
Assessment method
Where to
obtain
assessment
materials
2850301
Engineering
health and safety
Online multiple-choice
assessment
The assessment covers all of the
outcomes.
www.walledgarden.com
2850302
Engineering
principles
Online multiple-choice
assessment
The assessment covers all of the
outcomes.
www.walledgarden.com
17
18
Unit
Title
Assessment method
Where to
obtain
assessment
materials
2850310
Manual metal arc

welding of
materials
Assignment 2850-310
The assessment covers the
practical activities for all
outcomes and will also sample
underpinning knowledge to
verify coverage of the unit.
Centre devised assignment,
internally marked, externally
verified.
www.cityandgu
ilds.com
2850311
MIG welding of
materials
Assignment 2850-311
verified.
www.cityandgu
ilds.com
2850312
TIG welding of
materials
Assignment 2850-312
verified.
www.cityandgu
ilds.com
2850313
Platework
fabrication of
materials
Assignment 2850-313
verified.
www.cityandgu
ilds.com
2850314
Sheet metalwork
fabrication of
materials
Assignment 2850-314
verified.
www.cityandgu
ilds.com
Unit
Title
Assessment method
Where to
obtain
assessment
materials
2850315
Fabrication and
erection of
structural
steelwork
Assignment 2850-315
verified.
www.cityandgu
ilds.com
2850316
Pattern
development for
fabrication
Assignment 2850-316
verified.
www.cityandgu
ilds.com
2850317
Maintenance of
machine systems
Assignment 2850-317
verified.
www.cityandgu
ilds.com
2850318
Maintenance of
utility systems
Assignment 2850-318
verified.
www.cityandgu
ilds.com
2850319
Maintenance of
plant services
Assignment 2850-319
verified.
www.cityandgu
ilds.com
19
20
Unit
Title
Assessment method
Where to
obtain
assessment
materials
2850320
Maintenance of
hydraulic
systems
Assignment 2850-320
verified.
www.cityandgu
ilds.com
2850321
Maintenance of
pneumatic
systems
Assignment 2850-321
verified.
www.cityandgu
ilds.com
2850322
Power
generation
systems and
ancillary
equipment
Assignment 2850-322
verified.
www.cityandgu
ilds.com
2850323
Machining
materials by
turning
Assignment 2850-323
verified.
www.cityandgu
ilds.com
2850324
Machining
materials by
milling
Assignment 2850-324
verified.
www.cityandgu
ilds.com
Unit
Title
Assessment method
Where to
obtain
assessment
materials
2850325
Machining
materials by
grinding
Assignment 2850-325
verified.
www.cityandg
uilds.com
2850326
CNC machining
of materials
Assignment 2850-326
verified.
www.cityandg
uilds.com
2850327
Detailed fitting of
materials
Assignment 2850-327
verified.
www.cityandg
uilds.com
2850328
Maintenance of
electrical
equipment and
systems
Assignment 2850-328
verified.
www.cityandg
uilds.com
2850329
Produce
drawings using
CAD
Assignment 2850-329
verified.
www.cityandg
uilds.com
21
22
Unit
Title
Assessment method
Where to
obtain
assessment
materials
2850330
Organising and
managing
engineering
operations
Assignment 2850-330
verified.
www.cityandg
uilds.com
2850332
Mechatronics
systems
principles and
fault finding
Assignment 2850-332
verified.
www.cityandg
uilds.com
2850333
Computer
automated and
robotic systems
principles and
control
Assignment 2850-333
verified.
www.cityandg
uilds.com
2850334
Power supply
and analogue
and digital circuit
principles and
fault finding
Assignment 2850-334
verified.
www.cityandg
uilds.com
2850335
Electronic power
control principles
and practice
Assignment 2850-335
verified.
www.cityandg
uilds.com
Unit
Title
Assessment method
Where to
obtain
assessment
materials
2850336
MIG welding of
aluminium
Assignment 2850-336
verified.
www.cityandg
uilds.com
2850337
TIG welding of
aluminium
Assignment 2850-337
verified.
www.cityandg
uilds.com
2850338
Flux-cored arc
welding of
materials
Assignment 2850-338
verified.
www.cityandg
uilds.com
2850351
Advanced
mathematics and
science
Dated entry written exam paper

2850-351
www.cityandg
uilds.com
2850353
Principles of
welding

2850-353
www.cityandg
uilds.com
2850354
Principles of
fabrication

2850-354
www.cityandg
uilds.com
2850355
Principles of
fabrication and
Welding

2850-355
www.cityandg
uilds.com
2850356
Principles of
engineering
maintenance,
installation and
Commissioning

2850-356
www.cityandg
uilds.com
2850357
Principles of
mechanical
manufacturing
engineering

2850-357
www.cityandg
uilds.com
23
Unit
Title
Assessment method
Where to
obtain
assessment
materials
2850358
Principles of
electrical and
electronic
engineering

2850-358
www.cityandg
uilds.com
Time constraints
The following time constraints must be applied to the assessments of this
qualification:
Each assignment has specific time constraints; please refer to the
individual assignments. Centre staff should guide learners to ensure
excessive evidence gathering is avoided. Centres finding that
assignments are taking longer, should contact the Qualification
consultant for guidance
All assignments must be completed and assessed within the learners
period of registration. Centres should advise learners of any internal
timescales for the completion and marking of individual assignments.
Assessment strategy
Test specifications for the online multiple-choice assessment and the
dated entry written exam papers will be available online in March 2013.
Dated entry examinations will take place in June and December.
24
Units
Structure of units
These units each have the following:
City & Guilds reference number
unit reference number (URN)
title
level
credit value
guided learning hours
endorsement by a sector or other appropriate body
unit aim
information on assessment
learning outcomes which are comprised of a number of assessment
criteria
notes for guidance.
25
Unit 301
URN:
Y/503/0334
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
sector or regulatory
body:
This unit is endorsed by SEMTA.
Aim:
This unit is concerned with the requirements

that are essential to enable engineering
activities to be carried out safely and
effectively. It includes dealing with statutory
and organisational requirements in
accordance with approved regulations,
codes of practice and procedures. It covers
responsibilities relating to accident reporting
and the identification of hazards and risks
Learning outcome
The learner will:
1. understand compliance with statutory health and safety regulations
and organisational requirements
Assessment criteria
The learner can:
1.1 describe the health and safety regulations applicable to
1.2 explain employers responsibilities to maintain health and safety
1.3 describe essential operator and bystander health and safety
requirements
1.4 explain the Reportable Diseases and Dangerous Occurrences
Regulations (RIDDOR) relevant to engineering
1.5 explain the procedures for reporting accidents
1.6 explain how the management of health and safety regulations
are implemented
1.7 state the roles, responsibilities and powers of health and safety
personnel
1.8 explain the sources of health and safety literature/advice and how
to access it
1.9 describe how to carry out a risk assessment identifying potential
health hazards
1.10 state the general rules for the observance of safe practices.
26
Range
Regulations: Health and Safety at Work etc. Act, Control of Substances
Hazardous to Health Regulations (COSHH), Provision and Use of Work
Equipment Regulations (PUWER), Electricity at Work Regulations, Control
of Major Accident Hazards Regulations (COMAH), Control of Noise at
Work Regulations, Lifting Operations and Lifting Equipment Regulations
(LOLER)
Employers responsibilities:
safe: place of work, plant and equipment, system of work, working
environment, methods of handling, storing and transporting goods and
materials reporting of accidents (RIDDOR), information, instruction,
training and supervision of employees, a health and safety policy
Operator and bystander: Personal Protective Equipment (PPE),
Respiratory Protective Equipment (RPE) secure areas
Reporting accidents: summary of accident, name of victim(s), summary
of events prior to accident, details of witnesses, information on injury or
loss sustained, conclusions, recommendations, supporting material
(photographs, video), diagrams, date, signature of person(s) responsible
for report
Management of Health and Safety: including the four Cs of positive
health and safety (Competence, Control, Co-operation, Communication)
Health and safety personnel: Health and Safety Advisors, Health and
Safety Representatives, Health and Safety Executive Inspectors,
Environmental Health Officers
Risk assessment: potential hazards, slippery or uneven surfaces,
spillages, scrap or waste material, inflammable materials, faulty or
missing machine guards, faulty electrical connections or damaged
cables, material ejection, pressure and stored energy, unshielded
processes, volatile and toxic materials, dust and fumes, contaminants
and irritants, materials handling and transportation, working at heights
Safe practices: be alert, maintain personal hygiene, protect yourself
and other people, know emergency procedures, report all hazards
Learning outcome
The learner will:
2. understand compliance with statutory environmental regulations and
organisational requirements
Assessment criteria
The learner can:
2.1 describe the differences between the human and environmental
conditions leading to accidents in the workplace and the means of
controlling them
2.2 describe the Environmental Management Systems Standard ISO
14001 in terms of the engineering industry
2.3 describe the implementation of environmental legislation as it
applies to engineering industries
2.4 identify health and safety signs and explain their purpose
27
Range
Human and environmental conditions:
Causes of accidents
Human: lack of management control, carelessness; improper behaviour
and dress; lack of training, supervision and experience; fatigue; drugtaking and alcohol intake,
Environmental: unguarded or faulty machinery or tools; inadequate
ventilation; untidy, dirty, overcrowded workplace; inadequate
lighting
Controlling methods
Eliminate the hazard, replace the hazard with something less dangerous,
guard the hazard, personal protection, health and safety education and
publicity
Environmental legislation: Environmental Protection Act, Pollution
Prevention and Control Act, Clean Air Act, Radioactive Substances Act,
Controlled Waste Regulations, Dangerous Substances and Preparations
and Chemicals Regulations, Hazardous Waste Regulations
Signs: warning, prohibition, mandatory, information, fire
Learning outcome
The learner will:
3. know how to implement accident and emergency procedures
Assessment criteria
The learner can:
3.1
explain the need for the provision of first aid treatment
3.2 explain the health and safety procedures that prevent injury or
discomfort to skin, eyes, hands and limbs
3.3 explain the appropriate emergency action to be taken in cases of
electric shock
3.4 explain precautions to be taken to avoid electric shock
3.5 explain the causes of asphyxiation and the appropriate
emergency action to be taken
3.6 state what is meant by a dangerous occurrence and hazardous
malfunction
3.7 describe the procedures to be followed the event of the sounding
of an emergency alarm
3.8 describe methods of fire prevention.
28
Range
First aid: location of facilities, location of qualified first aiders
Health and safety procedures: personal hygiene, skin protection and
care, care of eyes, use of eye and face protectors which are to current EN
specifications, use of respirators, dangers of hair and loose clothing
getting caught in machinery, means of avoiding such dangers, benefits
and use of protective clothing, use of safety guards, screens and fences
Emergency action: isolate electrical supply, removal from electricity
supply, basic resuscitation procedures
Electric shock: hazards arising from the use of electrical equipment,
general health and safety rules: checking and inspection of cables, leads
and plugs; earthing; problems associated with the use of portable
equipment; use of reduced voltage equipment; health and safety
training; warning signs and notices; isolation procedures
Asphyxiation: confined working space, inadequate ventilation
Emergency alarm; evacuation system, escape routes, assembly points
(reporting to assembly points, not to return until authorised)
Fire prevention: risk assessments, methods of controlling fires, fire
procedures, adhering to fire safety legislation
Learning outcome
The learner will:
4. understand safe working practices and procedures
Assessment criteria
The learner can:
4.1 describe the range of Personal Protective Equipment (PPE) available
and relate its use to the operations that will be undertaken
4.2 explain use of Respiratory Protective Equipment (RPE) when
undertaking tasks involving exposure to hazardous substances and
the range available
4.3 describe how to carry out a risk assessment for using mechanical
lifting equipment
4.4 state the requirements of the Lifting Operations and Lifting
Equipment Regulations (LOLER)
4.5 explain the health and safety rules for the use of mechanical lifting
equipment
4.6 explain the purpose and methods of use of accessories to lifting
gear
4.7 describe the Manual Handling Operations Regulations as they apply
to engineering industries
4.8 explain the necessity of a permit to work procedure
4.9 explain the necessity of lock-off procedures
4.10 state the procedures used to notify/report hazards to appropriate
people
4.11 state situations in which it is unadvisable or unsafe to work in
isolation.
29
Range
RPE: chemicals and solvents, fumes, dust or harmful particulates, heat
Accessories: hooks, slings, eyebolts, shackles, chains, rings, special-topurpose equipment, rules for the use of slings
Appropriate people: supervisors, health and safety advisors, health
and safety representatives, fire marshals, works/site rescue team
Work in isolation: in confined spaces, above ground or in trenches, in
close proximity to unguarded machinery, when a fire risk exists, with
toxic or corrosive substances, on site
30
Unit 301
Supporting information
Guidance
Fire prevention: fire risk assessments, causes of fire, fire prevention,
spread of fire, methods of controlling fires, conditions required for
combustion and extinction, the fire triangle, fire procedures
(fire drills, fire fighting equipment for different types of fires, extinguishers
(types classification for types of fire), automatic equipment, adhering to
fire safety legislation)
LOLER: as a general rule loads over 20kg need powered lifting gear, never
exceed the maximum safe working load (SWL) indicated on the equipment
and the accessories, avoid shock loading the lifting equipment, swinging
and twisting, estimate the centre of gravity, position the lifting hook
above the centre of gravity of the load to maintain an even balance, avoid
pushing or pulling the load to adjust the balance, do not transport loads
over the heads of people or walk under a load, do not leave a load
hanging unnecessarily and, in any event, have someone to watch over it,
always lower the load gently into position; make sure it will not move once
the lifting equipment is removed, check date of equipment tests
Accessories: hooks (materials, design and certification) slings (materials,
design and certification, the importance of the angle at the top, forces in
the legs proportional to the angle at the top, design and construction of
rope slings [natural and man-made fibres, steel wire slings]), eyebolts
(design and construction to published standards, use when lifting
engines, gearboxes, the importance of ensuring that the eyebolt shoulder
is screwed flush to face of component) shackles (design and construction
to published standards, the importance of SWL for different sizes) chains
(design and construction; the importance of regular checking and testing
to avoid failure from damage and metal fatigue) rings (design and
construction to published standards; importance of use with slings
and chains), special-to-purpose equipment (use for lifting special
equipment, regular lifting eg oil drums, production components) rules for
the use of slings (never bend around sharp corners and edges and avoid
overbending, use of protective covers on corners of loads, never twist or
kink the sling never use a worn or damaged sling, always observe the safe
working load (SWL))
31
Unit 302
URN:
D/503/0433
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit is concerned with those

engineering principles that enhance the
performance of engineering operations. This
includes the extraction, interpretation and
use of a range of technical information
sources. It includes the use of basic
calculations and engineering science that
enables the candidate to better understand
the behaviour and properties of engineering
materials in order that appropriate materials
may be selected to satisfy specifications. The
identification and application of quality
control measures that are relevant to
engineering activities are also covered.
Learning outcome
The learner will:
1. know how to interpret engineering information
Assessment criteria
The learner can:
1.1 explain the relevance of engineering information
1.2 describe the difference between the abbreviations and notation
used on various standard engineering drawings, circuit diagrams or
piping layouts
1.3 interpret the information that can be extracted from reference
charts, tables, graphs and BS EN standard
1.4 explain the use of CAD systems to produce engineering drawings
1.5 explain the use of databases and spreadsheets to display
information
1.6 explain the basic principles of document control
1.7 interpret drawings, dimensioning and labelling
1.8 describe how to use charts, tables, graphs and BS EN standards
1.9 describe how to extract information from drawings
1.10 describe how to use engineering drawings to produce material lists
1.11 describe how to use engineering drawings to determine quality
requirements
32
Range
Engineering information: BS EN standards, instruction manuals,
technical handbooks, tables, charts (including: flow, Gantt, tally), graphs
(including histograms, scatter diagrams), Ishikawa diagrams (fishbone
diagrams or cause-and-effect diagrams), data sheets, text books and
reference materials, computer applications
Abbreviations and notation: symbols and abbreviations, application
to: engineering drawings, machining, welded joints, circuit diagrams and
piping layouts
Reference charts, tables, graphs and BS EN standards: tapping
sizes and threads, feeds and speeds, cable sizing, PIN configurations,
component ratings, welding symbols, machining symbols and
tolerances, piping components
Drawings, dimensioning and labelling: projections (orthographic
[first angle, third angle], isometric [including exploded], oblique);
reference points, lines, edges and surfaces, continuous dimensions,
baseline dimensions
Learning outcome
The learner will:
2. know how to differentiate between common engineering materials
Assessment criteria
The learner can:
2.1 describe the difference between a range and form of supply of
materials commonly used in engineering
2.2 describe the difference between characteristics of metallic and
non-metallic materials used in engineering
2.3 describe how carbon and alloying elements affect the properties of
carbon and low alloy steels
2.4 describe how heat treatments can affect the properties of carbon
and low alloy steels
2.5 explain the causes of corrosion in materials
2.6 state the defects that can occur in materials/products and explain
the importance of controlling them
2.7 select materials to meet specifications requirements in a typical
engineering environment
33
Range
Supply of materials: ferrous metals (low, medium and high carbon
steels; low alloy steels; stainless steels; cast irons), non-ferrous metals
(aluminium and aluminium alloys, copper, brass, bronze, nickel, lead,
titanium), non-metallic (hard and soft woods, composites, plastics:
thermoplastic, thermosetting), ceramics, reinforcing materials (glass
fibre, carbon fibre, aramid fibre)
Characteristics: selection of materials for engineering applications,
strength, rigidity, temperature stability (heat resistance, thermal
conductivity, electrical conductivity and insulation), wear resistance,
acoustic absorption, shock absorption, corrosion resistance, influence of
physical properties of materials on processing techniques (cutting,
forming, joining), identification of engineering materials (colour, surface
texture, appearance, density, magnetic/non-magnetic, spark test)
Heat treatments: iron-carbon thermal equilibrium diagram, annealing,
normalising, hardening, tempering
Corrosion: pitting, intergranular, galvanic, leaching, oxidation
Defects: critical, major, minor or non-critical
Learning outcome
The learner will:
3. know how to perform engineering calculations
Assessment criteria
The learner can:
3.1 express numerical solutions to a degree of accuracy that is
appropriate to the value being calculated
3.2 use a calculator to raise a number to a power and determine square
roots
3.3 use formulae to complete transpositions and solve problems
3.4 use algebraic expressions
3.5 plot and interpret straight line graphs
3.6 apply Pythagoras' Theorem
3.7 explain how to use Sine, Cosine and Tangent to solve typical
engineering problems
3.8 define density and relative density and solve related problems
using formula
3.9 define moments of a force and solve related problems using
formula
3.10 define work, power and energy and solve related problems
using formula
3.11 define friction and solve related problems using formula
3.12 describe the relationship between temperature changes and
changes in length
3.13 define types of heat and solve related problems using formula.
34
Range
Degree of accuracy: correct to three significant figures, correct to two
decimal places, express a decimal fraction in standard form, express
tolerance in terms of limits of size
Transpositions: involving addition, subtraction, multiplication and
division in any combination using a maximum of three terms, for example
Ohms Law solve problems: substitution of known values
Algebraic expressions: represent numerical quantities using symbols,
apply laws of precedence in the use of precedence (BODMAS)
Straight line graphs: determining suitable scales from given data,
defining and correctly labelling axes, determine the gradient, determine
the intercept, prove the law of the straight line graph is y = mx + c
Sine, Cosine and Tangent: state their ratios for angles up to 90,
determine their values for given angles up to 90, solve simple problems
Moments of a force: define and apply the Principle of Moments,
define the meanings of the terms 'torque' & 'couple'
Solve problems: associated with levers and couples work, power and
energy define work done in terms of force and distance moved
Work, power and energy: explain what is meant by energy; state that
the unit of energy is the joule (J), the unit of power is the watt (W) and the
unit of work is the joule (J); define power in terms of voltage/current and
work done per second, perform calculations for work, power and energy
Friction: definition, explain coefficient of friction, explain how friction
can be reduced, select materials that will rotate, or slide together with
low frictional value, perform calculations for friction
Temperature: define coefficient of expansion, solve numerical problems
to determine the change in length due to temperature.
Heat: define: specific heat capacity, specific latent heat (fusion,
evaporation) solve numerical problems associated with specific heat
capacity, specific latent heat of fusion, specific latent heat of evaporation
Learning outcome
The learner will:
4. understand quality control in engineering.
Assessment criteria
The learner can:
4.1 state what is meant by the term quality and apply quality to
contexts/perceptions
4.2 define the terms inspection and quality control
4.3 explain the principles of quality control and inspection
4.4 explain the need for materials and components, inward
inspection and correct documentation
4.5 state the function of an incoming raw materials inspection
department
4.6 explain the need for validating and calibrating test and
measuring equipment
4.7 explain how to check equipment is approved for use and how to
take appropriate action to return/report equipment that has passed
its approval date
4.8 explain the use of engineering standards in determining the fitness
of purpose of items/equipment used in engineering production,
construction and maintenance
35
4.9 describe the appropriate action to take when required standards

of performance are not met
4.10 explain limits of authority in respect of re-working, adjusting or
scrapping a component/product
4.11 explain the need to inform a responsible person of the variation
from the stated standard
4.12 state the need to document all actions agreed upon and taken
4.13 explain the importance of quality records and the type of
inspection records needed
4.14 explain the purpose of the ISO 9000 series of standards
4.15 describe how to complete quality documents/records of work
carried out and record test/inspection results
4.16 interpret results from quality measurements and compare them
with stated parameters
4.17 make recommendations whether to re-work, adjust or scrap
items/components that do not meet required standards.
Range
Quality: components, products or services being fit for purpose,
customer expectation, product, component or service reliability, the
need for interchangeability with regard to supplying spare parts, product
life cycle
Quality control and inspection: inspection: covering the examination,
measurement, testing and judgement of a product for conformation to a
predetermined requirement i.e. fitness for purpose, quality control:
activities embracing all stages of manufacture from initial design, raw
material and finished products, principles of inspection (random
sampling, sampling frequency)
Inward inspection: dimensional accuracy, correct documentation for
incoming goods/materials, importance of release and advice notes, faults
that may arise in documentation and storage of incoming goods,
methods of checking for faults in documentation, spot checks, random
checks; sampling (quarantine inspection) in terms of: importance of
release and advice notes, the reason for clear, identification of materials
with relevant batch numbers, procedures to be followed before
batch material is released into stores in accordance with storage
recommendations tests to be applied, identification of
acceptance/rejection criteria and the recording procedures involved,
remedial action to be taken when components/materials prove defective
Validating and calibrating: need for regular and controlled calibration
and validation of measuring equipment, need for traceable records of
calibration checks, use of international standards
Check equipment is approved: Equipment such as: torque wrenches,
lifting equipment, pressure gauges, micrometers, vernier instruments
Action: re-work, adjust, scrap
Quality records: record all test results, record all inspections carried
out, procedures to be taken upon completion of task (place into stores,
pass it to another department, mark it for re-work, adjust, mark it for
scrap or salvage
36
Unit 302
Guidance
Document control: where documents are obtained from, how
distribution and use of documents is controlled, the relevance of
document issue numbers, document approval and authorisation
procedures, procedure to be adopted if documents are lost or damaged
Characteristics: selection of materials for engineering applications,
strength, rigidity, temperature stability (heat resistance, thermal
conductivity, electrical conductivity and insulation), wear resistance,
acoustic absorption, shock absorption, corrosion resistance, influence of
physical properties of materials on processing techniques (cutting,
forming, joining), identification of engineering materials (colour, surface
texture, appearance, density, magnetic/non-magnetic, spark test), explain
the factors influencing the choice of materials (properties, cost, testing of
materials (non-destructive: visual, penetrant [dye and fluorescent],
magnetic particle [dye and fluorescent], radiography, ultrasonic;
destructive: tensile, shear, hardness [Brinell, Vickers, Rockwell],
toughness [Charpy, Izod], creep, fatigue, bending.
37
Unit 310

materials
URN:
F/503/0344
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit sets out the requirements for

manual metal arc welding in a modern
engineering environment, in terms of what
needs to be achieved by the candidate, ie:
welding a series of challenging joint
configurations across in a wide range of
positions that are compliant to welding
procedure specifications. The unit is
concerned with the technology and
practices involved in the application of
manual metal arc welding. The unit is
demanding in terms of technological content
and the complexity of the welding that
candidates are expected achieve. The unit is
broadly divided into health and safety,
welding equipment, welding consumables
(i.e. electrodes) and the practicalities of
producing a welded joint in relation to a
welding procedure specification (WPS) and a
quality specification.
Learning outcome
The learner will:
1. be able to apply safe working practices to manual metal arc welding
Assessment criteria
The learner can:
1.1 apply the health and safety regulations relevant to welding
1.2 assess hazards and risks in a welding environment and
recommend safety precautions, procedures and Personal
Protective Equipment (PPE) to overcome hazards
1.3 follow safe working practices
38
Range
Regulations: Health and Safety at Work etc. Act, COSHH, PUWER (scope
within the welding environment), RIDDOR, Management of Health and
Safety at Work Regulations, Personal Protective Equipment At Work
Regulations, Noise at Work Regulations
Hazards and risks: fume, fire, electricity, arc radiation, hot metal/slag
Safe working practices: safe start-up and shutdown procedures, safe
use of equipment, equipment checks by operator, routine maintenance
Learning outcome
The learner will:
2. be able to prepare equipment for performing manual metal arc
welding
Assessment criteria
The learner can:
2.1 list the range of welding equipment available
2.2 describe the functions of welding equipment
2.3 prepare welding equipment for a range of given applications
Range
Welding equipment: power sources, transformer/rectifier, inverter,
generator, measurement of electrical output and continuity, methods of
current regulation, power source characteristics,, leads, electrode
holders, return clamps, ancillary equipment
Learning outcome
The learner will:
3. be able to perform manual metal arc welding operations to meet
welding procedure specification requirements
Assessment criteria
The learner can:
3.1 critically compare welding consumables for a range of given
applications
3.2 differentiate between welding consumables by their classification
3.3 produce complex welded joints in a range of positions in
accordance with procedure specification (WPS) parameters
3.4 restore work areas to a clean and safe condition on completion of
welding operation
Range
Welding consumables: electrode coverings to current BS EN standard
(strength and elongation properties, impact properties, chemical
composition, type of the covering, recovery rate and current type,
welding positions, hydrogen content of the deposit), electrode coverings
(cellulosic, rutile, basic, iron powder, composition, applications, baking
requirements, hydrogen content, determination of electrode efficiency),
function of coverings (facilitates arc striking, stabilises and directs the
arc, assists control of the size and frequency of filler metal
globules/droplets, protects filler metal from atmospheric contamination
39
during transfer, protects deposited metal from contamination, provides

appropriate weld contour, prevents rapid cooling of weld metal [thermal
blanket effect], provides a flux for the molten pool to remove oxides and
impurities, supplies additional metal to weld pool [including alloying
elements], core wire composition (carbon steel, low alloy steel, stainless
steel, non-ferrous metals, cast iron), electrode coverings to current AWS
standard (strength and elongation properties, position, usability, suffix)
WPS: welding process, parent metal, consumables, pre welding
activities (cleaning, edge preparation, assembly, pre-heat), welding
parameters, welding positions (EN ISO 6947 PA, PB, PC, PD, PE, PF, PG),
number and arrangement of runs to fully fill/weld joints, electrode sizes
for joint thicknesses, techniques used when welding with electrodes
(cellulosic, rutile, basic, iron powder), electrical conditions required (type
of current, alternating [a.c.], direct [d.c.], electrode polarity
(positive, negative), welding current ranges, voltage (open circuit, arc),
control of heat input, interpass/run cleaning/back gouging methods, post
welding activities (slag removal, spatter removal, wiring brushing,
removal of excess weld metal where required), post-weld heat treatment
(normalising, stress relief)
Learning outcome
The learner will:
4. be able to evaluate welded joints for welding procedure
specification conformance
Assessment criteria
The learner can:
4.1 explain the implications of quality specifications used to determine
the integrity of welded joints
4.2 visually evaluate welded joints for conformance
4.3 prepare and destructively test joints to evaluate sub-surface for
conformance
Range
Integrity of welded joints: classification of defects, quality
specification (BS EN 25817 arc welded joints in steel guidance on
quality levels for imperfections), methods of avoiding, rectification
methods
Visually evaluate: use of visual techniques, lighting, low powered
magnification, fillet weld gauges, dye penetrant testing, preparation for
inspection, qualitive (defect levels, appearance), quantitive (extent, size,
dimensional accuracy)
Destructively test: nick-break (fracture), macroscopic examination (x5)
bend tests (butt welds, side, face, root), methods of preparation for
testing
40
Unit 310

materials
Guidance
Regulations: Health and Safety at Work etc. Act, COSHH (risk
assessment, consumable data sheets, training and awareness, safe
working procedures, hierarchy of control), PUWER (scope within the
welding environment), RIDDOR (application to welding process, major
injuries, over three day injuries, diseases, dangerous occurrences)
Management of Health and Safety at Work Regulations (risk assessment,
control measures, training and awareness, safe working procedures),
Personal Protective Equipment At Work Regulations (application to
welding process, employers duties, employees duties, protection
against hazards [fumes, airborne particles, arc radiation, hot metal,
sparks, falling objects, factors renderPersonal Protective Equipment (PPE)
provided as protection ineffective or unsafe]), Noise at Work Regulations
(action levels)
Hazards and risks: fume (composition, visible particulate, invisible
gaseous, risks to health, control measures to reduce exposure, extraction
[background, local, natural ventilation, e.g. on-site, air-fed headshields,
respirator, breathing apparatus, monitoring the effectiveness of control
measures), fire (sources of combustion, identification of hazards, methods
of reducing risks, identification of extinguishers), electricity (shock, fire,
burns, methods of avoiding shock hazards, emergency procedures in the
event of an electric shock, function of protection devices, earthing,
workpiece, plant), arc radiation (visible light, infra-red, ultra-violet, effects,
protection (Personal Protective Equipment (PPE), screening, warnings
[verbal, notices], hot metal/slag (methods of avoiding)
Welding equipment: power sources (output [alternating current [a.c.],
direct current [d.c.], transformer [function, winding ratio, input/output
ratio, construction], transformer/rectifier [function, operation,
construction {diodes, thyristors} function of smoothing capacitors],
inverter [function, operation, construction], generator [fuel driven, motor
driven, function, operation, construction], rated output [duty cycle]),
measurement of electrical output and continuity (voltage
use of voltmeter/multi-meter, current use of ammeter/shunts/coils,
continuity use of continuity tester/ohmmeter), methods of current
regulation (tapped reactor, moving core, moving coil, moving shunt,
saturable reactor, variable resistance), power source characteristics
(volt/ampere graph, drooping characteristic, constant current output),
leads used (welding, return, earth, construction, rated output [duty
cycle]), electrode holders (types, fully insulated, partially insulated), return
clamps (types, clamping mechanisms), ancillary equipment (angle
grinders, chipping hammer, wire brushes, hammer and chisel)
41
Restore work areas: leave the work area free of unused consumables,
cleaning the work area, putting tools and equipment into safe storage,
identify any materials used that are classified as hazardous and those that
can be recycled, reporting any damage caused by the maintenance or
installation activity where additional restoration work may be needed,
informing all interested parties know of any changes that may affect the
operation of the system, or of any new conditions that could exist in the
work area, work termination documents or reports that may be required
are completed and passed on to an authorised person (eg terminating
permits to work)
42
Unit 311
URN:
R/503/0347
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit sets out the requirements for metal

inert gas (MIG) welding in a modern
practices involved in the application of MIG
welding. The unit is demanding in terms of
technological content and the complexity of
the welding that candidates are expected
achieve. The unit is broadly divided into
health and safety, welding equipment,
welding consumables (i.e. electrodes) and
the practicalities of producing a welded joint
in relation to a welding procedure
specification (WPS) and a quality
specification
Learning outcome
The learner will:
1. be able to apply safe working practices to MIG welding
Assessment criteria
The learner can:
43
Range
Health and safety regulations: Health and Safety at Work etc. Act,
COSHH, Management of Health and Safety at Work Regulations, Personal
Protective Equipment at Work Regulations, Noise at Work Regulations
Hazards and risks: fume, fire, electricity, arc radiation, hot metal,
hazards associated with the storage, handling and use of pressurised gas
cylinders
cylinders (safe storage conditions, safe handling/moving, safe use)
Learning outcome
The learner will:
2. be able to prepare equipment for performing MIG welding
Assessment criteria
The learner can:
2.3 prepare the welding equipment for a range of given applications
2.4 prepare the welding shielding gases for a range of given
applications
Range
Welding equipment: power sources, inverter , generator, rated output,
measurement of electrical output and continuity, relationship between
wire feed speed control and welding current, power source
characteristics, function of induction, return, earth, construction, rated
output, welding guns, contact tip, return clamps, wire feed control,
ancillary equipment
Shielding gases: cylinders, manifold systems, regulators (fixed, singlestage, two-stage), gas flow meters, gas tubes and connectors, use of
solenoid valves, heaters for CO2
Learning outcome
The learner will:
3. be able to perform MIG welding operations to meet welding
procedure specification requirements
Assessment criteria
The learner can:
applications
3.2 differentiate between welding consumables by their
classification
accordance with welding procedure specification (WPS)
parameters
welding operation
44
Range
Welding consumables:
Electrode wires: BS EN 440: Welding consumables: wire electrodes and
deposits for gas shielded metal arc welding of non alloy and fine grain
steels, classification: (sizes [diameters, reel sizes available], strength and
elongation of the weld metal, impact properties of the weld metal,
chemical composition of the weld metal, deoxidisers, function of copper
coating, protection of bare wires), non-ferrous metals (types, availability,
typical sizes), storage (storage, identification, segregation (classification,
size)
Shielding gases: BS EN 439: Welding consumables: shielding gases for
arc welding and cutting, effects of shielding gases/gas mixtures (weld
pool/arc area protection, heat input, weld geometry, penetration profile,
travel speed, mode of metal transfer), applications for shielding
gases/gas mixtures (argon, helium, carbon dioxide, argon/carbon dioxide
mixtures, argon/oxygen/carbon dioxide mixtures, argon/oxygen
mixtures, helium/argon/oxygen/carbon dioxide mixtures), gas pressure
requirements, flow rates for applications
for joint thicknesses, mode of metal transfer (dip [short-circuiting,
globular, spray, pulse), electrical conditions required (type of current,
direct [d.c.], electrode polarity (positive), wire feed speed ranges, voltage
(open circuit, arc), control of heat input, shielding gas (type, flow rate)
interpass/run cleaning/back gouging methods, post welding activities
(spatter removal, wiring brushing, removal of excess weld metal where
required), post-weld heat treatment (normalising, stress relief)
Learning outcome
The learner will:
4. be able to evaluate welded joints for welding procedure specification
conformance
Assessment criteria
The learner can:
4.3 destructively test joins to evaluate sub-surface for conformance
45
Range
methods
destructively test: nick-break (fracture), macroscopic examination (x5)
testing
46
Unit 311
Guidance
sparks, falling objects, factors render PPE provided as protection
ineffective or unsafe]), Noise at Work Regulations (action levels)
protection [PPE, screening, warnings {verbal, notices}]), hot metal
(methods of avoiding), hazards associated with the storage, handling and
use of pressurised gas cylinders
Welding equipment: power sources (output direct current [d.c.],
transformer/rectifier [function, operation, construction {diodes, thyristors}
function of smoothing capacitors], inverter [function, operation,
construction], generator [fuel driven, function, operation, construction],
rated output [duty cycle]), measurement of electrical output and
continuity (voltage use of voltmeter/multimeter, current use of
ammeter/shunts/coils, continuity use of continuity tester/ohmmeter),
relationship between wire feed speed control and welding current, power
source characteristics (volt/ampere graph, flat characteristic, constant
voltage output), function of induction (principle, effect, fixed, stepped,
variable control, leads used (welding [water cooled, air cooled, harness
construction], return, earth, construction, rated output [duty cycle]),
welding guns/torches (water cooled, air cooled, construction, types
[push, pull, reel-on-gun] swan neck design, pistol design, nozzles [dip,
spray], contact tip [functions, material, sizes, clearing a burn-back), return
clamps (types, clamping mechanisms), wire feed control (variable speed
motor, direct control of wire feed rate, indirect control of welding current,
solenoid valves [shielding gas, water], relay for electrical power, jog-feed
control, gas purge control) ancillary equipment (angle grinders, wire
brushes, linishers, hammer and chisel)
47
permits to work)
BSI standards can be accessed at http://shop.bsigroup.com/en/
48
Unit 312
URN:
D/503/0349
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

tungsten inert gas (TIG) welding in a modern
practices involved in the application of TIG
welding. The unit is demanding in terms of
welding consumables and the practicalities
of producing a welded joint in relation to a
quality specification
Learning outcome
The learner will:
1. be able to apply safe working practices to TIG welding
Assessment criteria
The learner can:
49
Range
Regulations: Health and Safety at Work etc. Act, COSHH, Management
of Health and Safety at Work Regulations, Personal Protective Equipment
at Work Regulations, Noise at Work Regulations
cylinders
Learning outcome
The learner will:
2. be able to prepare equipment for performing TIG welding
Assessment criteria
The learner can:
applications
Range
Welding equipment: power sources, direct current [d.c.], transformer,
transformer/rectifier, inverter, generator, measurement of electrical
output and continuity, methods of current regulation, power source
characteristics, torches, collet, collet holder, gas lens, electrodes, return
clamps, ancillary equipment
solenoid valves
Learning outcome
The learner will:
3. be able to perform TIG welding operations to meet welding
Assessment criteria
The learner can:
applications
parameters
3.4 explain the effects of the electrical characteristics of the TIG
welding arc
welding operation
50
Range
Electrode wires: BS EN 1668: Welding consumables: rods, wires and
deposits for tungsten inert gas welding of non alloy and fine grain steels,
classification: BS EN 12072: Welding consumables: wire electrodes, wires
and rods for arc welding of stainless and heat-resisting steels.,
classification: (sizes [diameters, lengths], strength and elongation of the
weld metal, impact properties of the weld metal, chemical composition
of the weld metal, deoxidisers, function of copper coating, protection
of bare wires), non-ferrous metals (types, availability, typical sizes),
storage (storage, identification, segregation (classification, size)
Shielding gases: BS EN 439: welding consumables, shielding gases for
arc welding and cutting, effects of shielding gases/gas mixtures (weld
pool/arc area protection, heat input, weld geometry, penetration profile,
travel speed), applications for shielding gases/gas mixtures (argon,
helium, argon/helium mixtures, helium/argon mixtures, argon/hydrogen
mixtures, nitrogen, argon/nitrogen mixtures), gas pressure
requirements, flow rates for applications
for joint thicknesses, electrode, filler wire, electrical conditions required
(type of current, alternating [a.c.] direct [d.c.], electrode polarity
(negative), welding current ranges, methods of arc ignition (scratch,
high frequency, lift start), shielding gas (type, flow rate, pre-weld gas
flow, post-weld gas flow), techniques (including autogenous), control of
heat input, interpass/run cleaning/back gouging methods, post welding
activities (wiring brushing, removal of excess weld metal where
required), post-weld heat treatment (normalising, stress relief)
Electrical characteristics: effects of types of current (a.c./d.c.) and
electrode polarity (d.c.: positive, negative) upon: heat input/distribution,
electrode, weld bead profile, penetration; methods of a.c. arc
stabilisation (including: square wave); welding current features (pulse
current, slope in, slope out) voltage (open circuit, arc)
51
Learning outcome
The learner will:
conformance
Assessment criteria
The learner can:
4.3 prepare and destructively test joins to evaluate sub-surface for
conformance
Range
methods
testing
52
Unit 312
Guidance
sparks, falling objects, factors render PPE provided as protection
ineffective or unsafe]), Noise at Work Regulations (action levels)
protection [Personal Protective Equipment (PPE), screening, warnings
{verbal, notices}]), hot metal (methods of avoiding), hazards associated
with the storage, handling and use of pressurised gas cylinders
measurement of electrical output and continuity (voltage
use of voltmeter/multi-meter, current use of ammeter/shunts/coils,
continuity use of continuity tester/ohmmeter), methods of current
regulation (tapped reactor, moving core, moving coil, moving shunt,
saturable reactor, variable resistance), power source characteristics
(volt/ampere graph, drooping characteristic, constant current output),
leads used (welding [water cooled, air cooled, harness] return, earth,
construction, rated output [duty cycle]), torches (types, water cooled
air cooled, pencil, construction, connections, contactor/switch, foot
pedal/amptrol, back caps [long. medium, short, applications], nozzles
[long. medium, short, applications], collet, collet holder, gas lens
[construction, effects, benefits, limitations, applications), electrodes
(thoriated, zironiated, ceriated, lananathed, compositions, sizes,
identification, applications, preparation [grinding: techniques, equipment,
health and safety implications {dust, particulates, extraction, radioactivity
for thoriated}), return clamps (types, clamping mechanisms), ancillary
equipment (angle grinders, linishers, wire brushes, oxide removal,
degreasers)
53
permits to work)
54
Unit 313
materials
URN:
F/503/0375
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
sector or
regulatory body:
Aim:
This unit enables the candidate to develop the

skills and the underlying process technology
required for the fabrication of platework,
including bolted and welded fabrications,
developed platework, tubular node connection,
boxed girder construction and pressure vessels.
It covers health and safety aspects of
fabrication, necessary planning and template
development lay outs, marking out, cutting and
forming and joining for the production of
platework fabrications.
Learning outcome
The learner will:
1. be able to apply safe working practices to platework fabrication
Assessment criteria
The learner can:
1.2 assess hazards and risks associated with hot working and
Range
Hazards and risks: hot working (sources of combustion, identification
of hazards, methods of reducing risks, identification of extinguishers), arc
radiation (visible light, infra-red, ultra-violet, effects, protection (Personal
Protective Equipment (PPE), screening, warnings [verbal, notices], hot
metal/slag from (thermal cutting process, welding processes, grinding)
Safe working practices: thermal cutting and welding: safe start-up and
shutdown procedures, safe use of equipment, equipment checks by
operator, routine maintenance
55
Learning outcome
The learner will:
2. be able to prepare equipment for platework cutting
Assessment criteria
The learner can:
2.1 prepare fabrication cutting equipment for a range of given
applications
2.2 prepare thermal cutting equipment for a range of given
applications
2.3 critically compare methods of cutting thick plate using thermal
and mechanical methods
Range
Cutting equipment: drills (twist drill nomenclature, drilling machines
[pedestal, bench, radial arm, portable, hand, electric power, pneumatic]),
tank cutters, hole saws, rotary shears (portable shears, nibblers [shear
type, punch type, combination shears]), guillotines (mechanical,
pneumatic, CNC control, back stops, front stops, guides), universal
shearing machine, power punch (including CNC control), cold sawing
(circular saws, band saws [vertical, horizontal], reciprocating, friction),
portable angle grinders/sanders
Thermal cutting equipment: oxy-fuel gas cutting (principle, manual
cutting of plate and sections, machine cutting of plate, reason for threepoint support of plate, control of distortion), electric arc process
(plasma-arc, laser cutting)
Critically compare: cost of equipment, suitability, versatility, accuracy,
quality of cut
Learning outcome
The learner will:
3. be able to prepare the equipment for platework forming
Assessment criteria
The learner can:
3.1 prepare fabrication forming equipment for a range of given
applications
3.2 critically compare methods of forming thick plate mechanical
methods
56
Range
Forming equipment: rolling machines (pyramid type, pinch type [three
and four pinch], mechanical, angle-ring bending, section rolls), folding
machines (horizontal, vertical, double arm folder) press brake (tooling
[dies, forming tools], mechanical, electro-hydraulic, up-stroking,
downstroking, CNC control), fly press (tooling [dies, forming tools]);
methods of spring-back control for bending and folding, tooling design
for air bending techniques, specialised tooling for press brake,
use of polyurethane block for use with double arm folder, methods of
pre-setting plate edges for rolling
Methods of forming: cylinders, methods of conical and helical rolling,
methods of rolling sectional material, stops, guides fitted to aid
production; guarding (interlocking devices, fail safe circuits, light guards,
gates)
quality of finish
Learning outcome
The learner will:
4. be able to produce fabrications using platework techniques
Assessment criteria
The learner can:
4.1 perform fabrication assembly operations to produce square,
rectangular and circular forms from thick plate to 2.0 mm
tolerance
4.2 perform joining operations to produce fabricated platework
assemblies to 2.0 mm tolerance
the operation
57
Range
Fabrication assembly: transfer of patterns to metal, use of level
surfaces for assembling, methods used for alignment (strong backs and
wedges, draw cleats/lugs, draw bolts), methods of avoiding twist,
methods of controlling distortion, use of stays to maintain shape, use of
jigs and fixtures and clamping devices, use of tack bolts and tack welds,
care and use of lifting tackle, importance of close contact surfaces,
removal of all temporary tack weld and the reinstatement of a good
surface.
Joining:
thermal joining techniques: manual metal arc welding, MIG welding,
procedures, settings and consumables to produce sound and effective
tacking, interpret weld symbols to BS EN 22553, range of joint
configuration used in thick platework (open square corner joints, lap
fillets, tee fillets, cruciform joints, single and double vee butts, welding
techniques (single and multi-run, stringer beads and weaving), joint
design and welding sequence (weld strength, distortion control, weld
economics), jigs and fixtures to aid assembly; manipulators, positioners,
rotators to facilitate welding and control distortion/ maintain dimensional
accuracy;
mechanical methods of joining: bolting (bolts: [black bolts, high
strength friction grip bolts, close tolerance bolts, fitted bolts], bolting
requirements [cleanliness of contact surfaces, correct tensioning, hole
clearance, tolerances, alignment of holes])
dimensional accuracy: function of a datum line or surface, measuring
equipment to check dimensional accuracy, specific tolerances, methods
of checking accuracy (dimensions, alignment, form, squareness, freedom
from twist and distortion, surface condition)
58
Unit 313
materials
Guidance
welding environment), RIDDOR (application to fabrication process, major
sparks, falling objects, factors render Personal Protective Equipment (PPE)
(action levels)
permits to work)
59
Unit 314

of materials
URN:
A/503/0374
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit enables the candidate to develop

the skills and the underlying process
technology required for the fabrication of
thin plate, including developed thin plate
components, ducting, double curvature
work and light sheetmetal fabrication. It
covers the health and safety aspects of
fabrication work, cutting and forming of
sheet metal and the production of
fabrications using sheet metalwork
techniques, including joining by soldering
(soft and hard) and resistance welding (spot,
seam and projection)
Learning outcome
The learner will:
1. be able to apply safe working practices to sheet metalwork
fabrication
Assessment criteria
The learner can:
Range
of hazards, methods of reducing risks, identification of extinguishers)
60
Learning outcome
The learner will:
2. be able to prepare and use equipment and tools for sheetmetal
cutting
Assessment criteria
The learner can:
2.1 prepare fabrication cutting equipment for a range of given
applications
2.2 prepare fabrication cutting tools for a range of given applications
Range
Cutting equipment: drills (twist drill nomenclature, drilling machines
[pedestal, bench, portable, hand, electric power, pneumatic]),
trepanning, tank cutters, hole saws, rotary shears (portable shears,
nibblers [shear type, punch type, combination shears]), guillotines
(treadle, mechanical, pneumatic, CNC control, back stops, front stops,
guides), universal shearing machine, fly press, power punch (including
CNC control), portable angle grinders/sanders
Cutting tools: hand shears (straight, left hand, right hand, universal),
bench shears (hand-lever, throatless, corrugated), tinmans hand-level
punch
Learning outcome
The learner will:
3. be able to prepare the equipment and tools for sheetmetal forming
Assessment criteria
The learner can:
3.1 prepare fabrication forming equipment for a range of given
applications
3.2 prepare fabrication forming tools for a range of given applications
Range
Forming equipment: jennys (tooling), rolling machines (pyramid type,
pinch type, slip rolls, handoperated, mechanical, cone rolls, angle-ring
bending), folding machines (box and pan, universal swing-beam, angle
bending, simple bench mounted bending), press brake (tooling [dies,
forming tools], mechanical, electro-hydraulic, up-stroking, downstroking, CNC control), fly press (tooling [dies, forming tools]), stretch
forming/shrinking machines, vibratory forming machines
Forming tools: types and sizes of hammers, planishing hammers,
stretching hammers, blocking hammers, hollowing hammers, mallets,
wedge shaped mallets, wooden blocks, sand bags, range of bench stakes
61
Learning outcome
The learner will:
4. be able to produce fabrications using sheet metalwork techniques
Assessment criteria
The learner can:
4.1 perform fabrication techniques to produce square, rectangular,
cylindrical, conical forms (including offsets) and transition pieces
from sheetmetal to 2.0 mm tolerance
4.2 perform joining operations to produce fabricated sheetmetal
assemblies to 2.0 mm tolerance
4.3 evaluate fabrications for dimensional accuracy and fitness for
purpose
4.4 restore work areas to a clean and safe condition on completion
Range
Fabrication techniques: transfer of patterns to metal/plastics,
stiffening techniques (swaging, beading, wired edges [including false],
folds, flanging), forms (square, rectangular, cylindrical, conical: offset:
square, rectangular, cylindrical, conical; boxed, curved panels, double
curvatures, segmental bends), techniques used to produce transition
pieces (square to round, round to square, breeches), stretching and
shrinking techniques (hand forming, machine forming), hand forming
techniques (hollowing, raising, planishing, flanging, double curvature,
split and weld methods), wheeling techniques
Joining: methods of fabrication assembly, use of joints, including selfsecured, soldering and hard solder , types of fluxes, heat sources, braze
welding, resistance welding processes
Dimensional accuracy: function of a datum line or surface, measuring
62
Unit 314

of materials
Guidance
Regulations: Health and Safety at Work etc. Act, COSHH (risk assessment,
consumable data sheets, training and awareness, safe working
procedures, hierarchy of control), PUWER (scope within the welding
environment), RIDDOR (application to fabrication process, major injuries,
over three day injuries, diseases, dangerous occurrences) Management of
Health and Safety at Work Regulations (risk assessment, control
measures, training and awareness, safe working procedures), Personal
Protective Equipment At Work Regulations (application to welding
process, employers duties, employees duties, protection against
hazards [fumes, airborne particles, arc radiation, hot metal, sparks, falling
objects, factors render Personal Protective Equipment (PPE) provided as
protection ineffective or unsafe]), Noise at Work Regulations (action
levels)
Joining: methods of fabrication assembly (holding methods, clamping,
distortion control methods), use of joints, including self-secured (lap,
grooved seam, lock-formed, Pittsburgh lock, panned down, knocked-up,
jointing allowances, junctions that require notched corners), soldering
and hard solder (brazing) techniques (principles of soldering, benefits and
limitations, joint design, preparing the joint, cleaning the joint, types of
soft solder [melting points, applications], types of fluxes, heat sources
[copper bit, flame, hot plate, furnace, induction, resistance, dip], cleaning
the soldered joint), braze welding, resistance welding processes (spot,
seam, projection, principles of resistance welding [power source,
generation of heat, electrodes [sizes, types, functions, methods of
cooling, electrode arms)
permits to work)
63
Unit 315

URN:
J/503/0376
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

technology required for the fabrication and
erection of structural steelwork. The unit is
broadly divided into structural materials,
fixtures and fastenings, structural
fabrication, site work and safe working
practices during fabrication and on site.
Learning outcome
The learner will:
1. be able to apply safe working practices to steelwork fabrication and
erection
Assessment criteria
The learner can:
Range
of hazards, methods of reducing risks, identification of extinguishers), arc
radiation (visible light, infra-red, ultra-violet, effects, protection (PPE,
screening, warnings [verbal, notices], hot metal/slag from (thermal
cutting process, welding processes, grinding)
Safe working practices: thermal cutting and welding: safe start-up and
shutdown procedures, safe use of equipment, equipment checks by
operator, routine maintenance
64
Learning outcome
The learner will:
2. understand how to prepare structural materials for steelwork
fabrication
Assessment criteria
The learner can:
2.1 critically compare structural steels used in fabrication engineering
2.2 explain the commercial forms of supply of materials available
2.3 explain the forms of pre-fabricated sections and fixtures
commercially available
Range
Structural steels: low carbon steel, low alloy steels, high yield alloy
steels, weather resistant steels (WR 55 grades); applications, limitations,
load bearing capabilities, ease of fabrication (marking out, cutting,
joining), density; application for: (access) platforms, decking and
walkways, stairways and hooped ladders, handrailings; (support)
saddles, brackets and cleats, frameworks, bracings and ties
Forms of supply: sections (rolled steel angle [RSA] {equal leg, unequal
leg}, universal beam [UB], universal column [UC], rolled steel channel
[RSC], rolled steel joist [RSJ], tee bar) hollow sections (circular hollow
section [CHS], rectangular hollow section [RHS]) plates (plain, non-slip
[durbar and chequer], expanded, pierced and punched), flat bars
Pre-fabricated sections: plate birders, box girders, lattice girders,
castellated beams, cambered beams, laced stanchions, battened
stanchions, portal frames
Fixtures: cleats (beam to beam connections, beam to column
connections), columns (base plates, end plates, splice plates), gusset
plates
Learning outcome
The learner will:
3. be able to perform marking out and cutting operations on structural
materials
Assessment criteria
The learner can:
3.1 perform marking out operations on structural steelwork to meet
specification
3.2 perform cutting operations on structural material to meet
specification
3.3 critically compare methods of cutting structural steelwork using
thermal and mechanical methods
65
Range
Marking out: directly onto steelwork, using templates (types: plate,
sections, cleats; application of templates: box, battened, part), datum,
centre lines, set out points, avoidance of cumulative error in marking out
by the avoidance of string dimensions, non-slip plate (chequer) avoiding
wrong hand or mirror image errors, setting out a camber, derive the
shapes of bolted gusset plates from standard hole pitch and edge
distance
Cutting:
mechanical: drills, tank cutters, hole saws, rotary shears, guillotines,
universal shearing machine, power punch, cold, portable angle
grinders/sanders, reasons for reaming punched holes
thermal: oxy-fuel gas cutting, electric arc process
quality of cut
Learning outcome
The learner will:
4. be able to produce fabricated steelwork structures
Assessment criteria
The learner can:
4.1 perform fabrication assembly operations to produce welded
beam to beam connection from structural steelwork to 2.0 mm
tolerance
4.2 explain the form and applications of joining methods used in
4.3 evaluate fabrications for dimensional accuracy and fitness for
purpose
4.4 perform a trial erection of fabricated sections
4.5 tension bolts to the recommended torque
4.6 set out a roof truss and determine which members are struts and
which are ties
Range
Fabrication assembly: forming processes (plate rolls [pinch, pyramid],
section rolls, beam bender), use of level surfaces for assembling,
methods used for alignment (strong backs and wedges, draw cleats/lugs,
draw bolts), methods of avoiding twist, methods of controlling distortion,
use of stays to maintain shape, use of jigs and fixtures and clamping
devices, use of tack bolts and tack welds, care and use of lifting tackle,
importance of close contact surfaces, removal of all temporary tack weld
and the reinstatement of a good surface, reasons for part assemblies,
trial erections and sub-assemblies
Joining methods:
thermal joining techniques: manual metal arc welding, MIG welding,
procedures, settings and consumables to produce sound and effective
tacking, interpret weld symbols to BS EN 22553, range of joint
configuration used in thick steelwork (open square corner joints, lap
fillets, tee fillets, cruciform joints, single and double vee butts, welding
techniques (single and multi-run, stringer beads and weaving), joint
design and welding sequence (weld strength, distortion control, weld
66
economics), jigs and fixtures to aid assembly; manipulators, positioners,

rotators to facilitate welding and control distortion/ maintain dimensional
accuracy (restraint, welding sequence, presetting) methods of rectifying
excessive distortion in welded structures (mechanical force, heat)
mechanical methods of joining: bolting bolts (black, high tensile,
high strength friction grip [HSFG], load indicating, close tolerance,
torshear), washers (plain, hardened steel, load indicating, taper, tab, antivibration), shear connectors, factors that contribute to the quality of
bolted connections (cleanliness of surfaces in contact, alignment of
holes, correct tensioning [torque wrench, impact wrench])
Dimensional accuracy: function of a datum line or surface, measuring
Erection: levelling steelwork and steelwork bases, plumbing vertical
members, checking alignment, handle, move and lift structural sections
safely, use of ancillary equipment used on site to lift, move or adjust the
position of steelwork (pulleys, block and tackle, pull-lifts, hydraulic jacks,
podger spanners, drifts, wedges, temporary props and bracings,
falsework, modification techniques to steelwork on site (misaligned
holes, incorrect sized members, maximum thickness of packings,
fouling existing steelwork or services), consequences of cutting holes in
beams to facilitate service piping or ducting
67
Unit 315

Guidance
welding environment), RIDDOR (application to fabrication process, major
provided as protection,ineffective or unsafe]), Noise at Work Regulations
(action levels)
Cutting:
Mechanical: drills (twist drill nomenclature, drilling machines [pedestal,
bench, radial arm, portable, hand, electric power, pneumatic]), tank
cutters, hole saws, rotary shears (portable shears, nibblers [shear type,
punch type, combination shears]), guillotines (mechanical, pneumatic,
CNC control, back stops, front stops, guides), universal shearing machine,
power punch (including CNC control), cold sawing (circular saws, band
saws [vertical, horizontal], reciprocating, friction), portable angle
grinders/sanders, reasons for reaming punched holes Thermal: oxy-fuel
gas cutting (principle, manual cutting of plate and sections, machine
cutting of plate, reason for three-point support of plate, control of
distortion), electric arc process (plasmaarc, laser cutting)
permits to work)
68
Unit 316

fabrication
URN:
Y/503/0379
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

technology required for obtaining flat
layouts of 3D forms that can be used for
producing templates to mark out the
material for fabrication to the required form.
Learning outcome
The learner will:
1. be able to determine lines of intersection
Assessment criteria
The learner can:
1.1 determine lines of intersection using projection
1.2 determine lines of intersection using the principle of the common
central sphere
1.3 determine lines of intersection using the method of cutting planes
1.4 determine joint lines of ducts
Range
Common central sphere: right cylindrical branches onto transformer
pieces, oblique cones to right cones, oblique cones to oblique cones,
inclined right cylinder branches on right cones on and off centre,
cylindrical and rectangular branch intersections onto rectangular
hoppers, cylindrical and rectangular branches on spherical, doomed or
dished ends
Joint lines of ducts: where the centre lines lie on centre and in the
same plane, a right angled tee piece of equal cross-section, a right
angled tee piece of unequal cross-section, junctions of three cylinders
69
Learning outcome
The learner will:
2. be able to develop patterns using parallel line techniques
Assessment criteria
The learner can:
2.1 apply the parallel line method of pattern development
2.2 apply the parallel line method of pattern development to complex
forms
Range
Parallel line: segmental bends (right cylindrical and oblique), square or
rectangular ducts cut obliquely, right cylinders cut obliquely, oblique
cylinders cut obliquely
Complex forms: branch pipes on to boiler, shells, dished ends and
domed ends, cylindrical branches onto right and cylindrical segmental
bends to include interpenetration of the branch pipe, square and
rectangle branches onto right and oblique cones, swan neck transition
pieces, rectangle to rectangle in angular planes, transition pieces of
apparently twisted sides with openings at right angles and different
levels
Learning outcome
The learner will:
3. be able to develop patterns using radial line techniques
Assessment criteria
The learner can:
3.1 apply the radial line method of pattern development
3.2 apply the radial line method of pattern development to complex
forms
Range
Radial line: right cones and frusta, oblique cones and frusta, oblique
cones cut by a flat surface, oblique cones cut by a curved surface, two
way breeches piece made from right cones, two-way breeches piece
made from oblique cones
Complex forms: right cones in multiple connections of right cylinders
and right cones, breeches pieces involving oblique cones, tapered
segmental bends (lobster back bends)
Learning outcome
The learner will:
4. be able to develop patterns using triangulation
Assessment criteria
The learner can:
4.1 apply the triangulation method of pattern development
4.2 apply the triangulation method of pattern development to
complex forms
70
Range
Triangulation: hoppers based on square or rectangular based
pyramids, square or rectangle to round transformers, round to square or
rectangle transformers, transformers and hoppers on and off centre,
between parallel planes, transformers and hoppers between parallel and
non-parallel planes, right cylinders, oblique cylinders, right cones,
oblique cones
Complex forms: rectangular to round off-set transformers on a roof
apex, breeches pieces branching from cylindrical main to equal and
unequal diameter ducts, rectangular kinked sided hoppers (kinked to
produce maximum volume, kinked to produce minimum volume), spiral
blade segments by triangulation
Learning outcome
The learner will:
5. be able to produce templates of developed patterns
Assessment criteria
The learner can:
5.1 apply pattern development techniques to prepare templates for
the marking out of a fabrication
5.2 perform calculations to produce dimensions for checking
templates
5.3 review and revise layouts to accommodate material thickness
5.4 restore work areas to clean and safe condition on completion of
the operation
Range
Templates: purpose, means of checking, types and applications, use of
CAD packages, specialist packages, template production techniques,
tools used, materials, information contained on templates, drilling
requirements, cutting instructions, assembly reference mark, datum[s]
Calculations: length of cylinder (d), angle at the apex of a developed
right cone/frustra pattern/half pattern, use of triangles, use of
trigonometry, application of the neutral line
Material thickness: methods of marking out from templates, including:
external forms, internal forms, holes, back marks, pitch, use of datums;
determine modified set-outs to accommodate plate thickness
(application of the neutral line), use of instructions added to templates
and patterns produced by the triangulation method enabling them to be
used effectively
71
Unit 316

fabrication
Guidance
Templates: purpose (avoid repetitive measurements, avoid unnecessary
material wastage, act as a guide to cutting process[es], means of checking
[lengths, angles, shapes, forms], precise method of marking hole
positions, reliable means of assuring repeatability), types and applications
(pattern development, internal, external, roof truss, gusset, back-marks,
hole, bushed, box), use of CAD packages (standard CAD [eg AutoCAD],
specialist packages [pattern development software]), template production
techniques (template shop/loft, setting out floor), tools used (saws,
planes, drills, marking gauge, steel rule, compasses, dividers, trammels,
protractor, engineers square, flat (plate) square, straight edge, hammers,
centre/dot/nipple punches, chalk line and soft chalk, French chalk,
coloured and indelible pencils/crayons), materials (template paper,
hardboard, timber, sheetmetal, steel plate), information contained on
templates (job/contract number, size/thickness of material, steel section
and length, quantity required, bending/folding instructions, orientation
[eg this side up, left side, right hand, etc], drilling requirements, cutting
instructions, assembly reference mark, datum[s]
permits to work)
72
Unit 317
systems
URN:
R/503/0381
Level:
Level 3
Credit value:
GLH:
80
Endorsement
by a sector or
regulatory
body:
Aim:
This unit enables the candidate to develop the skills

and the underlying process technology required for
the routine maintenance, repair and modifications to
all types of manufacturing machine systems. This
consists of machine tools: drills, lathes, millers,
grinders (precision and off-hand), power saws and
boring machines. It includes the mechanical and fluid
power features of NC and CNC machines and robots,
but not the control systems. It also covers extrusion
equipment and presses; filling, bottling and
packaging plant and conveying and transfer
equipment (but not fork lift trucks and cranes or
other mobile devices). Candidates will not usually be
expected to know the constructional features of the
components of hydraulic, pneumatic or refrigeration
systems, or other specialist equipment, only the
function of each. However they should be able to
apply general engineering principles to identify the
causes of a fault and safely carry out any
replacements needed to bring the equipment back
on line.
73
Learning outcome
The learner will:
1. understand the function of machine systems
Assessment criteria
The learner can:
1.1 explain the structural requirements of a range of common
machine systems
1.2 explain the importance of alignment in machine systems and
methods to achieve it
1.3 explain the methods used to achieve rotational movement
1.4 explain the methods used to achieve linear movement
1.5 explain the methods used to change speeds
1.6 explain the methods used to control feed speeds
1.7 classify coolants and lubricants applicable to machine systems
1.8 explain the application of hydraulic and pneumatic systems to
the operation and control of machine systems
Range
Structural requirements: strength, rigidity, stability, control of
movement, materials (cast iron, cast steel, steel plate), structures (box
column, rib and box bed, fabricated base)
Alignment:
slideways: flat, vee, dovetail, cylindrical, comparison of their
capabilities, main features, accuracy of movement, means of adjustment,
lubrication, protection, friction related to applied loads and
surface finish
typical checks: coaxial alignment between main spindle axis, coaxial
alignment between two spindles, alignment of spindle to guideway,
squareness of slideways movement, concentricity and
end float of spindle, squareness of planes to spindle, setting of guards,
stops and automatic safety cut-outs bearings: plain bush (radial, radial
and axial) ball (radial, axial, radial and axial) roller (radial, axial, radial and
axial)
methods of alignment: standard tests, straight edge, precision level,
autocollimator, reflector and laser, roundness measuring machine
Rotational movement: flat belts, vee belts, toothed belts, chain drives,
correct tensioning belts and chains, friction clutches, dog clutches,
gears: worm and wheel, bevel gear, spur, gear nomenclature, gear
materials, non-ferrous alloys, calculate simple and compound gear ratios,
relationship between torque and power transmitted and the loads on
gear teeth, gear box layouts and means of selecting different output
speeds, gear defects, hydraulic actuators
Linear movement: screw and nut (vee, square [including multi-start],
ACME, relationship between the lead of a screw and the motion
transmitted, engaging screw drives [fixed nuts, split nuts]), rack and
pinion, recirculating ball-screw, crank and connecting rod, cams (lift,
dwell and types of motion produced) hydraulic actuator
Change speeds: sliding gears, cone pulleys, clutch operated, infinitely
variable, electrical/electronic
Control feed speeds: sliding gears (Norton gearbox), leadscrew and
nut, hydraulic drives
Coolants and lubricants: types of coolant pump, strainers and
74
filtration, filters, lubrication of headstock/gearbox assemblies of splash

and pressurised feed
Hydraulic and pneumatic systems: hydraulic reservoirs and pumps,
actuators (rotary and linear), valves and the methods of operation,
pneumatic/hydraulic pressure intensifiers, pneumatic silencers, methods
of providing clean, dry air to a machine tool from air mains
Learning outcome
The learner will:
2. be able to prepare for maintenance of machine systems
Assessment criteria
The learner can:
2.1 evaluate type and extent of work to be carried out
2.2 develop a plan that includes assessing any risks, securing the area
and isolating equipment
2.3 estimate the tools, materials, equipment and information that
will be needed
2.4 set-up to carry out the maintenance activity
Range
Plan: to include - emergency shut down and evacuation procedures for
the work, methods of isolating the equipment or system, procedures for
de-pressurising systems and testing them to be in a safe condition,
procedure for draining oil or other such substances and their safe and
legitimate disposal, spillage and contamination, fire, personal injury,
disposal of toxic waste and other such substances as defined by COSHH
and Environmental Protection Acts, working at heights and in confined
spaces, electrical installations and testing of equipment and appliances
according to the IEE and Electricity at Work Regulations: methods of
lifting, supporting, or otherwise making system components safe, how
the work to be undertaken may interact with or affect other systems or
production facilities
Learning outcome
The learner will:
3. be able to perform inspections and maintenance tasks
Assessment criteria
The learner can:
3.1 perform dismantling and assembling operations to ensure
effective operation on completion
3.2 perform inspections of components and draw conclusions
regarding its repair or replacement
75
Range
Dismantling and assembling: to allow for reassembly, identification of
parts (layout of parts), reassemble in correct order for recommissioning
of the system. Testing of parts and system to establish effectiveness of
repair/replacement.
Learning outcome
The learner will:
4. be able to reinstate machine systems
Assessment criteria
The learner can:
4.1 perform re-commissioning operations to brings system on-line
and adjust as required until the working requirements have been
fully met
maintenance and re-commissioning
Range
Re-commissioning: bring system back on-line and test/trial run to
establish full functionality
76
Unit 317
systems
Guidance
Rotational movement: flat belts, vee belts (single and matched sets)
toothed belts, chain drives, correct tensioning belts and chains, friction
clutches, dog clutches, gears: worm and wheel, bevel gear, spur, gear
nomenclature (addendum, dedendum, clearance, diametral pitch, circular
pitch, module), gear materials (cast iron alloy steels [including surface
hardened], non-ferrous alloys [brass and bronze derivations], plastics),
calculate simple and compound gear ratios, relationship between
torque and power transmitted and the loads on gear teeth, gear box
layouts and means of selecting different output speeds, gear defects
(pitting, flaking, scoring and scuffing, likely causes); hydraulic actuators
Hydraulic and pneumatic systems: hydraulic reservoirs and pumps,
actuators (rotary and linear), valves and the methods of operation
(mechanical, pilot, solenoid, directional control, flow control, pressure
control, uni-directional), pneumatic/hydraulic pressure intensifiers,
pneumatic silencers, methods of providing clean, dry air to a machine tool
from air mains
Plan: to include- emergency shut down and evacuation procedures for
the work, methods of isolating the equipment or system (isolating
switches, removal of fuses, closing and locking off of valves, removal of
valves and blanking of pipes) procedures for de-pressurising systems and
testing them to be in a safe condition, procedure for draining oil or other
such substances and their safe and legitimate disposal, spillage and
contamination (including any special Personal Protective Equipment (PPE)
such as breathing apparatus), fire, personal injury, disposal of toxic waste
and other such substances as defined by COSHH and Environmental
Protection Acts, working at heights and in confined spaces, methods of
Tools, materials, equipment and information: specific implications of
statutory regulations, codes of practice related to installing or maintaining
systems, special considerations as prescribed by the manufacturer
Dismantling and assembling: make identification (witness) marks on
components so that they can be correctly reassembled/re-aligned, label
and safely store parts that have been removed methods used to avoid
distortion and damage to, or leakage from, pipework (disconnecting,
aligning, connecting), precautions needed to avoid danger from, or
damage to, components whilst installing, dismantling and assembling
from: misalignment, use of wrong tools, excessive force, uncontrolled
release of springs, scoring of surfaces; protection of dismantled
components from contamination (blanking off open ports, use of correct
cleaning agents and lint-free cloths), sequence for tightening bolts and
applying specified torque, application of lubrication to seals, precautions
to be taken when refilling systems with specified oils, methods of safely
bleeding systems to eliminate air locks and avoid spillage, how to remove;
fit and replace: bearings, seals, springs, circlips, keys, brushes; prepare or
77
make new gaskets or joints (including preparation of surfaces and/or

housings) and repack glands Inspections: bearing surfaces, erosion and
pitting, split or worn seals, signs of overheating (discolouration); condition
of filters for: signs of metallic or other particles, indications of emulsions
or oil deterioration, correctly labelling re-built components for
replacement in a system or returning to stores, checking oil for signs of
oxidation and acidity, bench testing re-assembled components, pressure
testing pipework and pressure vessels, presenting information that can
be used to appraise the outcome of a maintenance or installation activity
Re-commissioning: refilling or recharging systems, opening up the
system to the sources of pressure, methods to safely drain, bleed and
purge systems to avoid undue leakage or contamination, set up and test
interlocks, sensors and limit switches, sequence of bringing systems
back to the specified working conditions (removal of protective covers
and blanks, opening appropriate valves or switches, operating the system
under gradually increasing pressures or loads, state the methods of
securing pipework and safety fittings (guards, handrails), methods of
replacing insulation, lagging and other protective coverings, applying
identification markings to different parts of a system (colour identification
of pipework to BS 1710, using appropriate and approved codings
for electrical connections and components)
permits to work)
78
Unit 318
Maintenance of utility systems
URN:
D/503/0383
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

technology required for the maintenance
and/or installation requirements of utilities
systems needed for industrial purposes.
These include compressed air, electricity
and steam (but not boilers).
The unit will cover system layouts and their
main components, the selection and use of
appropriate tools and equipment, the
procedures and techniques involved with
safely installing and isolating systems,
removing or replacing components,
commissioning, or restoring, a system to a
fully operative condition.
Learning outcome
The learner will:
1. understand the function of utility systems
Assessment criteria
The learner can:
1.1 explain the nature and behaviour of air under pressure
1.2 differentiate between the different types of air compressor and
their performance
1.3 explain the features of pipework and systems used for supplying
compressed air
1.4 explain the nature and properties of steam under pressure
1.5 explain the nature and effects of electricity
1.6 explain the applications of electrical systems
79
Range
Air: compressed air hazards, relationships between force, area and
pressure and how to use them for calculations, relationships between
volume, temperature and pressure and how to use them for calculations,
relationships between volume, temperature and pressure and how to
use them for calculations, relative humidity and its relationship with air
pressure and temperature
Compressor: performance capability in terms of pressure and
volumetric output of free air delivered (FAD): piston types single stage
and multi-stage, screw, centrifugal, basic component parts and layout of
each type of compressor, intercoolers and aftercoolers construction and
layout, air receivers (function, associated essential equipment fitted to
receivers, legal requirements for installation, inspection and testing), air
dryers (absorption, adsorption, refrigerant types [super dryers])
Pipework and systems
Air: factors affecting pressure drops and flow rates and the relationships
between these and pipe sizes, how information can be obtained by the
use of nomograms, pipework materials and applications, methods of
connecting and supporting different forms of pipework with respect to
access and vibration, mains layouts methods of isolating, draining
(including slope) and take off arrangements, the costs associated with
air leaks, service units filters, pressure regulators and lubricators
Steam: hazards, heat transfer principles and the applications to heat
exchangers, calculation of heat flows (temperature difference x surface
area x heat transfer coefficient), heat content of steam, relationships
between pressure and temperature (use of steam tables), types of steam
and applications (saturated, dry saturated, superheated)
Pipework and systems steam: materials and applications,
connecting methods for HP and LP systems, flanged joints (screwed and
welded), pipe support systems to allow for expansion and vibration,
jointing materials (fibre based, corrugated metallic and spiral wound),
lagging and insulation, causes and prevention of water hammer,
drainage methods, manual cocks and steam traps, functions and main
features of drain coolers, condensers and condensate return systems,
types and main features of steam valves used for (system isolation and
safety, pressure reduction and control, flow control), uses of LP and
exhaust steam for fan heaters, calorifiers and economisers,
Electricity: meaning of common electrical terms and state their units
and relationships as applicable (voltage, current and resistance [Ohms
law], power, voltage and current [relationship between electrical and
mechanical power], heating and magnetic effects, a.c. and d.c. voltages
differences and applications)
Electrical systems: electrical supply systems and their applications and
limitations (supply from grid, 3 phase 4 wire, single phase, 12V and 24V
requirements and uses), types and uses of transformers (fixed and
portable), isolating and control methods (isolators and circuit breakers,
switchgear and distribution panels, fuses, no-volt release and residual
current detectors), methods of electrical distribution, their applications
and limitations (cable forms and selection [size, insulation, including IMS
and screened], cable protection methods including conduit and
armoured, bus bars, extension reels [heating effects on coiled cable]),
meters for testing continuity, voltage and resistance
80
Learning outcome
The learner will:
2. be able to prepare for maintenance of utility systems
Assessment criteria
The learner can:
will be needed
Range
Learning outcome
The learner will:
Assessment criteria
The learner can:
Range
parts (layout of parts), reassemble in correct order for re-commissioning
repair/replacement.
Inspections: bearing surfaces, erosion and pitting, split or worn seals,
signs of overheating (discolouration); condition of filters for: signs of
metallic or other particles, indications of emulsions or oil deterioration,
correctly labelling re-built components for replacement in a system or
returning to stores, checking oil for signs of oxidation and acidity, bench
testing re-assembled components, pressure testing pipework and
pressure vessels, presenting information that can be used to
appraise the outcome of a maintenance or installation activity, methods
of testing electrical equipment/circuitry for insulation and continuity
81
Learning outcome
The learner will:
4. be able to reinstate utility systems
Assessment criteria
The learner can:
fully met
Range
82
Unit 318
Maintenance of utility
systems
Guidance
applying specified torque, application of lubrication to seals,
precautions to be taken when refilling systems with specified oils,
methods of safely bleeding systems to eliminate air locks and avoid
spillage, how to remove; fit and replace: bearings, seals, springs, circlips,
keys, brushes; prepare or make new gaskets or joints (including
preparation of surfaces and/or housings) and repack glands
of pipework to BS 1710, using appropriate and approved codings for
electrical connections and components)
83
informing all interested
parties know of any changes that may affect the operation of the system,
or of any new conditions that could exist in the work area, work
termination documents or reports that may be required are completed
and passed on to an authorised person (eg terminating permits to work)
84
Unit 319
URN:
H/503/0384
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

and/or installation requirements of systems
commonly used in industrial plant and
premises. These include heating and
ventilation, fresh water and waste, low water
systems, fuel and gas storage and
distribution. The unit will cover system
layouts and their main components, the
selection and use of appropriate tools and
equipment, the procedures and techniques
involved with safely isolating systems,
removing and replacing components and
restoring a system back to a full working
condition.
Learning outcome
The learner will:
1. understand the function of plant services
Assessment criteria
The learner can:
1.1 describe the difference between the cold, hot and process water
supply and disposal methods
1.2 explain the properties and requirements of fuel oil systems
1.3 explain the properties and requirements of gases and supply
systems
1.4 explain the principles of heating and ventilating systems
85
Range
Hot and process water supply and disposal methods: nature of
water and the treatments required, storage requirements and methods
including cleansing and testing services, types of water pump, types of
valve, pressure control including relief, flow control, pipework
requirements, heat exchangers, water sprinkler systems, detector types
and testing, storage and settling tanks, arrangements for the disposal of
clean and contaminated waters, toxic liquid waste
Fuel oil systems: fuel characteristics and combustion principles,
precautions when storing, handling and supplying fuels, types of fuel
pump, types of valve, pressure control, flow control, pipework
requirements, identification, protection lagging and tracing
Gases and supply systems: gases for fuel and processing applications
storage methods and requirements, safe practices for filling and
distribution, procedures for evacuating pipework and disposal of
contents removed according to current legislation, methods of testing
for gas presence and leaks, procedures to be followed when detected
gas levels are unsafe, line purging and pressure testing techniques, types
of valve used for plant and services equipment
Heating and ventilating systems: the requirements for acceptable
habitability, recommended number of air changes, the relationships
between air velocity, ducting area and volume of air delivered using
simple calculations or data tables, U values of common construction
materials, factors affecting pressure drops and losses in a system;
factors affecting pressure drops and losses in a system; specific heat
values for air and water and steam; sources of heat into an area, heating
and ventilating components and their symbols according to current BS
and ISO standards, circulating pumps, heating and cooling units
components, fans [centrifugal and axial], the effect of fan speed and
power needed for different airflow rates, filtration units, large particle
extraction, methods of mounting and fixing; types of pipework and
ducting; layouts of hot water central heating systems, layouts of single
and double duct systems, monitoring and control of, automatic
recorders for the analysis of system operation and efficiency
Learning outcome
The learner will:
2. be able to prepare for maintenance of plant services
Assessment criteria
The learner can:
2.3 estimate the tools, materials, equipment and information
required
86
Range
Learning outcome
The learner will:
Assessment criteria
The learner can:
Range
repair/replacement.
Learning outcome
The learner will:
4. be able to reinstate plant services
Assessment criteria
The learner can:
fully met
Range
87
Unit 319
Guidance
Hot and process water supply and disposal methods: nature of
water and the treatments required (acidic and alkaline corrosive effects,
dissolved solids effects and softening processes, bacterial content and
treatment, un-dissolved solids erosion), storage requirements and
methods including cleansing and testing services, types of water pump
(positive displacement, centrifugal), types of valve (isolating [gate and
screw down], pressure control including relief, flow control), pipework
requirements (materials, joining methods and fittings by means of flanged
and screwed connectors, the use of elbows and tee pieces, identification
[to BS 1710], identification and protection lagging and tracing), heat
exchangers (single and multi-pass, calorifiers), water sprinkler systems,
detector types and testing, storage and settling tanks, arrangements for
the disposal of: clean and contaminated waters, toxic liquid waste
Fuel oil systems: fuel characteristics and combustion principles (air/fuel
mixture, flammability and exclusivity, viscosity and flow characteristics,
light and heavy types, applications), precautions when storing, handling
and supplying fuels (types of tank and content measuring methods, need
for barrier walls and spillage trenches, isolating and emergency
procedure, warning and information signs and notices), types of fuel
pump (positive displacement, centrifugal), types of valve (isolating
[gate and screw down], pressure control, flow control), pipework
requirements (materials, joining methods and fittings (elbows, Y pieces,
tee pieces), identification (to BS 1710), protection lagging and tracing
Gases and supply systems: gases for fuel and processing applications
(propane, acetylene, oxygen, ammonia, nitrogen, argon) storage methods
and requirements (identification of cylinders and lines, ventilation, flame
proof switches, securing cylinders, security of access), safe practices for
filling and distribution, procedures for evacuating pipework and disposal
of contents removed according to current legislation, methods of testing
for gas presence and leaks, procedures to be followed when detected gas
levels are unsafe, line purging and pressure testing techniques, types
of valve used for plant and services equipment (isolating [gate and screw
down], pressure control, flow control)
Heating and ventilating systems: the requirements for acceptable
habitability in terms of temperatures, humidity, airborne particles, fumes,
odours and bacterial content; recommended number of air changes for
welding shops, general workshops, office blocks, stores and warehouses;
the relationships between air velocity, ducting area and volume of air
delivered using simple calculations or data tables, U values of common
construction materials - wood, bricks, concrete, insulation; factors
affecting pressure drops and losses in a system; factors affecting
pressure drops and losses in a system; specific heat values for air and
water and steam; sources of heat into an area (external from solar
radiation, internal from electrical equipment and occupants); heating and
ventilating components and their symbols according to current BS and
ISO standards (changeover, bypass and isolating valves and their
methods of actuation [manual, mechanical, electrical], circulating pumps,
heating and cooling units components [including drainage systems], fans
88
[centrifugal and axial], the effect of fan speed and power needed for
different airflow rates, filtration units, large particle extraction [wood
chips and similar particulates]; methods of mounting and fixing; types of
pipework and ducting (materials for construction and insulation, flange
connecting methods, noise reduction baffles); layouts of hot water central
heating systems, layouts of single and double duct systems [with heater
and cooler elements, etc]; monitoring and control of systems (from a
central control point, local sensors and overrides, testing of cooling water
sources for bacterial content (legionella), automatic recorders for the
analysis of system operation and efficiency
to be taken when refilling systems with specified oils, methods of safely
bleeding systems to eliminate air locks and avoid spillage, how to remove;
fit and replace: bearings, seals, springs, circlips, keys, brushes; prepare or
make new gaskets or joints (including preparation of surfaces and/or
housings) and repack glands
Inspections: bearing surfaces, erosion and pitting, split or worn seals,
signs of overheating (discolouration); condition of filters for: signs of
metallic or other particles, indications of emulsions or oil deterioration,
returning to stores, checking oil for signs of oxidation and acidity, bench
pressure vessels, presenting information that can be used to appraise the
outcome of a maintenance or installation activity
89

of pipework to BS 1710, using appropriate and approved codings
for electrical connections and components)
permits to work)
90
Unit 320
systems
URN:
T/503/0390
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

and/or installation requirements of hydraulic
power transmission systems. It involves
identifying hydraulic components and their
symbols and the interpretation of circuit
diagrams. It also covers the procedures and
techniques involved with isolating systems
safely, the ability to install or rebuild circuits
from given information, removing and
replacing components in a circuit and
restoring a system back to a full working
condition it also covers causes of common
faults in hydraulic systems. When training
rigs are used then a method of safely
applying reasonable loads to fully test the
operation of a circuit must be provided i.e.
not simply that the specified actuator
movements are obtained.
91
Learning outcome
The learner will:
1. understand the function of hydraulic systems
Assessment criteria
The learner can:
1.1 explain the relationships between force, pressure and area and
carry out simple calculations
1.2 explain the reasons for pressure drops and losses in a system
1.3 explain the effect of fluid flow rate on actuator speed and power
produced
1.4 explain the characteristics of hydraulic fluids
1.5 explain the function of hydraulic components and their current
standard symbols
1.6 describe the difference between the constructional features of
hydraulic components
1.7 explain the methods used for connecting pipework and hoses and
how systems are installed to minimise pressure drops and flow
restriction
1.8 describe the selection of components for particular purposes
1.9 explain the relative positions of components in a circuit
1.10 explain the possible causes of common faults
Range
Hydraulic fluids: viscosity, density and lubricity (including effects of
temperature and aeration), flash point and fire resistant forms, purpose
of oil additives, causes of deterioration of hydraulic oils, procedures for
storing and handling of hydraulic fluids, potential hazards
Hydraulic components: pumps, gear types, vane types, actuators,,
rotary, non-return, pressure, auxiliary components
Constructional features: types of seals and their applications (static
and dynamic), seal materials, compatibility and methods of assembly,
methods of mounting and fixing valves and actuators, attachment of
connectors and pipework
Relative positions of components: counterbalance, unloading and
offloading, meter-in, meterout and bleed off speed control, sequential
operation
Common faults: slow, erratic and intermittent motion of actuators, lack
of specified system pressure, cavitation, overheating of oil
92
Learning outcome
The learner will:
2. be able to prepare for maintenance of hydraulic systems
Assessment criteria
The learner can:
will be needed
Range
and Environmental Protection Acts, working at heights and in
confined spaces, electrical installations and testing of equipment and
appliances according to the IEE and Electricity at Work Regulations:
methods of lifting, supporting, or otherwise making system components
safe, how the work to be undertaken may interact with or affect other
systems or production facilities
Learning outcome
The learner will:
Assessment criteria
The learner can:
Range
Dismantling and assembly: to allow for reassembly, identification of
parts (layout of parts), reassemble in correct order for recommissioning
of the system, Tessting of parts and system to establish effectiveness of
repair/replacement.
93
Learning outcome
The learner will:
4. be able to reinstate hydraulic systems
Assessment criteria
The learner can:
4.1 perform re-commissioning operations to bring system on-line and
adjust as required until the working requirements have been fully
met
operation
Range
94
Unit 320
systems
Guidance
Hydraulic fluids: viscosity, density and lubricity (including effects of
temperature and aeration), flash point and fire resistant forms, purpose of
oil additives, causes of deterioration of hydraulic oils (chemical changes
due to oxidation overheating, contamination by suspended solids and
moisture, incorrect storage conditions), procedures for storing and
handling of hydraulic fluids, potential hazards (toxicity, harmful effects on
skin)
Hydraulic components: BS 2917, ISO 1219-1; pumps (piston types
[axial, radial and variable delivery swash plate], gear types [internal and
external], vane types [fixed and variable capacity]); actuators (linear
single acting, double acting, telescopic and differential [ram] type
cylinders ] uncushioned and cushioned forms], rotary [hydraulic motors]
piston and sliding vane types; valves and their methods of actuation
[manual, mechanical, electrical and pilot] (rotary and spool directional
control valves 2/2, 3/2, 4/2, 5/2 and 4/3 [including all neutral position
variants of 3 position types], non-return [plain and pilot operated],
pressure control pressure regulating and relief [simple and compound],
flow control simple restrictors, uni-directional and pressure
compensated types, modular [stacker] and cartridge valve assemblies,
identification of valve ports using current systems [PABT and numeric]);
auxiliary components (reservoirs, accumulators, pressure intensifiers,
filters)
testing them to be in a safe condition (including reservoirs and storage
vessels), procedure for draining oil or other such substances and their
safe and legitimate disposal, spillage and contamination (including any
special PPE such as breathing apparatus), fire, personal injury, disposal of
toxic waste and other such substances as defined by COSHH and
Environmental Protection Acts, working at heights and in confined
95

to be taken when refilling systems with hydraulic oil, methods of safely
bleeding systems to eliminate air locks and avoid spillage, procedures for
charging gas filled accumulators
Inspections: bearing surfaces, erosion and pitting (e.g. of gear teeth or
vane edges), split or worn seals, signs of overheating (discolouration);
condition of filters for: signs of metallic or other particles, indications of
emulsions or oil deterioration, correctly labelling re-built components for
interlocks, sensors and limit switches, sequence of bringing systems back
to the specified working conditions (removal of protective covers and
blanks, opening appropriate valves or switches, operating the system
permits to work)
96
Unit 321
systems
URN:
R/503/0395
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

and/or installation requirements of
pneumatic power transmission systems.
It involves identifying pneumatic
components and their symbols and the
interpretation of circuit diagrams. It also
covers the procedures and techniques
involved with isolating systems safely, the
ability to install or rebuild circuits from given
information, removing and replacing
components in a circuit and restoring a
system back to a full working condition and
causes of common faults in pneumatic
systems. When training rigs are used then a
method of safely applying reasonable loads
to fully test the operation of a circuit must be
provided i.e. not simply that the specified
actuator movements are obtained.
97
Learning outcome
The learner will:
1. understand the function of pneumatic systems
Assessment criteria
The learner can:
1.1 explain the relationships between force, pressure and area and
carry out simple calculations
1.2 explain the use of nomograms for pipe selection
1.3 explain the reasons for pressure drops and losses in a system
1.4 explain the effect of fluid flow rate on actuator speed and power
produced
1.5 explain the changes in energy throughout a system
1.6 explain the function of pneumatic components and their current
standard symbols
1.7 describe the difference between the constructional features of
pneumatic components
1.8 explain the methods used for connecting pipework and hoses
and how systems are installed to minimise pressure drops and flow
restriction
1.9 describe the selection of components for particular purposes
1.10 explain the relative positions of components in a circuit
1.11 explain the possible causes of common faults
1.12 explain the application of circuits with electro pneumatic
operation
Range
Pressure drops: leaks, changes in temperature, venting, etc.
Pneumatic components: actuators, rotary, rotary and spool directional
control valves, non-return, pressure control, simple restrictors and bypass forms, two pressure and shuttle valves [OR and AND logic], quick
exhaust, impulse generators, identification of valve ports using current
systems; auxiliary components
Constructional features: types of seals and their applications (static
and dynamic), seal materials, compatibility and methods of assembly,
methods of mounting and fixing valves and actuators
Connecting pipework: attachment of connectors and pipework to
components, types of pipework and connecting methods (rigid, flexible
and push-in), factors for efficient and safe routing of pipes to minimise
pressure drops and flow restriction
Relative positions of components: components needed for particular
purposes and their relative positions in a circuit to obtain speed control
and sequential operation, reasons for held (maintained) signals and
methods of overcoming this problem for circuits requiring up to three
group cascade layouts
Common faults: slow, erratic and intermittent motion of actuators, lack
of specified system pressure
Electro pneumatic: types of sensor or contact (induction, magnetic,
reed switches), relays, rotary switches; principles of programmable logic
controllers (PLCs) using a black box treatment only; basic the
programming methods and the need for requiring feedback signals
98
Learning outcome
The learner will:
2. be able to prepare for maintenance of pneumatic systems
Assessment criteria
The learner can:
will be needed
Range
Learning outcome
The learner will:
Assessment criteria
The learner can:
Range
of the system, testing of parts and system to establish effectiveness of
repair/replacement
99
Learning outcome
The learner will:
4. be able to reinstate pneumatic systems
Assessment criteria
The learner can:
fully met
operation
Range
and blanks, opening appropriate valves or switches, operating the
system under gradually increasing pressures or loads, state the methods
of securing pipework and safety fittings (guards, handrails), methods of
100
Unit 321
systems
Guidance
Pneumatic components: BS 2917, ISO 1219-1: actuators (linear single
acting, double acting, telescopic and differential [ram] type cylinders ]
uncushioned and cushioned forms], rotary [air motors] piston and
sliding vane types; valves and their methods of actuation [manual,
mechanical, electrical and pilot], rotary and spool directional control
valves [including all neutral position variants of 5/3 position types], nonreturn [plain and pilot operated], pressure control pressure regulating
and relief, flow control simple restrictors and by-pass forms, two
pressure and shuttle valves [OR and AND logic], quick exhaust, impulse
generators, identification of valve ports using current systems; auxiliary
components (reservoirs, accumulators, pressure intensifiers, filters,
silencers,)
testing them to be in a safe condition (including reservoirs and storage
vessels), procedure for draining oil or other such substances and their
safe and legitimate disposal, spillage and contamination (including any
special Personal Protective equipment (PPE) such as breathing
apparatus), fire, personal injury, disposal of toxic waste and other such
substances as defined by COSHH and Environmental Protection Acts,
working at heights and in confined spaces, electrical installations and
testing of equipment and appliances according to the IEE and Electricity at
Work Regulations: methods of lifting, supporting, or otherwise making
system components safe, how the work to be undertaken may interact
with or affect other systems or production facilities
to be taken when refilling systems with hydraulic oil, methods of safely
bleeding systems to eliminate air locks and avoid spillage, procedures for
charging gas filled accumulators
101
Inspections: bearing surfaces, erosion and pitting (e.g. of gear teeth or

vane edges), split or worn seals, signs of overheating (discolouration);
condition of filters for: signs of metallic or other particles, indications of
emulsions or oil deterioration, correctly labelling re-built components for
interlocks, sensors and limit switches, sequence of bringing systems back
to the specified working conditions (removal of protective covers and
blanks, opening appropriate valves or switches, operating the system
permits to work)
102
Unit 322

URN:
K/503/0435
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit is concerned with power

generation and associated systems, in terms
of: planning and preparation, components,
carrying out inspections, maintenance and
installation tasks and commissioning the
system
Learning outcome
The learner will:
1. be able to identify the components and features of utilities
Assessment criteria
The learner can:
1.1 identify the components and sub-systems needed for power
generation units from drawings that use standard symbols
1.2 identify the function of the essential components needed for
power generation plant or sub-systems
1.3 select components or equipment to meet specified functions in
terms of required volumes (fuel, air and steam), pressures and
temperatures using manufacturers catalogues or other data
Range
Power generation: principles of combustion of hydrocarbon fuels and
the products of combustion, need for the correct proportions of air and
fuel for complete combustion, ways in which energy forms can be
achieved (chemical to heat, heat to mechanical, kinetic to mechanical);
principles and factors affecting heat transfer by conduction, convection
and radiation, basic four stroke, two stroke cycle for spark, compression
ignition (CI) systems, valve timing diagrams (for all types ) defining lead,
lag and overlap, ignition and combustion requirements [obtaining the
correct air pressures and temperatures, uniform mixtures of air and fuel
in the required proportions, effects of incorrect mixtures, use of
pressure/volume and crank angle/pressure diagrams to show the stages
in combustion process]
Function of the essential components: general layouts of the
following types of engine: on-line, vee, methods of supplying air to IC
103
engines, main features of electrical systems

Components : parts of cooling water supply systems, water treatment
for preventing scaling, corrosion and freezing, relationship between
pressure and boiling point and resultant danger, parts of lubricating
systems, splash methods of lubricating cylinder walls and valve
mechanisms, types of oil and grease used specifically for IC engines,
starting methods for IC engines, general construction details of
reciprocating IC engines, bearing types and application, ball and roller
solid bush, split bearings, principles and construction of turbines, stages
of a gas turbine engine and the associated components, compressorblade materials, changes in air pressure and temperatures, compression
chambers, power take off arrangements, control methods for safe and
efficient running, dispersal methods for exhaust gases in accordance
with current regulations and good practice, stages of steam turbines and
the associated components, control nozzle arrangements, speed
governing and overspeed trips, exhaust steam arrangements and
condensers, materials used for different components and power units
and the reasons for their selection, possible causes of corrosion in IC
engines, possible causes of commonly observed symptoms related to IC
engines
Learning outcome
The learner will:
2. be able to plan and prepare for the maintenance or installation
operation
Assessment criteria
The learner can:
2.1 evaluate the type and extent of work to be carried out
2.2 describe how current legislation and codes of practice relate to
the given tasks
2.3 carry out a risk assessment by listing the procedures and
requirements for setting up safe working conditions
2.4 select manufacturers information, related records, circuit diagrams
and other necessary data
2.5 check availability of materials, tools and equipment and prepare
requisitions or works orders as required
2.6 assemble all tools, materials and other equipment required
104
Range
Extent of work: layout, function of components and operational
features of the pneumatic system to be installed or maintained (special
considerations as prescribed by the manufacturer, methods of lifting,
supporting or otherwise making system components safe, work to be
undertaken may interact with or affect other systems or production
facilities)
Current legislation: specific implications of Statutory regulations,
Codes of practice related to installing or maintaining steam generating
systems, disposal of toxic waste and other substances as defined by
COSHH and environmental protection acts, pressure systems and
portable gas containers and working at heights and in confined areas
legislation
Risk assessment: methods of isolating the equipment or system
(isolating switches, removal of fuses, closing or locking off of valves,
removal of valves and blanking of pipes, procedures for de-pressurising
systems and testing them to be in a safe condition, procedures for
draining oil and other substances and their safe and legitimate disposal,
need for providing equipment to deal with spillage and contamination
(including any special Personal Protective Equipment (PPE) such as
breathing apparatus), fire and personal injury, emergency shut down and
evacuation procedures for the work area
Learning outcome
The learner will:
3. be able to carry out inspections and general maintenance tasks
Assessment criteria
The learner can:
3.1 carry out an inspection
3.2 diagnose system faults and rectify components
3.3 reassemble system following repair
Range
Inspection: on power generation equipment or system
Inspection: methods used to avoid distortion and damage to, or leakage
from, pipework (disconnecting, aligning, connecting), precautions
needed to safely and effectively dismantle components, make
identification (witness)marks on components so they can be correctly re
assembled or re-aligned, label and safely store parts that have been
removed, precautions needed to avoid danger from, or damage to,
components whilst installing, dismantling and assembling from
misalignment, use or wrong tools or excessive force, uncontrolled
release of springs and scoring of surfaces; protect dismantled
cleaning agents and lint free cloths)
Diagnose system faults and rectify components: rectify by repair or
replace, essential points to be checked when inspecting pneumatic
components (bearing surfaces, erosion and pitting, split or worn seals,
signs of overheating (colour changes), condition of filters for signs of
metallic or other particles, indications of emulsions or oil deterioration.
Re-assembly: procedures for re-assembling components to avoid
105
damage using the approved sequence for tightening bolts and applying
specified torque and the application of lubrication to seals, need for
returning to stores, checking oil for signs for oxidation and acidity, bench
pressure vessels, precautions to be taken when refilling systems with
hydraulic oil, methods of safely bleeding systems to eliminate air locks
and avoid spillage, procedures for charging gas filled accumulators,
present information that can be used to appraise the outcome of a
maintenance or installation activity
Learning outcome
The learner will:
4. be able to commission or re-commission the system
Assessment criteria
The learner can:
4.1 bring the system online and adjust as required until the working
parameters have been fully met
4.2 restore the work area to a clean and safe condition on
completion of maintenance or installation
4.3 identify hazardous substances that may have been used or
discovered during the work and give the approved method of
disposal for each such substance
4.4 describe the reasons for handing over the system to the
authorised persons
4.5 complete a report on the action taken
Range
Online and adjust: precautions to be taken when refilling or recharging
the systems and opening up the system to the sources of pressure,
methods of safely draining, bleeding and purging systems to avoid undue
leakage or contamination, set up and test interlocks, sensors and limit
switches, removal of protective covers and blanks, opening appropriate
valves or switches, operating the system under gradually increasing
pressure or loads,
Hazardous substances: materials used that are classified as hazardous
and those that can be recycled,
Handing over: necessity for, and methods of, reporting any damage
caused by the maintenance or installation activity where additional
restoration work may be needed, need to let all interested parties know
of any changes that may affect the operation of the system, or of any
new conditions that could exist in the work area. Work termination
documents or reports that may be required are completed and passed
on to an authorised person, procedure for terminating any permits to
work.
106
Unit 322

Guidance
Function of the essential components: general layouts of the
following types of engine (in-line, vee, engine capacity in terms of bore,
stroke and number of cylinders, meaning of torque and its relationship
with engines speed and power produced, factors affecting the efficiency
of power generating systems, systems for supplying fuels to power units
(from storage point to engine, by carburettors, venture, throttle control,
main and idling jets, injection pumps, injectors [types and spray patterns]
gas flow regulating valves]) methods of supplying air to IC engines
(normally aspirated, under pressure [supercharged and turbocharged[,construction and positioning of chargers, need for correct
operating procedures to avoid damage during start up and shut down, air
filtration [wet and dry types]), main features of electrical systems (coil
ignition and components-switch, coil, condensers, contact breakers,
distributors, spark plug types, suppressors, magneto-rotating armature,
rotating magnet, contact breakers and mechanisms, a.c. alternators and
generators and including voltage regulators, d.c. batteries-checking of
condition and recharging).
Components : parts of cooling water supply systems (closed circulation
via heat exchangers [radiators], pump types, temperature control
methods [thermostats], water treatment for preventing scaling, corrosion
and freezing, relationship between pressure and boiling point and
resultant dangers), parts of lubricating systems (pressurised: pump
types, filters, pressure control and warning systems, oil coolers), splash
methods of lubricating cylinder walls and valve mechanisms, types of oil
and grease ( and additives ) used specifically for IC engines, starting
methods for IC engines (electric, compressed air, hydraulic, manual,
starting aids, volatile gas injection, heater plugs, excess fuel [choke],
decompression devices), general construction details of reciprocating IC
engines (cylinder blocks and heads [use wet and dry liners], crankshafts
and bearing arrangements, cam shafts and valve timing arrangements,
piston assemblies [gudgeon pins and types of piston ring], bearing types
and application, ball and roller solid bush, split bearings [white metalled
and shell types], principles and construction of turbines (rotor and stator
blade configurations, blade shapes-impulse and reaction types-multi
staging, methods of attaching blades onto rotor discs, need to allow for
expansion of gases and steamand gas), stages of a gas turbine engine and
the associated components, compressor-blade materials, changes in air
pressure and temperatures, compression chambers (materials, fuel
injection and mixing arrangements [primary and secondary], internal and
external combustion zones, blade materials, attachment methods
[including shrouding], power take off arrangements (reduction gearing),
control methods for safe and efficient running (acceleration control units,
steady speed governors, overspeed and temperature trips, use of
exhaust gases to preheat air inlet to combustion zones), dispersal
methods for exhaust gases in accordance with current regulations and
good practice, stages of steam turbines and the associated components,
107
control nozzle arrangements), speed governing and overspeed trips,

exhaust steam arrangements and condensers, materials used for
different components and power units and the reasons for their selection,
possible causes of corrosion in IC engines (cooling water, condensation,
reactions with combustion products, requirements and checks needed
for standard maintenance and installation routines associated with the
components and systems listed, possible causes of commonly observed
symptoms related to IC engines (smoke from exhaust, overheating,
knocking or pinking, misfiring or loss of power, excessive consumption [of
fuel or oil])
Restore the work area: methods of securing pipework and safety
fittings (guards, handrails), methods of replacing insulation, lagging or
other protective coverings, identification markings to different parts of a
system: colour identification of pipework to BS1710; using appropriate
and approved codings for electrical connections and components
108
Unit 323
turning
URN:
T/503/0437
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit is concerned with the underlying

process of machine alignment and
producing complex components whilst
following safe working practices. The unit is
designed to enable candidates to carry out a
full alignment test and record the results,
produce internal and external tapers,
measure angles and inspect with taper
gauges, cut internal and external multi start
threads, form profiles and identify cutting
tool shapes and describe the materials
Learning outcome
The learner will:
1. be able to carry out alignment tests and machine to required
dimensions
Assessment criteria
The learner can:
1.1 perform safety checks
1.2 use inspection equipment to perform full alignment tests
1.3 explain the functions and layout of the headstock gearbox
1.4 machine by turning to required dimensions
109
Range
Safety checks: risk assessment, inspect equipment prior to test, lock-off
system. re-instatement procedures, Personal Protective Equipment
(PPE), manual handling, emergency stops, COSHH requirements
(lubricants, cutting fluids, cleaning materials)
Equipment: mandrills (headstock, tailstock) dial test indicators (lever,
plunger) precision levels (spirit [vee grooved base], square block),
straight edge,
Alignment tests: headstock, tailstock, bed, guideways, centres
Headstock: shafts, gear clusters, ratios, gear systems (shaft [drive,
driven, lay], gears [straight, involute, rack], lubrication systems [drip,
splash, pump]) system of lubrication, calculations (geometric gear
progression [including produce graph], spindle speeds for each gear
ratio)
Machining by turning: external, internal, faces, recesses, undercuts,
between centres, parting off, drilling holes (centre drilling, pilot drilling,
through holes, blind holes, flat bottom holes), reamed holes, bored
holes, chamfers, parting off, knurling, types of chip produced (continuous
[materials, prevention, hazards], discontinuous [materials]), relationship
between feed rate and depth of cut and the effect on material removal
rate
Learning outcome
The learner will:
2. be able to produce self-holding and quick release tapers
Assessment criteria
The learner can:
2.1 use workholding devices when setting up for turning operations
2.2 perform turning operations to produce self-holding and quickrelease tapers to BS EN ISO 286 and surface finish 1.6 m
2.3 explain methods of manufacture
2.4 evaluate tapers using engineers blue, measuring and gauging
inspection techniques
Range
Workholding: between centres, faceplate, catch plates and carriers,
collets, magnetic and pneumatic devices, mandrels, steadies, fixtures,
spigots, bar feed, purpose
Tapers: morse, international, boring tools and holders, drills (twist,
core), reaming (purpose, types [machine, chucking, taper],
nomenclature, accessories [extension sockets, reduction sleeves,
machine tapers, floating reamer])
Manufacture: form tool, compound slide, offset tailstock, taper turning
attachment
Inspection: measure/gauge internal and external tapers (taper plug
gauge, taper ring gauge), engineers blue, gauge blocks, sine bar and
surface table/plate
110
Learning outcome
The learner will:
3. be able to produce single and two start threads
Assessment criteria
The learner can:
3.1 identify different standard thread forms
3.2 perform grinding operations to produce cutting tools to match
methods of thread cutting
3.3 perform lathe setting operations to produce internal and external
two-start threads
3.4 produce multi-start threads to medium fit specification
3.5 evaluate threads against the specification
Range
Thread forms: metric (course, fine, special) unified (course, fine) British
Standard (whitworth, fine, B.A.) square, acme
Grinding: tool grinder, profile, high speed steel, stellite
Lathe setting: on centre, square using gauge, half included angle, pitch
movement (compound slide, rotate spindle)
Threads: internal, external, cutting (plunge, half included angle,
chasers), calculate depth of flank angle, sine bar gauge blocks, surface
plate/table, precision balls, depth micrometer
Evaluate: three wire, thread measuring machine, shadow graph
projector, thread profile gauge, contour gauge, thread measuring
(effective diameter, major diameter, minor diameter)
Learning outcome
The learner will:
4. be able to differentiate between cutting methods
Assessment criteria
The learner can:
4.1 describe tool and tip shape
4.2 perform calculations to determine the cutting speeds in
relationship to tool material and material being cut
4.3 perform calculations to determine cutting speeds and feeds
4.4 describe form, oblique and orthogonal cutting
4.5 diagnose any problems encountered
111
Range
Tool and tip shapes: solid bits, brazed tips and inserts (disposable),
indexable tip tool shapes (square, triangular, diamond, round), tool
holding (clamp and cap screw, pin and wedge, pin and lever, screwed,
single post, quick-change tool post, four way tool post)
Tool material: high speed steel, alloyed carbon steel, stellite, tungsten
and ceramic carbides, diamond, temperature charges tool materials, tool
geometry (clearance, rake [positive, negative]), chip breakers, tip tool
colour coding
Materials: range of carbon steels, cast iron, aluminium, copper and
copper alloys
calculations: speed formula, feed in millimetres per revolution, factors
affecting choice of cutting speed (work material being cut, cutting tool
material, type of cutting operation, surface finish required, type of
cutting fluid), factors affecting choice of feed (finish required, rate of
material removal, type of cutting tool material, power of machine, type of
cutting operation)
Cutting: rake and clearance angles for form tool, cutting and feed forces
(tangential, feed, back, calculate the forces acting on a cutting tool) types
of cutting (oblique, orthogonal), types and properties of cutting fluid
(aqueous, oil-type, chemical, synthetic, gases)
Problems: oversize/undersize components (tool wear, slackness in
slides, deflection), inconsistency of product shape (deflection, clamping,
stops, alignment of fixtures), vibration (condition of machine, tooling, setup, speeds and feeds), surface damage to component (blunt tools,
clamping)
112
Unit 323
turning
Guidance
Workholding: between centres (centres and sleeves: dead, running, live)
faceplate (hold work directly on plate, hold work via a fixture, balancing)
catch plates and carriers, chucks (three jaw, hard jaws, soft jaws, four jaw
[normal reverse, regular shapes, irregular shapes, balancing), collets
(parallel, expanding), magnetic and pneumatic devices, mandrels (plain,
expanding), steadies (fixed, travelling), fixtures, spigots, bar feed, purpose
(locate workpiece, restrain workpiece against cutting forces)
Assessment Guidance
Outcome 3 - Thread should be retained to ensure that the thread is not
produced with a die and finished with a die-nut.
113
Unit 324
URN:
M/503/0436
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

process used in producing complex
components whilst following safe working
practices and using advanced milling
operations to a high level of precision.
The unit is designed to enable candidates to
set and operate a universal dividing head,
carry out differential indexing, establish
spindle speeds and feeds for individual
operations, machine multiple faces in a
single pass, mill straight and curved gears.
Learning outcome
The learner will:
1. be able to prepare for milling operation
Assessment criteria
The learner can:
1.1 explain the range, type and capabilities of milling machines
available
1.2 explain the checks required prior to machining
1.3 define cutting speed as relative speed between tool point and work
surface
1.4 explain the factors affecting choice of cutting speed
1.5 define and calculate feed rates
1.6 critically compare the types and properties of cutting fluid
1.7 explain the relationship between rotation of cutter and feed
direction
1.8 describe the range, setting, methods of use and characteristics of
workholding methods and devices
1.9 explain the types and applications of spindle held cutters
1.10 explain the types and applications and methods of securing of
other cutters
1.11 explain the tool geometry of milling cutter
1.12 explain the factors to be considered for effective production of
114
components
1.13 explain the possible production problems encountered and
possible remedies
1.14 perform milling machine set up to meet component and production
specifications
1.15 perform relevant alignment checks and check machine for defects
1.16 produce a speeds and feeds table
1.17 set required speeds and feeds
1.18 prepare and mount cutting tools for complex milling operations
Range
Milling machines: horizontal, vertical, universal, construction, parts,
applications, reasons for the choice of milling machine type; horizontal
milling operations: milling flat surfaces (horizontal, vertical), production
of slots, slitting thin plate, gang milling, straddle milling, cutting keyways,
gear cutting; vertical milling operations: milling flat surfaces (horizontal,
vertical), production of slots (tee, dovetail), sunk and recessed surfaces,
keyway cutting, including woodruff
Checks: safety switches, interlock devices, emergency stops, guarding,
alignment tests (table, vertical spindle/quill), operating and care
procedures (methods of starting, stopping, including emergency stop
procedure)
Cutting speed: work material being cut, cutting tool material, type of
cutting operation, type of cutter, surface finish required, type of cutting
fluid required, calculate cutting speeds for milling
Feed rates: cut/tooth, table feed rate (mm/min), calculate feed, formula
(feed/tooth x number of teeth x rev/min); factors affecting choice of feed
rate: finish required, rate of material removal (type of cutting tool
material, power of machine), type of cutting operation being carried out,
type of cutter; calculate feed rates for milling
Cutting fluid: types (aqueous, oil-type, chemical, synthetic), purpose
(provision of lubrication at tool point, absorption and removal of heat
from the cutting zone, maintaining clean cutting zone, washing away
chips
Relationship between rotation of cutter and feed direction: up-cut
milling, down-cut milling,
Workholding: clamping work to machine table, machine vice, tilting
table, sine table, rotary table, angle plate, vee blocks, dividing head [plain
and universal] (methods of workholding, indexing calculations [simple,
compound, differential and angular]), fixtures; purpose (locate
workpiece, restrain workpiece against cutter forces); potential
movement of the workpiece along and around the x, y, and z axes of the
machine
Spindle held cutters: face mills, inserted blade
Other cutters: drills, parallel and taper shank, machine reamers,
machine taps, boring tools
Tool geometry: factors affecting penetration of material by cutting
edge (hardness of cutting tool material in relation to material being cut,
sharpness of cutter, wedge form of cutter); angle of wedge shape and
their function and terminology (rake angle: positive, negative, neutral),
clearance angles; relationship between depth of cut and feed rate and
effect on material removal rate
Effective production of components: correct sequence of machining
operations to maximise production, eliminating unnecessary tool
115
changes, eliminate unnecessary materials handling (fixtures, stops and

guides), adjust parameters to improve quality and production efficiency
Problems: oversize/undersize products (tool wear, slackness in slides,
deflection), inconsistency of product shape (deflection, clamping, stops,
alignment of fixtures), vibration (condition of machine, tooling, set-up,
speeds and feeds), surface damage of component (blunt tools,
clamping), product schedules not being met
Learning outcome
The learner will:
2. be able to machine components using a universal dividing head
Assessment criteria
The learner can:
2.1 select and set workholding devices square and central to cutter
and set adjustable angle plate to prescribed angle
2.2 set-up universal dividing head for differential milling operations
2.3 perform calculations the indexing movement and gearing required
2.4 produce machined holes and slots around an external diameter
2.5 produce machined gears and cutter teeth around an external
diameter
2.6 machine arcs and angles, to within specified dimensions and
measure accuracy to 0.1mm, angular 1 and surface finish 1.6m
2.7 produce machined teeth on the peripheral of bevelled blanks
2.8 apply milling machine equipment to complex machining
operations
2.9 apply milling cutters and perform complex machining operations
to BS EN ISO286, angles 0.5 and surface finish 1.6m
2.10 perform inspection of components to determine the level of
accuracy by measuring and gauging
Range
Workholding devices: rotary table (indexing, scales (rotary, vernier),
swizzle vice, angle plate (fixed and adjustable), methods of securing and
centralising work
Universal dividing head: 40:1
Calculations: simple and differential indexing
Gears: straight and curved teeth for gear wheels and teeth for cutters,
straight, involute, splined hafts, serrated shafts
Bevelled blanks: end of shaft and/or bored
Equipment: tailstock, chuck, catch plate mandrel dial test indicator and
base
Milling cutters: end mills, slot drills, angle cutters and drills
Inspection: external micrometers (0 -25, 25-50 and 50-150mm), internal
micrometer, vernier callipers & protractor, surface texture gauges,
gauge blocks, sine bar
116
Learning outcome
The learner will:
3. be able to machine components by reaming and boring
Assessment criteria
The learner can:
3.1 set up machines and equipment to perform reaming and boring
operations
3.2 check and reset machines alignment
3.3 apply cutting tools to complex machining operations
3.4 mount cutters prior to multi facet milling in a single pass
3.5 produce precision holes by boring and reaming to within H8
3.6 perform inspection of components to determine the level of
accuracy by measuring and gauging
Range
Machines and equipment: vertical, horizontal, universal, off-set boring
head
Alignment: table, spindle
Cutting tools: reamers (machine, chucking, stub, shell, boring heads)
Inspection: internal micrometer, depth micrometer, vernier callipers &
protractor, surface texture gauges, gauges: plug, sine bar (construction,
size, calculations)
Learning outcome
The learner will:
4. be able to reinstate the work area
Assessment criteria
The learner can:
4.1 explain the health and safety and environmental legislations for
waste disposal, and implications of not following legal requirements
4.2 explain the importance of maintaining the safety and
cleanliness of machinery, tools equipment and the work area
4.3 explain the correct procedures for dealing with waste materials
4.4 explain the potential problems that may occur during restoring the
work area and actions to be taken
4.5 explain the actions to be taken in the event of a spillage
4.6 restore work area after machining operations
Range
Maintaining the safety and cleanliness: isolate machines, manual
cleaning, machine assisted cleaning, use and correct storing of cleaning
agents, identify and label products, inspection of components, tools and
equipment on the completion of work, sort items into reusable, rework
and waste, clean and store Personal Protective Equipment (PPE)
Spillage: barriers and safety signs, use of personal protective
equipment, aids to containment and prevention of spillage reaching
watercourse, aides for cleaning, who should be notified
117
Unit 324
Guidance
permits to work)
118
Unit 325
grinding
URN:
A/503/0438
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

process of producing high quality surface
textures on a range of components by
grinding whilst following safe working
practices. The unit is designed to enable
candidates to carry out a range of surface
grinding operations safely, carry out a range
of cylindrical grinding operations both
internally and externally, set and operate a
tool and cutter grinding machine to re-grind
milling cutters, lathe tools, test, inspect and
replace abrasive wheels and carry out an
inspection of surface texture.
Learning outcome
The learner will:
1. understand how to perform manufacturing operations safely on
grinding machines
Assessment criteria
The learner can:
1.1 explain the training requirements for removal and changing of
abrasive wheels
1.2 describe the methods of inspection and testing abrasive wheels
for damage
1.3 explain the wheel marking system
1.4 explain the characteristics of abrasive wheels
119
Range
Training requirements: reference to Provision and Use of Work
Equipment Regulations, appointed person responsibilities, mandatory
signs, Personal Protective Equipment (PPE), guarding, manual handling
Inspection and testing: safety checks (wheel speed, spindle speed,
visual, ring test), safety factors (centrifugal stress, operating stress [heat,
mechanical]), machine checks (oil levels [wheelhead, workhead],
lubrication points), ensure no end play in spindle, security of pipes and
couplings, safety devices and interlocks are working, emergency stops,
alignment , traverse stops are functional, guards in position and secure,
type and care of cutting fluids (purpose: absorption and carry away heat
from the cutting zone, rapid cooling, maintain clean cutting zone, flood
contact zone, remove dust and particles), filtering system for the cutting
fluid, dust extraction equipment (purpose and function, checking,
removal of waste), care of grinding wheels
Marking: types (1, 2, 3, 4, 5, 6, 11, 12, 13, 27, 27A)abrasives (aluminium
oxide, silicon carbide, cubic boron nitride [CBN]), grain size, grade,
structure and bond, wheels larger than 80 mm (rpm, dimensions,
specifications) wheels less than 80 mm (colour coded stripes, expiry
date), factors affecting wheel selection (material to be ground, amount of
material to be removed, arc/area of contact, type and condition of
machine, wheel and work speeds, dry or wet cutting
Characteristics: cutting action, hazards (bursting wheel, flying particles,
abrasive burns)
Learning outcome
The learner will:
2. be able to perform manufacturing operations to produce precision
finishes using surface grinding
Assessment criteria
The learner can:
2.1 perform surface grinding operations to produce precision flat
and parallel surfaces
2.2 use workholding devices when setting up for grinding operations
2.3 evaluate the dimensional accuracy to BS EN ISO 286 and 0.2m
surface texture
2.4 perform wheel balancing, truing and dressing operations
2.5 describe the possible faults in grinding wheels and ways of
rectifying them
120
Range
Surface grinder: horizontal spindle, vertical spindle, need for dust
extraction, feed systems, determination of wheel and work speeds,
reason for sparkout, reasons for the warm up period, settings
Workholding: magnet chuck,table, magnet blocks, double sided tape,
direct clamping, vices, fixtures, purpose
Surface grinding: dry grinding, wet grinding, guards (wheel, table),
machine movements and methods of setting (wheel, table)
Dimensional accuracy: co-ordinate measuring machine, micrometers
(external) surface measuring machine and charts
Balancing: false spindle, balancing stand compound slide, dressing
(diamond, stone)
Faults: wheel chatter, rough finish, wheel loading, short wheel life,
effects of heat when grinding, possible problems and remedies
Learning outcome
The learner will:
3. be able to perform manufacturing operations to produce precision
finishes using cylindrical grinding
Assessment criteria
The learner can:
3.1 perform external and internal grinding operations using a
cylindrical grinder to produce precision parallel and tapered bores
and shafts
3.2 use workholding devices when setting up for grinding operations
3.3 evaluate the dimensional accuracy to BS EN ISO 286 and 0.2 m
surface texture
3.4 perform wheel mounting, balancing, truing and dressing
operations
Range
Cylindrical grinder: machine parts, drive pin, face plate, table traverse
stops, guarding, table, grinding fluids
Workholding: between centres, faceplate, carriers, chucks, collets,
spigots,
External and internal grinding: centralising, work setting, setting table
traverse stops, steady rests, steady rest shoes, guarding, nomograms,
effects of arc area contact,
Dimensional accuracy: co-ordinate measuring machine, micrometers
(external, internal) surface measuring machine and charts
Mounting: handling and storage of wheels, truing and dressing (fixed
installation diamond, portable diamond), wheel balancing (parallel ways,
overlapping discs), hub flanges, effects of an unbalanced wheel, function
and construction of control wheel,
121
Learning outcome
The learner will:
4. be able to perform tool and cutter grinding operations
Assessment criteria
The learner can:
4.1 perform safe operation of tool and cutter grinders to re-grind
lathe tools and milling cutters
4.2 explain the tool geometry nomenclature for lathe tools and milling
cutters
4.3 calculate the off set for different angles
Range
Tool and cutter grinders: machine parts (wheel head, cutter head, stub
arbor, setting gauge, tailstock, tool rest), wheel dressing (off-hand),
principle parts (grinding wheel, control wheel, work rest blade),
directional movements (grinding wheel, control wheel, work), types of
feed (through, how feed is accomplished, work rest, in, end)
Tool geometry: range of lathe tools and milling cutter, collet held and
arbour mounted, methods of grinding (milling cutters, linear setting,
angular setting) clearance angles (primary, secondary),
addition equipment: gauges, tooth rest, and cutter heads
Calculate: linear setting to obtain clearance angle
122
Unit 325
Machining Materials by
Grinding
Guidance
Surface grinder: horizontal spindle (reciprocating table, down feed and
cross traverse, rotary table, down feed and cross traverse), vertical
spindle (reciprocating table and down feed, rotary table and down feed),
need for dust extraction, feed systems (table reciprocating and cross,
wheel), determination of wheel and work speeds, reason for sparkout,
reasons for the warm up period, settings (traverse stops, centres, rests,
guides, control wheel)
Workholding: magnet chuck (truing of surface), table, magnet blocks,
double sided tape, direct clamping, vices, fixtures, purpose (restrain
workpiece against wheel force, locate workpiece)
Faults: wheel chatter (true wheel, increase feed, use softer grade) rough
finish (finer grit wheel, use harder grade, increase work traverse) wheel
loading (use coarser grit, dress wheel, increase work traverse), short
wheel life, effects of heat when grinding (expansion/dimensional
accuracy, overheating/wheel life and additional costs) possible problems
and remedies (over and undersize components: wheel wear, slackness
inslides deflection; inconsistency of component shape: deflecting and
stops; vibration: condition of machine, set up, speeds and feeds; surface
finish of component: wheel fault and clamping)
Cylindrical grinder: machine parts (work head, tailstock, table, wheel
head [external internal), feed systems (table, wheel head), drive pin, face
plate, table traverse stops, guarding (external wheels, internal wheels),
table, grinding fluids (cooling, chip and dust removal, non-corrosive,
supply [pump, flow control, filtration])
External and internal grinding: centralising (work head, tailstock), work
setting (between centres, three jaw self centring chuck), setting table
traverse stops, steady rests, steady rest shoes, guarding (external
wheels, internal wheels, table), nomograms (work head speed, table
traverse speed), effects of arc area contact,
can be recycled
123
Unit 326
URN:
D/503/0416
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

the skills and knowledge necessary to
successfully machine by Computer
Numerical Control (CNC), it includes partprogramming, preparation of the machine,
selection and the preparing of the required
methods of workholding, the selection and
the correct mounting of tooling.
It also covers the operations required and
safe working practices to complete the
machining operations.
Learning outcome
The learner will:
1. be able to produce CNC part-programs
Assessment criteria
The learner can:
1.1 interpret engineering component drawings to determine CNC partprogramming requirements
1.2 explain the principles of computer numerical control as the control
of machine movements and management functions through coded
instructions
1.3 explain the types of program format
1.4 explain the meaning of the part programming terms
1.5 select a suitable datum to the component to be machined
1.6 describe the factors to be considered when planning a part
program
1.7 produce tables of co-ordinate dimension taken from specified
datum positions in the form of part program operation sheets
1.8 produce an instruction set to machine and engineering
component to size
1.9 explain tool geometry requirements for effective material removal
1.10 calculate speeds and feeds for CNC machine tools
1.11 explain the importance of modifying feed rates when profiling
internal and external radii
1.12 explain the constant surface speed mode for turning operations
124
1.13 explain the benefits of using tool nose radius compensation for
turning operations
1.14 explain circular interpolation and arc programming commands
1.15 apply trigonometry to calculate component cutter path coordinates
1.16 describe different programming formats including ISO word
address and other formats used by Fanuc, Heidenhain and other
controllers
1.17 describe word address, conversational and graphical programming
Range
Types of program format: fixed sequence/block, word address
Part-programming terms: character, word, block, modal and nonmodal functions
Planning: component material, dimensions and tolerances, required
surface finish, appropriate datum settings, roughing and finishing
operations, grouping of similar operations, relevant canned cycles,
loops, macros and subroutines, workholding methods to give accurate
location and secure (CNC milling: direct clamping, vices, fixtures, devices
modified for CNC operations; CNC turning: three jaw chucks, including
the use of soft jaws, four jaw chucks, collets)
Part program: work material, work datum position, workholding
requirements, tooling requirements including pre-setting data, sequence
of operations, miscellaneous functions
Instruction set: factors to be considered when planning safe tool paths
to ensure: operator safety, collisions with component and workholding
equipment are avoided, safe work and tool changing positions are
specified, defined areas to prevent collisions, cutter diameter
compensation for milling operations, assigned canned cycles, userdefined canned cycles, translation and transformation commands for:
mirror imaging, rotation, scaling, datum offset; canned cycles for turning
operations
Tool geometry: milling cutters, turning tools, characteristics and
applications, principles of mounting/clamping systems
Speeds and feeds: spindle speed (define cutting speed as relative linear
speed between work surface and tool point, use cutting tool
manufacturers data for work/tool combinations allowing for: type of
cutting operation, surface finish requirements, use of coolant); feed rate
(define feed rate as distance moved per minute (mm/min) or distance
moved per revolution (mm/rev), use of manufacturers feed rate data
allowing for: type of cutting operation, surface finish requirements,
cutting tool geometry, work/tool material combinations, delicacy of work
piece and workholding method
Trigonometry: Pythagoras theorem, trigonometric ratios, sine rule
125
Learning outcome
The learner will:
2. be able to set-up CNC machine tools
Assessment criteria
The learner can:
2.1 use the precautions to be taken to prevent accidents when setting
and operating CNC machines
2.2 explain the potential hazards when setting and operating CNC
machines input part-program
2.3 input data to CNC machine controls
2.4 check that guards, interlocking devices and fail safe mechanisms
are operating
2.5 set work datums and tool length offset values
2.6 describe the characteristics of preset and qualified tooling
2.7 describe the advantages of performing a trial run
Range
Input data: manual data input, portable systems, direct computer link,
via data storage devices
Trial run: (dummy run) finding any unwanted rapid tool movements,
make adjustments to speeds and feeds, adjustments to compensate for
errors, reduce unnecessary tool movements, rearrange the machining
sequence; methods of editing the part program: manual data input (MDI),
off line using a text editor
Learning outcome
The learner will:
3. be able to produce parts using CNC machine tools
Assessment criteria
The learner can:
3.1 produce block diagrams showing the elements of open and closed
loop control systems
3.2 produce line diagrams to identify primary and secondary axes of
motion for vertical and horizontal spindle CNC machines indicating
positive and negative movement
3.3 compare work and tool holding/changing systems on CNC machine
tools
3.4 explain the principles of tooling systems, libraries and monitoring
3.5 explain the function of workholding and setting devices used on
CNC machine tools
3.6 explain the construction and operation of CNC machine tools
and recognise the importance to accurate performance in milling
and turning
3.7 explain problems of swarf removal and the methods used to
overcome them
3.8 differentiate between different types of machine control and the
application to which they are suited
3.9 use the precautions to be taken to prevent accidents when setting
126
and operating CNC machines

3.10 explain the potential hazards when setting and operating CNC
machines input part-program
3.11 check that, guards, interlocking devices and fail safe mechanisms
are operating
3.12 prove part programs to check for program errors and edit to
achieve optimum production performance
3.13 explain the importance of optimising production during program
proving
3.14 produce suitable components to required specifications
3.15 inspect finished component against specifications
Range
Axes of motion: X Y and Z conventions used for primary axis motion for
various CNC machine configurations; U V and W conventions used for
secondary axis motion for various CNC machine configurations; A B and
C conventions used for rotation about the primary axes
Tooling: systems: preset, qualified, modular cutting unit, tool adapter;
libraries: tool identification, geometry, offset values, speed, feed and tool
life data; monitoring: sensing devices and electronic probes tool life
and cutting conditions, tool breakage detection, tool offset
measurements, tool identification, torque variations, acoustic emissions
Workholding and setting devices: conventional workholding devices
modified to suit CNC operation; positioning work datum relative to
machine datum, the need for zero shift controls and how they are used,
the use of air and hydraulic workholding devices for gripping delicate
components; methods of setting workholding devices accurately relative
to machine slide movements
Construction and operation: structural requirements: strength,
rigidity, vibration damping; correct alignment, feedback transducers, recirculating ball and leadscrew; operating principles of linear and rotary
transducers used in CNC systems, differences between open and closed
loop control systems (positional feedback, drive method)
Swarf removal: volume produced, conveyor systems, slant bed design,
cutting fluid reclamation
Machine control: typse: point to point control, linear (paraxial)control,
continuous path control; applications: point to point drilling and tapping
operations, linear profiles and slots, curved profiles and slots
Hazards: tool collisions, swarf/chips, rapid movement of machine parts
and tooling, entrapment, etc.; avoidance using machine over-ride
controls, hazards when using the constant surface speed function on
CNC lathes, location and function of emergency stop and program stop
controls, guards, interlocking devices and fail safe mechanisms
Optimising production: adjusting speeds and feeds to give maximum
metal removal rates considering: surface finish requirements, tool life
requirements; reducing unnecessary tool movements; rearranging the
machining sequence; adjustments to compensate for errors and tool
wear (tool offsets and length offset values, cutter radius/diameter
compensation)
127
Learning outcome
The learner will:
4. be able to reinstate the work area.
Assessment criteria
The learner can:
4.1 restore the work area to agreed requirements
4.2 describe the difference between waste and reusable or recyclable
materials
Range
Restore the work area: leave the work area free of unused
consumables, cleaning the work area, putting tools and equipment into
safe storage, identifying and recording finished work, manual cleaning
machine tools, machine assisted cleaning, use and storage of cleaning
agents, labelling/identifying products, inspecting components, tools and
equipment on completion of work, cleaning and storing personal
protection equipment
128
Unit 326
Guidance
Part program: work material, work datum position, workholding
requirements, tooling requirements including pre-setting data, sequence
of operations [part program] ( X, Y, Z, dimensional information, machine
management information [preparatory functions: rapid movement, time
dwell, zero shift, feed rates, absolute/incremental dimensions, inch/metric
units]; miscellaneous functions [end of program, spindle forward/reverse,
tool change, coolant on/off]; speeds and feeds; tooling requirements)
Instruction set: factors to be considered when planning safe tool paths
to ensure: operator safety, collisions with component and workholding
equipment are avoided, safe work and tool changing positions are
specified, defined areas to prevent collisions (safe zone, warning zone,
prohibited zone); cutter diameter compensation for milling operations,
assigned canned cycles (role and benefits; milling: circular interpolation,
rectangular/circular pocket milling, slot mill; drilling: drill, drill and dwell,
deep hole drilling); user-defined canned cycles (role and benefits; loops,
macros, subroutines); translation and transformation commands for:
mirror imaging, rotation, scaling, datum offset; canned cycles for turning
operations (stock removal in turning, stock removal in facing, thread
cutting, peck drilling in Z axis)
safe storage, identifying and recording finished work, manual cleaning
machine tools, machine assisted cleaning, use and storage of cleaning
agents, labelling/identifying products, inspecting components, tools and
equipment on completion of work, cleaning and storing personal
protection equipment
129
Unit 327
URN:
M/503/0419
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

the skills and knowledge that are essential
for detailed fitting being carried out safely
and efficiently. It includes the preparation of
equipment, materials, service supplies,
works areas, together with production and
quality requirements.
Learning outcome
The learner will:
1. be able to determine tooling and equipment requirements
Assessment criteria
The learner can:
1.1 follow safe working practices and procedures when carrying out
maintenance activities
1.2 explain the hazards associated with bench fitting activities
1.3 interpret information from engineering drawings
1.4 identify the tools and equipment required to undertake a bench
fitting activity
1.5 describe the functions of equipment and systems
1.6 explain the factors affecting accuracy
1.7 explain the forces exerted on pins and keys
130
Range
Safe working practices: wearing appropriate protective clothing and
equipment (overalls, safety footwear, eye protection, hearing protection,
use of barrier cream), maintaining a clean and tidy work area, preparing
the work area, leaving the work area in a safe and clean condition, risk
assessments
Hazards: handling of coolants and cutting oils/compounds, misuses of
tools, use of damaged or badly maintained tools
Engineering drawings: dimensional, geometrical, materials
Tools and equipment: marking out, hand tools, measuring instruments,
gauges, dial test indicators, surface finish/texture, cutting and shaping,
scrapers, levers and pullers, drills, taps, use of charts for selecting
tapping sizes and dies, reamers, forms of power supply, powered hand
tools, forming equipment, guillotines, folders
Equipment and systems: bearings, bushes and seals; shafts and
couplings; pins and keys; power transmission and pulley mechanisms;
fabrications and castings; gaskets; locking devices; springs;
linkages/rollers
Factors affecting accuracy: environmental, equipment, human
Forces exerted on pins and keys: axial, radial, shear
Learning outcome
The learner will:
2. be able to prepare to perform detailed fitting operations
Assessment criteria
The learner can:
2.1 explain the purpose of workholding
2.2 describe the different types and features of machines
2.3 explain the meaning and applications of different threads
2.4 explain the purpose of reaming holes
2.5 explain the purpose of scraping
2.6 explain the purpose of shafts and plain bearings
2.7 explain the type, construction and purpose of ball and roller
bearing systems
2.8 identify the different type of seals
2.9 explain the purpose of flanges
2.10 explain the purpose of gear assemblies
2.11 explain the purpose of transmission systems
2.12 explain the type, construction and purpose of cylinders/actuators
and auxiliary components
2.13 critically compare types of pump available
2.14 critically compare types of valve available
2.15 explain the type, construction and purpose of auxiliary components
2.16 prepare to produce assemblies by detailed fitting
131
Range
Workholding: locate work, restrain the forces exerted by the tool,
workholding devices
Machines: bench/pillar drills, portable drills (mains operated, battery,
pneumatic) grinding machines (bench, angle)
Threads: terms: pitch and lead, left and right hand threads, single and
multi-start; applications: fastening device, transmit motion; manual
methods cutting threads: internal taps, internal special taps and thread
inserts, external dies, external solid die nuts
Reaming holes: parallel through, blind, tapered
Scraping: flat surfaces, bearings
Shafts and plain bearings: correct clearances, checking clearance,
lubrication and methods of distribution
Ball and roller bearing systems: factors influencing cleanliness,
classes of fit (inner race fits tightly on shaft, outer race slides into
housing, inner and outer races both tightly fitting), types of selfalignment bearings, distinguish between thrust bearings designed to
take: axial loads only, axial and radial loads; tools used for fitting ball and
roller bearings (drifts, special spanners, extractors), inspecting bearings
for faults (pitting, crazing, discolouration, assessment of the necessity for
replacement); sealing bearing assemblies lubricated by grease or
lubricating oils (felt and synthetic rubber ring seals, minimum machined
clearance between bearing housing and shaft, labyrinth seals)
Type of seals: metallic, non-metallic, combination of metallic and nonmetallic; selection: applications, temperature and pressure, speed of
moving parts, replacement period and corrosion
Flanges: faces clean and flat, checking O rings or gaskets for size,
shape and depth/condition of recesses, tightening flange bolts in the
correct sequence
Gear assemblies: how to obtain: contact area of tooth surfaces,
alignment of gear faces, tooth surface clearance; methods of obtaining
positive clearance
Transmission systems: tensioning belt/pulley systems, tensioning
chain/sprocket systems
Cylinders/actuators and auxiliary components: single acting, double
acting, auxiliary components: reservoirs, accumulators, filters
Types of pump: gear, vane, piston
Types of valve: manual, mechanical, pilot, directional control values
spool and rotary, non-return, pressure control, flow control
132
Learning outcome
The learner will:
3. be able to perform detailed fitting operations
Assessment criteria
The learner can:
3.1 use workholding devices safely
3.2 use drilling and grinding machines to shape material safely
3.3 sharpen tools by grinding
3.4 produce and apply internal and external threads for engineering
uses
3.5 produce reamed holes
3.6 apply scraping technique to flat surfaces and bearings
3.7 assemble component parts and sub systems
3.8 isolate equipment
3.9 check accuracy of components against specification
Range
Workholding: locate work, restrain the forces exerted by the tool,
workholding devices
Sharpen tools by grinding: cold chisels, twist drills
Machines: bench/pillar drills, portable drills (mains operated, battery,
pneumatic) grinding machines (bench, angle)
Threads: manual methods cutting threads: internal taps, internal special
taps and thread inserts, external dies, external solid die nuts
Reamed holes: parallel through, blind, tapered
Scraping: flat surfaces, bearings
Component parts and sub systems
shafts and bearings: methods of obtaining clearances by: filing,
scraping, shimming; checking clearance: feeler gauges, dial test indicator
(DTI), lead wire, lubrication
ball and roller bearings: cleanliness: personal cleanliness hands, tools
and work surfaces, cleaning journals and housings prior to fitting,
retaining bearings in protective wrapping until required; methods of
positioning by: pressing into the housing, tapping, heating and sliding
onto the shaft, cooling; use tools for fitting ball and roller bearings,
inspect bearings for faults, seal bearing assemblies lubricated by grease
or lubricating oils
seals: metallic, non-metallic, combination of metallic and non-metallic;
selection: applications, temperature and pressure, speed of moving
parts, replacement period and corrosion
flanges: faces clean and flat, checking O rings or gaskets for size, shape
and depth/condition of recesses, tightening flange bolts in the correct
sequence
gear assemblies: contact area of tooth surfaces, alignment of gear
faces, tooth surface clearance; methods of obtaining positive clearance
by: increasing the centre distance between gears, reducing tooth profile
one gear, reducing tooth thickness of both gears; fitting gears on shafts:
press fit, push fit
transmission systems: methods of tensioning belt/pulley systems,
tensioning chain/sprocket systems
133
cylinders/actuators: single acting, double acting

pumps: gear, vane, piston, auxiliary components: reservoirs,
accumulators, filters
valves: methods of activation: manual, mechanical, pilot, directional
control values spool and rotary, non-return, pressure control, flow
control
isolating equipment: removal of fuses from electrical prime movers,
disconnect drive shaft, closing and locking-off valves, closing auxiliary
supplies, drain down pipework
Accuracy of components: factors affecting accuracy: misalignment of
work and measuring equipment, parallax error
Learning outcome
The learner will:
4. be able to reinstate the work area
Assessment criteria
The learner can:
4.1 restore the work area to agreed requirements
4.2 identify waste and reusable or recyclable materials
Range
Waste and reusable or recyclable materials: types of waste
produced, storage and waste removal, disposal methods (recycling, solid
waste, liquid waste)
Actions to be taken in the event of a spillage: barriers and safety
signs, use of personal protection equipment, aids to containment and
prevention of spillage reaching the watercourse, aides for cleaning, who
should be notified
134
Unit 327
Guidance
Tools and equipment: marking out (scribers, scribing block, punches
[centre and dot], surface plate/table, angle plate, parallels and vee blocks)
hand tools (files, screwdrivers, hammers and mallets, spanners (openended, socket sets, ring, torque wrenches), measuring instruments (rules,
inside and outside calipers, protractor, micrometers (external, depth),
verniers (height gauge, protractor, callipers), gauges (feeler, blocks/slip,
radius, thread) dial test indicators, surface finish/texture (comparison
plates, tactile machines), cutting and shaping (saws [hand, mechanical],
scrapers, levers and pullers, drills (high speed steel [HSS] carbide tips drill
speed tables, cutting speed formula [cutting speed = dN/1000]), taps
(spiral flute, straight flute [taper, second, bottoming], use of charts for
selecting tapping sizes) and dies (circular split, rectangular loose, solid die
nut, pipe thread), reamers (hand, taper), forms of power supply (230V,
110V, pneumatic, battery), powered hand tools (drills, screwdrivers, angle
grinders, saws), forming equipment (bench folders, fly press), guillotines,
folders
Equipment and systems: bearings, bushes and seals; shafts and
couplings; pins and keys; power transmission and pulley mechanisms
(gears, chains and sprockets, belts and pulleys); fabrications and castings;
gaskets; locking devices; springs; linkages/rollers
Factors affecting accuracy: misalignment of work and measuring
equipment, parallax error; affects of temperature variation upon:
measuring, joining by co-efficient of expansion/contraction
Component parts and sub systems
Shafts and bearings: methods of obtaining clearances by: filing,
scraping, shimming; checking clearance: feeler gauges, dial test indicator
(DTI), lead wire, lubrication Ball and roller bearings: cleanliness: personal
cleanliness hands, tools and work surfaces, cleaning journals and
housings prior to fitting, retaining bearings in protective wrapping until
required; methods of positioning by: pressing into the housing, tapping,
heating and sliding onto the shaft (oil bath or electrically), cooling; use
tools for fitting ball and roller bearings (drifts, special spanners,
extractors), inspect bearings for faults (pitting, crazing, discolouration,
assessment of the necessity for replacement); seal bearing assemblies
lubricated by grease or lubricating oils (felt and synthetic rubber ring
seals, minimum machined clearance between bearing housing and shaft
Transmission systems: methods of tensioning belt/pulley systems (idler
pulleys, adjustment of the centres between shafts, hinged mounted
pulleys), tensioning chain/sprocket systems (idler wheel, adjustment of
sprocket by set screws)
safe storage, identifying and recording finished work, isolate machines,
manual cleaning machine tools, machine assisted cleaning, use and
storage of cleaning agents, labelling/identifying products, inspecting
components, tools and equipment on completion of work, cleaning and
storing Personal Protection Equipment (PPE)
135
Unit 328
URN:
H/503/0420
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
The unit is concerned with basic electrical

theory and electrical components associated
with the maintenance of electrical
equipment.
The candidate will understand the
operations necessary for the planning and
carrying out of maintenance in an industrial
and commercial environment.
Learning outcome
The learner will:
1. understand the components and features of electrical systems
Assessment criteria
The learner can:
1.1 explain electrical system components and units in conjunction
with system drawings
1.2 explain the function of electrical components and the way in
which they can be assembled
1.3 identify components and systems to meet required functions
136
Range
Function of electrical components: electromagnets, magnetic
materials, iInductors capacitors, electrolytic capacitors, discharge
resistors, semi-conductor devices, diodes, thyristor and triac, half and
full wave rectification, heat sinks, smoothing circuits, single thyristor
circuits, transformers.
Components and systems containment systems, Busbar systems,
underfloor ducting, rising mains, steel wire armoured (SWA) and Mineral
Insulated Copper cable (MICC), circuit breakers switches, fuses, isolators
supply systems, earthing arrangements TT, TN-S, TN-C-S, lightning
protection, no-volt releases, residual current devices. d.c machines
ratings, insulation and enclosures. d.c. generators excitation and voltage
control. d.c motors, series, shunt & compound, alternating current
machines, types- induction and synchronous, construction-cylindrical
and salient pole, power factor correction equipment,single phase
motors, series universal, split phase induction start, capacitor start,
capacitor start and run, motor starters and motor speed controllers test
equipment, insulation resistance testers, low resistance ohmmeters,
wattmeters, earth loop impedance and prospective short circuit testers
tachometers and stroboscopes.
Learning outcome
The learner will:
2. be able to plan and prepare for the maintenance operation
Assessment criteria
The learner can:
2.1 evaluate the extent of work to be carried out
2.2 describe the current legislation and codes of practice relating to
electrical equipment and systems
2.3 carry out a risk assessment by listing the procedures and
requirements for setting up safe working conditions
2.4 analyse manufacturers information, related work records, circuit
diagrams and other necessary data
2.5 identify tools and equipment
2.6 prepare works orders or requisitions
137
Range
Extent of work: area, safety requirements, equipment, barriers and
enclosures, notification of personnel and other workers, Personal
Protective Equipment (PPE)
Legislation: Electricity at Work Regulations, IEE Wiring Regulations, GS
38
Risk assessment: method statements, safe isolation procedure, Permit
to Work
Data: manufacturers data, catalogues, internet, component data sheets,
availability and assemble of materials, company stores, wholesalers and
component suppliers.
Tools and equipment: hand and power tools, battery operated drills,
safety checks.
Learning outcome
The learner will:
3. be able to carry out monitoring and inspection of maintenance work
Assessment criteria
The learner can:
3.1 carry out inspection
3.2 conduct diagnosis and carry out repairs
3.3 complete maintenance record
Range
Inspection: on equipment or systems.
e.g. visual inspection of plant, cables and containment
Diagnosis and carry out repairs on faulty system and/or
components
e.g. Faults to lighting, plant containment and other components. Motors
and Generators, safe dismantling, recording of faults, install range of
electrical systems. containment of oils and greases, protection and
storage of parts, wear due to corrosion, erosion and pitting, worn seals,
removal and fitting bearings, seals, springs, circlips, manufacture and
fitting of gaskets, bench testing of components , maintenance records.
Learning outcome
The learner will:
4. be able to re-commission the system and restore the work area.
Assessment criteria
The learner can:
4.1 re commissions the system and adjust as required to working
parameters
4.2 restore work area to a clean and safe condition upon completion
of maintenance
4.3 classify hazardous substances and the state the approved
method of disposal
4.4 produce a report to record the actions taken during hand over
138
Range
Re commission system: safety before re-energising, check all systems
in place and re-set, prescribed start up procedures, electrical,
mechanical and pneumatic/hydraulic checks.
Hazardous substances: oils, greases, cleaning agents, solvents,
insulation, adhesives, fillers, packing, lagging.
Report: complete maintenance schedules, clear permits to work and
sign off, diaries, materials used, record likely future requirements, update
maintenance schedule, hand over to authorised personnel.
139
Unit 328
Guidance
Restore work area. Return reusable materials to store, clean and check
tools, return tools to store/storage.
140
Unit 329
Produce drawings using CAD
URN:
M/503/0422
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

the skills and knowledge in computer aided
design (CAD), in terms of producing 2D and
3D drawings, including the use of 3D
modelling methods.
Although most of the commands referred to
are generic and would apply to all CAD
systems, some terms may be specific to one
particular application (eg AutoCAD). Where
this is the case an equivalent alternative
application commands may be appropriate
Learning outcome
The learner will:
1. be able to set-up to produce CAD drawings
Assessment criteria
The learner can:
1.1 explain the function of hardware components used for CAD which
are unique to CAD
1.2 explain the function of data input devices used in CAD
1.3 explain the function of data output devices used in CAD
1.4 explain CAD software requirements
1.5 evaluate methods of data storage and make recommendations for
their use
1.6 explain the reasons for backup files and saving drawings at regular
intervals
1.7 describe the role of drawings in communicating technical
information
1.8 critically compare CAD systems with manual draughting methods
1.9 explain the purpose of prototype drawings and how they are used
1.10 set drawing aids
1.11 create layers
1.12 set drawing limits to suit component dimensions
1.13 set suitable drawing parameters
1.14 use main menu drawing commands to produce a variety of
141
different shapes
1.15 create, save and load a range of library drawings
Range
Hardware: effects of hardware specifications on efficiency of the
system, processor type and speed, available RAM, video processor card,
VDU resolution and screen size, size of hard disk drive
Data input devices: keyboard, mouse, digitising tablet and puck, light
pen, scanning, touch pad, track ball, CAD functions (command input,
cursor movement, selecting menu items, picking points)
Data output devices: VDU, printers, plotters, transfer data to a
computer-aided manufacturing (CAM), principles of CAD/CAM
Software requirements: memory allocation, driving input and output
devices, CAD software, graphics creation, manipulation, manipulation,
editing, storage, user software, customising menus and parameter,
symbols library, macros, applications software including: parts listing,
costing, stress analysis; operating system functions: create directories
(folders), organise the contents of directories, locate, copy, delete and
rename files
Data storage: hard disk drive, CD ROM, CD RW, DVD ROM, DVD RW, USB
storage devices, other storage media (eg. Internet), maintaining careful
filing systems for manual reference and data storage (creation and
maintenance of manual reference files for ease of access, index system
for storage of disks), methods of restricting user access using passwords
where required
Compare CAD: speed of drawing creation, checking and editing, ease of
creating modified revisions, quality and consistency of finished drawing,
memory facility, storage and retrieval of finished drawings, cost,
compatibility with CAM systems
Learning outcome
The learner will:
2. be able to produce 2D CAD drawings
Assessment criteria
The learner can:
2.1 set drawing parameters on the CAD system
2.2 explain the reasons for using structured layers and how they are
created
2.3 explain the function of the commands used in producing 2D CAD
drawings
2.4 produce 2D CAD drawings that contain essential technical
information
2.5 apply standard conventions to 2D CAD drawings
2.6 differentiate between absolute, relative (incremental) and polar coordinate systems
2.7 differentiate between world and user co-ordinate systems
2.8 review and revise 2D CAD drawings by editing and manipulating
graphical data
2.9 produce text on 2D CAD drawings
2.10 import and position library items onto 2D CAD drawings
2.11 apply conventions relating to dimensioning to 2D CAD drawings
142
2.12 apply the conventions for cross-hatching areas to 2D CAD

drawings
2.13 save drawings using appropriate file names
2.14 load and edit existing drawings
2.15 evaluate the process of producing a 2D CAD drawing and
recommend improvements to the process
Range
Parameters: limits to suit component dimensions and paper size,
drawing aids to draw entities accurately (grid spacing, snap interval,
object snap mode, orthogonal mode, units benefits and limitations of
using the drawing aids)
Layers: apply meaningful names, assign line types, assign colours,
control the visibility of layers
Commands: line, polyline, circle, arc, polygon, rectangle, ellipse,
doughnut, erase (single entities, multiple entities)
Technical information: projection type (pictorial: isometric, oblique;
orthographic: first angle, third angle) units, scale, shape, size including
tolerance, surface finish, number off, material requirements, special
treatments,
Conventions: BS 8888, types of line, representation of common features
Editing: zoom in/zoom out, pan, erase, copy, mirror, offset, move, array
(rectangular and polar), trim, extend, scale, stretch, break, fillet, chamfer,
modify properties (line type, colour, layer)
Text: position, font style, font height, rotation
Dimensioning: linear, aligned, angular, diameters, radii, leader,
tolerances, limits, methods of edit existing dimensions, baseline,
continuous, associative dimensions
Cross-hatching: simple and complex areas, pre-defined hatch patterns,
user defined hatch patterns, application to cross-sectioning
Learning outcome
The learner will:
3. be able to produce 3D CAD drawings
Assessment criteria
The learner can:
3.1 explain the role of detail and assembly drawings
3.2 critically compare the 3D CAD drawing visual representation
methods available
3.3 explain the function of the commands used in producing 3D CAD
drawings
3.4 produce 3D CAD drawings that contain essential technical
information
3.5 review and revise 3D CAD drawings by editing and manipulating
graphical data
3.6 apply the shading and rendering to 3D CAD drawings
3.7 save drawings using appropriate file names
3.8 load and edit existing drawings
143
Range
Visual representation: isometric projection, wire frame modelling,
extruded forms, solid modelling (B-REP, CGS, hybrid) surface modelling,
parametric and variational geometry
Commands: line, polyline, circle, arc, polygon, rectangle, ellipse,
doughnut, erase (single entities, multiple entities), extrude, revolve, 3D
primitives (box, cuboid, sphere, cylinder, cone, torus, wedge), combine
primitives using Boolean operations (addition, union, join, subtraction,
cut, intersection), surfacing commands, shade, hide, render, rotate,
camera, 3D views, 3D viewports (multiple views), model space, paper
space
Learning outcome
The learner will:
4. be able to produce hard copies of CAD drawings
Assessment criteria
The learner can:
4.1 print/plot hard copies of different sized CAD drawings
4.2 print/plot hard copies of modified CAD drawings
4.3 critically compare types of printer/plotter available
4.4 import drawings into presentation software for demonstration
purposes
4.5 transfer CAD data to a computer-aided manufacturing Computer
Aided Manufacturing (CAM) system
Range
Print/plot: print/plot command, printer/plotter configuration settings,
device selection, paper size (A4, A3, etc.), paper orientation (portrait,
landscape) paper source, print quality, pen assignments where
appropriate, display parameters, extents, limits, view, window, text
resolution, units, scale, rotation and origin, print preview
Presentation: produce a presentation that fulfils one or more of the
following criteria:
o demonstrates the stages of the drawing process
o shows the capabilities of the engineering item drawn
presents the item from a sales and marketing perspective
144
Unit 330

URN:
A/503/0424
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit enables the candidate to develop an

understanding of the principles of organisation
and management and the ways in which
engineering activities can be efficiently
planned and implemented. It covers the topics:
relationships between installation, production
and maintenance operations, the necessity for
good planning in order to provide an efficient
and cost effective service and why good
recording processes are needed and how data
is collected, used to forecast and/or solve
problems. The unit also covers the main
sources of labour and physical resources and
developing good relationships with all levels of
personnel and the ways in which their duties
need to be carried out. The candidate is not
expected to have an in-depth understanding of
all engineering activities and strategies but
should be familiar with the events/terminology
that they will come into contact with during
normal working conditions
Learning outcome
The learner will:
1. be able to organise engineering activities
Assessment criteria
The learner can:
1.1 explain the organisational structures employed in engineering
1.2 describe the function of engineering sections
1.3 explain the procedures for organising and running meetings
145
Range
Organisational structures: roles and responsibilities, lines of
communication, decision making and implementation procedures, types
of organisation chart
Engineering sections: installation, production, maintenance
Meetings: duties of the chair and secretary
Learning outcome
The learner will:
2. be able to schedule engineering activities
Assessment criteria
The learner can:
2.1 explain the factors that need to be considered when planning
operations
2.2 explain the need for reviewing production and maintenance
procedures at regular intervals in order to ensure maximum
efficiency and economy
2.3 prepare flow and Gantt (bar) charts for planning, scheduling and
checking on progress
2.4 produce worksheets or job cards for typical engineering tasks
2.5 explain the need for establishing priorities and the most effective
sequences of operations
2.6 explain how modification, repair or replace policies are
determined
2.7 explain how reliability can be achieved and production targets
maintained
Range
Planning: obtaining specialist tools and equipment, personnel
requirements (existing staff, specialist skills available and possible
training needs, temporary [sub contract, casual], contingencies and
overtime), items that must be considered when preparing contracts
(working conditions and health and safety implications, supervisory and
legal responsibilities, penalties for non compliance with conditions,
insurance cover), provision of materials and spares, effects on other
departments or changes to working practices (permanent or temporary),
estimation of time needed for different activities
Operations: production, maintenance or installation
Sequences of operations: Critical Path Analysis (CPA) and/or
Performance Evaluation and Review Techniques (PERT) principles (using
examples but without necessarily carrying out an analysis), contingency
plans for: inclement conditions, shortage of materials or staff, equipment
failure
Modification, repair or replace: plant history records, manufacturers
recommendations, changes in production output, age of plant or
equipment, technological changes
Reliability: good maintenance, identification of recurring problems or
faults, initiating or modifying new procedures, updating systems,
equipment and machinery
146
Learning outcome
The learner will:
3. be able to analyse the costs associated with engineering installation,
production and maintenance
Assessment criteria
The learner can:
3.1 analyse the cost-related information needed when
estimating/budgeting for an activity
3.2 estimate the cost of an activity
3.3 estimate the total life cycle costs of machinery
3.4 describe the difference between direct and indirect costs
3.5 compare production performance, maintenance or installation
costs using cost analysis
3.6 use bar and/or pie charts to identify the optimum levels of
production or maintenance costs
3.7 explain how commonly used cost ratios are employed to determine
the value of maintenance
3.8 evaluate the significant importance on costs of machinery and
items held in stores as indicated by a Pareto analysis
3.9 explain the relationship between capital expenditure and
depreciation for plant and equipment
3.10 explain the need to manage stock levels in stores for economic and
efficient operation and production
Range
Estimating/budgeting: extent of the task(s), time allowed for
completion, the skills and experience of personnel to be involved,
machinery, equipment, materials and spares that will be needed,
purchase or hire of specialist equipment
Activity: production, maintenance or installation
Total life cycle costs: design features, maintenance, expected length of
serviceable use, disposal value or costs that may be incurred during
decommissioning and dismantling
Direct and indirect costs: direct costs (materials, labour [company
employed and sub-contract], overheads [rent, rates, taxes, energy
consumption]), indirect costs (organisation and management, lost
production, depreciation of equipment, training)
Learning outcome
The learner will:
4. be able to apply research methods to assist the installation,
production or maintenance process
Assessment criteria
The learner can:
4.1 describe the implications of using computers to access records
and product information
4.2 explain how feedback data can be used to improve planning and
scheduling
4.3 collect data and use it to report on installation, production or
147
maintenance requirements
4.4 identify the information required to determine the prime
cause of a fault or production problem
4.5 produce an algorithm to help trace a fault or production problem
4.6 explain the importance of collecting and recording information
following the failure of equipment or machinery for calculation of
Mean Time Between (or To) Failures (MTBF and MTTF)
4.7 evaluate available data to decide whether to repair or replace
equipment
Range
Computers: increased number of access points, ease of updating, wide
range of information available (including access to Internet), appropriate
siting and cost of installation, maintaining security of data and limiting
access to authorised persons only, training of personnel, automatic data
collection and recording methods for controlling operations
Information required to determine the prime cause of a fault or
production problem: to include detailed knowledge of the principles of
the plant and equipment, observed and measured data, information
obtained from operators, history of the equipment, details of changes in
running conditions or modifications made, information from suppliers or
manufacturers
148
Unit 330

Guidance
Engineering sections: installation (site preparation, installing new or
modified equipment and systems, commissioning machinery and
systems), production (preparation of drawings and specifications,
ensuring that appropriate machinery, manpower and materials are
available, producing work allocations and rotas to ensure efficient
operation, dealing with production problems and shortages),
maintenance (carrying out routine servicing schedules, repair and
replacement following breakdowns, monitoring and performance testing
of machinery, equipment and systems)
Meetings: duties of the chair (preparation of agendas, allocating
personnel to deliver agenda items, conduct and control meetings), duties
of the secretary (arrange time, venue and catering requirements, take
minutes during meeting, produce finalised minutes and distribute to
concerned persons
149
Unit 332
URN:
R/503/0428
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
sector or
regulatory body:
Aim:
This unit is concerned with pneumatic, hydraulic,

mechanical and electrical actuation systems. The
topics covered will enable the candidate to
interpret diagrams, explain the operation of
circuits and systems and be able to identify and
test electrical and mechanical components. The
candidate will also be able to perform diagnostic
checks on prepared (simple) systems, and make
deductions from the results of these checks which
lead to a correct fault diagnosis.
Learning outcome
The learner will:
1. understand the principles of the Total Engineering Approach to
production systems
Assessment criteria
The learner can:
1.1 classify the basic building blocks of industrial systems
1.2 explain, with the aid of block diagrams, the architecture of various
types of industrial systems
1.3 describe the differences between the features of conventional and
mechatronic systems
Range
Building blocks: typical input devices, prime movers, gearing,
controllers, typical output devices
Architecture: controller, correction element, process, outputs, logical
sequence of events, construct block diagrams
Features: centralised control or distributed control, hard wiring or
networks, sequence control or intelligent individual control, relay logic or
software programming, plant maintenance or predictive maintenance
150
Learning outcome
The learner will:
2. be able to apply the principles of typical sensors
Assessment criteria
The learner can:
2.1 interface contact and non-contact sensors into a control system.
2.2 explain the operation and application of sensors
2.3 explain typical connections and tuning arrangements for sensors
2.4 explain the action and importance of signal conditioning
systems
2.5 explain the importance of terms applied to sensors used in an
industrial system
Range
Sensors: micro switch, snap action limit switch, wobble stick, pressure
mat, positively guided safety switch, inductive proximity, capacitive
proximity, optical proximity, light curtain, thermocouple, strain gauge
differential pressure, impeller flow, encoder (incremental and absolute),
resolver
Signal conditioning systems: voltage to current, current to voltage,
pressure to voltage, pressure to current, analogue to digital, digital to
analogue, frequency to voltage, frequency to current, sink to source,
source to sink
Terms: sensitivity, repeatability, resolution, dead band, alignment,
compatibility, cross talk, grounding, calibration
Learning outcome
The learner will:
3. be able to apply the principles of pneumatic, hydraulic, mechanical
and electrical actuation systems
Assessment criteria
The learner can:
3.1 design and implement control and actuation systems
3.2 explain the operation and application of each part of a pneumatic
power system
3.3 explain the operation and application of valves employed in
pneumatic systems
3.4 explain the operation and application of actuators employed in
pneumatic systems
3.5 explain the operation and application of each part of a hydraulic
power system
3.6 explain the operation and application of valves employed in
hydraulic systems
3.7 explain the operation and application of actuators employed in
hydraulic systems
3.8 classify symbols used in pneumatic, hydraulic, mechanical and
electrical actuation systems
3.9 explain the operation and application of each part of a mechanical
system
151
3.10 explain the operation and application of each part of a electrical

system
3.11 explain the application of components in a fieldbus network
Range
Control and actuation systems: pneumatic, hydraulic, electrical
Pneumatic power system: prime mover (i.e., motor), compressor (i.e.,
two stage reciprocating), silencer, filter, pressure relief valve, cooler,
filter and water trap, air receiver, pipe work distribution system
Valves - pneumatic systems:
directional control valves (DCV) spool, 3/2, 4/2, 5/2, directly
operated, pilot operated, solenoid operated, poppet
directional valves one way, one way restrictor return
pressure control valves pressure regulating, pressure limiting,
pressure sequence, proportional
process control valves pneumatic diaphragm actuator, linear
contoured, equal; percentage
actuators:
linear actuators single acting, double acting, fluid muscle, tandem,
multi position, stick slip
rotary actuators use of linear actuator to produce rotation, vane-type
semi-rotary, vane motor
Hydraulic power system: prime mover (i.e., motor), pump, non return
valve, pressure relief valve, accumulator (i.e. bladder-type), sump,
hydraulic oil, pipe work distribution system and return
Valves - hydraulic systems:
directional control valves (DCV) spool, 3/2, 4/2, 5/2, directly
operated, pilot operated, solenoid operated, poppet
directional valves one way, one way restrictor return
pressure control valves pressure regulating, pressure limiting,
pressure sequence, proportional
Symbols: flow path, flow shut-off, initial connections, push button
operation, lever operation, roller operation, plunger operation, spring
operation, solenoid operation, pedal operation, pilot operation, 2/2
valve, 3/2 valve, 4/2 valve, 5/2 valve, non return valve, pressure limiting
valve, regulator, pressure source, exhaust, filter, single acting cylinder,
double acting cylinder, rotary actuator
Mechanical system: prismatic motion, revolute motion, sliding joints,
revolving joints, force amplification (i.e., levers), change of speed (i.e.,
gears), transfer of rotation (i.e., belts and chains), types of motion (i.e.,
quick return mechanism), cams and cam followers, change of direction
(i.e., bevel and worm gear), linear to revolute / revolute to linear (i.e., rack
and pinion), bearings (i.e., plain roller needle and ball)
Electrical system:
switching devices push buttons, relays, thyristor, triac, solid state
relay
solenoid devices
motors series d.c., shunt d.c., separately excited d.c., stepper, servo,
single phase induction, three phase induction
motor control basic d.c. motor speed control (i.e., inverter drive),
basic induction motor speed control (i.e., inverter drive), basic stepper
motor controllers, basic servo motor controllers
152
Components: benefits over hard wired systems, communications

interface to control system, basic requirements of wiring medium (i.e.
CAT 5, grounding), types of distributed input / output modules (i.e.,
digital, analogue)
Learning outcome
The learner will:
4. be able to apply the principles of embedded control
Assessment criteria
The learner can:
4.1 write simple expressions to describe logic instructions.
4.2 explain the function of the main components in Programmable
Logic Controller (PLC) architecture
4.3 explain Ladder Logic programming as used in PLC programming
4.4 explain the content of simple programs written using Ladder Logic
programming
4.5 explain the function of the main components in Programmable
Interface Controller (PIC) architecture
4.6 apply the content of programs written for simple programme
languages PIC programming
4.7 explain the operation of embedded control systems
4.8 explain the logical function of logic gates
Range
Logic instructions: simple instructions to describe input/output
conditions, correct terminology
Components (PLC): control unit, programming device, input/output
modules, memory, system clock, use block diagrams to aid description
Ladder Logic programming: basic instructions, examine if
open/closed, output, latched output, bit / flag instructions, timers,
counters
Components (PIC): Central Processing Unit (CPU), analogue to digital
converter (ADC), input / output ports, communication port, timers,
memory, system clock, block diagrams to aid description
Programme Languages: low level assembly language - RISC (Reduced
Instruction Set Computing)
high level language - requiring a compiler (i.e., Basic) e.g simple robot
arm movements
Embedded control systems: dedicated controllers, slave controllers
Logic gates: And, Or, ExOr, Not, Nand, Nor
153
Learning outcome
The learner will:
5. be able to carry out fault finding on pneumatic, hydraulic, mechanical
and electrical actuation systems
Assessment criteria
The learner can:
5.1 diagnose simple faults on control and actuation systems
5.2 explain methods of fault location
5.3 explain the operation and applications of test instruments
5.4 explain safe isolation procedures for systems
5.5 evaluate the effects of faulty or inefficient pneumatic systems and
hydraulic systems.
Range
Control and actuation systems: pneumatic, hydraulic, electrical
Methods: half split method, input to output/output to input, component/
unit substitution, component/unit response, visual inspection,
consideration of symptoms, pressure monitoring
Test instruments: signal injector, logic probe, multimeter, signal
sources (i.e., 4 mA 20 mA), data logger
Systems: electrical power, electrical control, pneumatic radial,
pneumatic ring, hydraulic
Pneumatic systems: cost of producing, lost air, environmental effects
Hydraulic systems: dangers of pressurised liquids, environmental
effects
154
Unit 333
Computer automated and

robotic systems principles and
control
URN:
R/503/0431
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
sector or
regulatory body:
Aim:
This unit is concerned with automated and

robotic systems.
It covers the operation of various types of
control systems, open and closed loop control,
robotic drive systems, effective robot tooling
design, basic robotic control and programming
tasks, plc applications in integrated control
environments and analysis techniques for
various modes of control for automation
systems
Learning outcome
The learner will:
1. understand the architecture and uses of computer automated and
robotic systems
Assessment criteria
The learner can:
1.1 explain the architecture of computer based automation systems
1.2 explain variable names used in computer based automation
systems
1.3 explain the significance and use of mathematical modelling of
system components and the concept of transfer functions
1.4 explain the basic physical construction of a robotic system
1.5 explain movements and joints in robotic systems
1.6 classify robotic arms
1.7 explain wrist design features
1.8 explain the factors which determine the choice of end effectors
1.9 classify types of robot for different applications
1.10 obtain characteristic responses for simple control and robotic
systems
1.11 describe the benefits and possible implications of using an
automated control system
155
1.12 explain the design considerations in relation to implementation

of a robotic system
1.13 explain the physical layouts for robotic systems
1.14 explain robot/automation safety aspects relating to both
machines and personnel.
Range
Architecture: process, inputs, outputs, energy source, measurement
system, controller, feedback loops
Variable names: controlled variable, manipulated variable,
measurement variable, disturbance variable, error, set-point controller
output
Physical construction: jointed manipulator, end effector, controller,
programming unit
Movements: arm sweep, shoulder swivel, elbow extension, X plane
(width movement), Y plane (height movement), Z plane (depth
movement), roll, pitch, yaw, prismatic, revolute, symbols for prismatic
and revolute joints, six degrees of freedom
Joints: prismatic, revolute, symbols for prismatic and revolute joints
Robotic arms: Cartesian, cylindrical, polar, jointed arm, SCARA
(Selective Compliance Assembly Robot Arm), partial spherical
(pendulum), multiple joint (spline)
Wrist design: three revolute degrees of freedom, accuracy of end
effecter manipulation
Choice of end effectors: vacuum, stepper motor driven, specialist
design
Types of robot: programmable manipulator, pick and place, loading and
unloading, production
Characteristic responses: input/output, effect of variables
Benefits: increased productivity, improved quality, increased efficiency,
improved safety, convenience, power assistance, repeatability, accuracy,
speed, use in hazardous areas
Implications: effect on jobs, capital costs, variable costs, available
space, maintenance costs, loss of production due to failures, upgrade
costs, safety
Design considerations:
planning personnel involved, application, feasibility review
development task, part presentation, handling equipment, process
machines, quality control process
mock-up & testing commissioning, de-bugging, trial runs, quality
control checks
installation pilot production runs, parallel running with manual cells,
final implementation
Physical layouts: radial layout, in-line track mounted, in-line fixed
Safety aspects: category B, category 1, category 2, category 3,
category 4, operator competence, operator training, emergencies
156
Learning outcome
The learner will:
2. understand the operation of various types of control systems
Assessment criteria
The learner can:
2.1 describe the difference between control system types
2.2 explain classifications of control systems
2.3 explain the operation of digital and analogue motion control
systems
2.4 evaluate the relationship between functions in a motion control
system
Range
Control system types: regulatory/following, numerical/
servo/sequential
Classifications:
set-point changes infrequent change regulatory system, frequently
changed following system
industry found in processing process control, continuous system,
batch system
part manufacturing machine control numerical control systems,
robotic control systems
category of controller or control Programmable Logic Controller,
event sequenced control, time sequenced control, industrial, controller
Digital motion control system: set-point, gain, output signal, feedback
devices, actuator types, error codes
Analogue motion control system: rectification, d.c. bus, chopping
circuit, output section
Functions: frequency/speed, speed/torque, switching frequency/noise
Learning outcome
The learner will:
3. be able to apply open and closed loop control systems
Assessment criteria
The learner can:
3.1 explain the requirements and true value inputs of a
measurement system
3.2 classify signal conditioning in measurement systems
3.3 explain input transducer circuit arrangements and operations
3.4 explain the principles of damping in open and closed loop systems
3.5 explain the actions and meaning of terms and expressions of
open and closed loop systems
3.6 apply formulae to derive controller output
3.7 describe the difference between integral and derivative control
3.8 explain the basic principles of output analysis
3.9 build and analyse circuits on open and closed loop control
systems
157
Range
Requirements: reliability, repeatability, range (reproducibility),
sensitivity, stability, response time, rise time, settling time, steady state,
desired value, loading effects/errors
True value inputs: measurement system, measured value of variable
output
Signal conditioning: voltage to voltage, voltage to current, frequency
to voltage, resistance to voltage
Input transducer: transducer action, analogue input interfaces, digital
input interfaces, signal conditioning circuits, calibration procedures
Damping: under-damped, over-damped, critical damping
Actions: system block diagrams, reliability, repeatability, range
(reproducibility), sensitivity, stability, response time, rise time, settling
time, steady state, desired value, loading effects / errors
Terms and expressions: two step control, continuous control,
proportional band, dead band, off-set, hysteresis, Proportional gain (Kp),
Derivative gain (Kd), Integral gain (Ki)
Formulae: controller output = Kp(error + Ki x integral of error + Kd x
derivative of error), output = kp(e+kie + kd de/dt)
Integral and derivative control (statements): integral control is a
controller output that is proportional to the integral to the error with
respect to time, derivative control is a controller output that is
proportional to the rate of change of the error with respect to time
Output analysis: input signals stepped, ramped, sinusoidal measuring
equipment PC-based data logger, storage scope
Build and analyse circuits: configure inputs, analyse outputs,
simulated analysis, system tuning using tables / charts
Learning outcome
The learner will:
4. be able to use transducers in control and robotic systems
Assessment criteria
The learner can:
4.1 explain typical applications for sensors employed in control and
robotic systems
4.2 interpret and use technical information contained in manufacturers
data sheets relating to thermocouples, pt100devices, proximity
sensors, tacho generators and differential pressure devices
4.3 classify digital, analogue, safety and internal and external sensors
4.4 explain actions and calibration of actuators
4.5 explain common connection types used with transducers
4.6 explain the connection of proximity switches in parallel and
series to achieve Boolean Logic external to a controller
4.7 explain technologies required for circuits that operate in areas of
high radio frequency interference, and electromagnetic
interference (RFI/EMI)
4.8 explain the connection of devices to proximity sensors
4.9 explain sensor power supply considerations
4.10 set up sensors
4.11 set up actuators
158
4.12 select an appropriate sensor for a given application

4.13 wire a selection of transducers with different connection types into
a control system
4.14 wire proximity switches to obtain AND and OR functions
4.15 wire proximity switches in sink and source mode
Range
Applications: measuring machine parameters for robot control loops,
determining the position of objects in 3-D space, adjusting the robot
control for the environment, detecting and preventing failures, detecting
and avoiding collisions, monitoring the interaction with the environment,
monitoring the environmental changes / temperature, inspecting the final
product
Thermocouple and pt100 devices: zero, range, span, junction
compensation, type
pt100 devices: zero, range, span
Proximity sensors:
types - inductive, capacitive, optical
information sensing range, material tuning, required output (sink
source), switching capability, banking capability
Tacho generators:
devices resolvers, encoders
information setting volts / rpm, setting of volts / mm, setting of data
sequence
Differential pressure devices:
devices turbine, strain gauge, piezo electric, ultrasonic
information resistive bridge trimming, trimming of volts / seconds,
trimming of power level
Digital sensors: limit switch, proximity switch, photo electric switch,
Hall effect switch, float switch, ultrasonic switch
Analogue sensors: temperature sensor, flow switch, load cell, laser,
pressure transducer, vision system
Safety sensors: gate plug, light curtain, safety mat
Internal and external sensors:
internal potentiometer, LVDTs, synchros, resolvers, optical encoders,
load cells, photoelectric
external proximity, limit switch, optical systems, Hall effect switch,
ultrasonic switch
Actuators:
proportional valves trimming of input signals, span, zero
servo motors setting of absolute datum optical sensor / drive to stall,
deriving maximum holding torque
Connection types:
2 wire d.c. & a.c. normally open (NO) contact, normally closed (NC)
contact, grounding connections, residual load current
3 wire d.c. transistor switched outputs (NPN & PNP types), normally
open, normally closed
4 wire d.c. transistor switched outputs (NPN & PNP types), normally
open/closed
Connection of proximity switches: parallel and series connection
(benefits and limitations), parallel connection using 2 wire technology,
parallel connection using 3 wire technology, series connection using 2
159
wire technology, series connection using 3 wire technology

RFI/EMI: need for screening, need for short cable lengths, segregation of
data and power conductors, power supply filtering, limit error signals at
source
Connection of devices: controllers, relays, display elements, current
consumption considerations, load resistance considerations, sensor
current considerations, transient protection
Sensor power supply: switch-on spikes, supply voltage ripple,
stabilisation
Learning outcome
The learner will:
5. be able to use robotic drive systems
Assessment criteria
The learner can:
5.1 explain common methods used to power robotic systems
5.2 explain the configuration and operation of typical robotic control
and drive systems
5.3 explain the operation of, and give applications for, transmission
systems
5.4 use suitable actuators in a robotic control system
Range
Power: fluid, pneumatic, electrical, production of compressed air
(pneumatic power), production of compressed fluid (hydraulic power)
Robotic control systems: control element, actuator, transmission
element, load, sensor, feedback, comparator
Robotic drive systems: pneumatic cylinder single acting, pneumatic
cylinder double acting, hydraulic cylinder double acting, pneumatic
rotary actuator, hydraulic rotary actuator, electro-mechanical solenoid,
spool valve, stepper motor
Transmission systems: spur gears, helical gears, straight bevel gears,
spiral bevel gears, worm gears, rack and pinion, ball and roller screws,
pulley drives and tendons, linkages, bearings
Atuators: pneumatic, hydraulic, electric, reasons for choice
Learning outcome
The learner will:
6. be able to apply effective robot tooling design
Assessment criteria
The learner can:
6.1 explain component design considerations with regard to
component automation
6.2 explain the application, operation and limitations of end
effectors
6.3 apply suitable end effectors
160
Range
Component design considerations: symmetry, datums, tangling,
feeding, insertion, alignment
Application: welding, grinding, painting, gripper and effector, vacuum,
clamp, intelligent hand
Operation: vacuum cup, pneumatic gripper, servo controlled gripper,
intelligent hand
Limitations: rated payload and gripper mass, force required to
accelerate and decelerate payload (F = ma), force required to change
payload direction, clamping force, co-efficient of friction between gripper
and part
Learning outcome
The learner will:
7. be able to apply basic robotic control and programming tasks
Assessment criteria
The learner can:
7.1 use programming tools employed in robotic systems
7.2 explain online and offline programming considerations
7.3 produce robot program designs utilising flow charts and block
diagrams
7.4 explain the use of kinematic and isometric diagrams to relay
information relating to a robot system
7.5 explain the relationship and interaction between control systems
7.6 explain performance specifications for robots
7.7 explain safety implications of combined discipline systems
Range
Programming tools: control pendants, software, simulation
On-line programming: axis limit control, point to point, contouring, line
tracking
Off-line programming: safety, 3D visualisation of a robot arm, need for
computing ability, specialist programming language, absolute and
incremental co-ordinates, trouble shooting, planning, communication
between CAD and CAM systems (Computer Aided Drawing/Computer
Aided Manufacture)
Flow charts: symbols, labelling, inputs
Block diagrams: layout, process, sequence
Control systems: robot, motion
Performance specifications: payload, normal and maximum, static and
rated, static and dynamic, repeatability, speed, limit on certain motion,
weight restrictions
Safety implications: verification of inputs, collision detection, working
envelope
161
Learning outcome
The learner will:
8. be able to perform plc applications in integrated control
environments
Assessment criteria
The learner can:
8.1 explain the function of the component parts of PLC architecture
8.2 explain programming languages used to program PLCs
8.3 explain programming device communications configuration
methods
8.4 explain the characteristics and methods of configuring different
types of interface module
8.5 perform simple operations on a PLC controlled system
Range
Component parts: control unit, programming device, input / output
modules, memory
Programming languages: industrial standard languages, IEC 61131-3,
statement list, structured text, function block, sequential function chart,
basic instructions in Ladder Logic, examine in open / closed, output,
latched output, bit / flag instructions, timers, counters, move and logic,
arithmetic and compare
Communications configuration: upload programmes from a PLC,
modify programmes both online and offline, test programmes and reevaluate operation, use software and hardware to troubleshoot
problems in a PLC based control system, document and save
programmes
Interface module: digital I/O, analogue, remote I/O, RFID (Radio
Frequency Identification) scanning systems, bar code readers, camera
vision systems
Simple operations: programming using Ladder Logic, communications
configuration, PLC programme download/upload tests, PLC programme
modification, interface module configuration, e.g programme a robot
arm to carry out a simple task
162
Learning outcome
The learner will:
9. be able to use analysis techniques for various modes of control for
automation systems
Assessment criteria
The learner can:
9.1 describe methods used to describe sequential processes
9.2 explain the principles of control modes used in automation
systems
9.3 explain the characteristics of automation systems employing
combinations of control modes
9.4 explain methods used to optimise/tune the response of a control
system for various types of control mode
9.5 explain methods used to analyse the response of a control
system to determine the levels of stability in a system
9.6 carry out simple analysis operations on a PLC controlled system
Range
Sequential processes:
time driven statement algorithm, timing diagrams
event driven ladder diagrams, Boolean expressions, sequential
function charts, state diagrams, process timing diagrams
Control modes: proportional (P), integral (I), derivative (D),
combinations (PI and PID)
Methods: process reaction curve, ultimate cycling method,, self tuning
adaptive controllers
Analyse the response: Bode diagrams for phase and gain, phase and
gain margins
Analysis operations: program simple time/event driven processes
using a PLC as the controller, tune simple control systems, frequency
response check for various modes of control wire proximity switches in
sink and source mode e.g , a frequency response check for various
modes of control
163
Learning outcome
The learner will:
10. be able to integrate computer based operator interfaces
Assessment criteria
The learner can:
10.1 explain the main elements, features and functions of PC based
(SCADA) systems
10.2 explain software data linking standards used to exchange data
between software applications
10.3 explain methods used to link real I/O to PC based applications via
database objects
10.4 explain the use of functions and features available with HMI
systems
10.5 explain the main features and functions of system interfaces
10.6 configure control interfaces on PLC based control systems.
Range
Elements, features and functions: linked animated graphics, PC
control of system functions, display and logging of system errors, need
for archiving of process errors, alarm functions of variable priority,
display of process trends in various graphical formats
Data linking standards: dynamic data exchange (DDE), object linking
and embedding (OLE)
Database objects: I/O PLC based, HMI (human machine interface) based
Functions and features: function key control, touch screen controls,
communication links available with typical systems, creation of graphical
objects and configuring links to PLC and SCADA based systems
System interfaces: PC based operator, HMI based
Control interfaces: SCADA or HMI, graphical interface to include
control / animation / alarming / archiving / trends, data exchange link
between software applications
164
Unit 334
Power supply, and analogue

and digital circuit principles
and fault
URN:
Y/503/0432
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit is concerned with d.c. power

supplies, analogue circuits including
amplifiers and oscillators, and digital circuits
including logic families, sequential logic, and
digital transmission systems. The topics
covered will enable the candidate to
interpret circuit diagrams, explain the
operation of circuits, produce waveform
diagrams for given points in a circuit, and be
able to identify and test electronic
components. The candidate will also be able
to perform circuit and diagnostic checks on
prepared boards, and make deductions from
the results of these checks which lead to a
correct fault diagnosis.
Learning outcome
The learner will:
1. understand power supply circuits to component level
Assessment criteria
The learner can:
1.1 explain the operation of low voltage dc power regulator circuits
1.2 explain the key components, and the operation of, a switch
mode power supply (SMPS)
1.3 evaluate the advantages and disadvantages of SMPS compared
with series and shunt regulator circuits
1.4 explain principles of fault location in power supply circuits
165
Range
Power regulator circuits: series regulator, shunt regulator, voltage
doubler, dc-dc converter, inverters, feedback control for voltage/current
regulation, over-current protection circuits, safety critical components
Key components: d.c. input, power switching, chopper control, startup, feedback, d.c. output generation, safety critical components, rf
suppression components, transient suppression components
Operation: power switching, chopper control, start-up, feedback, overvoltage protection, over-current protection, stand-by mode, d.c. output
generation, expected waveforms and voltages
Advantages and disadvantages: efficiency, circuit complexity,
physical size, heat output, current output capabilities, factors
determining choice of PS
Fault location: recognise symptoms, relate symptoms to fault
conditions, expected changes in waveforms and voltages for given fault
conditions, use of dummy loads, typical adjustment methods
Learning outcome
The learner will:
2. understand analogue circuits to component level
Assessment criteria
The learner can:
2.1 explain the operation of single and multi-stage bipolar transistor
voltage amplifiers
2.2 explain the different classes and modes of operation of bipolar
transistor circuits
2.3 explain how to obtain response plots for amplifier circuits
2.4 explain the operation of MOSFET amplifier, transistorised
power amplifier and operational amplifier circuits
2.5 explain the meaning of common terms relating to operational
amplifiers
2.6 state the conditions for oscillation in amplifier circuits
2.7 explain the operation of common oscillator circuits and 555
timer circuits
2.8 apply fault location to component level using appropriate test
instruments
166
Range
Bipolar transistor voltage amplifiers: common circuit arrangements,
inter-stage coupling, typical component values, effects of collector load
resistor value on voltage gain, effects of negative feedback (both a.c. and
d.c.), expected waveforms and voltages, causes and effects of distortion
Classes and modes of operation: A, AB, B, C, common emitter,
common base, common collector (emitter follower)
Response plots: frequency response, bandwidth measurement (@ 3dB), voltage gain
MOSFET amplifier: common circuit arrangements, typical component
values, expected waveforms and voltages
Transistorised power amplifier: Class A bipolar, Class B
transformerless push-pull, MOSFET designs, need for a.c. and d.c.
feedback, integrated circuit types
Operational amplifier circuits: common circuit arrangements,
feedback circuits, virtual earth, inverting input, non-inverting input,
integrator differentiator, differential amplifier, comparator, Schmitt
trigger, high / low pass filters
Common terms: drift, offset, slew
Conditions for oscillation: effects of positive feedback, feedback factor
Common oscillator circuits: crystal, ceramic resonator, RC phase shift,
Wien bridge, LC, VCO (voltage controlled oscillator) using PLL (phase
locked loop), expected waveforms and voltages
555 timer circuits: astable, monostable, deriving a sawtooth output
Fault location to component level: identification of fault area from
fault symptoms, visual inspection, half split method, input to
output/output to input, component substitution, choice of suitable test
instrument(s) for a given fault condition, tests are appropriate to the fault
condition, correct setup of test instruments, correct interpretation of
results, recording results of applied tests, correct diagnosis of defective
component(s)
Learning outcome
The learner will:
3. understand digital electronics and data transmission systems
Assessment criteria
The learner can:
3.1 classify common logic device encapsulations
3.2 explain common terms used with digital electronics
3.3 classify and compare devices in logic families
3.4 explain the operation of logic devices using waveform diagrams
3.5 connect bistable logic devices to produce counting and dividing
circuits
3.6 explain the operation of synchronous and asynchronous
integrated counters
3.7 explain the effects of mechanical switch / relay contact bounce on
logic circuits
3.8 explain the principles of Time Division Multiplexing (TDM)
3.9 critically compare digital encoding methods employed in data
transmission systems
167
3.10 critically compare transmission medium for data transmission

employing TDM
3.11 explain error detection and correction techniques employed in
digital systems
Range
Logic device encapsulations: device numbering, type of packaging,
pinout numbering
Common terms: supply voltages, supply current, high level input
voltage, low level input voltage, noise margin, input and output currents,
rise and fall times, propagation delay, power dissipation, absolute
maximum ratings, fan in/fan out
Logic families: 4000 Series, 74LS Series, 74HC Series, 74HCT Series,
74AHC Series
Logic devices: JK bistable, D-Type bistable, MasterSlave JK bistable
Counting and dividing circuits: modulo-n dividers, up/down counters,
associated timing diagrams and waveforms
Integrated counters: decade counters, modulo-n counters, modulo-n
dividers, ring counters, twisted ring, shift registers, associated timing
diagrams and waveforms
Contact bounce: causes, effects on circuit operation, methods for
suppression (de-bounce circuits)
Time Division Multiplexing (TDM): sampling, sampling rate,
multiplexing, demultiplexing
Encoding methods: RZ (Return to Zero) encoding, NRZ (Non Return to
Zero) encoding, Manchester code, Gray code, BCD (Binary Coded
Decimal)
Transmission medium: copper cable, fibre-optic cable
Error detection and correction: parity check, CRC (Cyclic Redundancy
Check)
Learning outcome
The learner will:
4. be able to find faults on digital circuits and data transmission
systems
Assessment criteria
The learner can:
4.1 assemble, test and find faults on digital circuits
4.2 explain common causes of failure of integrated circuits (ICs)
during use and servicing
4.3 explain methods for preventing IC damage by electrostatic
discharge during assembly/servicing
4.4 explain the uses and limitations of test equipment in relation to
logic circuits
4.5 explain fault finding techniques
168
Range
Assemble, test and find faults : effects of floating inputs, output
loading effects, input drive options, connect circuits via a fibre-optic link,
use of TDM to transmit multiple signals across a single transmission path,
use of logic tutors to investigate circuit operation and verify Data Sheet
information, circuits using JK and D-type bistable ICs, integrated shift
registers employing ICs such as 74XX194, integrated synchronous and
asynchronous modulo-n counters employing ICs such as 74XX74 /
74XX112 / 74XX193 / 74XX380, switch bounce, locate faults in digital
equipment such as combinational logic circuits/synchronous and
asynchronous counters, shift registers, bistables/remote controls/D-A
and A-D converters/7 segment displays
Failure of ICs during use: incorrect supply voltages, electrostatic
discharge (ESD), lightning strike, excessive heat, mechanical vibration
Failure of ICs during servicing: incorrect orientation when fitting /
replacing, poor soldering techniques, insertion/removal whilst power is
applied, shorting of pins during measurements, electrostatic discharge
(ESD)
Methods for preventing IC damage: storage/transportation of ICs,
non-static floor coverings / work surfaces, non-static clothing, wrist/heel
straps, conductive matting
Test equipment: multimeter, logic probe and clip, logic pulser, logic
analyser, current tracer, signature tracer, oscilloscope
Fault finding techniques: visual inspection, consideration of
symptoms, half split method, input to output / output to input,
component substitution, recording results of applied tests
169
Unit 335
Electronic power control

principles and practice
URN:
H/503/0434
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit is concerned with the basic

principles of three phase mains power,
power electronic components, the
electronics employed in process control and
automation systems, and basic customer
care.
The topics covered will enable the candidate
to interpret circuit diagrams, explain the
operation of circuits, and perform tests on
circuits. The candidate will also be able to
carry out simple PLC programming, and
describe methods of customer care
Learning outcome
The learner will:
1. understand power electronics principles and circuits
Assessment criteria
The learner can:
1.1 explain the principles of a 3-phase mains electricity supply
1.2 explain typical functions for low voltage 3-phase power supplies
1.3 explain the wiring configurations for typical 3-phase power
connectors
1.4 explain the operation of 3-phase rectification circuits
1.5 explain the operation of, and applications for, heavy current
components
1.6 use methods for testing heavy current components
1.7 describe applications for low voltage/heavy current switched
mode power supplies
1.8 explain controlled a.c. power transmission systems employed in
localised power networks
1.9 explain the operation of Uninterruptible Power Supplies (UPS)
170
Range
3-phase mains electricity: 3-phase 4 wire output from a substation,
line to line and phase voltages, graphical representation of 3-phase
waveforms, star and delta connections, typical applications for 3-phase
supplies
Functions: reduced PSU output ripple, increased efficiency
Power connectors: IEC60309 connector, 3-phase + earth, 3-phase +
neutral + earth
3-phase rectification: half wave, full wave, input/output waveform
relationships for rectifier circuits, output ripple, ripple frequency
Heavy current components: capsule thyristors, thyristor/diode
modules, triacs, capsule rectifier diodes, stud mount rectifier diodes, fast
diode modules, power insulated gate FETs (IGFETs), insulated gate
bipolar transistors (IGBTs), insulated gate commutated thyristors (IGCTs)
Switched mode power supplies: single phase, three phase
a.c. power transmission systems: Flexible a.c. Transmission Systems
(FACTS), Uninterruptible Power Supplies (UPS)
Uninterruptible Power Supplies (UPS): on-line UPS, off-line UPS
Learning outcome
The learner will:
2. be able to process control and transducers
Assessment criteria
The learner can:
2.1 describe common control methods
2.2 describe common terms used in control systems
2.3 describe the operation of block diagrams for systems used in
process control
2.4 explain the operation of transducers and sensors employed in
control systems
2.5 explain the operation of feedback as employed in control systems
2.6 locate faults in systems listed in block diagrams
Range
Control methods: On/Off, proportional derivative (PD), proportional
integral derivative (PID)
Common terms: critical damping, stability, proportional band, dead
band, transport lag
Block diagrams: micro-controller based linear control system,
temperature control systems, speed control systems, position control
systems, fluid control systems, gas flow control systems
Transducers and sensors: analogue output, digital output, digitally
encoded output, signal conditioners, temperature, motion sensors,
rotary encoders, optical transducers, displacement transducers, image
sensors, proximity sensors, fluid/gas flow transducers
Feedback: positive, negative, voltage derived series applied, voltage
derived shunt applied, current derived series applied, current derived
shunt applied
171
Learning outcome
The learner will:
3. be able to apply motor drive systems
Assessment criteria
The learner can:
3.1 explain typical applications for d.c. motors employing different
methods of excitation
3.2 explain typical applications for different types of a.c. motor
3.3 select suitable motors for tasks where particular characteristics
are required
3.4 explain and illustrate the operation of motor speed control
systems
3.5 explain the operation of stepper motors and their drive systems
3.6 measure values to determine characteristics of motor drive
systems
Range
Methods of excitation: series, shunt, split field, permanent magnet
a.c. motor: capacitor start induction run single phase, three phase
induction with d.o.l. starting, synchronous three-phase
Characteristics: constant torque, high speed, low speed, low
maintenance, precise positional control
Speed control systems: a.c. motor, d.c. motor
Stepper motors: permanent magnet, variable reluctance, hybrid
Characteristics: feedback signals, start/running currents, torque/speed
characteristics
Learning outcome
The learner will:
4. be able to program industrial automation systems
Assessment criteria
The learner can:
4.1 explain the operation of programmable logic controllers (PLCs)
4.2 classify PLC inputs and outputs
4.3 explain briefly the operation of field device networking
protocols
4.4 write programs for PLCs using ladder diagrams
4.5 program a PLC to perform an operation in response to a sensor
input.
172
Range
Programmable logic controllers (PLCs): PLC as a system, PLC as a
part of an automated production system
PLC inputs:
instruction inputs keypads, selector switches
sensor inputs limit switches, proximity switches, photosensors
PLC outputs:
low current small solenoid valves, motors, electromagnetic clutches
high current large solenoid valves, three-phase motors
indicators pilot lamps, digital display
Field device networking protocols: Actuator Sensor Interface (ASInterface, or ASi), Profibus
Programs for PLCs: standard ladder diagram symbols, logic functions,
latching, timers, markers, counters, shift registers
173
Unit 336
URN:
H/503/0353
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit sets out the requirements for metal

inert gas (MIG) welding of aluminium and
aluminium alloys in a modern engineering
environment, in terms of what needs to be
achieved by the candidate, ie: welding a
series of challenging joint configurations
across in a wide range of positions that are
compliant to welding procedure
specifications.
The unit is concerned with the technology
and practices involved in the application of
MIG welding of aluminium and aluminium
alloys. The unit is demanding in terms of
welding consumables (i.e. electrodes) and
the practicalities of producing a welded joint
in relation to a welding procedure
specification.
Learning outcome
The learner will:
1. be able to apply safe working practices to MIG welding
Assessment criteria
The learner can:
174
Range
Hazards and risks: fume, fire, electricity, arc radiation, hot metal,,
cylinders
Learning outcome
The learner will:
2. be able to prepare equipment for performing MIG welding of
aluminium and aluminium alloys
Assessment criteria
The learner can:
applications
Range
Welding equipment: power sources, inverter , generator, rated output,
measurement of electrical output and continuity, relationship between
wire feed speed control and welding current, power source
characteristics, function of induction, return, earth, construction, rated
output, welding guns, contact tip, return clamps, wire feed control,
ancillary equipment
Learning outcome
The learner will:
3. be able to perform MIG welding operations to meet welding
Assessment criteria
The learner can:
applications
3.2 describe the difference between welding consumables by their
classification
3.3 produce complex welded aluminium and aluminium alloy joints in a
range of positions in accordance with welding procedure
specification (WPS) parameters
welding operation
175
Range
Electrode wires:
BS EN ISO 18273: Welding consumables. Wire electrodes, wires and
rods for welding of aluminium and aluminium alloys, classification: (sizes
[diameters, lengths], strength and elongation of the weld metal, chemical
composition of the weld metal, storage, identification, segregation
(classification, size), application to aluminium alloy groups (1000 7000
series)
Shielding gases:
BS EN 439: Welding consumables. Shielding gases for arc welding and
cutting, effects of shielding gases/gas mixtures (weld pool/arc area
protection, heat input, weld geometry, penetration profile, travel speed,
mode of metal transfer), applications for shielding gases/gas mixtures
(argon, helium, argon/helium mixtues, helium/argon mixtures), benefits
and limitations, gas pressure requirements, flow rates for applications
activities (cleaning [including scraping, filing, abrasives, stainless steel
wire brushing, degreasing, chemical etching and associated care in use],
edge preparation, assembly, pre-heat relation to thickness, effect upon
fusion, material composition]), welding), welding parameters, welding
positions (EN ISO 6947 PA, PB, PC, PD, PE, PF, PG), number and
arrangement of runs to fully fill/weld joints, electrode sizes for joint
thicknesses, mode of metal transfer (spray, pulse, synergic pulse),
electrical conditions required (type of current, direct [d.c.], electrode
polarity (positive), wire feed speed ranges, voltage (open circuit, arc),
control of heat input input (preheat temperatures and methods of
application), shielding gas (type, flow rate) interpass/run cleaning/back
gouging methods, post welding activities (spatter removal, wiring
brushing, removal of excess weld metal where required), post-weld heat
treatment (normalising, stress relief)
Learning outcome
The learner will:
conformance
Assessment criteria
The learner can:
conformance
176
Range
specification (BS EN ISO 10042 Welding, arc-welded joints in aluminium
and its alloys, quality levels for imperfections), methods of avoiding,
rectification methods
inspection, qualitative (defect levels, appearance), quantitative (extent,
size, dimensional accuracy)
testing
177
Unit 336
Guidance
Personal Protective Equipment at Work Regulations (application to
(action levels)
continuity (voltage use of voltmeter/multi-meter, current use of
178
permits to work)
179
Unit 337
URN:
Y/503/0351
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

tungsten inert gas (TIG) welding of aluminium
and aluminium alloys in a modern
procedure specifications.
The unit is concerned with the technology
and practices involved in the application of
TIG welding of aluminium and aluminium
alloys. The unit is demanding in terms of
the welding aluminium and aluminium alloys
that candidates are expected achieve. The
unit is broadly divided into health and safety,
and the practicalities of producing a welded
joint in relation to a welding procedure
specification.
Learning outcome
The learner will:
1. be able to apply safe working practices to TIG welding
Assessment criteria
The learner can:
protective Equipment (PPE) to overcome hazards
180
Range
cylinders
Learning outcome
The learner will:
2. be able to prepare equipment for performing TIG welding of
aluminium and aluminium alloys
Assessment criteria
The learner can:
applications
Range
Welding equipment: power sources, direct current [d.c.], transformer,
transformer/rectifier, inverter, generator, measurement of electrical
output and continuity, methods of current regulation, power source
characteristics, torches, collet, collet holder, gas lens, electrodes, return
clamps, ancillary equipment
solenoid valves
Learning outcome
The learner will:
3. be able to perform TIG welding operations to meet welding
Assessment criteria
The learner can:
applications
parameters
3.4 explain the effects of the electrical characteristics of the TIG
welding arc
welding operation
181
Range
Electrode wires:
BS EN ISO 18273: Welding consumables: wire electrodes, wires and
rods for welding of aluminium and aluminium alloys, classification (sizes
[diameters, lengths], strength and elongation of the weld metal, chemical
composition of the weld metal, storage, identification, segregation
(classification, size), application to aluminium alloy groups (1000 7000
series)
Shielding gases:
BS EN 439: Welding consumables: shielding gases for arc welding and
protection, heat input, weld geometry, penetration profile, travel speed),
applications for shielding gases/gas mixtures (argon, helium,
argon/helium mixtures, helium/argon mixtures), benefits and limitations,
gas pressure requirements, flow rates for applications
activities (cleaning [including scraping, filing, abrasives, stainless steel
wire brushing, degreasing, chemical etching and associated care in use],
edge preparation, assembly, pre-heat relation to thickness, effect upon
fusion, material composition]), welding), welding parameters, welding
positions (EN ISO 6947 PA, PB, PC, PD, PE, PF, PG), number and
thicknesses, electrode, filler wire, electrical conditions required (type of
current, alternating [a.c.] direct [d.c.], electrode polarity (positive),
welding current ranges, methods of arc ignition (scratch, high frequency,
lift start), shielding gas (type, flow rate, pre-weld gas flow, post-weld gas
flow), techniques, control of heat input (preheat temperatures and
methods of application), interpass/run cleaning/back gouging methods,
post welding activities (wiring brushing, removal of excess weld metal
where required), post-weld heat treatment (normalising, stress relief)
Electrical characteristics: effects of types of current (a.c./d.c.) and
electrode polarity (d.c.: positive, negative) upon: heat input/distribution,
electrode, weld bead profile, penetration; methods of a.c. arc
stabilisation and maintenance (including: square wave); welding current
features (pulse current, slope in, slope out) voltage (open circuit, arc)
Learning outcome
The learner will:
conformance
Assessment criteria
The learner can:
conformance
182
Range
specification (BS EN ISO 10042 welding, arc-welded joints in aluminium
and its alloys, quality levels for imperfections), methods of avoiding,
rectification methods
testing
183
Unit 337
Guidance
(action levels)
measurement of electrical output and continuity (voltage use of
voltmeter/multi-meter, current use of ammeter/shunts/coils, continuity
use of continuity tester/ohmmeter), methods of current regulation
(tapped reactor, moving core, moving coil, moving shunt, saturable
reactor, variable resistance), power source characteristics (volt/ampere
graph, drooping characteristic, constant current output), leads used
(welding [water cooled, air cooled, harness] return, earth, construction,
rated output [duty cycle]), torches (types, water cooled air cooled, pencil,
construction, connections, contactor/switch, foot pedal/amptrol, back
caps [long. medium, short, applications], nozzles [long. medium, short,
applications], collet, collet holder, gas lens [construction, effects, benefits,
limitations, applications), electrodes (thoriated, zironiated, ceriated,
lananathed, compositions, sizes, identification, applications, preparation
[grinding: techniques, equipment, health and safety implications {dust,
particulates, extraction, radioactivity for thoriated}), return clamps (types,
clamping mechanisms), ancillary equipment (angle grinders, linishers,
wire brushes, oxide removal, degreasers)
184
permits to work)
185
Unit 338
Flux-cored Arc welding

materials
URN:
K/503/0354
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit sets out the requirements for fluxcored arc welding in a modern engineering
environment, in terms of what needs to be
achieved by the candidate, ie: welding a
series of challenging joint configurations
across in a wide range of positions that are
compliant to welding procedure
specifications. The unit is concerned with the
technology and practices involved in the
application of flux-cored arc welding. The
unit is demanding in terms of technological
content and the complexity of the welding
that candidates are expected achieve. The
unit is broadly divided into health and safety,
(i.e. electrodes) and the practicalities of
producing a welded joint in relation to a
quality specification
Learning outcome
The learner will:
1. be able to apply safe working practices to flux-cored arc welding
Assessment criteria
The learner can:
186
Range
Regulations: Health and Safety at Work etc. Act, COSHH, PUWER (scope
within the welding environment), RIDDOR, Management of Health and
Safety at Work Regulations, Personal Protective Equipment At Work
Regulations, Noise at Work Regulations
Hazards and risks: fume, fire, electricity, arc radiation, hot metal/slag
cylinders (safe storage conditions, safe handling/moving, safe use
Learning outcome
The learner will:
2. be able to prepare equipment for performing flux-cored arc welding
Assessment criteria
The learner can:
applications
Range
Welding equipment: power sources, transformer/rectifier, inverter,
generator, measurement of electrical output and continuity, methods of
current regulation, power source characteristics, leads, electrode
holders, return clamps, ancillary equipment
Learning outcome
The learner will:
3. be able to perform flux-cored arc welding operations to meet welding
Assessment criteria
The learner can:
applications
parameters
welding operation
187
Range
Electrode wires:
BS EN 756: Welding consumables, solid wires, solid wire-flux and tubular
cored electrode-flux combinations for submerged arc welding of non-alloy
and fine grain steels, classification: (sizes [diameters, reel sizes available],
strength and elongation of the weld metal, impact properties of the weld
metal, chemical composition and types of flux core (rutile, basic, metalcored, self-shielded, gas-shielded)
Shielding gases:
BS EN 439: Welding consumables: shielding gases for arc welding and
protection, heat input, weld geometry, penetration profile, travel speed,
mode of metal transfer), applications for shielding gases/gas mixtures
(carbon dioxide, argon/carbon dioxide mixtures, argon/oxygen/carbon
dioxide mixtures), gas pressure requirements, flow rates for applications
WPS: welding process, parent metal, consumables, pre welding activities
(cleaning, edge preparation, assembly, pre-heat), welding parameters,
welding positions (EN ISO 6947 PA, PB, PC, PD, PE, PF, PG), number and
thicknesses, mode of metal transfer (dip [short-circuiting, globular, spray,
pulse), electrical conditions required (type of current, direct [d.c.],
electrode polarity (positive or negative depending upon the wire), wire
feed speed ranges, voltage (open circuit, arc), control of heat input,
shielding gas (type, flow rate) interpass/run cleaning/back gouging
methods, post welding activities (spatter removal, wiring brushing,
removal of excess weld metal where required), post-weld heat treatment
(normalising, stress relief)
Learning outcome
The learner will:
conformance
Assessment criteria
The learner can:
4.3 destructively test joins to evaluate sub-surface for conformance
Range
Integrity of welded joints: classification of defects, quality specification
(BS EN 25817 arc welded joints in steel guidance on quality levels for
imperfections), methods of avoiding, rectification methods
testing
188
Unit 338
Flux-cored Arc welding

materials
Guidance
Personal Protective Equipment at Work Regulations (application to
(action levels)
protection [PPE, screening, warnings {verbal, notices}]), hot metal/slag
continuity (voltage use of voltmeter/multi-meter, current use of
189
permits to work)
190
Unit 351

science
URN:
K/503/0449
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
sector or
regulatory body:
Aim:
This unit enables the candidate to develop the

skills in and understanding of mathematics and
science to facilitate progression onto awards
that require a Level 3 mathematics and science
component. It is primarily aimed at those
candidates who wish to progress to higher
education and has been applied to practical
engineering principles of mathematics topics.
Learning outcome
The learner will:
1. be able to perform calculations involving indices, logarithms and
algebra
Assessment criteria
The learner can:
1.1 use powers and roots to solve problems
1.2 use logarithms to solve problems
1.3 use number bases to solve problems
1.4 use algebra to solve problems
Range
Powers and roots: meanings of the terms: base, index, power, root and
reciprocal; a0 = 1, a-n = 1/an, a 1/n = na, evaluate: aman, a(n + m), am/an, am n,
(am)n, amn, am/n
express decimal fractions in standard form, solve algebraic problems
involving transposition of terms with indices
Logarithms: define a logarithm as a power applied to a base number,
logarithms to the base 10, logarithms to the base e stating its
application, logarithms to simplify calculations
Number bases: application of binary and hexadecimal numbering
systems in data transmission, storage and progamming, calculations
using binary and hexadecimal numbers, conversions of numbers
between denary, binary and hexadecimal bases
Algebra: algebraic and graphical methods to solve simultaneous and
191
quadratic equations, define the roots of an equation, simple arithmetic

and geometric series, factorial notation for combinations and
permutations
Learning outcome
The learner will:
2. be able to perform calculations using trigonometry
Assessment criteria
The learner can:
2.1 perform calculations involving trigonometric ratios for the four
quadrants
2.2 apply the Sine Rule (A/sina + B/sinb + C/sinc) to practical problems
2.3 apply the Cosine Rule (a2 = b2 + c2 2.b.c cosa) to practical
problems
2.4 plot graphs of the functions y = Rsin ( t + ) and y = Rcos ( t + )
2.5 perform calculations to solve problems involving areas
2.6 differentiate between different trigonometric identities
2.7 explain that a complex number is a combination of j notation and a
rational number
2.8 explain the graphical represent vector quantities and polar
quantities
Range
Areas: non right-angled triangles, angles between lines, true length of
lines, true angle between planes
Trigonometric identities: tan = sin/cos, cot = 1/tan, sec = 1/cos, cosec
= 1/sin
Vector quantities: complex numbers, modulus, argument
Polar quantities: complex numbers, argand diagrams, rotating vector,
polar to cartesian form and vice-versa
192
Learning outcome
The learner will:
3. be able to perform calculations using calculus
Assessment criteria
The learner can:
3.1 apply the rules of differentiation
3.2 apply Simpson's Rule to the calculation of areas of irregular
sections
3.3 apply the rules of integration
3.4 perform calculations that apply differentiation to problems such as
velocity and acceleration
3.5 perform calculations involving maxima and minima to determine
the minimum material required to produce a regular-shaped square
or circular container of maximum volume
3.6 perform calculations that apply integration to problems such as
summation of irregular areas, volumes of revolution, centroid of
area and second moment of area
Range
Differentiation: dy/dx = nxn-1 , products, quotients, function of a
function and algebraic expressions (polynomial expressions, exponential
expressions, simple trigonometrical functions), calculations involving a
second derivative
Integration: axndx = a/n+1(xn+1), polynomial expressions, exponential
expressions, simple trigonometric functions, integration by substitution,
integration by parts
Learning outcome
The learner will:
4. be able to perform calculations involving statistics
Assessment criteria
The learner can:
4.1 calculate the mean and standard deviation for a sample of
engineering components
4.2 perform estimates of failure rates of engineering artefacts or
systems
4.3 define probability
4.4 define dependent and independent events, addition and
multiplication laws of probability, permutations and combinations
applied to probability, normal probability distribution, confidence
limits and statistical testing
193
Range
Mean and standard deviation: gather and collate data from various
sources and solve problems involving: frequency distributions (mean,
median, mode, standard deviation), extrapolated data, interpolated data,
use a calculator to perform statistical calculations
Learning outcome
The learner will:
5. be able to determine stress, strain and elasticity of materials
Assessment criteria
The learner can:
5.1 perform tensile tests on a range of materials and determine
Young's Modulus for each material
5.2 perform shearing tests and determine the modulus of rigidity of
materials
Range
Tensile tests: direct stress, direct strain, elastic limit, yield stress, tensile
strength, breaking point, Modulus of Elasticity, factor of safety,
calculations comparing the properties of different materials
Shearing tests: shear stress, shear strain, Modulus of Rigidity, Poisson's
ratio, calculations comparing the properties of different materials
Learning outcome
The learner will:
6. be able to solve problems involving kinematics
Assessment criteria
The learner can:
6.1 define velocity and acceleration
6.2 solve practical problems involving bodies in linear motion and
trajectories
6.3 use vector diagrams to determine achieved tracks and relative
velocities
194
Range
Velocity and acceleration: velocity as a vector quantity that is the rate
of change of distance with respect to time, area under a velocity/time
curve represents the distance travelled, acceleration is the rate of
change of velocity with time, area under an acceleration/time curve
represents velocity
Linear motion: solve problems for linear and rotary motion both
graphically and using the formulae:
s = 1/2(u + v)t, = 1/2(1 + 2)t; a = (v - u)/t, = (2 - 1)/t; v = u + at, 2 =
1 + t;
s = ut + 1/2at2, = 1t + 1/2t2; v2 = u2 + 2as, 22 = 12 + 2s
Vector diagrams: velocities of bodies subjected to linear motion (ships
in tides, aircraft in winds)
Learning outcome
The learner will:
7. be able to solve problems involving dynamics
Assessment criteria
The learner can:
7.1 explain Newton's Laws of Motion
7.2 define acceleration due to gravity as 9.81 ms-2
7.3 define that 1 newton is the force required to accelerate a mass of 1
kg at the rate of 1 ms-2
7.4 solve practical problems involving accelerating/decelerating
masses both graphically and using the formulae f = ma
7.5 define momentum as the product of mass and velocity
7.6 solve practical problems involving colliding bodies by calculation
7.7 use calculations to find the moment of inertia of disks and rimmed
flywheels
7.8 define radius of gyration
7.9 define potential energy and solve practical problems involving P.E =
mgh
7.10 explain the relationship between work done in raising a body to
potential energy
7.11 define linear and angular kinetic energy in terms of 1/2 mv2 and
1/2I2
7.12 solve energy conversion problems both graphically and using
formulae
7.13 solve problems associated with stored energy both graphically and
using the formulae SE = 1/2fx
195
Learning outcome
The learner will:
8. be able to solve problems involving bending beams
Assessment criteria
The learner can:
8.1 construct shear force and bending moment diagrams for simply
supported beams and cantilevers
8.2 perform calculations to determine maximum bending moments
8.3 define units of second moment of area as m4
8.4 solve problems associated with the stresses produced in bending
beams
8.5 compare the resistance in bending of tee, I and channel beam
cross-sections
Range
Maximum bending moments: point loads, uniformly distributed loads,
combinations of point and uniformly distributed loads, identify points of
contraflexure, assumptions made in calculating stress due to bending
Learning outcome
The learner will:
9. be able to solve problems involving fluids
Assessment criteria
The learner can:
9.1 define Boyle's law
9.2 define Charles' law
9.3 define the combined gas laws
9.4 solve practical gas law problems by calculation
9.5 solve practical fluid flow rate problems by calculation
Range
Gas law problems: Boyle's law, Charles' law, combined gas laws
Fluid flow problems: velocity of flow, volume flow rate, mass flow rate,
continuity equation for an incompressible liquid
196
Learning outcome
The learner will:
10. be able to demonstrate the effects of electromagnetism and
alternating current
Assessment criteria
The learner can:
10.1 demonstrate the effect of a magnetic field on a current carrying
conductor
10.2 demonstrate the effect of a magnetic field on a moving conductor
10.3 apply Fleming's Left-hand Rule to establish the direction of the
force on a current flowing at right angles to the direction of a
magnetic field
10.4 perform calculations to determine the magnitude of the force on a
current flowing at right angles to a magnetic field using the formula
F = B.I./
10.5 explain the practical applications of force exerted on a current in
a magnetic field
10.6 define Faraday's law of electromagnetic induction
10.7 explain the practical applications of electromagnetic induction
Range
Force exerted on a current in a magnetic field: electric motor,
moving coil loudspeaker
Faraday's law: effect of moving a conductor across a magnetic field,
use calculations the value of an induced e.m.f. using the formula E = Blv
Electromagnetic induction: electric generator, eddy-current brake,
method of generating an alternating electro-motive force (emf), sketch
the graph of instantaneous conductor emf against angular position of
coil, define the period and frequency of an alternating current
197
Unit 353
URN:
D/503/0335
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:
This unit enables the candidate to

understand the underlying principles that
enable effective welding to take place,
without focusing on specific welding
processes. Welding metallurgy, the physical
science of welding, weld symbols, joint
design, distortion, defects and testing: nondestructive (NDT) and destructive
(mechanical) are included.
Learning outcome
The learner will:
1. understand the fundamentals of welding
Assessment criteria
The learner can:
1.1 explain the characteristics of an electric arc used for welding
purposes
1.2 explain the purpose of electrode coverings used for welding
purposes
1.3 explain the effects of fluxes and electrode coverings/cores upon
welding processes
1.4 explain the purpose of shielding gases used for welding purposes
Range
Electric arc: voltage distribution across the arc, heat generation at the
cathode and anode, arc characteristics (alternating current [a.c.], direct
current [d.c.]), effects and influence of magnetic fields, factors that
influence metal transfer (surface tension, gravity, electromagnet
[Lorentz] force, hydrodynamic forces due to gas flow, pinch effect
Electrode coverings: rutile, basic, cellulosic, iron powder
Effects: facilitates arc striking, stabilises and directs the arc, assists
control of the size and frequency of filler metal globules/droplets,
protects filler metal from atmospheric contamination during transfer,
protects deposited metal from contamination, provides appropriate weld
contour, prevents rapid cooling of weld metal (thermal blanket effect),
provides a flux for the molten pool to remove oxides and impurities,
198
supplies additional metal to weld pool

Shielding gases: tungsten inert gas (TIG) welding, metal inert gas (MIG)
welding, inert gases (argon, helium), inert gas mixtures (CO2, Ar/CO2,
Ar/O2/CO2, Ar/He/O2/CO2, Ar/O2, Ar/H2, N2, Ar/N2) [where: Ar = argon, He =
helium, O2 = oxygen, H2 = hydrogen, N2 = nitrogen, CO2 = carbon
dioxide]; influence of shielding gases (protection from gases in the
atmosphere, composition of atmosphere, arc characteristics, mode of
metal transfer, penetration, weld bead profile, speed of welding,
wetting/undercutting tendency, cleaning action, weld metal mechanical
properties
Learning outcome
The learner will:
2. know how to apply welding symbols to joint preparations
Assessment criteria
The learner can:
2.1 describe the difference between the features of welded joints
2.2 describe how to apply BS EN 22553 to types of joints
2.3 describe how to apply weld dimensions to weld symbols
Range
features: face, toes, root, HAZ (heat affected zone), convex fillet profile,
concave fillet profile, mitred fillet profile, root face, root gap, root radius
(U butt profile), land (U butt profile), bevel angle, included angle, weld
width, throat thickness, leg length(s), fusion zone (depth of fusion),
excess weld metal, penetration, fusion line (boundary)
Types of joints: Welded, brazed and soldered joints symbolic
representation on drawings, symbols for the communication of the
designation of welded joints; types of joint (butt, tee, lap, corner); types
of weld preparation (square butt [open], square butt [closed], flanged
butt, single-vee butt, double-vee butt, single U butt, double U butt,
fillet, single-bevel butt, double-bevel butt, single J butt, double J butt,
spot, seam, projection, surfacing, plug, edge, surface, inclined, fold);
application of types of weld preparation (arrow line, reference line,
identification line, symbol, non-symmetrical welds, symmetrical welds);
supplementary and complimentary symbols (finished flush by grinding,
finished flush by machining, convex, concave, backing [sealing] run,
permanent backing strip, removable backing strip, toes blended
smoothly, peripheral welds, field or site welds, numerical indication of
welding process [EN 24063 Welding, brazing, soldering and braze
welding of metals nomenclature of processes and reference numbers
for symbolic representation on drawings]
Weld dimensions: leg length, throat thickness, fillet welds, square butt
welds, root gaps, intermittent fillet welds, staggered intermittent fillet
welds
199
Learning outcome
The learner will:
3. understand the affects of distortion and residual stresses due to
welding
Assessment criteria
The learner can:
3.1 explain the reasons for distortion due to welding
3.2 classify types of distortion
3.3 explain the methods of distortion control
3.4 explain the methods of distortion rectification
3.5 explain the residual stress effects of welding
Range
Reasons for distortion: uneven expansion and contraction, degree of
restraint
Types of distortion: longitudinal, transverse, angular, buckling,
bowing, dishing, twisting
Distortion control: presetting, pre-bending, weld sequencing, skip
welding, back-stepping, balanced welding, intermittent welding, tack
welding, pre and post weld heat treatment, joint design, chills, restraint
(clamping, jigs, back-to-back assembly)
Distortion rectification: mechanical methods (peening, jacking,
pressing, bending, rolling, hammering, planishing); thermal methods (use
of heat strips, use of heat triangles); combination of mechanical and
thermal methods (hot working)
Residual stress: causes (restraint due to uneven expansion and
contraction [natural], restraint due to distortion control methods
[clamping, jigs, back-to-back assembly, balanced welding]), effects
(pattern across joint cross-section [areas of tension, areas of
compression], influence upon mechanical properties in service), stress
relieving methods (normalising, thermal stress relief)
Learning outcome
The learner will:
4. understand the metallurgical effects of welding
Assessment criteria
The learner can:
4.1 explain the heat distribution during welding
4.2 explain the effects of heat due to welding
4.3 explain the relationship between the iron-carbon (Fe-C) thermal
equilibrium diagram for plain carbon steels and welded joints
4.4 explain the reasons for cracking due to welding
4.5 explain the effects of dilution on fully fused joints in dissimilar
metals.
200
Range
Range
Heat distribution: thermal gradients, heat flow, weld thermal cycle,
effects upon the structure of the weld metal, effects upon the structure
of the parent metal (heat-affected zone [HAZ], HAZ sub-zones
[overheated, refining, transition]
Effects of heat: temperature, methods of heat production (electric arc,
electrical resistance, combustion), determination of heat input during arc
welding (J/s, [k]J/mm), pre and post weld heat treatment, stress relief,
methods of temperature measurement (pyrometer, temperature
indicating crayons), means of heat transfer/loss (conduction, convection,
radiation)
Thermal equilibrium diagram: influence of percentage carbon content
in iron, influence of temperature, upper critical point, lower critical point,
eutectoid, relationship to heat treatment processes, relationship to weld
and HAZ
Cracking: cold-cracking due to hydrogen in steels, definition, conditions
necessary for cold cracking, influence of hydrogen, influence of stresses,
influence of susceptible microstructure, methods of avoiding, reheat
cracking, definition, types of steels sensitive to reheat cracking, reheat
cracking due to heat treatment, reheat cracking due to multi-pass
welding
Dilution: determine the amount of dilution in a weld deposit, factors
affecting dilution, welding procedure, methods of reducing dilution, use
of solid phase welding processes
Learning outcome
The learner will:
5. know how to determine the integrity of welded joints.
Assessment criteria
The learner can:
5.1 classify the types of weld defects (EN 26520)
5.2 explain the application of visual examination methods to welded
joints
5.3 explain the application of penetrant testing methods to welded
joints
5.4 explain the application of magnetic particle testing methods to
welded joints
5.5 explain the application of radiography methods to welded joints
5.6 explain the application of ultrasonic testing methods to welded
joints
5.7 explain the application of mechanical testing methods to welded
joints
5.8 explain the methods of container testing.
201
Range
Weld defects: cracks (longitudinal, transverse, edge, HAZ, crater,
centreline, fusion zone, underbead), lack of fusion (root, side wall, interrun), porosity (scattered, cluster, isolated pore, root, blow holes, worm
holes), piping (craters), solid inclusions (slag, copper, tungsten, oxide),
lack of penetration, undercut, oxidation, excessive weld metal (including
penetration), underfill, concavity, overlap, burn-through, possible
causes, remedial action
Visual examination: applications, requirements (equipment, personnel)
benefits, limitations
Penetrant testing: dye, fluorescent, test procedure, applications,
equipment requirements, limitations
Magnetic particle testing: magnetic flow (types of magnet [horseshoe,
yoke]), current flow (a.c. [skin effect], d.c., types of magnetisation [prods,
bar, coil, tubular, kettle element]), test procedure, applications,
equipment requirements, benefits, limitations
Radiography: sources of radiation (x-ray, gamma ray), principle,
applications, equipment requirements, benefits, limitations, radiation
hazards (effects of radiation on the human body, radiation monitoring,
personal monitoring, radiation enclosures, precautions for site
radiography), radiographic techniques (plate, pipe [single wall single
image {including panoramic}, double wall single image, double wall
double image [ellipse, superimposed])
Ultrasonic testing: applications, procedure, applications, equipment
requirements (ultrasonic testing set [cathode ray tube {oscilloscope},
controls, calibration], probes [normal, angle, probe index, selection
criteria, beam spread, far zone, near zone, dead zone], leads, calibration
blocks, couplant), benefits, limitations, techniques (thickness testing,
lamination testing, transmission method, reflection method),
determination of geometry (beam angle, skip distance), procedures for
reporting and recording flaws in welded components
Mechanical testing: impact tests (izod, charpy), bend tests (root, face,
side), tensile (determination of tensile strength, determination of yield
stress, determination of percentage elongation, transverse, all weld
metal, tensile/shear [application to lap joints, application to double lap
joints]), fracture (nick break), macro examination (specimen preparation,
magnification), micro examination (specimen preparation, magnification),
hardness surveys (weld zone, HAZ, parent metal, location of indents,
testing methods (Vickers, Brinell, Rockwell), testing of spot welded joints
(peel test, tensile/shear, cross tensile, U tensile, twist or torsion
Container testing: hydraulic pressure, pneumatic pressure, by filling, by
immersion, health and safety considerations
202
Unit 353
Guidance
Electrode coverings: processes manual metal arc (MMA) welding, types
of covering (rutile, basic, cellulosic, iron powder)
Cracking: cold-cracking due to hydrogen in steels, definition, conditions
necessary for cold cracking, influence of hydrogen (sources of hydrogen,
control of hydrogen in the deposited weld metal) influence of stresses
(nature of stresses, methods of avoiding) influence of susceptible
microstructure (nature, methods of avoiding), cracking mechanism in the
weld metal and the HAZ, effect of preheating, use of stainless steel weld
metal; lamellar tearing, definition, causes (through thickness properties,
inclusions) methods of avoiding (influence of joint design, bead sequence,
influencing factors [manganese/sulphur ratio, copper content, oxygen
content, depth to width ratio of the weld, crack susceptibility); reheat
cracking, definition, types of steels sensitive to reheat cracking, reheat
cracking due to heat treatment, reheat cracking due to multi-pass welding
Dilution: determine the amount of dilution in a weld deposit, factors
affecting dilution, welding procedure (welding process, welding
technique), methods of reducing dilution (buttering, control of heat input
[including welding current {use of small electrodes at low current,
allowing the work to cool between runs/layers, fast travel speed, avoiding
the use of pre-heat (not always possible), careful selection of welding
process}], use of solid phase welding processes
203
Unit 354
URN:
H/503/0336
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

apply to the selection of materials and
mechanical joining processes used in
fabrication, without focusing on specific
fabrication disciplines. Included is fabrication
materials, allowances for bending and
rolling, the principles of shearing, joining
using non-thermal methods and finishing
Learning outcome
The learner will:
1. know how to classify common materials used in fabrication
engineering
Assessment criteria
The learner can:
1.1 critically compare materials from a range found in fabrication
engineering
1.3 state the criteria used for the selection of materials for a given
application
1.4 explain the different material structures
1.5 explain the variation in properties that result from different types of
metallic structures
1.6 explain the requirements for the heat treatment of metals
204
Range
Materials: metallic (low-carbon steel, low alloy steels, high yield steels,
austenitic stainless steels, clad and coated materials [galvanised steel, tin
plated steel, plastic coated steel, clad steels, anodised aluminium],
aluminium/aluminium alloys, copper/copper alloys, titanium/ titanium
alloys), polymers (thermoplastics, thermosetting), composites (glass fibre,
carbon fibre, aramid fibre)
Forms of supply: sheet, plate, section (RSJ, channel, column, beam, tee,
angle (equal leg, unequal leg), hollow section (square, rectangular, round
[tubular]), pipe, fibre reinforcing materials (FRP)
Selection: strength/weight ratio, resistant properties (heat, corrosion,
wear), cost, weldability, malleability
Structures: crystalline, chain molecules, amorphous
Metallic structures: fine grained structure, coarse grained structure,
effect of grain size upon working properties
Heat treatment: annealing (steels, stainless steels, non-ferrous metals),
normalising of steels, hardening of steels, tempering of steels,
precipitation hardening of aluminium alloys
Learning outcome
The learner will:
2. know how to determine the bending and rolling allowances for
fabricated forms and the principles of shearing
Assessment criteria
The learner can:
2.1 explain the mechanics of bending
2.2 define the term neutral line
2.3 explain the purpose of bending allowances and apply bending
allowance formulas
2.4 explain the purpose of rolling allowances and apply rolling
allowance formulas
2.5 calculate the included angle of patterns of right cones using formula
2.6 explain the principles of shearing
Range
Mechanics of bending: tensile stresses, compressive stresses, neutral
plane, springback, compensation for springback
Neutral line: principle, application to bending and rolling
Bending allowances: definition, radius of bend, application (thin sheet
materials, thick plate materials, pipe, circular forms, U bends, right-angle
bends, non-right-angle bends, compound forms)
Rolling allowances: definitions (diameter of cylinder, length/height of
cylinder, circumference of cylinder), application (circular cylinders,
elliptical cylinders, taking into account material thickness, determination
of the length of presetting required to avoid flats when rolling
Principles of shearing: shear angle, rake angle, clearance, shearing
action (area under shear, shear force required), mechanical advantage of
lever system for hand-operated shears (bench, hand), principle of
moments for lever system for hand-operated shears (bench, hand),
piercing and blanking (area under shear, shear force required)
205
Learning outcome
The learner will:
3. understand the difference between different non-thermal joining
methods
Assessment criteria
The learner can:
3.1 classify bolting methods from a range found in fabrication
engineering
3.2 classify mechanical fastenings applied to thin plate fabrication
engineering
3.3 explain the reasons for and the methods available to protect metal
surfaces prior to and after assembly
3.4 classify joint configurations from a range found in fabrication
engineering
3.5 explain the benefits of using jigs and fixtures
3.6 explain the use of adhesive bonding in the joining of fabricated
assemblies
3.7 calculate joining allowances
Range
Bolting: black bolts, high strength friction grip (HSFG), close tolerance
bolts, fitted bolts, load indicating bolts, torshear, importance of
cleanliness of contact surfaces, correct tensioning, hole diameters,
tolerances and alignment of holes to produce satisfactory bolted
connections
Mechanical fastenings: bolts, captive nuts, studs, self-tapping screws,
special thin plate fastenings, solid and tubular rivets, blind rivets (pop
rivets)
Joint configurations: self secured, lap joints, flanged joints,
thermal/mechanical bonded, grooved seams, double grooved seams,
knocked up, panned down, slip joints, flexible joints, threaded joints
Benefits of using jigs and fixtures: position of component(s), joint
alignment, mass production/repetitive work, distortion
control/dimensional accuracy, economy of operation
Adhesive bonding: methods available (heat activated, solvent
activated, impact activated), preparation of surfaces, applications, health
and safety considerations
Joining allowances: joints joined by: riveting, bolting, adhesive bonding
206
Learning outcome
The learner will:
4. understand different methods used for finishing fabricated
components
Assessment criteria
The learner can:
4.1 explain the methods of removal of surface contaminants prior to
finishing
4.2 explain the common causes of corrosion and degradation of
common engineering materials
4.3 classify the methods of corrosion prevention or retardation
commonly found in fabrication engineering
4.4 classify the methods of application for common surface coatings
4.5 evaluate the merits and suitability of purpose of the various
surface preparations and protections.
Range
Surface contaminants: for: scale, oxide, slag, excessive build up and
weld metal penetration, spatter
Causes of corrosion: oxidation of ferrous materials, direct chemical
attack on metals, electrolytic corrosion, conditions and regions that can
be conducive to corrosive activity (bi-metallic joints, immersed in
aqueous solutions, adjacent to changes in grain structure [heavily
worked material-stress corrosion], surface flaws, increased temperature
Corrosion prevention: painting, cladding with corrosion and/or heat
resistant materials, cladding with plastics, metallic coatings, cathodic
protection, anodic protection, fouling and anti-fouling coatings,
corrosion inhibitors
Methods of application: painting (brush, dip, spray), metallic coatings
(metal spraying, hot dip galvanising, electroplating)
Merits and suitability: cost, portability, functional effectiveness
(influence upon: environmental performance, application of surface
coatings, aesthetic appeal, material selection)
207
Unit 355

Welding
URN:
K/503/0337
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

understand the underlying principles of
fabrication and welding, without focusing on
specific fabrication disciplines or welding
processes.
Fabrication materials, joining using nonthermal methods, weld symbols, joint
design, distortion, weld defects and testing:
non-destructive (NDT) and destructive
(mechanical) are included.
Learning outcome
The learner will:
1. understand how to classify common materials used in fabrication
engineering
Assessment criteria
The learner can:
1.1 critically compare materials from a range found in fabrication
engineering
1.3 state the criteria used to select materials for a given application
1.4 explain the different material structures
1.5 explain the variation in properties that result from different types of
metallic structures
1.6 explain the requirement for the heat treatment of metals
208
Range
Materials: metallic (low-carbon steel, low alloy steels, high yield steels,
austenitic stainless steels, clad and coated materials [galvanised steel, tin
plated steel, plastic coated steel, clad steels, anodised aluminium],
aluminium/aluminium alloys, copper/copper alloys, titanium/ titanium
alloys), polymers (thermoplastics, thermosetting), composites (glass
fibre, carbon fibre, aramid fibre)
Forms of supply: sheet, plate, section (RSJ, channel, column, beam,
tee, angle (equal leg, unequal leg), hollow section (square, rectangular,
round [tubular]), pipe, fibre reinforcing materials (FRP)
Criteria: strength/weight ratio, resistant properties (heat, corrosion,
wear), cost, weldability, malleability
Structures: crystalline, chain molecules, amorphous
Metallic structures: fine grained structure, coarse grained structure,
effect of grain size upon working properties
Heat treatment: annealing (steels, stainless steels, non-ferrous metals),
normalising of steels, hardening of steels, tempering of steels,
precipitation hardening of aluminium alloys
Learning outcome
The learner will:
2. know how to apply welding symbols to joint preparations
Assessment criteria
The learner can:
2.1 describe the difference between features of welded joints
2.2 describe how to apply BS EN 22553 to types of joints
2.3 describe how to apply weld dimensions to weld symbols
Range
Features: face, toes, root, HAZ (heat affected zone), convex fillet profile,
Types of joint: Welded, brazed and soldered joints symbolic
of weld preparation
welds
209
Learning outcome
The learner will:
3. know different non-thermal joining methods
Assessment criteria
The learner can:
3.1 classify bolting methods from a range found in fabrication
engineering
3.2 classify mechanical fastenings applied to thin plate fabrication
engineering
3.3 explain the reasons for and the methods available to protect metal
surfaces prior to and after assembly
3.4 classify joint configurations from a range found in fabrication
engineering
3.5 explain the benefits of using jigs and fixtures
3.6 explain the use of adhesive bonding in the joining of fabricated
assemblies
3.7 calculate joining allowances
Range
Features: face, toes, root, HAZ (heat affected zone), convex fillet profile,
of weld preparation
welds
Learning outcome
The learner will:
4. understand the affects of distortion and residual stresses due to
welding
Assessment criteria
The learner can:
4.1 explain the reasons for distortion due to welding
4.2 classify types of distortion
4.3 explain the methods of distortion control
4.4 explain the methods of distortion rectification
4.5 explain the residual stress effects of welding
210
Range
Reasons for distortion: uneven expansion and contraction, degree of
restraint
types of distortion: longitudinal, transverse, angular, buckling, bowing,
dishing, twisting
Distortion control: presetting, pre-bending, weld sequencing, skip
welding, back-stepping, balanced welding, intermittent welding, tack
welding, pre and post weld heat treatment, joint design, chills, restraint
(clamping, jigs, back-to-back assembly)
Distortion rectification: mechanical methods (peening, jacking,
pressing, bending, rolling, hammering, planishing); thermal methods (use
of heat strips, use of heat triangles); combination of mechanical and
thermal methods (hot working)
Residual stress: causes (restraint due to uneven expansion and
contraction [natural], restraint due to distortion control methods
[clamping, jigs, back-to-back assembly, balanced welding]), effects
(pattern across joint cross-section [areas of tension, areas of
compression], influence upon mechanical properties in service), stress
relieving methods (normalising, thermal stress relief)
Learning outcome
The learner will:
5. know how to determine the integrity of welded joints.
Assessment criteria
The learner can:
5.1 classify the types of weld defects (EN 26520) and identify possible
causes and remedial action
5.2 explain the application of visual examination methods to welded
joints
5.3 explain the application of penetrant testing methods to welded
joints
5.4 explain the application of magnetic particle testing methods to
welded joints
5.5 explain the application of radiography methods to welded joints
5.6 explain the application of ultrasonic testing methods to welded
joints
5.7 explain the application of mechanical testing methods to welded
joints
5.8 explain the methods of container testing
211
Range
Weld defects: cracks (longitudinal, transverse, edge, HAZ, crater,
centreline, fusion zone, underbead), lack of fusion (root, side wall, interrun), porosity (scattered, cluster, isolated pore, root, blow holes, worm
holes), piping (craters), solid inclusions (slag, copper, tungsten, oxide),
lack of penetration, undercut, oxidation, excessive weld metal (including
penetration), underfill, concavity, overlap, burn-through, possible
causes, remedial action
Visual examination: applications, requirements (equipment, personnel)
benefits, limitations
Penetrant testing: dye, fluorescent, test procedure, applications,
equipment requirements, limitations
Magnetic particle testing: magnetic flow (types of magnet [horseshoe,
yoke]), current flow (a.c. [skin effect], d.c., types of magnetisation [prods,
bar, coil, tubular, kettle element]), test procedure, applications,
equipment requirements, benefits, limitations
Radiography: sources of radiation (x-ray, gamma ray), principle,
applications, equipment requirements, benefits, limitations, radiation
hazards (effects of radiation on the human body, radiation monitoring,
personal monitoring, radiation enclosures, precautions for site
radiography), radiographic techniques (plate, pipe [single wall single
image {including panoramic}, double wall single image, double wall
double image [ellipse, superimposed])
Ultrasonic testing: applications, procedure, applications, equipment
requirements (ultrasonic testing set [cathode ray tube {oscilloscope},
controls, calibration], probes [normal, angle, probe index, selection
criteria, beam spread, far zone, near zone, dead zone], leads, calibration
blocks, couplant), benefits, limitations, techniques (thickness testing,
lamination testing, transmission method, reflection method),
determination of geometry (beam angle, skip distance), procedures for
reporting and recording flaws in welded components
Mechanical testing: impact tests (izod, charpy), bend tests (root, face,
side), tensile (determination of tensile strength, determination of yield
stress, determination of percentage elongation, transverse, all weld
metal, tensile/shear [application to lap joints, application to double lap
joints]), fracture (nick break), macro examination (specimen preparation,
magnification), micro examination (specimen preparation, magnification),
hardness surveys (weld zone, HAZ, parent metal, location of indents,
testing methods (Vickers, Brinell, Rockwell), testing of spot welded joints
(peel test, tensile/shear, cross tensile, U tensile, twist or torsion
Container testing: hydraulic pressure, pneumatic pressure, by filling, by
immersion, health and safety considerations
212
Unit 355

Welding
Guidance
designation of welded joints; types of joint (butt, tee, lap, corner); types of
weld preparation (square butt [open], square butt [closed], flanged butt,
single-vee butt, double-vee butt, single U butt, double U butt, fillet,
single-bevel butt, double-bevel butt, single J butt, double J butt, spot,
seam, projection, surfacing, plug, edge, surface, inclined, fold);
application of types of weld preparation (arrow line, reference line,
identification line, symbol, non-symmetrical welds, symmetrical welds);
supplementary and complimentary symbols (finished flush by grinding,
finished flush by machining, convex, concave, backing [sealing] run,
permanent backing strip, removable backing strip, toes blended
smoothly, peripheral welds, field or site welds, numerical indication of
welding process [EN 24063 Welding, brazing, soldering and braze
welding of metals Nomenclature of processes and reference numbers
for symbolic representation on drawings]
213
Unit 356
214
maintenance, installation and
commissioning
URN:
M/503/0338
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

apply to all commonly used processes and
elements that are essential to most
maintenance, installation and commissioning
activities. It takes into account the fact that
some industries and organisations employ
engineering personnel that perform both of
these activities, whereas others, particularly
specialist contractors for installation and
commissioning, may only cover a limited
range. The content of this unit can be
applicable to both situations as it is
considered essential for all candidates to
have a wide range of engineering knowledge
and experience. It covers the maintenance,
installation and commissioning
requirements, including equipment and
lubrication that are commonly associated
with the maintenance, installation and
commissioning of plant and machinery and
the ways in which they are used or applied.
Candidates are not expected to have an indepth understanding of all maintenance and
installation and commissioning strategies,
but they should become familiar with the
events, terminology and practices that they
will need as part of their normal work.
Learning outcome
The learner will:
1. understand how to plan maintenance, installation and
commissioning activities
Assessment criteria
The learner can:
1.1 explain the reasons for carrying out maintenance activities
1.2 explain the methods and procedures necessary to make an area
safe
1.3 describe the contents of a maintenance plan
1.4 explain how to carry out installation activities
1.5 describe the contents of a report completed following
maintenance or installation activities
1.6 describe the difference between symptoms and the causes of faults
Range
Maintenance activities: upholding or improving safety standards,
maintaining production output at the required levels and quality,
maximising the useful working life of engineering assets, increasing
production efficiency (reduction of rejected work or downtime), activities
include: carrying out routine servicing schedules or planned preventative
maintenance, repair and replacement following breakdowns, monitoring
and performance testing
Procedures: using barriers and/or tapes, placing warning signs in
appropriate positions, informing any persons who may be affected,
isolating power or pressure sources, obtaining official clearance (permit
to work), cleaning work areas after spillage, leakage or contamination
(absorbent substances, detergents and solvents, approved waste
disposal methods)
Maintenance plan: tools and equipment, materials and spares
(minimising downtime [avoid loss of production, avoid poor customer
relations {internal and external}], wage overheads), estimate the length of
time needed for maintenance
Installation activities: installing machinery and systems into new sites
or locations, replacement of machinery and equipment following or
extending facilities, monitoring and performance testing, factors to
consider: site conditions and locations of components, storage of parts
and materials, tools and equipment, provision of services electricity,
compressed air, water and drainage, minimising disruption to adjacent
work areas, how to estimate the length of time needed for the
installation and commissioning
Report: work undertaken, location(s), dates/times (commencement,
completion and handover), parts and consumables used, test data,
permit to work or certification references
215
Learning outcome
The learner will:
2. know how to install and commission instruments and components
Assessment criteria
The learner can:
2.1 explain the applications of instruments used for testing and
monitoring the condition of systems and machinery
2.2 explain the methods used to set-up and align components
2.3 describe how to perform installation and commissioning operations
of instruments and/or components
Range
Instruments: terms: range, sensitivity, response, accuracy,
repeatability, analogue and digital signals, transducers and amplifiers;
pressure: manometers, Bourdon tube based instruments; temperature:
expansion types, electrical resistance types and thermocouples, thermal
paints and crayons; flow: direct (bellows and piston types), inferential
(rotameters, venturi and orifice plates, and turbine types); rate and
speed: tachometers (mechanical and electrical), stroboscopes, pulse
counters; content: direct (dipsticks and sight glasses), indirect (load cells
and electrical transducers); electrical multimeters (megameters,
multimeters); vibration, data recorders; need for regular calibration of
instruments and the methods used; methods of mounting instruments
and the ways in which they can be protected from: external damage or
unauthorised interference, excess loads and surges (use of snubbers and
reservoirs), heat and vibration
Set-up and align components: straight edges and squares, feeler
gauges and test indicators, plumb lines and spirit levels, taut wire, optical
and laser based instruments
Learning outcome
The learner will:
3. understand how to evaluate methods to overcome friction and
corrosion
Assessment criteria
The learner can:
3.1 explain the nature of surfaces and the effects of these on friction
3.2 explain the purpose of lubrication to reduce the effects of friction
3.3 explain the nomenclature used to describe lubricant properties
3.4 evaluate types of oils and greases for given applications
3.5 explain the nature and causes of corrosion and methods of
minimising the effects
216
Range
Friction: actual surface contact area (on peaks) and hence causes of
cold welding, surface wear (breaking of peaks), generation of heat,
forces required to overcome friction (static and dynamic); reducing the
adverse effects by use of: low friction materials, material combinations
that control wear to only one of the two contacting elements, partial
lubrication, full film lubrication
Lubrication: hydrodynamic wedge principle requirements: bearing
types and design, clearances, points of oil admission; lubrication
methods: total loss, recirculatory (construction and component parts of
reservoirs, filtration methods and positioning, heat exchangers, pressure
controls and warning devices), splash, grease guns and nipples, self
lubricating (cast iron and impregnated metals)
Nomenclature: viscosity, viscosity index, emulsions, foaming,
compatibility (with other oils, seals and bearing material), pour and flash
points, additives
Oils: mineral, animal and vegetable, synthetic; properties (load,
temperature) environmental considerations, reasons for deterioration
(excess heat, oxidation, contamination, breakdown of structure due to
prolonged overloading, poor storage conditions)
Greases: the base (matrix), lubricants, methods of application, including
the need to prevent over-packing and churning
Corrosion: types: oxidation, electrolytic; methods of minimising effects:
selection of materials to suit conditions, insulation of dissimilar metals,
use of sacrificial anodes, use of protective coatings, paint, galvanising
and anodising, plating and coating; methods of releasing corroded nuts
(release and penetrating oils, application of heat, nut splitters or similar
techniques)
Learning outcome
The learner will:
4. know how to evaluate connection methods
Assessment criteria
The learner can:
4.1 explain the purposes of bearings and their applications
4.2 explain the methods available for removal and fitting of bearings
4.3 explain the purposes of threaded joints and their applications
Range
Bearings: plain bearings, roller bearings, ball bearings, shielded and
sealed forms of roller and ball
Removal and fitting: onto shafts and into housings
Threaded joints: thread forms (pitch and lead, major and root
diameters, truncation), identification using screw pitch gauges and
charts, applications, methods of insertion and extraction of studs,
dealing with sheared studs (extractors, drilling and re-tapping), use of
rawlbolts and ragbolts for masonry and concrete (hole preparation and
fitting, health and safety aspects in relation to reinforced concrete)
217
Unit 356
maintenance, installation and
commissioning
Guidance
Bearings: plain bearings (materials used [including non-ferrous alloys,
non-metallic], split and solid forms and their housing methods, shell and
white-metalled types), roller bearings (cylindrical, tapered, double row,
spherical, needle), ball bearings (single row deep groove and angular
contact, double row deep groove and angular contact, self-aligning),
shielded and sealed forms of roller and ball bearings
Removal and fitting: methods of removing and fitting bearings (special
extractors and mandrels, hand (mandrel) and hydraulic presses,
appropriate lubricants or grease
218
Unit 357
URN:
T/503/0339
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

apply to all common machine tool systems,
covering: the alignment of machine tools,
power transmission, an evaluation of the
application of CNC to machine tools and the
understanding of maintenance requirements
for machine tool systems. Within the unit
candidates are expected to prepare a
maintenance programme, prepare a
lubrication chart, produce a CNC partprogramme and critically compare CNC
machining to non-CNC machining.
Learning outcome
The learner will:
1. understand how to determine the alignment of machine tools
Assessment criteria
The learner can:
1.1 describe the range of machine tools available in terms of size,
capacity, accuracy and production capability
1.2 explain the structural requirements of a range of common
machine tools
1.3 explain the common methods of mounting machine tools
1.4 explain the importance of alignment in machine tools and
methods to achieve it
Range
Machine tools: lathes (centre, turret), milling machines (horizontal,
vertical, universal), drilling machines (bench, pedestal, radial arm, multispindle, co-ordinate table, special purpose), grinding machines (surface
[horizontal spindle, vertical spindle], cylindrical [plain, universal], internal,
special purpose), electro machining (electrodischarge machining [EDM]
{ram feed, wire feed}, ultrasonic machining [USM], electrochemical
machining [ECM], laser machining, computer numerical control (CNC)
219
Structural requirements: strength, rigidity, stability, control of

movement, materials (cast iron, cast steel, steel plate), structures (box
column, rib and box bed, fabricated base)
Mounting: cork pad, adjustable mounting, rag bolt, expanding nut
Alignment:
slideways: flat, vee, dovetail, cylindrical, comparison of their
capabilities, main features, accuracy of movement, means of adjustment,
lubrication, protection
stick-slip: definition, recirculating ball leadscrews, hydrostatic slides
typical checks: coaxial alignment between main spindle axis, coaxial
alignment between two spindles, alignment of spindle to guideway,
squareness of slideways movement, concentricity and end float of
spindle, squareness of planes to spindle, setting of guards, stops and
automatic safety cut-outs
bearings: plain bush (radial, radial and axial) ball (radial, axial, radial and
axial) roller (radial, axial, radial and axial)
methods of alignment: standard tests, straight edge, precision level,
autocollimator and reflector, roundness measuring machine
Learning outcome
The learner will:
2. know how to differentiate between methods of power transmission
in machine tools
Assessment criteria
The learner can:
2.1 explain the methods used to achieve rotational movement
2.2 explain the methods used to achieve linear movement
2.3 explain the methods used to change speeds
2.4 explain the methods used to control feed speeds
2.5 explain the methods used to control feeds and speeds of hydraulic
components on machine tools
2.6 explain the application of pneumatic systems to the operation
and control of machine tools
Range
Rotational movement: belt drives (flat, vee and tooth), gears, hydraulic
actuators
Linear movement: screw and nut (vee, square [including multi-start],
ACME, relationship between the lead of a screw and the motion
transmitted, engaging screw drives [fixed nuts, split nuts]), rack and
pinion, recirculating ball-screw, crank and connecting rod, cams (lift,
dwell and types of motion produced) hydraulic actuator
Change speeds: sliding gears, cone pulleys, clutch operated, infinitely
variable, electrical/electronic
Control feed speeds: sliding gears (Norton gearbox), leadscrew and
nut, hydraulic drives
Hydraulic components: variable capacity pump, filter, pressure gauge,
pressure relief valve, directional control valve, actuator, signal elements,
one way flow control valve, differential cylinders, meter in, meter out,
bleed off, pressure control valves, sequence valves, electrical and
electromagnetic control systems (switching devices, solenoids,
interlock systems, timing shafts and cams, coded information, stepper
220
motors), advantages and limitations of hydraulic actuation and control,

common defects which may occur on a hydraulic system and methods of
repair
Pneumatic systems: variable output compressor, service unit, pressure
gauge, signal elements, directional control valves, actuator, supply air
throttling, exhaust air throttling, pressure reducing valve, pressure
operated valves, time delay valve, electrical and electromagnetic
control systems (switching devices, solenoids, interlock systems, timing
shafts and cams, coded information, stepper motors), advantages and
limitations of pneumatic actuation and control, common failures which
may occur on a pneumatic system and methods of repair
Learning outcome
The learner will:
3. understand how to evaluate the application of CNC to machine tools
Assessment criteria
The learner can:
3.1 explain the operating principles of computer numerically
controlled machine tools
3.2 describe how to produce a part-programme to demonstrate the
relative work/tool movement of a CNC machine tool
3.3 describe how to prove the part-programme using simulation
software
3.4 critically compare CNC machine tools against non-CNC machine
tools
3.5 describe how to evaluate cutting tools materials for given
applications (CNC and non-CNC)
Range
Operating principles: open loop system, closed loop system, control
systems (closed loop servo motors and associated transmission, stepper
motors and associated transmission), types and function of position
transducers (rotary type, optical gratings), digital control
Part-programme: co-ordinate positioning (absolute, incremental), use
of sub routines, macros and canned cycles, role of CADCAM
Critically compare: production (mass, flow, batch, job), ease of
programming, repeatability, prototypes, skill levels and other factors
Cutting tools materials: high carbon steel (HCS), high speed steel (HSS)
tungsten carbide, ceramic
221
Learning outcome
The learner will:
4. understand the maintenance requirements of machine tool systems
Assessment criteria
The learner can:
4.1 describe the differences between types of maintenance carried
out on machine tools
4.2 describe a maintenance programme for a typical machine tool
4.3 describe what would be included in a lubrication chart for a
typical machine tool workshop
4.4 classify coolants and lubricants applicable to machine tool
systems
4.5 classify the methods of application for common surface coatings
4.6 explain the commissioning/maintenance procedures carried
out on machine tools
Range
Types of maintenance: running, preventive, breakdown, routine
Maintenance programme: inspection, lubrication, adjustment,
rectification, overhaul
Lubrication chart: machine designation, types of lubricant, quantities of
lubricant, frequency
Coolants and lubricants: types of coolant pump, strainers and filtration
methods (including separating tanks and magnetic drum), filters,
lubrication of headstock/gearbox assemblies of splash and pressurised
feed (lead and feed screws, separation of coolant from lubricants in the
lathe cross slides/carriage assemblies)
Commissioning/maintenance procedures: checks, operational
function, compare checks and operational functions with manufacturers
or production departments requirements, complete reports and job
sheets, submit report
222
Unit 357
Guidance
Rotational movement: flat belts, vee belts (single and matched sets)
toothed belts, chain drives, correct tensioning belts and chains, friction
clutches, dog clutches, gears: worm and wheel, bevel gear, spur, gear
nomenclature (addendum, dedendum, clearance, diametral pitch, circular
pitch, module), gear materials (cast iron alloy steels [including surface
hardened], non-ferrous alloys [brass and bronze derivations], plastics),
calculate simple and compound gear ratios, relationship between torque
and power transmitted and the loads on gear teeth, gear box layouts and
means of selecting different output speeds, gear defects (pitting, flaking,
scoring and scuffing, likely causes); hydraulic actuators
Commissioning/maintenance procedures: checks (alignment and
levels, electrical power supplies/insulation, safety switches/devices and
interlocking, security of pipes and couplings, oil levels), operational
function (run at light load: check, oil temperature, oil pressure,
cooling/coolant system as appropriate; run at full load and carry out the
same checks again), compare checks and operational functions with
manufacturers or production departments requirements, complete
reports and job sheets (work carried out to commission/restore machine
tool to operational condition, complete maintenance schedule, report and
recommendation on system condition), submit report
223
Unit 358
Principles of electrical &

electronic engineering
URN:
K/503/0340
Level:
Level 3
Credit value:
GLH:
80
Endorsement by a
body:
Aim:

apply across electrical and electronics
engineering. The unit covers supply systems,
protection and earthing, electronic
measurement, functions of electrical
machines, transformers and switchgear and
electronic components and circuits
Learning outcome
The learner will:
1. understand electrical supply systems, protection and earthing
Assessment criteria
The learner can:
1.1 explain electricity supply systems
1.2 explain the function of transformers and switchgear
1.3 explain the purpose of earthing systems
1.4 explain protection systems
Range
Supply systems: from generation to utilisation, generation,
transmission and distribution voltages, star and delta connections, single
and 3 phase power.
Transformers: principle of operation, input, output and losses,
transformer rating in kVA, auto transformer; LV & HV switchgear.
Protection systems: short circuits, overloads, earth leakage, fuses,
circuit breakers. residual current devices, residual current breakers
(RCDs) with overload (RCBO)
224
Learning outcome
The learner will:
2. understand the function of electrical and electronic components
Assessment criteria
The learner can:
2.1 apply basic electrical units
2.2 describe resistors
2.3 describe magnetism and magnetic circuits
2.4 describe inductance and inductive components
2.5 describe capacitors and capacitance
2.6 describe graphically inductance and capacitance when connected
to d.c. supplies
2.7 state the effects of resistance, inductance and capacitance
connected to an a.c. circuit
2.8 describe semiconductor devices
2.9 describe electronic circuits and components including
applications
Range
Units: energy,current,charge,voltage, power & resistance
Resistors: resistance depends upon dimensions, material and
temperature, resistivity Ohms law, series and parallel d.c circuits.
Magnetism: fields and flux paths, relationship between flux, area and
flux density
Inductance: inductors as wound components,self and mutual induction,
Lenzs law, force on a conductor
Capacitors. electric field and stress, Ddelectrics, relate potential
difference charge and capacitance, construction and types, series
parallel connections.
d.c. supplies: C & L connected to d.c circuits, series circuits, charge and
discharge, time constants.
a.c. circuit: R,L & C in a.c circuits. R,L & C in series / parallel, power,
power factor, kW, kVA & kVAr
Semiconductor devices: action of semiconductor devices, thyristors,
bridge rectifiers, smoothing circuits.
Electronic circuits: function of amplifier, oscillator, filter, power supply,
application of common components, photocell, photodiode etc.
Learning outcome
The learner will:
3. know how to carry out electronic measurement
Assessment criteria
The learner can:
3.1 describe how to use multimeters to measure current, voltage and
resistance
3.2 describe how to use oscilloscopes in different modes
3.3 describe how to use electronic instruments for component
testing and prepared circuits
225
3.4
3.5
describe how to use electronic instruments as signal sources for

prepared circuits
describe the use of computers in component testing
Range
Multimeters: auto range, data capture and transfer, correct range
settings.
Oscilloscopes: use to carry out a range of tests and measurements, real
time and storage.
Component testing: transistors, a series RLC circuit: a resistor, inductor
and capacitor (L,C & R), power gain or loss in dB, voltage/current gain.
Signal sources: advantages and disadvantages of oscilloscopes
Computers: diagnostic information, technical information, websites, use
and function as digital multimeter, oscilloscope, spectrum analyser
Learning outcome
The learner will:
4. understand functions of electrical machines
Assessment criteria
The learner can:
4.1 describe the principles of rotating electrical machines
4.2 describe the function of 3 phase induction motors
4.3 describe the function of single phase a.c motors
Range
Electrical machines: a.c and d.c generators, interdependence of
frequency, speed, pole pairs, EMF and field strength. d.c motor,
dynchronous and asynchronous machines, rotating magnetic field
3 phase induction motors: cage rotor, wound rotor.
Single phase: Series Universal, split phase, permanent capacitor,
capacitor start/ run
226
Appendix 1
Sources of general
information
The following documents contain essential information for centres

delivering City & Guilds qualifications. They should be referred to in
conjunction with this handbook. To download the documents and to find
other useful documents, go to http://www.cityandguilds.com/ProvideTraining/Centre-Support.
Our Quality Assurance Requirements encompasses all of the relevant

requirements of key regulatory documents
Regulatory Arrangements for the Qualifications and Credit Framework
(2008)
and sets out the criteria that centres should adhere to pre and post centre
and qualification approval.
The homepage section of the City & Guilds website also contains useful
information such on such things as:
Walled Garden: how to register and certificate learners on line
Events: dates and information on the latest Centre events
Online assessment: how to register for e-assessments.
Centre manual Delivering International Qualifications contains
detailed information about the processes which must be followed and
requirements which must be met for a centre to achieve approved
centre status, or to offer a particular qualification. Specifically, the
document includes sections on:
The centre and qualification approval process and forms
Assessment, verification and examination roles at the centre
Registration and certification of learners
Non-compliance
Complaints and appeals
Equal opportunities
Data protection
Management systems
Maintaining records
Assessment
Internal and External quality assurance
Frequently asked questions.
227
City & Guilds

Believe you can
Useful contacts
International learners and

centres
General qualification information
Please contact your regional

office. Details can be found at
www.cityandguilds.com or
alternatively
E: [email protected]
Every effort has been made to ensure that the information contained in
this publication is true and correct at the time of going to press.
However, City & Guilds products and services are subject to continuous
development and improvement and the right is reserved to change
products and services from time to time. City & Guilds cannot accept
liability for loss or damage arising from the use of information in this
publication.
If you have a complaint, or any suggestions for improvement about any
of the services that we provide, email:
[email protected]
About City & Guilds

As the UKs leading vocational education organisation, City
& Guilds is leading the talent revolution by inspiring people
to unlock their potential and develop their skills. We offer
over 500 qualifications across 28 industries through 8500
centres worldwide and award around two million
certificates every year. City & Guilds is recognised and
respected by employers across the world as a sign of
quality and exceptional training.
City & Guilds Group
The City & Guilds Group operates from three major hubs:
London (servicing Europe, the Caribbean and Americas),
Johannesburg (servicing Africa), and Singapore (servicing
Asia, Australia and New Zealand). The Group also includes
the Institute of Leadership & Management (management
and leadership qualifications), City & Guilds Land Based
Services (land-based qualifications), the Centre for Skills
Development (CSD works to improve the policy and
practice of vocational education and training worldwide)
and Learning Assistant (an online e-portfolio).
Copyright
The content of this document is, unless otherwise
indicated, The City and Guilds of London Institute and
may not be copied, reproduced or distributed without prior
written consent. However, approved City & Guilds centres
and learners studying for City & Guilds qualifications may
photocopy this document free of charge and/or include a
PDF version of it on centre intranets on the following
conditions:
centre staff may copy the material only for the purpose
of teaching learners working towards a City & Guilds
qualification, or for internal administration purposes
learners may copy the material only for their own use
when working towards a City & Guilds qualification
The Standard Copying Conditions (see the City & Guilds
website) also apply.
Please note: National Occupational Standards are not The
City and Guilds of London Institute. Please check the
conditions upon which they may be copied with the
relevant Sector Skills Council.
Published by City & Guilds, a registered charity established
to promote education and training
City & Guilds

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QU ALIF ICAT ION H AN D B OOK

City & Guilds number

Age group approved

Online multiple choice

Consult the Walled Garden/Online

Title and level

City & Guilds

Level 3 Diploma in Engineering Welding

Level 3 Diploma in Engineering

Level 3 Diploma in Engineering

Level 3 Diploma in Engineering

Level 3 Diploma in Engineering

Level 3 Diploma in Engineering

City & Guilds Level 3 Diploma Engineering (IVQ) (2850-85/86/87/88/89/90)

Learner entry requirements

Engineering health and safety

Manual metal arc welding of materials

MIG welding of materials

TIG welding of materials

Platework fabrication of materials

Sheet metalwork fabrication of materials

Fabrication and erection of structural steelwork

Pattern development for fabrication

Maintenance of machine systems

Maintenance of utility systems

Maintenance of plant services

Maintenance of hydraulic systems

Maintenance of pneumatic systems

Power generation systems and ancillary equipment103

Machining materials by turning

Machining materials by milling

Machining materials by grinding

CNC machining of materials

Detailed fitting of materials

Maintenance of electrical equipment and systems136

Produce drawings using CAD

Organising and managing engineering operations145

City & Guilds Level 3 Diploma Engineering (IVQ) (2850-85/86/87/88/89/90)

Mechatronics systems principles and fault finding150

Computer automated and robotic systems principles

Power supply, and analogue and digital circuit

Electronic power control principles and practice 170

MIG Welding of aluminium

TIG Welding of aluminium

Flux-cored Arc welding materials

Advanced mathematics and science

Principles of fabrication and Welding

Principles of engineering maintenance, installation

Principles of mechanical manufacturing engineering219

Principles of electrical & electronic engineering 224

Sources of general information

City & Guilds Level 3 Diploma Engineering (IVQ) (2850-85/86/87/88/89/90)

This certificate is aimed at learners who:

What does the

It allows learners to learn, develop and practise the

It allows learners to progress into employment or to

2565 -02 Level 3 IVQ Technician Diploma in

City & Guilds Level 3 Diploma Engineering (IVQ) (2850-85/86/87/88/89/90)

To achieve the Level 3 Diploma in Engineering - Welding, learners

Engineering health and