Welding

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Welding is the process of joining materials to fabricate or repair a variety of structures such as structural steel frames, handrails, oil and gas transmission lines, ship building and repairs using the following processes:

  1. Shielded Metal Arc Welding (SMAW) process
  2. Gas Tungsten Arc Welding (GTAW) process and
  3. Flux Core/ Gas Metal Arc Welding (FCAW/ GMAW) process

Welders generally plan their work from drawings and blueprints and they utilize personal protective equipment (PPE), hand tools, power tools, speciality welding tools as well as heavy machinery to fabricate, assemble and weld materials to produce the various structures.

Welding provides a rewarding career, with highly transferable skill sets that can be utilized in the construction, energy and maritime sectors. Welders can become entrepreneurs as well as work for local and multi-national agencies.

At this level he/she works under supervision to prepare the work area , tools and equipment for welding activities. This includes performing basic cutting and grinding operations, performing fillet welds, and performing housekeeping in the work area after welding.

He or she must also be able to prepare and interpret simple drawings, maintain an effective work environment by following health and safety requirements when performing welding tasks.

  1. Maintain and apply health, safety and environmental regulations, legislation and procedures in the workplace.
  2. Identify potential hazards and take appropriate action to minimise the risks posed. It also includes identifying and dealing with emergency situations.
  3. Establish and maintain productive work relationships and communicate work related information.
  4. Read and interpret simple sketches and drawings.
  5. Perform welding activities such as preparing materials and equipment under supervision and reporting completion of work activities.
  6. Perform basic cutting and grinding operations safely for welding activities such as setting up cutting and grinding equipment, securing material and reporting completion of work activities.
  7. Perform fillet welds in all welding positions using the Shielded Metal Arc Welding (SMAW) process. It involves preparing materials and equipment for welding, performing fillet welds as well as examining fillet welds.
  1. Written and Oral Communication
  2. Application of numbers/ computation
  3. Work in teams
  4. Critical Thinking
  5. Computer Literacy
  6. Continuous learning
  7. Adaptability
  8. Work ethic
  9. Acuity Test refers to an eye exam that measures how well you see at various distances.
  10. Hand- Eye Coordination
  11. Follow instructions from supervisor
  1. Certificate in Welding Craft Practice from an Accredited Training Provider
  1. The welding assistant or apprentice would have completed the apprenticeship training (minimum of 3 years). Thereafter, a skills test consisting of destructive and non-destructive testing at level 1 is used to determine competence to be considered as a B Class Welder.
  2. The B Class Welder with a minimum of 5-7 years’ industrial experience who has successfully completed a skills test on destructive and non-destructive testing at level 2 can progress or be considered as an A Class Welder.

Technical and Core Skills:

  1. Maintain and apply health, safety and environmental regulations, legislation and procedures in the workplace.
  2. Identify potential hazards and take appropriate action to minimise the risks posed. It also includes identifying and dealing with emergency situations.
  3. Establish and maintain productive work relationships and communicate work related information.
  4. Read and interpret simple sketches and drawings.
  5. Perform welding activities such as preparing materials and equipment under supervision and reporting completion of work activities.
  6. Perform basic cutting and grinding operations safely for welding activities such as setting up cutting and grinding equipment, securing material and reporting completion of work activities.
  7. Perform fillet welds in all welding positions using the Shielded Metal Arc Welding (SMAW) process. It involves preparing materials and equipment for welding, performing fillet welds as well as examining fillet welds.

Employability Skills:

  1. Written and Oral Communication
  2. Application of numbers/ computation
  3. Work in teams
  4. Critical Thinking
  5. Computer Literacy
  6. Continuous learning
  7. Adaptability
  8. Work ethic
  9. Acuity Test refers to an eye exam that measures how well you see at various distances.
  10. Hand- Eye Coordination
  11. Follow instructions from supervisor

Qualification and Experience:

  1. Certificate in Welding Craft Practice from an Accredited Training Provider

Articulation:

  1. The welding assistant or apprentice would have completed the apprenticeship training (minimum of 3 years). Thereafter, a skills test consisting of destructive and non-destructive testing at level 1 is used to determine competence to be considered as a B Class Welder.
  2. The B Class Welder with a minimum of 5-7 years’ industrial experience who has successfully completed a skills test on destructive and non-destructive testing at level 2 can progress or be considered as an A Class Welder.

At this level he/she who can work alone or as a member of a team to perform cutting and grinding operations and welds materials using SMAW, GTAW and FCAW/GMAW processes according to the weld procedure specifications (WPS).

He or she must also be able to maintain an effective work environment and be knowledgeable on the health and safety requirements before/during/after welding operations.

  1. Maintain and apply health, safety and environmental regulations, legislation and procedures in the workplace.
  2. Identify potential hazards and take appropriate action to minimise the risks posed. It also includes identifying and dealing with emergency situations.
  3. Establish and maintain productive work relationships and communicate work related information.
  4. Cut and grind materials for welding activities such as marking out/off materials, cutting materials using thermal cutting processes and grinding materials.
  5. Weld materials using the Shielded Metal Arc Welding (SMAW) Process, Gas Tungsten Arc Welding (GTAW) Process and the Flux Core/ Gas Metal Arc Welding (FCAW/ GMAW) Processes.
  6. Perform basic inspection of a welding activity such as visual examination.
  7. Prepare basic technical reports which includes identifying and reporting requirements, obtaining information from sources, analyzing information and preparing reports.
  1. Written and Oral Communication
  2. Application of numbers/ computation
  3. Working in teams
  4. Document use may include blueprints and drawings, weld procedure specifications (WPS).
  5. Critical Thinking
  6. Computer Literacy
  7. Adaptability
  8. Work Ethic
  9. Acuity Test refers to an eye exam that measures how well you see at various distances.
  10. Hand- Eye Coordination
  11. Reliability
  12. Planning and Organizing
  13. Detail Oriented
  14. Follow instructions from supervisor
  1. Advanced Certificate /Diploma in Welding Craft Practice from Accredited Training Provider
  2. National Skills Development Programme (NSDP) Journeyman Programme
  3. NEC Craft Certificate/Diploma
  4. Retest and recode at 6G weld position
  1. Specialist Welder
  2. Welder Foreman
  3. Welder Supervisor
  4. Certified Welding Inspector (CWI)

Technical and Core Skills:

  1. Maintain and apply health, safety and environmental regulations, legislation and procedures in the workplace.
  2. Identify potential hazards and take appropriate action to minimise the risks posed. It also includes identifying and dealing with emergency situations.
  3. Establish and maintain productive work relationships and communicate work related information.
  4. Cut and grind materials for welding activities such as marking out/off materials, cutting materials using thermal cutting processes and grinding materials.
  5. Weld materials using the Shielded Metal Arc Welding (SMAW) Process, Gas Tungsten Arc Welding (GTAW) Process and the Flux Core/ Gas Metal Arc Welding (FCAW/ GMAW) Processes.
  6. Perform basic inspection of a welding activity such as visual examination.
  7. Prepare basic technical reports which includes identifying and reporting requirements, obtaining information from sources, analyzing information and preparing reports.

Employability Skills:

  1. Written and Oral Communication
  2. Application of numbers/ computation
  3. Working in teams
  4. Document use may include blueprints and drawings, weld procedure specifications (WPS).
  5. Critical Thinking
  6. Computer Literacy
  7. Adaptability
  8. Work Ethic
  9. Acuity Test refers to an eye exam that measures how well you see at various distances.
  10. Hand- Eye Coordination
  11. Reliability
  12. Planning and Organizing
  13. Detail Oriented
  14. Follow instructions from supervisor

Qualification and Experience:

  1. Advanced Certificate /Diploma in Welding Craft Practice from Accredited Training Provider
  2. National Skills Development Programme (NSDP) Journeyman Programme
  3. NEC Craft Certificate/Diploma
  4. Retest and recode at 6G weld position

Articulation:

  1. Specialist Welder
  2. Welder Foreman
  3. Welder Supervisor
  4. Certified Welding Inspector (CWI)

At this level he/she performs a broad range of functions that includes supervising the welding operations using various welding processes, for example SMAW process, GTAW process and the FCAW/GMAW which may include carbon steels and exotic metals for example nickel, stainless steel.

He or she must have the ability to maintain an effective work environment, respond to emergencies and be knowledgeable on health and safety requirements to perform welding operations

Technical and Core Skills:

  1. Maintain and apply health, safety and environmental regulations, legislation and procedures in the workplace.
  2. Identify potential hazards and take appropriate action to minimise the risks posed. It also includes identifying and dealing with emergency situations.
  3. Establish and maintain productive work relationships and communicate work related information.
  4. Weld exotic materials such as nickel, stainless steel according to weld procedure specifications (WPS).
  5. Weld materials using the Shielded Metal Arc Welding (SMAW) process, Gas Tungsten Arc Welding (GTAW) process, Submerge Arc Welding (SAW) process and the Flux Core/Gas Metal Arc Welding (FCAW/GMAW) processes.
  6. Perform inspection of welds for conformance to the relevant specifications. It also includes assessing findings to rectify any discontinuities /defects / variations.
  7. Monitor welding activities performed by welders as well as resolving welding problems and providing recommendations for welding activities performed.
  8. Supervise a team by leading work tasks, as well as ensuring the competence of staff required to perform a work task.
  9. Prepare advanced technical reports, conduct research, analyse the information, and prepare and present the report.

Employability Skills:

  1. Written and Oral Communication
  2. Working in teams
  3. Problem solving
  4. Document use may include weld procedure specifications WPS, Bill of Quantities.
  5. Teaching/ Continuous learning
  6. Work ethic
  7. Planning and organization
  8. Quality Control/Quality Assurance (weld tests)
  9. Time management
  10. Supervisory Skills
  11. Follow instructions from supervisor

Qualification and Experience:

  1. Supervisory Management Certificate from an Accredited/recognised training institution
  2. Diploma in Welding Craft Practice from Accredited Training Provider
  3. National Skills Development Programme (NSDP) Journeyman Programme
  4. CWI – Certified Welding Inspector Certification – AWS
  5. Considerable industrial experience – minimum 15 years

Articulation:

  1. Workshop Superintendent/Manager
  1. Maintain and apply health, safety and environmental regulations, legislation and procedures in the workplace.
  2. Identify potential hazards and take appropriate action to minimise the risks posed. It also includes identifying and dealing with emergency situations.
  3. Establish and maintain productive work relationships and communicate work related information.
  4. Weld exotic materials such as nickel, stainless steel according to weld procedure specifications (WPS).
  5. Weld materials using the Shielded Metal Arc Welding (SMAW) process, Gas Tungsten Arc Welding (GTAW) process, Submerge Arc Welding (SAW) process and the Flux Core/Gas Metal Arc Welding (FCAW/GMAW) processes.
  6. Perform inspection of welds for conformance to the relevant specifications. It also includes assessing findings to rectify any discontinuities /defects / variations.
  7. Monitor welding activities performed by welders as well as resolving welding problems and providing recommendations for welding activities performed.
  8. Supervise a team by leading work tasks, as well as ensuring the competence of staff required to perform a work task.
  9. Prepare advanced technical reports, conduct research, analyse the information, and prepare and present the report.
  1. Written and Oral Communication
  2. Working in teams
  3. Problem solving
  4. Document use may include weld procedure specifications WPS, Bill of Quantities.
  5. Teaching/ Continuous learning
  6. Work ethic
  7. Planning and organization
  8. Quality Control/Quality Assurance (weld tests)
  9. Time management
  10. Supervisory Skills
  11. Follow instructions from supervisor
  1. Supervisory Management Certificate from an Accredited/recognised training institution
  2. Diploma in Welding Craft Practice from Accredited Training Provider
  3. National Skills Development Programme (NSDP) Journeyman Programme
  4. CWI – Certified Welding Inspector Certification – AWS
  5. Considerable industrial experience – minimum 15 years
  1. Workshop Superintendent/Manager

At this level he/she manages all welding activities in the work area, to achieve the welding productivity as per the production targets of the projects, ensure the project specific welding procedures & guidelines are implemented, comply with Company procedures ensuring compliance with HSE policies and customer requirements satisfaction.

Technical and Core Skills:

  1. Provides leadership to the departmental team to achieve high quality, productivity and enforced safety standards
  2. Insures compliance to production schedules, process quality, efficiency standards, budget, inventory and data reporting.
  3. Facilitates employee hiring, training, development and performance evaluations. Administers corrective action as needed. Ensures training and education on specific tasks and company related functions. Maintains training matrix.
  4. Facilitates improvement through team involvement, training and education on specific tasks, safety issues and other company-related functions.
  5. Prepares departments budget and adheres to them.
  6. Assists in the capital equipment implementation process.
  7. Develops accurate and cost effective bills of quantities for projects.
  8. Responsible for maintaining adequate supply of departmental shop supplies and consumables.
  9. Good working knowledge of various international welding codes and standards.
  10. Assures proper maintenance of equipment, tools and housekeeping.
  11. Provides effective coaching to progressively improve performance of personnel and department.
  12. Provides project progress records and reports to management.

Employability Skills:

  1. Excellent verbal and written communication skills
  2. Knowledge of Health and Safety requirements
  3. Understanding company quality procedures
  4. Manage others to achieve results
  5. Decision making skills
  6. Team leadership
  7. Motivational skills
  8. Skill in the use of Project Management Software
  9. Skill in programme/project planning and implementation
  10. Problem solving and decision making skills

Qualification and Experience:

  1. Bachelor’s degree in Mechanical Engineering or other relevant technical discipline
  2. Membership of relevant professional bodies
  3. Must have experience/ knowledge in different materials welding, welding process, welding filler metals and different welding machines
  4. Diploma in Project Management
  5. Minimum 15 years welding experience or related experience
  6. Experience in manpower planning, supervision and coordination is essential
  7. Supervisory Management Certificate from an Accredited/recognised training institution

Articulation:

  1. Metallurgist
  2. Welding Engineer
  1. Provides leadership to the departmental team to achieve high quality, productivity and enforced safety standards
  2. Insures compliance to production schedules, process quality, efficiency standards, budget, inventory and data reporting.
  3. Facilitates employee hiring, training, development and performance evaluations. Administers corrective action as needed. Ensures training and education on specific tasks and company related functions. Maintains training matrix.
  4. Facilitates improvement through team involvement, training and education on specific tasks, safety issues and other company-related functions.
  5. Prepares departments budget and adheres to them.
  6. Assists in the capital equipment implementation process.
  7. Develops accurate and cost effective bills of quantities for projects.
  8. Responsible for maintaining adequate supply of departmental shop supplies and consumables.
  9. Good working knowledge of various international welding codes and standards.
  10. Assures proper maintenance of equipment, tools and housekeeping.
  11. Provides effective coaching to progressively improve performance of personnel and department.
  12. Provides project progress records and reports to management.
  1. Excellent verbal and written communication skills
  2. Knowledge of Health and Safety requirements
  3. Understanding company quality procedures
  4. Manage others to achieve results
  5. Decision making skills
  6. Team leadership
  7. Motivational skills
  8. Skill in the use of Project Management Software
  9. Skill in programme/project planning and implementation
  10. Problem solving and decision making skills
  1. Bachelor’s degree in Mechanical Engineering or other relevant technical discipline
  2. Membership of relevant professional bodies
  3. Must have experience/ knowledge in different materials welding, welding process, welding filler metals and different welding machines
  4. Diploma in Project Management
  5. Minimum 15 years welding experience or related experience
  6. Experience in manpower planning, supervision and coordination is essential
  7. Supervisory Management Certificate from an Accredited/recognised training institution
  1. Metallurgist
  2. Welding Engineer
Metallurgist

At this level he/she can work in a number of areas including civil engineering, aircraft manufacture, automotive engineering and the defence industry. He or she studies the properties of metals and then apply their findings to practical applications, such as metal production. They work with a range of metals including copper, precious metals, iron, steel, zinc and aluminium alloys.

 

Technical and Core Skills:

  1. Coordinates inspection and testing of metallic materials to determine physical characteristics and detect defects
  2. Evaluates suitability of materials for various engineering applications, considering factors such as design, cost and availability
  3. Develop and monitors implementation of processes involved in manufacture of ferrous and non-ferrous metals
  4. Prepares welding specifications for fabrication and construction of vessels, structures or metallic components to ensure reliability of welded joints
  5. Prescribes pre-heat and post-heat treatment schedules to alter mechanical properties of metals and modify characteristics such as hardness, crack resistance, and strength
  6. Designs systems to protect metal structures against corrosion
  7. Conducts failure analyses to determine causes of problems in the manufacture, use and repair of metallic materials and components and recommends precautions against reoccurrence
  8. Consults with other professionals to develop manufacturing methods and design and implement inspection and testing procedures
  9. Supervises laboratory personnel and ensures maintenance of accurate records
  10. Performs required administrative functions and prepare technical reports

 

Employability Skills:

  1. Innovation
  2. Organisation
  3. Problem-solving skills
  4. Communication skills
  5. Team working skills
  6. Computer Literacy skills
  7. Analytical skills
  8. Initiative, drive and enthusiasm for improving metals and methods used
  9. Numeracy skills
  10. Attention to detail to interpret design requirements and produce reports
  11. Ability to utilize machining and welding equipment if required by the job; exposure to extreme temperatures and heat treatments may be possible
  12. Ability to do design mappings and drawings
  13. Knowledgeable and conform to all environmental and safety laws and regulations

 

Qualification and Experience:

  1. Bachelor’s Degree in Metallurgy
  2. Engineering computer software, such as AutoCAD software
  3. Membership of relevant professional bodies
  4. Minimum 20 years’ experience or related field

Welding Engineer

At this level he/she reviews customer contract specifications, drawings and code requirements to determine the welding requirements for procedure and personnel qualifications in accordance with standards and project specific requirements.

 

Technical and Core Skills:

  1. Comply with and commit to safety procedures and company policies.
  2. Initiate welders for preparation of Welding Procedure Specification (WPS) and Welding Materials test samples.
  3. Formalise and release WPS and Procedure Qualification Record (PQR) for complete welders and approved test results.
  4. Initiate procurement action by preparing and processing purchase orders for all weld material test and all welder performance and procedure qualification sample testing.
  5. Set up and maintain master WPS and PQR files in accordance with ASME requirements.
  6. Set up and maintain record of welder qualification tests.
  7. Prepare and issue/maintain operator qualification matrix.
  8. Apply knowledge of production specifications, properties and characteristics of metals and metal alloys to develop welding techniques, procedures and application of welding equipment to problems involving fabrication of metals.
  9. Develop and test new fabrication process and procedures, improve existing or develop new welding equipment, develop new or modify current welding methods, techniques and procedures.
  10. Serve as customer contact for technical issues regarding welding requirements.

 

Employability Skills:

  1. Excellent written and verbal communication
  2. Leadership abilities
  3. Problem solving and analytical skills
  4. Personnel computer based skills – Microsoft Office (Word, Excel, PowerPoint)
  5. Team oriented
  6. Customer oriented
  7. Flexible
  8. Innovative
  9. Detail oriented
  10. Problem solving and analysis
  11. Strategic orientation

 

Qualification and Experience:

  1. Bachelor degree in Welding engineering
  2. Experience in ASME section IX Welding code and /or AWS D1.1, AWS D1.6 Structural Welding Codes
  3. Minimum 20 years’ experience or related field

Metallurgist

At this level he/she can work in a number of areas including civil engineering, aircraft manufacture, automotive engineering and the defence industry. He or she studies the properties of metals and then apply their findings to practical applications, such as metal production. They work with a range of metals including copper, precious metals, iron, steel, zinc and aluminium alloys.

  1. Coordinates inspection and testing of metallic materials to determine physical characteristics and detect defects
  2. Evaluates suitability of materials for various engineering applications, considering factors such as design, cost and availability
  3. Develop and monitors implementation of processes involved in manufacture of ferrous and non-ferrous metals
  4. Prepares welding specifications for fabrication and construction of vessels, structures or metallic components to ensure reliability of welded joints
  5. Prescribes pre-heat and post-heat treatment schedules to alter mechanical properties of metals and modify characteristics such as hardness, crack resistance, and strength
  6. Designs systems to protect metal structures against corrosion
  7. Conducts failure analyses to determine causes of problems in the manufacture, use and repair of metallic materials and components and recommends precautions against reoccurrence
  8. Consults with other professionals to develop manufacturing methods and design and implement inspection and testing procedures
  9. Supervises laboratory personnel and ensures maintenance of accurate records
  10. Performs required administrative functions and prepare technical reports
  1. Innovation
  2. Organisation
  3. Problem-solving skills
  4. Communication skills
  5. Team working skills
  6. Computer Literacy skills
  7. Analytical skills
  8. Initiative, drive and enthusiasm for improving metals and methods used
  9. Numeracy skills
  10. Attention to detail to interpret design requirements and produce reports
  11. Ability to utilize machining and welding equipment if required by the job; exposure to extreme temperatures and heat treatments may be possible
  12. Ability to do design mappings and drawings
  13. Knowledgeable and conform to all environmental and safety laws and regulations
  1. Bachelor’s Degree in Metallurgy
  2. Engineering computer software, such as AutoCAD software
  3. Membership of relevant professional bodies
  4. Minimum 20 years’ experience or related field

At this level he/she reviews customer contract specifications, drawings and code requirements to determine the welding requirements for procedure and personnel qualifications in accordance with standards and project specific requirements.

  1. Comply with and commit to safety procedures and company policies.
  2. Initiate welders for preparation of Welding Procedure Specification (WPS) and Welding Materials test samples.
  3. Formalise and release WPS and Procedure Qualification Record (PQR) for complete welders and approved test results.
  4. Initiate procurement action by preparing and processing purchase orders for all weld material test and all welder performance and procedure qualification sample testing.
  5. Set up and maintain master WPS and PQR files in accordance with ASME requirements.
  6. Set up and maintain record of welder qualification tests.
  7. Prepare and issue/maintain operator qualification matrix.
  8. Apply knowledge of production specifications, properties and characteristics of metals and metal alloys to develop welding techniques, procedures and application of welding equipment to problems involving fabrication of metals.
  9. Develop and test new fabrication process and procedures, improve existing or develop new welding equipment, develop new or modify current welding methods, techniques and procedures.
  10. Serve as customer contact for technical issues regarding welding requirements.
  1. Excellent written and verbal communication
  2. Leadership abilities
  3. Problem solving and analytical skills
  4. Personnel computer based skills – Microsoft Office (Word, Excel, PowerPoint)
  5. Team oriented
  6. Customer oriented
  7. Flexible
  8. Innovative
  9. Detail oriented
  10. Problem solving and analysis
  11. Strategic orientation
  1. Bachelor degree in Welding engineering
  2. Experience in ASME section IX Welding code and /or AWS D1.1, AWS D1.6 Structural Welding Codes
  3. Minimum 20 years’ experience or related field