Level 3 Certificate in Engineering - cdn. · PDF file1 apply BS EN 22553 to types of joints 2...

Level 3 Certificate in Engineering Principles Units

2800

www.city-and-guilds.co.uk July 2003

2 Level 3 Certificate in Engineering

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Level 3 Certificate in Engineering 3

Contents

Unit 003 Principles of welding 4

Unit 004 Principles of fabrication 21

Unit 005 Principles of fabrication and welding 30

Unit 006 Principles of engineering maintenance, installation and commissioning 45

Unit 007 Principles of materials processing 56

Unit 008 Principles of materials forming 65

Unit 009 Principles of mechanical manufacturing engineering 73

Unit 010 Principles of electrical engineering 84

Unit 011 Principles of electronics 91

Unit 012 Principles of integrated engineering 97

Unit: 013 Principles of shipbuilding 105

Further information 113


Unit 003 Principles of welding

Rationale

This unit is concerned with the underlying principles that enable effective welding to take place, without focusing on specific welding processes. Included is welding metallurgy, physical science of welding, weld symbols, joint design, distortion, defects and testing (non-destructive (NDT) and mechanical). Outcomes

There are five outcomes to this unit. The candidate will be able to 1 identify the fundamentals of welding 2 identify the geometry of effective joint design 3 identify the affects of distortion and residual stresses due to welding 4 identify the metallurgical effects of welding 4 determine the integrity of welded joints. Connection with other awards

This unit relates to Units 004-014, 017-021, 030, 031, 046 & 054 of the City & Guilds Level 3 NVQ in Fabrication & welding (1681). It also relates to ECS 3.09. Assessment

The outcomes from this unit will be assessed using evidence from a centre set question paper using questions from a City & Guilds devised question bank.


Outcome 1 Identify the fundamentals of welding

Practical Activities The candidate will be able to investigate 1 modes of heat transfer 2 the influence of electrode coverings 3 the influence of shielding gases/gas mixtures 4 the effect of welding fluxes 5 the effects of welding flame conditions Underpinning knowledge

The candidate will be able to 1 describe the welding arc a voltage distribution across the arc b heat generation at the cathode and anode c arc characteristics i alternating current (ac) ii direct current (dc) d effects and influence of magnetic fields e factors that influence metal transfer i surface tension ii gravity iii electromagnet (Lorentz force) iv hydrodynamic forces due to gas flow v pinch effect 2 explain the purpose of electrode coverings and fluxes a coverings and fluxes used in welding processes i manual metal arc (MMA) welding ii submerged arc welding iii flux-cored arc welding b types of covering i rutile ii basic iii cellulosic iv iron powder c types of flux i fused ii agglomerated iii mixed d types of cored wire i flux cored ii iron cored e gas welding, brazing and soldering fluxes


f effects of fluxes and electrode coverings/cores on welding processes i facilitates arc striking ii stabilises and directs the arc iii assists control of the size and frequency of filler metal globules/droplets iv protects filler metal from atmospheric contamination during transfer v protects deposited metal from contamination vi provides appropriate weld contour vii prevents rapid cooling of weld metal (thermal blanket effect) viii provides a flux for the molten pool to remove oxides and impurities ix supplies additional metal to weld pool g effects of fluxes on welding brazing and soldering processes i wetting effect ii oxide removal 3. explain the purpose of shielding gases a tungsten-inert gas (TIG) welding b metal inert gas/metal active gas (MIG/MAG) welding c plasma welding d inert gases i argon ii helium e inert gas mixtures i Ar/CO2 ii CO2 iii Ar/O2/CO2 iv Ar/H2 v Ar/N2 vi Ar/He/O2/CO2 vii N2 (Ar = argon, He = helium, O2 = oxygen, H2 = hydrogen, N2 = nitrogen, CO2 = carbon dioxide) f influence of shielding gases i protection from gases in the atmosphere A composition of atmosphere ii arc characteristics iii mode of metal transfer iv penetration v weld bead profile vi speed of welding vii wetting/undercutting tendency viii cleaning action ix weld metal mechanical properties 4. explain the effects of combustion a geometry of oxy-fuel gas welding flame i inner cone ii outer envelope


b composition of oxy-acetylene welding flame i chemical composition of inner cone ii chemical composition of outer envelope iii products of combustion iv effects of different flame types A neutral B oxidising C reducing (carburising) v heat distribution in flame.


Outcome 2 Identify the geometry of effective joint design

Practical Activities The candidate will be able to 1 apply BS EN 22553 to types of joints 2 select joint preparations for applications 3 apply weld dimensions to drawings. Underpinning knowledge The candidate will be able to 1. describe the features of a welded joint a face b toes c root d HAZ (heat affected zone) e convex fillet profile f concave fillet profile g mitred fillet profile h root face i root gap j root radius (‘U’ butt profile) k land (‘U’ butt profile) l bevel angle m included angle n weld width o throat thickness p leg length(s) q fusion zone (depth of fusion) r excess weld metal s penetration t fusion line (boundary) 2. outline the use of BS EN 22553 (Welded, brazed and soldered joints — symbolic representation on drawings symbols for the communication of the designation of welded joints) a types of joint i butt ii tee iii lap iv corner


b types of weld preparation i square butt (open) ii square butt (closed) iii flanged butt iv single-vee butt v double-vee butt vi single ‘U’ butt vii double ‘U’ butt viii fillet ix single-bevel butt x double-bevel butt xi single ‘J’ butt xii double ‘J’ butt xiii spot ix seam x projection xi surfacing xii plug xiii edge xiv surface xv inclined xvi fold c application of types of weld preparation to types of joint in a. i arrow line ii reference line iii identification line iv symbol v non-symmetrical welds vi symmetrical welds d supplementary and complimentary symbols i finished flush by grinding ii finished flush by machining iii convex iv concave v backing run vi permanent backing strip vii removable backing strip viii toes blended smoothly ix peripheral welds x field or site welds xi 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)


e dimensioning of welds i leg length ii throat thickness iii fillet welds iv square butt welds v root gaps vi intermittent fillet welds vii staggered intermittent fillet welds 3. recognise joint design, to accommodate a backing strips i permanent ii temporary b consumable inserts i types


Outcome 3 Identify the effects of distortion and residual stresses due to welding

Practical Activities The candidate will be able to investigate 1 the effects of distortion 2 methods of distortion control 3 methods of distortion rectification 4 the effects of residual stress. Underpinning knowledge The candidate will be able to 1 describe the reasons for distortion a uneven expansion and contraction b degree of restraint 2 identify the types of distortion a longitudinal b transverse c angular d buckling e bowing f dishing g twisting 3. explain the methods of distortion control a presetting b pre-bending c weld sequencing d skip welding e back-stepping f tack welding g pre and post weld heat treatment h joint design i balanced welding j intermittent welding k chills l restraint i clamping ii jigs iii back-to-back assembly


4. explain the methods of distortion rectification a mechanical methods i peening ii jacking iii pressing iv bending v rolling vi hammering vii planishing b thermal methods i use of heat strips ii use of heat triangles 5. describe the residual stress effects of welding a causes of residual stress i restraint A due to uneven expansion and contraction (natural) B due to distortion control methods ii clamping iii jigs iv back-to-back assembly v balanced welding b effects of residual stress i pattern across joint cross-section A areas of tension B areas of compression ii influence upon mechanical properties in service c stress relieving methods i normalising ii thermal stress relief


Outcome 4 Identify the metallurgical effects of welding

Practical Activities The candidate will be able to 1 investigate the heat input of a welded joint 2 investigate the heat distribution in a welded joint 3 investigate the heat-affected zone in a welded joint 4 use methods of temperature measurement 5 investigate heat transfer/loss 6 use the iron-carbon (Fe-C) thermal equilibrium diagram for plain carbon steels 7 investigate heat treatment temperatures from the iron-carbon (Fe-C) thermal equilibrium diagram 8 determine HAZ sub-zones from the iron-carbon (Fe-C) thermal equilibrium diagram 9 determine types and causes of weld cracking and methods of avoidance. Underpinning knowledge The candidate will be able to 1 outline the heat distribution during welding a thermal gradients b heat flow c weld thermal cycle d effects on the structure of the weld metal e effects on the structure of the parent metal i heat-affected zone (HAZ) A HAZ sub-zones ii overheated iii refining iv transition 2. outline the effects of heat a temperature b methods of heat production used in welding and related activities i welding processes A arc B resistance C gas welding ii determination of heat input during arc welding (J/s, [k]J/mm) iii pre and post weld heat treatment iv stress relief c methods of temperature measurement used in welding and related activities i pyrometer ii temperature indicating crayons d means of heat transfer/loss i conduction ii convection iii radiation


4. outline the iron-carbon (Fe-C) thermal equilibrium diagram for plain carbon steels a influence of percentage carbon content in iron b influence of temperature c identify i upper critical point ii lower critical point iii eutectoid d relationship to heat treatment processes e relationship to welding and HAZ 5 outline the reasons for cracking of welds a define cold-cracking due to hydrogen in steels i conditions necessary for cold cracking A hydrogen ii sources of hydrogen iii measurement and control of hydrogen in the deposited weld metal A stress iv nature of stress v methods of avoiding A microstructure vi nature of a susceptible microstructure vii methods of avoiding a susceptible microstructure viii cracking mechanism in the weld metal and the HAZ ix the effect of preheating x use of stainless steel weld metal b define lamellar tearing i causes A through thickness properties B inclusions ii methods of avoiding A influence of joint design B bead sequence C use of buttering techniques c define hot cracking i solidification cracking ii liquation cracking iii influencing factors A manganese/sulphur ratio B copper content C oxygen content D depth to width ratio of the weld E crack susceptibility d define reheat cracking i types of steels sensitive to reheat cracking ii reheat cracking due to heat treatment iii reheat cracking due to multi-pass welding


6. outline the effects of dilution on fully fused joints in dissimilar metals a determining the amount of dilution in a weld deposit b factors affecting dilution c welding procedure i welding process ii welding technique d methods of reducing dilution i buttering ii control of heat input (including welding current) A use of small electrodes at low current B allowing the work to cool between runs/layers C fast travel speed D avoiding the use of pre-heat (not always possible) E careful selection of welding process iii use of solid phase welding processes


Outcome 5 Determine the integrity of welded joints

Practical Activities The candidate will be able to 1 identify weld defects and causes correctly 2 use non-destructive testing (NDT) methods 3 use mechanical testing methods. Underpinning knowledge The candidate will be able to 1 describe types of weld defects (EN 2652) a types of cracks i longitudinal ii transverse iii edge iv crater v centreline vi fusion zone vii underbead viii weld b lack of fusion i side wall ii root iii interpass c porosity i scattered ii cluster iii isolated pore iv root v blow holes vi worm holes d piping i craters ii solid inclusions iii slag iv copper A tungsten B oxide e lack of penetration f undercut g oxidation h excessive weld metal i underfill j concavity k overlap l burn-through


2 explain possible causes of weld defects 3 describe the visual examination of welded joints a applications b requirements i equipment ii personnel c benefits d limitations 4 describe penetrant testing a dye b fluorescent c test procedure d applications e equipment requirements f limitations 5 describe magnetic particle testing a magnetic flow b types of magnet i horseshoe ii yoke c current flow i ac A skin effect ii dc iii types of magnetisation A prods B bar C oil D tubular E kettle element d test procedure e applications f equipment requirements g benefits h limitations


6. describe radiography a sources of radiation i x-ray ii gamma ray b procedure c applications d equipment requirements e benefits f limitations g radiation hazards i effects of radiation on the human body ii radiation monitoring iii personal monitoring iv radiation enclosures v precautions for site radiography h radiographic techniques i plate ii pipe iii single wall – single image (including panoramic) iv double wall – single image v double wall – double image A ellipse B superimposed 7. describe ultrasonic testing a applications b procedure c applications d equipment requirements i ultrasonic testing set A cathode ray tube (oscilloscope) B controls C calibration ii probes A normal B angle C probe index D selection criteria E beam spread F far zone G near zone H dead zone iii leads iv calibration blocks v couplant e benefits f limitations


g techniques i thickness testing ii lamination testing iii transmission method iv reflection method h determination of geometry i beam angle ii skip distance i procedures for reporting and recording flaws in welded components 8. describe the mechanical testing of welded joints a impact tests i izod ii charpy b bend tests i root ii face iii side c tensile i determination of tensile strength ii determination of yield stress iii determination of percentage elongation iv transverse v all weld metal vi tensile/shear A application to lap joints B application to double lap joints d fracture (nick break) e macro examination f micro examination i specimen preparation g hardness surveys i weld zone ii heat-affected zone (HAZ) iii parent metal iv location of indents v testing methods A Vickers B Brinell C Rockwell h spot welded joints testing i peel test ii tensile/shear iii cross tensile iv ‘U’ tensile v twist or torsion


9. describe container testing methods a hydraulic pressure b pneumatic pressure c by filling d by immersion


Unit 004 Principles of fabrication

Rationale

This unit is concerned with the underlying principles that 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. Outcomes

There are four outcomes to this unit. The candidate will be able to 1. identify and select common materials used in fabrication engineering 2. determine the bending and rolling allowances for fabricated forms and describe the principles of shearing 3. identify non-thermal methods of joining 4. identify methods used for finishing fabricated components. Connection with other awards

This unit relates to Units 022-029, 032-055 of the City & Guilds Level 3 NVQ in Fabrication & welding (1681). It also relates to ECS 3.04 and 3.06. Assessment



Outcome 1 Identify and select common materials used in fabrication engineering

Practical Activities The candidate will be able to 1. identify and carry out initial assessment of materials 2. classify materials and identify appropriate grouping and category 3. select materials for a given application. Underpinning knowledge The candidate will be able to 1. describe the range of common materials used in fabrication engineering a metallic i low-carbon steel ii low alloy steels iii high yield steels iv austenitic stainless steels v clad and coated materials A galvanised steel B tin plated steel C plastic coated steel D clad steels E anodised aluminium I aluminium/aluminium alloys II copper/copper alloys III titanium/ titanium alloys b polymers i thermoplastics ii thermosetting c composites i glass fibre ii carbon fibre iii aramid (Kevlar)


2. describe the range of commercial forms of supply a sheet b plate c section i RSJ ii channel iii column iv beam v tee vi angle A equal leg B unequal leg vii hollow A square B rectangular C round (tubular d pipe e fibre reinforcing materials (FRP, GRP) 3. outline the criteria for the selection of materials for a given application a strength/weight ratio b appearance c resistant properties i heat ii corrosion iii wear d cost e weldability/malleability 4. explain the different material structures a crystalline b chain molecules c amorphous 5. explain the variation in properties that result from different types of structure a fine grained structure b coarse grained structure c effect of grain size upon working properties 6. explain heat treatment requirements a annealing i steels ii stainless steels iii non-ferrous metals b normalising of steels c hardening of steels d tempering of steels e precipitation hardening of aluminium alloys


Outcome 2 Determine the bending and rolling allowances for fabricated forms and describe the principles of shearing

Practical activities The candidate will be able to 1 investigate and compensate for the effects of springback 2 determine the bending allowances for fabricated forms from data information sources 3 determine the rolling allowances for fabricated forms from data information sources 4 determine the included angle of patterns of right cones from data information sources 5 determine the shear force required to cut material using equipment. Underpinning knowledge The candidate will be able to 1 describe the mechanics of bending a tensile stresses b compressive stresses c neutral plane d springback e compensation for springback 2 define the term neutral line 3 explain the purpose of bending allowances 4 define the term radius of bend 5 define the term bend allowance 6 apply bending allowance formulas a thin sheet materials b thick plate materials c pipe d circular forms e ‘U’ bends f right-angle bends g non-right-angle bends h compound forms 7. explain the purpose of rolling allowances 8. define the term diameter of cylinder 9. define the term length/height of cylinder 10. define the term circumference of cylinder


11. apply rolling allowance formulas a circular cylinders b elliptical cylinders c taking into account material thickness d determination of the length of presetting required to avoid ‘flats’ when rolling 12. determine the included angle of patterns of right cones 13. describe the principles of shearing a shearing angle b rake angle c clearance d shearing action i area under shear ii shear force required e mechanical advantage of lever system for hand-operated shears i bench ii hand f principle of moments for lever system for hand-operated shears i bench ii hand g piercing and blanking i area under shear ii shear force required


Outcome 3 Identify non-thermal methods of joining

Practical Activities The candidate will be able to 1. identify and carry out assessment of joining methods 2. select joining methods for a given application. Underpinning knowledge The candidate will be able to 1. outline the use of bolts and methods of tensioning a black bolts b high strength friction grip (HSFG) c close tolerance bolts d fitted bolts e load indicating bolts f torshear 2 explain the importance of cleanliness of contact surfaces, correct tensioning, hole diameters, tolerances and alignment of holes to produce satisfactory bolted connections a black bolts b high strength friction grip bolts c fitted and close tolerance bolts 3. describe the methods of mechanical fastenings applied to thin plate fabrication a bolts b captive nuts c studs d self tapping screws e special thin plate fastenings f solid and tubular rivets g blind rivets (pop rivets) 4. state reasons for and the methods of protecting metal surfaces prior to and after assembly 5. describe the method and use of hot riveting a hand b machine


6. describe the range of joint configuration used in fabrication a self secured b lap joints c flanged joints d thermal, mechanical, bounded e grooved seams f double grooved seams g knocked up h paned down i slip joints j flexible joints k threaded joints 7. explain the benefits of using jigs and fixtures a position of component/s b joint alignment c mass production/repetitive work d distortion control/dimensional accuracy e economy of operation 8. explain the use of adhesive bonding in the joining of fabricated assemblies a methods available i heat activated ii solvent activated iii impact activated b preparation of surfaces c applications d safety 9. determine the joining allowances a riveted b bolted c adhesive bonded


Outcome 4 Identify methods used for finishing fabricated components

Practical activities The candidate will be able to 1. use different material combinations to determine the effectiveness of cathodic protection 2. use appropriate post cleaning, cladding methods to meet given specification 3. carry out tests to determine the effects of corrosion. Underpinning knowledge The candidate will be able to 1 describe the methods used for the removal of a scale b oxide c slag d excessive build up and weld metal penetration e spatter 2. describe common causes of degradation and corrosion of common engineering materials a oxidation of ferrous materials b direct chemical attack on metals c electrolytic corrosion 3. state the conditions and regions that can be conducive to corrosive activity a bi-metallic joints b immersed in aqueous solutions c adjacent to changes in grain structure (heavily worked material-stress corrosion) d surface flaws e increased temperature 4 describe the common methods of retarding or preventing corrosion a painting b cladding with corrosion and/or heat resistant materials c cladding with plastics d metallic coatings e cathodic protection f anodic protection g fouling and anti-fouling coatings h corrosion inhibitor 5 state the methods used to apply common surface coatings a paint b metallic coatings i metal spraying ii hot dip galvanising iii electroplating


6 state the relative merits and suitability of purpose of the various surface preparations and protections with regard to a cost b portability c functional effectiveness 7 explain the importance of surface finish in terms of its influence on a environmental performance b application of surface coatings c aesthetic appeal d material selection


Unit 005 Principles of fabrication and welding

Rationale

This unit is concerned with the underlying principles of fabrication and welding, without focusing on specific fabrication disciplines or welding processes. Included is fabrication materials, joining using non-thermal methods, weld symbols, joint design, distortion, weld defects and testing (non-destructive (NDT and mechanical. Outcomes

There are five outcomes to this unit. The candidate will be able to 1. identify and select common materials used in fabrication engineering 2. identify the geometry of effective joint design 3. identify methods of joining 4. identify the affects of distortion and residual stresses due to welding 5. determine the integrity of welded joints. Connection with other awards This unit relates to Units 004-055 of the City & Guilds Level 3 NVQ in Fabrication & welding (1681). It also relates to the ECS 3.04, 3.06 and 3.09. Assessment



Outcome 1 Identify and select common materials used in fabrication engineering

Practical Activities The candidate will be able to 1. identify and carrying out initial assessment of materials 2. classify materials and identifying appropriate grouping and category 3. select materials for a given application. Underpinning knowledge The candidate will be able to 1. describe the range of common materials used in fabrication engineering a metallic i low-carbon steel ii low alloy steels iii high yield steels iv austenitic stainless steels vi clad and coated materials A galvanised steel B tin plated steel C plastic coated steel D clad steels E anodised aluminium vii aluminium/aluminium alloys viii copper/copper alloys ix titanium/ titanium alloys b polymers i thermoplastics ii thermosetting c composites i glass fibre ii carbon fibre iii aramid (Kevlar)


2. describe the range of commercial forms of supply a sheet b plate c section i RSJ ii channel iii column iv beam v tee vi angle A equal leg B unequal leg vii hollow A square B rectangular C round (tubular) d pipe e fibre reinforcing materials (FRP, GRP) 3 outline the criteria for the selection of materials for a given application a strength/weight ratio b appearance c resistant properties i heat ii corrosion iii wear d cost e weldability f malleability 4 explain the different material structures a crystalline b chain molecules c amorphous 5 explain the variation in properties that result from different types of structure a fine grained structure b coarse grained structure c effect of grain size upon working properties 6 explain heat treatment requirements a annealing i steels ii stainless steels iii non-ferrous metals b normalising c hardening d tempering e precipitation hardening of aluminium alloys


Outcome 2 Identify the geometry of effective joint design

Practical Activities The candidate will be able to 1. apply BS EN 22553 to types of joints 2. select joint preparations for applications 3. apply weld dimensions to drawings. Underpinning knowledge The candidate will be able to 1 describe the features of a welded joint a face b toes c root d HAZ (heat affected zone) e convex fillet profile f concave fillet profile g mitred fillet profile h root face i root gap j root radius (‘U’ butt profile) k land (‘U’ butt profile) l bevel angle m included angle n weld width o throat thickness p leg length(s) ) q fusion zone (depth of fusion) r excess weld metal s penetration t fusion line (boundary)


2. outline the use of BS EN 22553 (Welded, brazed and soldered joints — Symbolic representation on drawings) symbols for the communication of the designation of welded joints a types of joint i butt ii tee iii lap iv corner b types of weld preparation i square butt (open) ii square butt (closed) iii flanged butt iv single-vee butt v double-vee butt vi single ‘U’ butt vii double ‘U’ butt viii fillet ix single-bevel butt x double-bevel butt xi single ‘J’ butt xii double ‘J’ butt xiii spot xiv seam xv projection xvi surfacing xvii plug xviii edge xix surface xx inclined xxi fold c application of types of weld preparation to types of joint in i arrow line ii reference line iii identification line iv symbol v non-symmetrical welds vi symmetrical welds


d supplementary and complimentary symbols i finished flush by grinding ii finished flush by machining iii convex iv concave v backing run vi permanent backing strip vii removable backing strip viii toes blended smoothly ix peripheral welds x field or site welds xi 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 e dimensioning of welds i leg length ii throat thickness iii fillet welds iv square butt welds v root gaps vi intermittent fillet welds vii staggered intermittent fillet welds 3. recognise joint design, to accommodate a backing strips i permanent ii temporary b consumable inserts i types


Outcome 3 Identify non-thermal methods of joining

Practical Activities The candidate will be able to 1. identify and carry out assessment of joining methods 2. select joining methods for a given application. Underpinning knowledge The candidate will be able to 1. outline the use of bolts and methods of tensioning a black bolts b high strength friction grip bolts (HSFG) c close tolerance bolts d fitted bolts e load indicating bolts f torshear 2. explain the importance of cleanliness of contact surfaces, correct tensioning, hole diameters, tolerances and alignment of holes to produce satisfactory bolted connections a black bolts b high strength friction grip bolts c fitted and close tolerance bolts 3. describe the methods of mechanical fastenings applied to thin plate fabrication a bolts b captive nuts c studs d self tapping screws e special thin plate fastenings f solid and tubular rivets g blind rivets (pop rivets) 4. state reasons for and the methods of protecting thin plate metal surfaces prior to and after assembly 5. describe the method and use of hot riveting a hand b machine


6. describe the range of joint configuration used in thin plate fabrication a self secured b lap joints c flanged joints d grooved seams e double grooved seams f knocked up g paned down h slip joints i flexible joints j threaded joints 7. explain the benefits of using jigs and fixtures a position of component/s b joint alignment c mass production/repetitive work d distortion control/dimensional accuracy e economy of operation 8. explain the use of adhesive bonding in the joining of fabricated assemblies a methods available i heat activated ii solvent activated iii impact activated b preparation of surfaces c applications d safety 9. determine the joining allowances a riveted b bolted c adhesive bonded 10. describe the methods of thermal joining a fusion (continuous) b fusion (non-continuous) c non-fusion d manual e automated f solid state 11 describe the range of joint configurations for thermal joining a tags b fillet (‘T’ and o/c) c butt (s)ingle/double v) d ‘U’ (s)ingle/double u) e ‘J’ (s)ingle/double j)


Outcome 4 Identify the affects of distortion and residual stresses due to welding

Practical Activities The candidate will be able to investigate 1. the effects of distortion 2. methods of distortion control 3. methods of distortion rectification 4. the effects of residual stress. Underpinning knowledge The candidate will be able to 1. describe the reasons for distortion a uneven expansion and contraction b degree of restraint 2. identify the types of distortion a longitudinal b transverse c angular d buckling e bowing f dishing g buckling h twisting 3. explain the methods of distortion control a presetting b prebending c weld sequencing d skip welding e back-stepping f tack welding g pre and post weld heat treatment h joint design i balanced welding j intermittent welding k chills l restraint i clamping ii jigs iii back-to-back assembly 4. explain the methods of distortion rectification a mechanical methods i peening ii jacking iii pressing iv bending v rolling vi hammering vii planishing


b thermal methods i use of heat strips ii use of heat triangles 5. describe the residual stress effects of welding a causes of residual stress i restrain A due to uneven expansion and contraction (natural) B due to distortion control methods ii clamping iii jigs iv back-to-back assembly v balanced welding b effects of residual stress i pattern across joint cross-section A areas of tension B areas of compression ii influence upon mechanical properties in service c stress relieving methods i normalising ii thermal stress relief


Outcome 5 Determine the integrity of welded joints

Practical Activities The candidate will be able to 1. identify weld defects and causes correctly 2. use non-destructive testing (NDT) methods 3. use mechanical testing methods. Underpinning knowledge The candidate will be able to 1. describe types of weld defects (EN 26520) a types of cracks i longitudinal ii transverse iii edge iv crater v centreline vi fusion zone vii underbead viii weld b lack of fusion i side wall ii root iii interpass c porosity i scattered ii cluster iii isolated pore iv root v blow holes vi worm holes d piping e craters f solid inclusions i slag ii copper iii tungsten iv oxide g lack of penetration h undercut i oxidation j excessive weld metal k underfill l concavity m overlap n burn-through


2 explain possible causes of weld defects 3. describe the visual examination of welded joints a applications b requirements i equipment ii personnel c benefits d limitations 4. describe penetrant testing a dye b fluorescent c test procedure d applications e equipment requirements f limitations 5. describe magnetic particle testing a magnetic flow i types of magnet A horseshoe B yoke b current flow i ac A skin effect ii dc iii types of magnetisation A prods B bar C coil D tubular E ‘kettle element’ c test procedure d applications e equipment requirements f benefits g limitations


6. describe radiography a sources of radiation i x-ray ii gamma ray b procedure c applications d equipment requirements e benefits f limitations g radiation hazards i effects of radiation on the human body ii radiation monitoring iii personal monitoring iv radiation enclosures v precautions for site radiography h radiographic techniques i plate ii pipe A single wall – single image (including panoramic) B double wall – single image C double wall – double image I ellipse II superimposed 7. describe ultrasonic testing a applications b procedure c applications d equipment requirements i ultrasonic testing set A cathode ray tube (oscilloscope) B controls C calibration ii probes A normal B angle C probe index D selection criteria E beam spread F far zone G near zone H dead zone iv leads v calibration blocks vi couplant e benefits f limitations


g techniques i thickness testing ii lamination testing iii transmission method iv reflection method h determination of geometry i length of near fields ii length of far fields iii beam angle iv skip distance i procedures for reporting and recording flaws in welded components 8. describe the mechanical testing of welded joints a impact tests i izod ii charpy b bend tests i root ii face iii side c tensile i determination of tensile strength ii determination of yield stress iii determination of percentage elongation iv transverse v all weld metal vi tensile/shear A application to lap joints B application to double lap joint d fracture (nick break) e macro examination f micro examination i specimen preparation g hardness surveys i weld zone ii heat-affected zone (HAZ) iii parent metal iv location of indents v testing methods A Vickers B Brinell C Rockwell h spot welded joints testing i peel test ii tensile/shear iii cross tensile iv ‘U’ tensile v twist or torsion


9. describe container testing methods a hydraulic pressure b pneumatic pressure c by filling d by immersion


Unit 006 Principles of engineering maintenance, installation and commissioning

Rationale

This unit identifies the basic principles, 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 staff who perform both of these activities, whereas others, particularly specialist contractors for installation and commissioning, may only cover a limited range. The content of this award 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 basic maintenance, installation and commissioning requirements including the processes and organisation for dealing with them. It also includes components, tools and equipment 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 in-depth 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. Outcomes There are four outcomes to this unit. The candidate will be able to 1. use safe, effective and efficient working practices 2. select appropriate working methods and use tools, equipment and instruments 3. select and apply approved lubrication, insulation and protection techniques 4. select and use appropriate methods of supporting, locating and fastening engineering components and deal with associated problems. Connection with other awards This unit relates to Units 001-059 of the City & Guilds Level 3 NVQ in Engineering maintenance (1688). It also relates to ECS 1.01, 1.03, 1.12, 1.13, 1.15-1.23, 2.10 -2.16. Assessment The outcomes from this unit will be assessed using evidence from a centre set question paper using questions from a City & Guilds devised question bank.


Outcome 1 Use safe, effective and efficient working practices

Practical Activities The candidate will be able to 1. inspect the site or location where the maintenance or installation is to be carried out, determine all requirements and prepare a report on the findings 2. obtain the necessary clearances or approvals for the work to be undertaken 3. carry out logical fault finding procedures. Underpinning knowledge The candidate will be able to 1. describe the methods and procedures necessary to make an area safe before starting work by a using barriers and/or tapes b placing warning signs in appropriate positions c informing any persons who may be affected d isolating power or pressure sources e obtaining official clearance (Permit to Work) 2. state the basic reasons for carrying out maintenance a upholding or improving safety standards b maintaining production output at the required levels and quality c maximising the useful working life of engineering assets d increasing production efficiency (reduction of rejected work or downtime) 3. describe the general types of work that need to be included in maintenance activities a carrying out routine servicing schedules or planned preventative maintenance b repair and replacement following breakdowns c monitoring and performance testing 4. state the factors that need to be considered when planning a maintenance operation a tools and equipment b materials and spares c the importance of minimising downtime to avoid i loss of production ii poor customer relations (internal and external) iii wage overheads d how to estimate the length of time needed for maintenance 5. describe the general types of work that need to be included in installation activities a installing machinery and systems into new sites or locations b replacement of machinery and equipment following or extending facilities c monitoring and performance testing


6. state the factors that need to be considered when planning an installation a site conditions and locations of components b storage of parts and materials c tools and equipment d provision of services – electricity, compressed air, water and drainage e minimising disruption to adjacent work areas f how to estimate the length of time needed for the installation and commissioning 7. list tool and equipment identification methods (use of catalogue numbers and bar codes and the procedure for obtaining parts 8. state the storage requirements of tools, materials and equipment for security and safety (long and short term) 9. state the necessity of returning any unused materials/equipment back to the stores or other authorised areas and in a suitable condition (using the proper packaging and protective covers 10. state what information needs to be supplied when completing a report following a maintenance or installation activity a work undertaken b location(s) c dates/times (commencement, completion and handover d parts and consumables used e test data f permit to work or certification references 11. describe procedures for cleaning work areas after spillage, leakage or contamination using a absorbent substances, detergents and solvents b approved waste disposal methods 12 identify the symbols and conventions used for system and circuit diagrams according to BS 1553 13. describe the difference between a symptom and the cause of a fault 14. list the general procedure to be followed immediately after a fault has been detected a start enquiry immediately b ensure no evidence will be destroyed c note existing conditions when failure occurred 15. describe the different fault diagnostic techniques and give situations when each would be applicable a six point b half split c input to output d output to input


Outcome 2 Select appropriate methods and use tools, equipment and instruments

Practical Activities The candidate will be able to 1. set up access equipment for safe working at heights and/or in confined spaces 2. demonstrate safe and efficient practices for moving large or non standard loads 3. determine the lifting requirements for different applications 4. attach appropriate lifting devices and equipment to machinery and equipment 5. take responsibility for lifting and manoeuvring a load 6. select and use the appropriate tools for the specified optional activities 7. select and use instruments for fault diagnosis, monitoring and commissioning purposes Underpinning knowledge The candidate will be able to 1. describe the setting up and safe use of access equipment a ladders b scaffolding c mobile hoists and platforms 2. estimate the approximate weight of an item using a manufacturers’ data b volume and specific gravities 3. explain the importance of finding a the centre of gravity of a machine or piece of equipment b stress in lifting tackle and strain in slings (particularly when using synthetic materials) c changes in stress resulting from the angles at which slings are used by means of simple triangles of force 4. state the legal requirements for lifting tackle in terms of a frequency and methods of testing items as prescribed in the Factories Act b the need for marking and registering lifting tackle 5. describe the inspection procedures to be carried out before using lifting equipment 6. state the applications of different types of lifting tackle and ancillary equipment a rope and wire slings b chain slings (s)ingle and multi-legged c hooks, shackles, swivels and eyebolts (including methods of securing) d magnetic and vacuum lifting attachments 7. describe methods of attaching slings to avoid danger and damage to machinery or system components (protective padding)


8. describe types of cranes, hoists and lifts and state their applications a jacks (screw and hydraulic, elevating tables) b overhead (travelling bridge and gantry cranes) c jib cranes and derricks d mobile cranes e fork lift trucks f electric and pneumatic hoists 9. describe the construction and use of temporary lifting devices and the need for a leg chains on tripods b methods of attachment for shackles and pulley blocks 10. describe standard signalling methods used when controlling a lift and positioning of personnel using steady lines 11. describe the methods available for moving heavy equipment across flat and sloping surfaces by means of a lubricated plates b rollers and skates c crowbars d pull-lifts 12. identify the types and methods of using tools and equipment for specialised tasks a torque spanners/wrenches b impact wrenches c pipe wrenches/Stillsons d pipe cutting and threading equipment e steam or chemical cleaning of equipment and components 13. explain the meaning of the following terms as applied to instrumentation a range b sensitivity c response d accuracy e repeatability f analogue and digital signals g transducers and amplifiers 14. state the types and applications of instruments used for testing and monitoring the condition of systems and machinery a pressure i manometers ii Bourdon tube type instruments b temperature i expansion types ii electrical resistance types and thermocouples iii thermal paints and crayons c flow i direct (bellows and piston types) ii inferential (rotameters, venturi and orifice plates, and turbine types)


d rate and speed i tachometers (mechanical and electrical) ii stroboscopes iii pulse counters e content i direct (dipsticks and sight glasses) ii indirect (load cells and electrical transducers) f electrical meters i megameters ii multimeters g vibration h data recorders 15. describe the methods of mounting instruments and the ways in which they can be protected from a external damage or unauthorised interference b excess loads and surges (use of snubbers and reservoirs) c heat and vibration 16. briefly describe the need for regular calibration of instruments and the methods used 17. describe methods of setting up and aligning components a straight edges b feeler gauges and test indicators c plumb lines and spirit levels d taut wire e optical and laser types of instrument 18. describe equipment and methods of bending small diameter pipes, tubes and conduit a calculations to determine bending allowance b causes of cracking, creasing and flattening of bends c use of internal methods of supporting pipes i internal springs ii use of fillers d use of templates and formers e manual and hydraulic bending equipment 19. describe and state the uses of cutting and heating equipment 20. describe the setting up of oxy-gas equipment a preparing and attaching regulators to bottles b selecting and connecting appropriate air/gas lines, torches and nozzles c lighting torches and applying heat as required


Outcome 3 Select and apply approved lubrication, insulation and protection techniques

Practical Activities The candidate will be able to 1. install or maintain lubrication systems 2. select suitable oils and greases to match conditions and requirements 3. determine faults in lubrication systems. Underpinning knowledge The candidate will be able to 1. describe the nature of surfaces and the effects of these on friction in terms of a actual surface contact area (on ‘peaks’) and hence causes of ‘cold welding’ b surface wear (breaking of ‘peaks’) c generation of heat d forces required to overcome friction (static and dynamic) 2. state how the adverse effects of friction can be reduced by the use of a low friction materials b material combinations that control wear to only one of the two contacting elements c partial lubrication d full film lubrication 3. describe the hydrodynamic wedge principle and system requirements a bearing types and design b clearances c points of oil admission 4. list methods of applying lubricants a total loss b recirculatory i construction and component parts of reservoirs ii filtration methods and positioning iii heat exchangers iv pressure controls and warning devices c splash d grease guns and nipples e self lubricating (cast iron and impregnated metals) 5. explain the meaning of terms used to describe lubricant properties a viscosity b viscosity index c emulsions d foaming e compatibility (with other oils, seals and bearing material) f pour and flash points g additives


6. list types of oil and their applications in respect of load, temperature and environmental considerations for a mineral b animal and vegetable c synthetic 7. identify the nature of greases and their applications with respect to a the base (matrix and lubricants) b methods of application, including the need to prevent over packing and churning 8. state the reasons for oil deterioration a excess heat b oxidation c contamination d breakdown of structure due to prolonged overloading e poor storage conditions 9. describe the nature and causes of corrosion a oxidation b electro-chemical reactions 10. describe methods of minimising corrosive effects a selection of materials to suit conditions b insulation of dissimilar metals c use of sacrificial anodes d use of protective coatings i paint ii galvanising and anodising iii plating and coating 11. describe methods of insulating and protecting systems and plant to prevent or minimise a heat losses or gains b transmission of noise and/or vibration c external damage


Outcome 4 Select and use appropriate methods of supporting, locating and fastening engineering components and deal with associated problems

Practical Activities The candidate will be able to 1. select and use appropriate locating, fastening and locking devices for different conditions 2. deal effectively with corroded and/or sheared fasteners 3. select bearings from manufacturers’ data and remove and install different types of bearing. Underpinning knowledge The candidate will be able to 1. state that bearings are used for support and to take up radial and axial forces but allow freedom of movement in limited directions 2. Identify types of bearing and state their applications a plain bearings i materials used (non-ferrous and their alloys, no-metallic) ii split and solid forms and their housing methods iii shell and white-metalled types b roller bearings i cylindrical ii tapered iii double row iv spherical v needle vi above types that used for axial loads (thrust) c ball bearings i single row deep groove and angular contact ii double row deep groove and angular contact iii self aligning iv above types that used for axial loads (thrust) d shielded and sealed forms of roller and ball bearings 3. describe methods of removing and fitting bearings onto shafts and into housings by applying forces to the bearings in a manner that avoids damage by using a special extractors and mandrels b hand (mandrel and hydraulic presses) c appropriate lubricants or grease 4. explain the terminology used to describe thread forms a pitch and lead b major and root diameters c truncation 5. identify thread forms using screw pitch gauges and charts


6. calculate the forces/moments associated with the generation of torque using T = F x L 7. state the applications of different thread types related to a tensile strength as applied to nuts and bolts. b the methods of grading the strength of black bolts (R, S, T, V and X) and ISO Metric fasteners (8.8, 4.6 and the meanings of these numbers) c Torque settings. Manufacturer’s recommendations or calculated from:- Torque (Nm)= 1.962 x bolt load (N) x Nominal bolt diameter (mm)/1000 8. state the different gripping and locking devices available and their respective securing capabilities a lock nuts (and method of using) b castellated nuts c nuts with inserts d serrated nuts e tab and grip washers f wire locking g chemical locking methods h load indicating bolts 9. describe the types and applications of studs a methods of insertion and extraction b dealing with sheared studs by i extractors ii drilling and re-tapping 10. describe methods of releasing corroded nuts a use of release and penetrating oils b application of heat c nut splitters or similar techniques 11. state that riveting is classified as a permanent fastening method and describe a different types and classification of rivets b hot and cold riveting methods c tools and equipment used for riveting 12. identify types of locating dowels and tenons a positioning of dowels and tenons to ensure precise and repeated location b methods of inserting and extracting dowels 13. describe the types and applications of adhesives for joining engineering components 14. describe methods of attaching components and equipment to different surfaces and structures a use of rawlbolts and ragbolts for masonry and concrete i hole preparation and fitting ii safety aspects in relation to reinforced concrete b use of rigid and flexible mountings (including glue pads) c limitations regarding attachment to pressure vessels and gas bottles. d section sheet and cladding e constructional girders and steelwork


15. describe the use of cartridge insert guns a essential safety aspects b need for certification of operators


Unit 007 Principles of materials processing

Rationale

This unit is concerned with the underlying principles that apply to the processing and joining of material(s) used in the production of components, patterns or models, without focusing on specific pattern/model-making or casting processes. Included are the behaviour and properties of materials, principles of design, related finishing techniques and the quality control of processing operations. Outcomes There are four outcomes to this unit. The candidate will be able to 1. identify and select materials used in pattern/model-making and casting operations 2. interpret and apply design principles to material(s) processing operations 3. identify suitable finishing techniques for material(s) processing operations 4. monitor and control material(s) processing operations. Connection with other awards This unit relates to Units 001-025 of the City & Guilds Level 3 NVQ in Materials processing and finishing (1683). It also relates to ECS 1.12, 1.15 – 1.17, 2.05, 3.15. Assessment The outcomes from this unit will be assessed using evidence from a centre set question paper using questions from a City & Guilds devised question bank.


Outcome 1 Identify and select materials used in pattern/model-making and casting operations

Practical Activities The candidate will be able to 1. identify and carrying out initial assessment of properties of materials 2. classify materials and identify structures and behaviour 3. select materials for a given application. Underpinning knowledge The candidate will be able to 1. describe the range of common materials used in processing operations a metallic i low/medium/high carbon steels ii low alloy steels iii cast irons iv austenitic stainless steels v aluminum/aluminum alloys vi copper/copper alloys b polymers i thermoplastics ii thermosetting A phenolic B expoxy c composites i glass fibre ii carbon fibre d natural i wood ii rubber iii clays 2. describe the range of commercial forms of supply a billets b bar c sheet d plate e hollow f square g rectangular h fibres i pipe and tube j round


h section i channel ii tee iii angle A equal leg B unequal leg 3. outline the criteria for the selection of materials for a given application a strength to weight ratio b appearance c ductility d resistant properties i heat ii corrosion iii wear e cost f weldability g bonding capability h machinability 4. describe the different material structures a crystalline i body centre cubic (bcc) ii face centre cubic (fcc) iii hexagonal close packed (hcp) b chain molecules i long chain ii cross linked c amorphous 5. describe the different crystalline structures a chill b columnar c equiaxed 6. explain the variation in properties that result from different types of structure and grain size a fine grained structure b coarse grained structure c effect of grain size upon working properties 7. describe the influence of cooling rate on grain size 8. explain the difference between macrostructure and microstructure a low magnification b high magnification


Outcome 2 Interpret and apply design principles to material(s) processing operations

Practical activities The candidate will be able to 1. identify design parameters for the effective/efficient processing of materials 2. identify the factors that give precedence to material(s) processing operations 3. identify the factors that affect behaviour and service performance 4. distinguish between different of service conditions that contribute to failure. Underpinning knowledge The candidate will be able to 1. describe the range of operations used in materials processing a machining b sanding and abrading c drilling d planing e casting i sand ii die (gravity and pressure) iii specialized f bonding g pinning h packing and pressurizing i finishing 2. state the design criteria for effective and efficient material processing a suitability of material b shape geometry (profile) c section continuity and reinforcement d effective modelling e bonding and joining techniques 3. state the factors that determine the selection of material(s) processing for the production of components a single stage manufacture b complexity of shape c dimensional control and accuracy d prototyping 4. describe the design factors that affect service performance a unsuitable design b fatigue c incorrect jointing methods d metallurgical e deformation


5. state the behavioural problems associated with material(s) processing operations a distortion b residual stress c defects d splitting 6. explain the different service conditions that contribute to failure a stress b impact c temperature extremes d corrosion e erosion


Outcome 3 Identify suitable finishing techniques for material(s) processing operations

Practical Activities The candidate will be able to 1. identify the range of finishing processes for materials processing operations 2. select equipment and materials appropriate to finishing applications. Underpinning knowledge The candidate will be able to 1. state the range of finishing processes used in materials processing operations a sanding b filing c sawing d chipping e grinding f blasting i bead ii grit g mechanical cutting h thermal cutting i painting j polishing 2. state the materials/consumables used in finishing applications a ceramic chips b oil based and water based paints c compressed gases d abrasive wheels e abrasive discs f polishing mops 3. describe the range of applications of finishing processes a surface finishing of patterns and models b surface painting of patterns and models c removal of casting defects and imperfections d abrasive cleaning of castings e cutting off riser fins f truing up surfaces g shaping components


4. state the range of equipment required for finishing operations a sealed cabinets b compressed air supply and blasting equipment c saws i circular ii reciprocating(hand/mechanical iii chop iv band d drilling machines and drill bits e thermal cutting equipment f files and scrapers g planing equipment h paint brushes i range of general hand tools


Outcome 4 Monitor and control material(s) processing operations

Practical Activities The candidate will be able to 1. identify the quality assurance requirements for materials processing operations 2. maintain efficient and effective materials processing operations Underpinning knowledge: The candidate will be able to 1. state the relevant British and European standards relating to material(s) processing operations a BS 1452 b BS 1490 c EN/ISO equivalents d technical terms and symbols specific to material(s) processing operations 2. state the requirements for safe working conditions in material(s) processing environments a PPE b RPE c lifting and handling devices d heat protection e noise protection i noise at work regulations(1989) actions to be taken A first level 85dB(A) B second level 90 dB(A) C third level 140 dB(A) 3. state the need for control of dimensional accuracy a length b flatness c surface finish and texture d angles e profiles f roundness and concentricity g parallelism h accuracy of form 4. explain the need to handle equipment, tools and materials safely and correctly during material(s) processing operations 5. state the need to maintain an efficient supply of materials during processing operations 6. explain the difference between tolerances and limits in relation to material(s) processing


7. state the factors that can affect an efficient operation a process interruptions b process faulty equipment c unsuitable or defective material d breakdowns e untrained personnel f lack of supervision 8. explain the purpose of work scheduling a operations charts b progress charts c time charts


Unit 008 Principles of materials forming

Rationale

This unit is concerned with the underlying principles that apply to the forming and moulding of material(s) used in the production of components, without focusing on specific forming and moulding processes. Included are the behaviour and properties materials, principles of design, related finishing techniques and the quality control of forming and moulding operations. Outcomes There are four outcomes to this unit. The candidate will be able to 1. identify and select materials used in forming and moulding operations 2. interpret and apply design principles to material(s) forming and moulding process operations 3. identify suitable finishing techniques for material(s) forming and moulding process operations 4. monitor and control material(s) forming and moulding operations. Connection with other awards This unit relates to Units 074, 075, 081, 082, 084, 088 of the City & Guilds Level 3 NVQ in Mechanical manufacturing (1682) and Units 047-052 and 055 of the City & Guilds Level 3 NVQ in Fabrication and welding (1681). It also relates to ECS 1.12, 1.15 – 1.17, 2.06, 3.16. Assessment The outcomes from this unit will be assessed using evidence from a centre set question paper using questions from a City & Guilds devised question bank.


Outcome 1 Identify and select materials used in forming and moulding operations

Practical Activities The candidate will be able to 1. identify and carrying out initial assessment of properties of materials 2. classify materials and identify structures and behaviour 3. select materials for a given application Underpinning knowledge The candidate will be able to 1. describe the range of common materials used in processing operations a metallic i low alloy steels ii carbon steels A low B medium C high iii cast irons iv austenitic stainless steels v aluminium/aluminium alloys vi copper/copper alloys b polymers i thermoplastics ii thermosetting iii composites c composites i fibre reinforced materials (FRP) d rubber i natural ii synthetic 2. state the range of commercial forms of supply a billets b bar c sheet d plate e section i rolled steel joist (RSJ) ii column (UC) iii beam (UB) iv channel v tee vi angle f equal leg g unequal leg h hollow sections i square ii rectangular iii round (tubular) i pipe and tube j rods and fibres


3. outline the criteria for the selection of materials for a given application a strength to weight ratio b appearance c ductility d resistant properties e heat f corrosion g wear h cost i weldability j bonding capability k machinability 4. describe the different material structures a crystalline i body centre cubic (bcc) ii face centre cubic (fcc) iii hexagonal close packed (hcp) b chain molecules i long chain ii cross linked 5. describe the different crystalline structures a equiaxed (coarse grain) b equiaxed (fine grain) c elongated d distorted (flow) 6. explain the variation in properties that result from different types of structure and grain size a fine grained structure b coarse grained structure c effect of grain size upon working properties 7. describe the influence of mechanical working on properties a hot working b cold working 8. describe the influence of cooling rate on grain size 9. state the difference between macrostructure and microstructure a low magnification b high magnification


Outcome 2 Interpret and apply design principles to material(s) forming and moulding operations

Practical activities The candidate will be able to 1. identify design parameters for the effective/efficient forming of materials 2. identify the factors that give precedence to material(s) forming operations 3. identify the factors that affect behaviour and service performance 4. distinguish between different service conditions that contribute to failure Underpinning knowledge The candidate will be able to 1. describe the range of operations used in materials forming and moulding a machining b drilling c shaping i extruding ii forging iii rolling iv vacuum forming v blow moulding vi injection moulding vii calendaring d bonding and joining e pinning f finishing 2. state the design criteria for effective and efficient material forming and moulding a suitability of material b strength of material c working/forming temperature d shape geometry (profile) e section continuity and reinforcement f bonding and joining techniques 3. state the factors that determine the selection of material(s) forming and moulding for the production of components a single stage manufacture b complexity of shape c dimensional control and accuracy d inherent strength of formed components 4. describe the design factors that affect service performance a unsuitable design b process defects c metallurgical d material deformation


5. state the behavioural problems associated with material(s) forming and moulding operations a residual stress b distortion c defects d overheating 6. explain the different service conditions that contribute to failure a stress b fatigue c impact d temperature extremes e corrosion f erosion


Outcome 3 Identify suitable finishing techniques for material(s) forming and moulding operations

Practical Activities The candidate will be able to 1. identify the range of finishing processes for materials processing operations 2. select equipment and materials appropriate to finishing applications Underpinning knowledge The candidate will be able to 1. state the range of finishing processes used in materials processing operations a filing b sawing c grinding d mechanical cutting & machining e thermal cutting f polishing 2. state the materials/consumables used in finishing applications a compressed gases b abrasive wheels c abrasive discs d polishing mops 3. describe the range of applications of finishing processes a surface finishing of dies and tools b removal of forming/moulding defects and imperfections c abrasive cleaning of components d cutting off flashes and fins e truing up surfaces f shaping components 4. state the range of equipment required for finishing operations a saws i band ii chop iii reciprocating (hand and mechanical) b drilling machines and drill bits c thermal cutting equipment d files and scrapers e machining equipment f range of general hand tools


Outcome 4 Monitor and control material(s) forming and moulding operations

Practical Activities The candidate will be able to 1. identify the quality assurance requirements for materials forming and moulding operations 2. maintain efficient and effective materials forming and moulding operations. Underpinning knowledge The candidate will be able to 1. state the relevant British and European standards relating to material(s) forming and moulding operations 2. state the technical terms and symbols specific to material(s) forming and moulding operations 3. state the requirements for safe working conditions in material(s) forming and moulding environments a PPE b RPE c lifting and handling devices d heat protection e noise protection 4. state the need for control of dimensional accuracy a length b flatness c surface finish and texture d angles e profiles f roundness and concentricity g parallelism h accuracy of form 5. explain the need to handle equipment, tools and materials safely and correctly during material(s) forming and moulding operations 6. state the need to maintain an efficient supply of materials during forming and moulding operations 7. explain the difference between tolerances and limits in relation to material(s) forming and moulding operations


8. state the factors that can affect an efficient operation a process interruptions b process faulty equipment c unsuitable or defective material d breakdowns e untrained personnel f lack of supervision 9. explain the purpose of work scheduling a operations charts b progress charts c time charts


Unit 009 Principles of mechanical manufacturing engineering

Rationale This unit is concerned with the underlying principles that enable engineering activities to be carried out prior to and on the completion of the machining of components. Included are forms of technical communication, interpreting engineering drawing and specifications, resource and plant requirements, methods of cost control, and the identification and testing of materials. Outcomes There are three outcomes to this unit. The candidate will be able to 1. evaluate technical resource requirements and plant for machining operations 2. apply analyses and cost control methods and techniques 3. identify and test materials. Connection with other awards This unit relates to Units 004-054 of the City & Guilds Level 3 NVQ in Mechanical manufacturing engineering (1682). It also relates to the ECS standards 1.13, 2.02, 2.03, 6.02, 6.03 and 6.06. Assessment The outcomes from this unit will be assessed using evidence from a centre set question paper using questions from a City & Guilds devised question bank.


Outcome 1 Evaluate technical resource requirements and plant for machining operations

Practical Activities The candidate will be able to 1. select and evaluate the most suitable machining process or technique to produce the component part 2. prepare an operation schedule selecting the most effective and efficient method, and sequence of manufacture for machining operations 3. produce a schedule to ensure the work environment a is accessible and free from obstruction b has provision for storage of tools, ancillary equipment and materials c has services available and connected d conforms to appropriate health and safety regulations, guidelines and procedures to rectify conditions that are not appropriate Underpinning Knowledge The candidate will be able to 1. describe the main types of production a jobbing b batch c flow d mass 2. outline the benefits, limitations and suitability of 1. 3. describe the effects on production of a absenteeism b lateness c machine downtime d rework e scrap 4. outline the requirements of a production system a labour b machinery and equipment c materials d energy e location f market 5. describe ways of improving productivity by optimising the use of a personnel b machine availability c materials d energy


6. explain the importance of continued trading in terms of a customer satisfaction i product ‘fitness for purpose’ A cost B performance ii the effect of not complying with delivery dates iii reliability b legal obligations of sales contract 7. outline the range and types of machine available in terms of size, capacity, accuracy and production capability a lathes i centre ii capstan iii turret b milling machines i horizontal ii vertical iii universal c drilling machines i bench ii pedestal iii radial arm iv multi-spindle v co-ordinate table vi special purpose d grinding machines i surface A horizontal spindle B vertical spindle ii cylindrical A plain B universal iii internal iv special purpose e electro machining i electrodischarge machining (EDM) A ram feed B wire feed ii ultrasonic machining (USM) iii electrochemical machining (ECM) iv laser machining f computer numerical control (CNC) g computer aided design (CAD) h computer aided manufacture (CAM) 8. state the parts, features and applications for machines listed in 7.


9. describe the basic structure of machine tools a materials used i cast iron ii cast steel iii steel plate b types of structure i box column ii rib and box bed iii fabricated base c drive systems i belts ii gears and gear boxes iii screwthreads iv clutches v bearings 10. describe the principle of cutting tools a materials i high carbon steel (HCS) ii high speed steel (HSS) iii tungsten carbide iv ceramic 11. outline the factors influencing selection of machines in terms of a accuracy b cost c quality d suitability e time f forms of material supplied 12. describe the logical sequence of operations to achieve a economy of labour b economy of materials c accuracy i dimensional ii geometric d surface finish e quantity required f quality required g prevention of deformation 13. describe inspection and testing procedures a the contribution of inspection and testing to ensure customer satisfaction whilst minimising production costs b the calibration of instruments to appropriate standards i national ii international


c the function of different methods of inspection i first-off ii patrol iii in process iv viewing v final test vi checks for physical characteristics vii functional tests 14. describe briefly the factors to be considered in establishing an appropriate working environment for testing and inspection a temperature control b noise control c sterile and clean environment 15. describe the methods that aid product flow a position of machines b personnel i work study ii progress chaser iii who to inform of resource requirements 16. outline the requirements for producing a work schedule a analyse drawings and technical data b personnel c machines d tools and equipment e components/materials f consumables 17. describe the requirements for a project action plan to organise and control an activity a aim of project b collating data c time scale for completion d legislation that needs to be considered e documentation required 18. explain the reasons for keeping work area free from obstruction in terms of a employees’ responsibility b employers’ responsibility 19. state the importance of checking the availability of the required services and who to inform when not available a electricity b compressed air line c waste disposal d water


20. state the requirements for acceptable work environment, in terms of a light b heat c ventilation d fire precautions/procedures e access f storage facilities g hazards


Outcome 2 Apply analysis and cost control methods and techniques

Practical Activities The candidate will be able to produce a 1. report on the analysis method of cost machining activities 2. listing of costs for given engineering activities 3. cost estimate for the production of a machined product Underpinning knowledge The candidate will be able to 1. describe the analysis methods and techniques that can be used a Gantt charts b performance ratios i machining times ii labour hours iii material consumption and waste iv down time 2. outline the types of problems that can be solved, and the difficulties that can occur when using analysis methods and techniques 3. outline the resources that are associated with different types of engineering activities a buildings b staff c equipment d materials 4. describe the sources of information on which cost estimates are based a cost elements i fixed ii variable iii overheads b working drawings c worksheets d specification/technical data e historical data i schedules ii time sheets iii operation sheets iv internal and external department records


5. explain the stages in compiling a cost estimate a collect and analyse information b clarify outstanding points with customer c produce an operation sheet d produce estimate showing i labour costs ii materials costs A materials B components C consumables 6. explain who bears the cost of different resources and activities 7. state the factors in planning and control of work to achieve cost-effective manufacture a personnel b tools, equipment and plant c materials, components and consumables d reference date, drawings and documentation e internal/external communications f plant maintenance g requirements of ‘one-off’ orders 8. explain the cost implications of not using resources efficiently and effectively 9. list the applications of computers in industry a production b product control c design d quality control e measurement f forecasting g administration


Outcome 3 Identify and test materials

Practical Activities The candidate will be able to 1. test the hardness of different materials 2. carry out a tensile test and plot the appropriate graph 3. check the surface texture of different machined surface using a comparison blocks b specialist machine. Underpinning Knowledge The candidate will be able to 1. describe briefly the factors which render dissimilar material combinations difficult to work a linear coefficient of i expansion ii contraction b treated conditions i mechanical ii thermal c material types 2. describe the behaviour of materials under load and their a static and dynamic loading b shock loading i mechanical ii thermal c the importance of the stress-strain relationship of a material i stiffness of a material as stress divided by strain ii strength of different materials A aluminium B ceramics C low carbon steel D plastics d the concept of working stress and safety factor e determine the strength of a material subjected to a tensile load f applications where forces are used to advantage in manufacturing i clamping/workholding ii drilling/milling/turning iii punch and dies iv clutches 3. describe the corrosion or degradation process of engineering materials a oxidation of ferrous materials b direct chemical attack on metals c electrolytic action d ultra violet light e age


4. describe the methods of retarding corrosion a painting b corrosion inhibitors c cathodic protection d metallic coating i galvanising ii tin iii nickel e cladding materials i anti-corrosion ii heat resistant iii plastics 5. explain how the quality of finish influences a friction properties b product life i durability ii avoidance of flaws iii fatigue resistance c production costs 6. describe the terms used in the assessment of surface texture a lay b roughness c waviness d flaws 7. outline the degree of finish related to machining process a primary i drilling ii milling iii turning b secondary i grinding ii reaming iii lapping iv honing v polishing 8. describe the methods of measuring surface texture 9. list the properties of cutting fluids a anti-corrosive b detergent action c long life d economic cost e medically safe 10. describe the types and applications of cutting fluid a aqueous b oil-type c synthetic d chemical


11. describe the purpose of materials testing as the determination of a material behaviour under operational conditions b materials properties i mechanical ii thermal iii electrical c materials structure, composition and characteristics d detection of flow 12. describe the difference between destructive and non-destructive testing 13. describe mechanical testing and the techniques used a tensile b compression c hardness i Brinell ii Rockwell iii Vickers iv Shore scleroscope d impact i Izod ii Charpy 14. determine for different heat treated carbon steels a force/extension diagrams b maximum load c elastic extension d yield point e uniform plastic extension f necking g breaking point 15. describe non-destructive testing, the equipment and techniques used a penetration radiation b ultrasonic c electromagnetic induction d magnetic field e liquid penetration f filtered particles


Unit 010 Principles of electrical engineering

Rationale This is concerned with the underlying principles that enable engineering activities to be carried out prior to and on the completion of electrical repair and maintenance. Outcomes There are three outcomes to this unit. The candidate will be able to understand 1. the functions of electrical components 2. electrical supply systems, protection and earthing 3. the functions of electrical machines and motors Connection with other awards This unit relates to Units 201, 206, 209, 211 and 302-341of the City & Guilds Level 3 NVQ in Electrical and electronics servicing (1687). This unit does not relate to OSC Eng ECS. Assessment The outcomes from this unit will be assessed using evidence from a centre set question paper using questions from a City & Guilds devised question bank.


Outcome 1 Understand the functions of electrical systems/components

Underpinning knowledge The candidate will be able to 1. state the basic electrical units and describe their relationship a energy – joule b current – charge per unit time c charge – It d voltage – energy per unit charge e power - energy per unit time – VI f resistance – voltage per unit current 2. describe resistors a define the term resistance, state that resistance depends on the dimensions, type of material and temperature, define resistivity b state the relationship between the resistance of a conductor and its length, cross-sectional area and its resistivity c determine the current, voltage, resistance and power in simple series and parallel circuits using Ohm’s Law; calculate the power dissipated 3. describe magnetism and magnetic circuits a define magnetic fields b state that magnetic fields are considered to consist of lines of magnetic flux c state the rules applicable to lines of magnetic flux d describe and sketch the flux paths of typical magnetic circuits e state the relationship between magnetic flux, cross-sectional area and magnetic flux density 4. describe inductance and inductive components a describe inductors as wound components b state how an electric current may be generated by dynamic or static induction c define magnetic flux d explain the difference between self and mutual induction e determine the emf of self or mutual induction, given the i inductance and change of rate of current ii number of turns and rate of change of flux iii rate of cutting flux by conductor f state Lenz’s Law g relate inductive components in electrical machines (e.g. field coils, transformer winding) h determine the force on a current carrying conductor in a magnetic field using F= Bl? i describe an electro – magnet and the effect of an iron core


5. describe capacitors a define capacitance the electrical field, electric stress, dielectrics; relate potential difference, charge and capacitance b identify the constructional features of different types of capacitor; parallel plate, variable and semi-variable air spaced, solid dielectric c determine capacitance given ε0, εr, area and distance between plates d state the dangers associated with capacitors e calculate resultant capacitance for capacitors in series and parallel 6. describe batteries a list the factors influencing the choice of a secondary battery for a given application i cost ii available space iii applied load iv initial and end point voltage v operating environment b outline the procedures necessary to maintain a battery in good condition c state the procedures involved in checking the condition of a battery and the readings expected, the use of voltmeters, hydrometers and high current discharge testers. d state the safety precautions required in relation to battery charging and battery charging rooms 7. a describe graphically the effect of inductance and capacitance when connected to a dc supply i R and L in series ii R and C in series (charge and discharge) iii Identify time constant, transient state and steady state 8. a state the effects of resistance and inductance in a.c circuits i sketch the circuit, waveform and phasor diagrams for the following circuits A purely resistive B purely inductive C R and L in series b state the effects of resistance and capacitance in an a.c circuit i sketch the circuit diagram and phasor diagram for A a purely capacitive circuit B R and C in series c state the effects of R, L & C in an ac circuit i R, L & C in series ii R L & C in parallel d describe the effects of series and parallel resonance e determine power developed (or dissipated) in single phase circuits i using V, I and power factor ii state the average power in a A resistor is VI B pure inductance is zero C pure capacitance is zero iii determine A power B power factor C kVA, kW and kVAr


9. describe the types and use of test instruments including the use of a multimeters for measurement of current, voltage and resistance b insulation testers c wattmeter to measure power d instruments to measure earth loop impedance e tachometer and stroboscope to measure rotational speed f CRO to measure i the magnitude of direct voltage ii the amplitude and frequency of alternating voltages 10. describe semiconductor devices a describe the action of semiconductor devices in simple rectifier circuits i state that the diode is a device which allows current to flow in one direction ii define PIV iii state that the conduction in a thyristor is controlled by a gate electrode iv describe the requirement for heatsinks v recognise circuits and input/output waveforms for half wave, full wave and bridge circuits vi describe the action of smoothing circuits b describe the action of both bi-polar and uni-polar transistors when used i as a switch ii as an amplifier 11. describe basic electronic circuits and components a identify listed components from their packaging i resistor ii capacitor iii transistor iv diode v integrated circuit b state the function of the listed circuits i amplifier ii oscillator iii filter iv power supply 12. describe the operating conditions and typical applications of a photocell b photodiode c phototransistor d optocoupler e infra-red source and sensor f fibre optic link g solid state temperature measurement device h Hall effect device i Vacuum fluorescent display j Gas plasma display


Outcome 2 Understand electricity supply systems, protection and earthing Underpinning Knowledge The candidate will be able to 1. describe electricity supply systems a distinguish between, and state the function of, transmission and distribution systems b list the stages in power supply i generation ii super grid iii grid substation iv local substation c state how power stations are interconnected and list the advantages of the interconnection d state the reasons for high voltage transmissions e with reference to the systems listed at b i – iv above, state i the standard voltages used ii the voltages at which specific consumer groups are supplied iii the effects of voltage drop and losses and carry out simple calculations f describe how single phase, three phase three wire and three phase four wire systems are produced from a three phase generator g draw circuit diagrams of loads connected in star and delta h calculate line and phase values of voltage and current in three phase star and delta connected balanced systems i determine the power in three phase balanced loads using v3VI x power factor 2. describe transformers a state the principle of operation of transformers b state the relationship between input, output and losses c perform simple calculations on input, output and losses d perform calculations involving current, voltage and turns for ideal transformers e explain the term ‘rating of a transformer’ and the reason for rating in kVA f determine the maximum line current of a three phase transformer from kVA rating g describe auto transformers and state associated danger 3. describe switchgear (both LV and HV) a state the function of listed switchgear i circuit breakers ii switches iii isolators 4. describe earthing systems a state the reasons for earthing i low voltage systems ii high voltage systems


5. describe protection systems a list the abnormal conditions for which protection systems need to be provided i dangerous currents due to short circuits ii earth leakage iii overload b state methods of protection to counteract abnormal conditions listed at a i fuses ii circuit breakers iii residual current devices iv RCBOs


Outcome 3 Understand the functions of electrical machines and motors

Underpinning Knowledge The candidate will be able to 1. describe the principles of operation of electrical rotating machines a state the principles of operation of the alternating current generator b describe the principle of operation of unidirectional current generators including the function of the communicator c describe the interdependence of i frequency, speed and pole pairs ii emf, speed and fields strength d describe the principle of operation of the d.c machine as a motor e state that a rotating magnetic field is produced by a three phase winding system f determine synchronous speed using frequency and pole pairs g distinguish between synchronous and asynchronous machines 2. identify three phase conduction motors, distinguish between a cage rotor b wound rotor 3. identify single phase a.c motors (rated below 1 kW) distinguish between a series wound b split phase c capacitor d capacitor start\run


Unit 011 Principles of electronics

Rationale This unit concerns the electronic principles and applications associated with reactance, resonance, transformers, transducers and semi-conductor devices. Outcomes There are two outcomes to this unit. The candidate will be able to 1. understand the function of electronic components 2. carry out electronic measurement and test Connection with other awards This unit relates to Units 201, 206, 209, 211 and 302-341of the City & Guilds Level 3 NVQ in Electrical and electronics servicing (1687). This unit not relate to OSC Eng ECS. Assessment The outcomes from this unit will be assessed using evidence from a centre set question paper using questions from a City & Guilds devised question bank. Note: For this unit, in all practical and theoretical exercises, standard value components should be used.


Outcome 1 Understand the function of electronic components

Practical Activities The candidate will be able to 1. use electronic instruments to carry out practical tests 2. test transformers in both static and dynamic states Underpinning Knowledge The candidate will be able to 1. a calculate inductive and capacitive reactance b identify reactance graphs c calculate the impedance, phase angle and voltages in an RLC series circuit, and draw appropriate phasor diagrams d solve problems using impedance, voltage and power triangles e sketch the variation of reactance with frequency for LR and CR circuits and identify 3dB points for i high pass filter ii low pass filter iii band pass filter iv band stop filter f state the effect of component values on the current in series and parallel a.c. circuits g plot current against frequency for LR and CR circuits 2. a explain the condition of resonance for series and parallel circuits by reference to phasors b calculate frequency of resonance for series and parallel a.c. circuits with significant resistance c identify typical resonance curves and state the effect of damping, Q and bandwidth 3. a compare the construction of transformers for typical applications i a.f. ii r.f. iii power, including switch mode power b state the transformation ratio and the need for tappings c calculate current, voltage, VA, impedance and turns ratio, on an ideal transformer d identify specifications for a range of transformers e explain how magnetic and electrostatic shielding is provided f identify transformer thermal protective devices 4. explain maximum power transfer for a resistive load.


5. a list the relative merits of silicon and germanium diodes and transistors b explain the operation, typical application and fault identification of i bi-polar junction transistors ii field effect transistors iii laser diode iv silicon controlled rectifiers (s)CR v solid state relays vi diacs vii triacs 6. describe typical operating principles for a vacuum fluorescent displays b gas plasma displays 7. describe the operating conditions and typical application of a photocell b photodiode c phototransistor d optocoupler e infra-red source and sensor f fibre optic link g solid state temperature measurement device h Hall effect device 8. explain the safe discharge of devices.


Outcome 2 Carry out electronic measurement and test

Practical Activities The candidate will be able to 1 select suitable shunts and multipliers to extend the range of analogue and

digital panel meters 2 use a digital multimeter for measurement of current, voltage and resistance 3 use an analogue oscilloscope in different modes 4 use a digital real time oscilloscope 5 use a digital storage oscilloscope 6 use electronic instruments for component testing 7 use electronic instruments to make measurements on a prepared circuit 8 use electronic instruments as signal sources for prepared circuits 9 make dB measurements using an intelligent digital multi-meter 10 use instruments to measure earth loop impedance and mains polarity 11 use instruments to measure protective conductor resistance (earth bond) test 12 use instruments to measure insulation resistance Underpinning Knowledge The candidate will be able to 1. a define accuracy, resolution and linearity b state calibration requirements c describe analogue and digital panel meters d explain shunts and multipliers for analogue and digital instruments e specify adaptation of panel meters for a.c., including the use of a current transformer f state dangers associated with current techniques 2. a explain analogue and digital multimeters i circuit features for switched ranges ii block diagrams iii frequency limitations b define multimeter facilities i auto range ii capture of readings iii peak readings iv clamp current adaptor for a.c. v overload protection vi RS232 data transfer c describe i the concept of true rms ii how rms value varies with waveshape iii input impedance iv average value and its relevance to meters v instrument loading 3. explain a the advantages of logarithmic units when dealing with large ranges of numbers b logarithmic frequency scales


c the definition of Bel, deciBel, dBm 4. describe the need for and the function of instrument buses a IEEE488 b RS 232 5. a describe the use and function of an analogue oscilloscope i its circuit features ii distinguish between dual trace and dual beam operation b describe the use of oscilloscope features i a.c./d.c. coupling ii triggering employed by a general purpose oscilloscope iii input impedance iv high impedance probes v frequency response vi phase measurement vii internal calibration facilities 6. describe the use and function of a digital oscilloscope a real time b digital storage 7. state the benefits and limitations of analogue and digital oscilloscopes. 8. a describe i BJT and FET testing using analogue and digital multimeters ii transistor testing iii component testing for L, C and R iv the bridge concept b interpret block diagrams and recognise circuit features of a: i digital counter/timer ii frequency counter iii lf signal generator iv function generator with sweep facility v pulse generator c explain measurement of i power gain or loss in dB ii voltage and current gain or loss in dB iii the signal to noise ratio in dB. 9. a explain the use of computers to provide i diagnostic information ii technical information from CD ROMs iii data from websites b describe the use and function of computers to provide virtual instrumentation as a i digital multimeter ii oscilloscope iii spectrum analyser. 10. describe safety testing and electromagnetic compatibility a explain the following in the context of PAT testing i the difference between insulation Classes 1 and 2 ii Class 1 and 2 insulation resistance testing iii protective conductor resistance (earth bond test) iv earth loop impedance and mains polarity


v legal requirements vi CE marking b explain in an emc context the importance of i lead dressing ii mains plug filters iii shielding equipment iv mains connectors c describe the low voltage directive LVD EN 600065 EN 60950 d state the importance of COSHH information for i contact cleaners ii solvent cleaners iii adhesives iv sealants


Unit 012 Principles of integrated engineering

Rationale This unit is concerned with the principles underpinning modern integrated engineering practice and operations. This includes the use of a range of information sources to extract and interpret technical information. It includes the use of basic calculations and engineering science to enhance the candidate’s understanding of the interactions and relationships between multi-disciplined applications. It also includes the selection and setting up of engineering tasks to achieve total engineering solutions. Outcomes There are five outcomes to this unit. The candidate will be able to 1. understand digital fundamentals applicable to industrial control systems 2. explain the characteristics and features of various types of control system transducers 3. identify and select common engineering solutions 4. apply recognised cell design techniques 5. carry out basic flow programming operations Connection with other awards This unit relates to Units 011-017, 039, 040, 057-059 of the City & Guilds Level 3 NVQ in Engineering maintenance (1688) and Units 002, 003 of the City & Guilds Level 3 NVQ in Mechanical manufacturing engineering (1682). It relates to the OSCEng ECS 1.17, 1.18, 2.17 and 2.18 Assessment The outcomes from this unit will be assessed using evidence from a centre set question paper using questions from a City & Guilds devised question bank.


Outcome 1 Understand digital fundamentals applicable to industrial control systems

Practical Activities The candidate will be able to 1 convert numerical values between the following numbering systems: binary,

octal, decimal or hexadecimal 2 determine the ‘twos complement’ of a negative binary number 3 complete the truth table for any two-input logic gate 4 design a decoder/encoder for a given code scheme 5 write the Boolean function for the output of each gate in a logic diagram 6 convert a Boolean equation into a truth table or Karnaugh map 7 convert a truth table or Karnaugh map into a Boolean equation 8 use looping in a Karnaugh map to obtain the simplified Boolean expression 9 construct a simple digital circuit to solve a Boolean expression Underpinning Knowledge The candidate will be able to 1. explain and apply numbering systems a decimal numbering system i column weighting as powers of ten ii base and radix b binary numbering system i column weighting as powers of two ii base and radix c octal numbering system i column weighting as powers of eight ii base and radix d hexadecimal numbering system i column weighting as powers of sixteen ii base and radix e conversion between any of the above number systems f representation of negative numbers as i sign plus magnitude ii twos complement 2. explain and apply logic principles a basic elements i NOT, AND, OR, NAND, NOR, EXOR ii Truth tables for each of the above iii use of codes and encoders and decoders in control systems e.g. Grey code in optical encoders b basic Boolean algebra i simple Boolean expressions for each of the logic gates ii Boolean expressions on the outputs of simple logic circuits iii conversion from truth table to Boolean expression iv conversion from Karnaugh map to Boolean expression v conversion from Boolean expression to truth table or Karnaugh map


Outcome 2 Explain the characteristics and features of various types of control system transducers

Underpinning Knowledge The candidate will be able to 1. explain the terminology associated with measurement devices: a accuracy b repeatability c reproducibility d resolution linearity e hysteresis f dead band g range h response time i span j sensitivity 2. explain the difference between the static and dynamic characteristics of measurement devices 3. describe the static characteristics of devices: a repeatability b reproducibility c linearity 4. describe dynamic characteristics of devices: a step response b damping c ramp response d frequency response 5. explain how to obtain information on the accuracy and repeatability of a measurement device from a calibration report 6. describe methods by which sensors and actuators are interfaced to controllers using various methods of signal conditioning to include: a amplification b buffering c inverting d summing e comparing f filtering g linearising h data sampling and ‘sample and hold’ circuits i analogue to digital conversion and digital to analogue conversion j bridge circuits


7. outline the characteristics and principles of operation of various types of sensors for measuring a position i potentiometer ii LVDT iii synchro iv resolver v optical encoder vi proximity sensor vii photoelectric sensor b motion i dc/ac tachometer ii digital velocity signal from optical encoders c acceleration i accelerometer d force i strain gauge force sensor ii pneumatic force sensor 8. outline the characteristics and principles of operation of various types of sensor to measure process variables for: a temperature i bimetallic strip ii resistance thermometer iii thermistor iv thermocouple v optical b flow rate i differential pressure sensor ii turbine type iii vortex shedding iv magnetic c pressure i strain gauge diaphragm ii capacitance diaphragm d level sensors i displacement float ii static pressure iii capacitance iv ultrasonic 9. outline the characteristics and principles of operation of various types of actuators: a pushbuttons, switches (limit, level, pressure) b relays, contactors, motor starters, time delay relays c solid state switching devices – SCR, triac d electro pneumatic/hydraulic cylinders and motors e process control valves f electric motors i dc/ac motors ii servo motors iii stepper motors iv adjustable speed drives


Outcome 3 Identify and select common engineering solutions

Practical Activities The candidate will be able to 1. match types and operation of controllers 2. apply sensor, actuators, and controllers to solve engineering problems Underpinning Knowledge The candidate will be able to 1. identify typical engineering applications for types of sensor a positive action i micro switch ii magnetic reed switch iii safety interlocks iv wobble sticks b proximity i inductive ii capacitate iii optical iv reflective v pneumatic c position and velocity i tachogenerator ii resolver iii incremental encoder iv absolute encoder d flow/pressure i capacitate ii ultrasonic iii resistive 2. identify typical engineering applications for types of actuator a control i fluid power: spool valves, non-return valves, sequences ii electrical power: relays, contactors, solid state relays (ssr) iii mechanical power: cams, levers, gears b linear motion i fluid power: single acting, double acting, rodless cylinders ii electrical power: linear motors, thrusters, electric cylinders c rotary motion i fluid power: motors, rotary cylinders ii electrical power: induction motors, stepper motors, servo motors


3. Identify types of controller and outline their principles of operation a hard i fluid power logic ii electrical power ladder diagrams b soft i PLC architecture and configuration ii embedded micro controllers iii PC managed c motion control i analogue motor control systems ii digital motor control systems 4. describe sensor, actuator, and controller interaction to solve common engineering problems a pick and place: convey products/machinery/tooling through 3D space b accurate placement: convey products/machinery/tooling through 3D space to provide an accurate result c motion control: acceleration, velocity, torque


Outcome 4 Apply recognized cell design techniques

Practical Activities The candidate will be able to 1. use software to design production cell layouts Underpinning Knowledge The candidate will be able to 1. explain the importance of software packages in the design procedure a CAD b simulation c programming 2. state the requirements of machine safety in cell design 3. state the need for cell zoning with reference to a safety b collisions c operation time 4. describe the use of HMI a position b operation c security 5. explain the ergonomic importance of cell design 6. state the importance of a positional sketches b isometric sketches c kinematic sketches 7. state the layout of typical flexible manufacturing systems with relating to a storage b handling c machining d transportation e inspection


Outcome 5 Carry out basic flow programming operations Practical Activities The candidate will be able to produce 1. block diagrams 2. flow charts 3. sequence charts Underpinning Knowledge The candidate will be able to 1. explain requirements of block diagrams relating to a layout b process c sequence 2. explain the relevance and importance of flow charts in a specifications b programming c algorithms 3. describe applications of sequence charts in a control b power

Unit: 013 Principles of shipbuilding

Rationale This unit provides the skills required to work within a shipbuilding/ship repair establishment and is concerned with ship design, identity of types in typical forms and major components, linked to design features. Outcomes: There are four outcomes to this unit. The candidate will be able to 1. describe shipbuilding technical drawings and Computer Aided Engineering 2. identify ship types, design features and major components 3. identify the principal structural components of a ship 4. describe the assembly and erection of ship parts. Connection with other awards It relates to the OSCEng ECS 1.12, 1.13, and 4.02 Assessment The outcomes from this unit will be assessed using evidence from a centre set question paper using questions from a City & Guilds devised question bank.


Outcome 1 Describe shipbuilding technical drawings and Computer Aided Engineering.

Underpinning Knowledge The candidate will be able to 1. state the terminology used on marine industry drawings and specifications - a port, starboard, forward, aft, amidships, bow, stern. b outboard of, inboard of, in way of, scantlings. c length (overall, between perpendiculars and on summer load waterline d forward and after perpendiculars e breadth and depth (moulded and extreme) f draught, freeboard, freeboard marks, displacement, deadweight g rise of floor, camber, flare, bilge, bilge radius, bilge keel, flat of bottom, tumblehome, superstructure, forecastle h tanktop, stringer, floor, bulkhead, shell, frame/frame station, deck, deckhead, longitudinal, transverse, butt seam. i gross, net and displacement tonnage 2. state the abbreviations used on marine industry technical drawings and data a P.S.F.A. – Port, Starboard, Fore, Aft b L.O.A. - Length overall c L.B.P - Length between perpendiculars d L - Length e F.P. - Forward perpendicular f A.P. - After perpendicular g B - Breadth h D - Draught i S.L.W.L. - Summer load waterline j T.F - Tropical fresh k F. - Fresh l T. - Tropical m S. - Summer n W. - Winter o W.N.A. - Winter North Atlantic 3. describe shipbuilding technical drawings, plans and tables a the role of shipbuilding detail and assembly drawings, block plans and location drawings. b listed plans and tables i body plans ii lines plans iii sheer profile iv off-set tables c the relationship between listed plans and tables


4. describe lines plans and offset tables. a Interpret a lines plan, displacement stations, frame stations and their relationship b tables of offsets to produce ship shapes, illustrating fairing of form in three dimensions: frames, waterlines, buttocks c shell expansion plans d draught and freeboard markings 5. describe the work of the mould loft using the following techniques a Full scale lofting b Scale lofting c Numerical control (computer lofting) 6. state the purpose of templates a avoidance of repetitive marking and measuring b material optimisation c checking angles, contours etc. d guidance for repetitive profile cutting e nesting f materials suitable for templates 7. describe computer aided engineering techniques used and their application in shipbuilding a computer aided design b computer aided draughting c computer aided manufacture d Industrial robots 8. describe the benefits and limitations of techniques listed in 7 compared with conventional techniques a increased productivity b improved product quality c increased competitiveness d increased profit e storage space saving f the impact of technology on working practices g impact on society locally h security of software: i protection against fire, corruption, theft ii access 9. describe the role, application and benefits of the computer in the mould loft a purpose of the computer in the mould loft b benefit of computer aided lines fairing c various stages in the production of tapes to control cutting and forming machinery d benefits of numerical control compared to the production and use of templates


Outcome 2 Identify ship types, design features and major components

Underpinning Knowledge The candidate will be able to 1. recognise ship types in typical forms (profiles) a cargo i general cargo ii bulk carrier iii oil tanker iv container v liquefied natural gas vi refrigerated b naval vessels i aircraft carrier ii troop carrier iii submarine iv fleet oiler c passenger vessels i passenger liner ii ferry iii cruise liner iv roll on – roll off d service craft. i oil support vessel ii tug iii ice breaker 2. state the design features of ships listed in 1. a cargo i double bottom arrangements ii decks iii bulkheads iv engine room space v cargo spaces vi fore and after peaks vii accommodation spaces b naval vessels i watertight sub –divisions ii accommodation spaces iii armament and equipment spaces iv operations area c passenger vessels i loading and unloading arrangements ii accommodation areas iii recreation areas iv crew accommodation v access routes


d service craft, sub–division for i engines ii operations iii crew iv storage, etc 3. describe major components of ships listed in 1. a cargo space b double bottom tanks c peak tanks d engine rooms e accommodation spaces f deep tanks g cofferdams h pump rooms i chain locker j cargo access arrangements k cargo handling equipment 4. describe fore and after end construction a fore peak construction i collision bulkhead ii floors iii types of stem iv bulbous bows v deep tanks: construction and usage vi chain locker and hawse pipes vii bow thrust units and supporting structure viii access and egress from fore peak. b after peak construction i stern construction (types) ii flats, floors and wash plates iii steering gear flat, construction and supporting structure iv stern frame connections v function, construction and operation of rudders vi types of rudder


Outcome 3 Identify the principal structural components of a ship

Underpinning knowledge The candidate will be able to 1. describe the factors influencing the strength of a ship’s structure a state the main forces acting on a ship’s structure i the variation of liquid pressure with head and its effect on a ship’s structure ii forces on submerged surfaces, calculations of: A internal loads from cargo, fuel oil B external loads from sea iii the reaction of the ship to applied forces: A hogging and sagging B panting C racking 2. describe the principal structural components of a ship a double bottoms, tank top, framing, bulkheads, transverses, shell, pillars and girders, superstructure, decks deckhouses, forecastle, bridge, poop, workshop flats b transverse, longitudinal and combined framing systems of ships c components of transverse and longitudinal framed double bottoms: watertight, plate and bracket floors, bottom and tank top stiffening and connections, centre and side girders, margin plate, tank top d shell structure for transversely and longitudinally framed ships, connections to deck and bottom structure. e components of deck structure, pillars and girders, deck openings f the constructional features of different types of transverse and longitudinal bulkheads g hatches and doors, function and methods of construction i deck openings and supporting structure ii side and end hatch coamings iii hatch closing arrangements iv oil tanker hatches v watertight hatches and doors fitted in naval vessels h constructional features and methods of attachment to the hull of: i bulwarks ii guard rails i methods of obtaining continuity of strength, the avoidance of abrupt changes in contour


Outcome 4 Describe the assembly and erection of ship parts

Underpinning knowledge The candidate will be able to 1. describe the importance of accuracy and alignment throughout the ship’s construction cycle a the importance of accuracy and alignment of structure b the procedure to avoid accumulation of error c personal responsibility for accuracy in a & b d carry out alignment checks using levelling equipment i laser ii dumpy level 2. state the purpose of the inspection and describe methods of checking the accuracy of dimensions, form and finish a the function of a datum surface and datum line b standard measuring equipment c define tolerance with regard to accuracy d the methods of checking accuracy of dimensions, alignment, form, squareness and freedom from twist or distortion 3. describe the main procedure for erection a identify and describe the equipment and instruments necessary for fairing, joining, plumbing and levelling b the reasons for datum lines in ship construction c the procedure necessary for the assembly of plates and sections d the reasons for assembling thick plate fabrications on a level surface e how a level surface may be prepared f the reasons for part assemblies and trial erections g the sequence of erection and methods used to temporary fasten and maintain shape i logical sequence of erection for ship construction ii methods used to avoid twist and distortion iii use of assembly jigs and fastening devices iv use of tack bolts and tack welds h the need for continual alignment checks 4. describe the lifting procedures and safety precautions necessary in the lifting of fabricated units a the procedure necessary to lift large fabricated units considering, centre of gravity, safe working loads, swinging loads b the importance of determining centre of gravity of regular and irregular shaped units c the problems associated with the lifting of large units d the particular health and safety hazards associated with the lifting of large fabricated units


5. describe the methods used to secure the sections in the initial position 6. describe self propelled modular trailers (SPMT) a types b capacity c operation d communication e power 7. explain the need to refer to case studies and history records to predict structural behaviour of assemblies and sub assemblies


Further information

Further information regarding centre/scheme approval or any aspect of assessment of our qualifications should be referred to the relevant City & Guilds regional/national office: Region

Telephone

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City & Guilds Scotland

0131 226 1556

0131 226 1558

City & Guilds North East

0191 402 5100

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City & Guilds North West

01925 897900

01925 897925

City & Guilds Yorkshire

0113 380 8500

0113 380 8525

City & Guilds Wales

02920 748600

02920 748625

City & Guilds West Midlands

0121 359 6667

0121 359 7734

City & Guilds East Midlands

01773 842900

01773 833030

City & Guilds South West

01823 722200

01823 444231

City & Guilds London and South East

020 7294 2820

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020 7294 2724

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City & Guilds East

01480 308300

01480 308325

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028 9032 5689

028 9031 2917

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Stock code: SP-03-2800

Level 3 Certificate in Engineering - cdn. · PDF file1 apply BS EN 22553 to types of joints 2...

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Transcript of Level 3 Certificate in Engineering - cdn. · PDF file1 apply BS EN 22553 to types of joints 2...