All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.

SOUTH AFRICAN QUALIFICATIONS AUTHORITY

REGISTERED UNIT STANDARD THAT HAS PASSED THE END DATE:

Produce welded tube and pipe

SAQA US ID	UNIT STANDARD TITLE
119058	Produce welded tube and pipe
ORIGINATOR
SGB Manufacturing and Assembly Processes
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-
FIELD			SUBFIELD
Field 06 - Manufacturing, Engineering and Technology			Manufacturing and Assembly
ABET BAND	UNIT STANDARD TYPE	PRE-2009 NQF LEVEL	NQF LEVEL	CREDITS
Undefined	Regular	Level 4	NQF Level 04	60
REGISTRATION STATUS		REGISTRATION START DATE	REGISTRATION END DATE	SAQA DECISION NUMBER
Passed the End Date - Status was "Reregistered"		2018-07-01	2023-06-30	SAQA 06120/18
LAST DATE FOR ENROLMENT		LAST DATE FOR ACHIEVEMENT
2024-06-30		2027-06-30

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.

This unit standard does not replace any other unit standard and is not replaced by any other unit standard.

PURPOSE OF THE UNIT STANDARD

Learners who are involved in producing welded steel tube and pipe require the skills, values and knowledge reflected in this unit standard. Qualifying learners can prepare for and produce welded steel tube and pipe. They will understand the importance of effective equipment control and how this is achieved. This will include monitoring the forming and welding process, identifying non-conformances and taking corrective action. The learning outcomes in this unit standard also contribute to the exit level outcomes required for the National Certificate in Steel Tube and Pipe Manufacturing (Seamless Hot-Finished, Welded or Cold-Formed) (NQF level 4) and related qualifications.

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING

It is assumed that learners has demonstrated competency in: Communication and mathematical literacy at NQF Level 3 or equivalent The unit standards: "Set up process for tube and pipe production" "Perform tube and pipe product tests and interpret results"

UNIT STANDARD RANGE

The learner should be able to work autonomously with minimal supervision and according to worksite and manufacturer specifications and occupational safety, health and environmental legislation Work is generally, but not exclusively, carried out in a team environment The manufacturing process includes uncoiling, forming, welding, scarfing, seam annealing and sizing processes Production quantity goals are met Product complies with production and customer specifications Availability and utilisation of equipment is maximised Costs incurred are within prescribed budgetary constraints Process tools, equipment and consumables are utilised according to operational and manufacturer's requirement Accurate production data is recorded, process documentation is timeously processed and affected parties liased with Continuous quality product flow is maintained Critical process and sub-process parameters and efficiency are monitored, analysed and adjusted Non-conformances in process and defects in equipment is timeously identified, actioned and continuously monitored Applicable procedures are followed and understood Process constraints are managed Strategies, options and choices are described an discussed

Specific Outcomes and Assessment Criteria:

SPECIFIC OUTCOME 1

Plan the manufacturing process.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Plan the process against production schedule requirements

ASSESSMENT CRITERION 2

Check availability of materials, tools and equipment necessary for process

ASSESSMENT CRITERION 3

Communicate product quantity and quality requirements with appropriate personnel

ASSESSMENT CRITERION RANGE

Process plan includes planning for product and shift changeover situations Materials include flux, welding wire and impeders

SPECIFIC OUTCOME 2

Form product.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Start up production and sub-processes

ASSESSMENT CRITERION 2

Monitor and control process variables and deviations

ASSESSMENT CRITERION 3

Compare process performance to optimise equipment operation

ASSESSMENT CRITERION 4

Monitor and adjust process flow

ASSESSMENT CRITERION 5

Interpret sample analysis

ASSESSMENT CRITERION 6

Identify root cause of quality problems

ASSESSMENT CRITERION 7

Make adjustments to bring process back into line

ASSESSMENT CRITERION 8

Test corrective action to determine if problem is solved

ASSESSMENT CRITERION 9

Manage waste

ASSESSMENT CRITERION 10

Control costs to within budget

ASSESSMENT CRITERION 11

Shut down process

ASSESSMENT CRITERION 12

Record activities and process results

ASSESSMENT CRITERION RANGE

Process constraints include stoppages and breakdowns Product forming process includes uncoiling, forming, welding, scarfing, seam annealing and sizing processes Material preparation for welding includes bevelling and edge trimming Product forming defects include misalignment, slivers and roll marks Results include settings and adjustments made to ensure repeatability

SPECIFIC OUTCOME 3

Weld product.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Set up welding equipment

ASSESSMENT CRITERION 2

Establish welding parameters

ASSESSMENT CRITERION 3

Weld product

ASSESSMENT CRITERION 4

Finish weld

ASSESSMENT CRITERION 5

Dispose of waste materials

ASSESSMENT CRITERION 6

Store reusable materials

ASSESSMENT CRITERION 7

Control costs to within budget

ASSESSMENT CRITERION RANGE

Weld parameters include welding current, electrode force, welding time and electrode material Weld finishing includes scarfing and seam annealing (where applicable) Weld process includes Electric Resistive Welding (ERW) and Electrical Submerged Arc Welding (ESAW)

SPECIFIC OUTCOME 4

Identify defects, non-conformances and hazardous conditions and take corrective action.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Defects, non-conformances and hazardous conditions are identified

ASSESSMENT CRITERION 2

Corrective action and preventative methods for the non-conformances are applied and taken.

SPECIFIC OUTCOME 5

Execute changeover process.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Execute process and product changeover as required by production schedule requirements

ASSESSMENT CRITERION 2

Instruct and discuss forward actions with workgroup members who will take over the running of the process

ASSESSMENT CRITERION RANGE

Changeovers include product and shift changeover situations

SPECIFIC OUTCOME 6

Work safely with due care for self, fellow workers, equipment, materials and the environment.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Apply safety, health, environmental and quality procedures

ASSESSMENT CRITERION 2

Appropriate safety equipment and clothing are utilised

UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS

Anyone assessing a learner or moderating the assessment of a learner against this unit standard must be registered as an assessor with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA. Any institution offering learning that will enable the achievement of this unit standard must be accredited as a provider with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA. Assessment and moderation of assessment will be overseen by the relevant Education, Training, Quality, Assurance (ETQA) Body, or by an ETQA that has a Memorandum of Understanding with the relevant ETQA, according to the ETQA's policies and guidelines for assessment and moderation. Moderation must include both internal and external moderation of assessments, unless ETQA policies specify otherwise. Moderation should also encompass achievement of the competence described in the Unit Standard. Anyone wishing to be assessed against this unit standard may apply to be assessed by any assessment agency, assessor or provider institution that is accredited by the relevant ETQA.

UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE

1. Names and functions of: Consumables Materials Components, controls, instruments and equipment Hydraulic, pneumatic, heating, cooling, electrical, oxygen and gas systems Welded steel tube and pipe product Types of process welding e.g. ER and ESA welding Product testing 2. Attributes, descriptions, characteristics & properties: Typical welded product and process non-conformances including dimensional, mechanical properties and internal material defects e.g. lamination, inclusions, cracks, forming and roll marks Common causes of weld and product defects Steel welded tube and pipe specifications Materials to be processed Company product range and application Equipment, machines and tooling Manufacturing and welding processes Machinery specifications and capacity Local and international product specifications Properties of metals Preventative maintenance Common causes of equipment failure Common areas of wear and tear on equipment Process control software 3. Purpose of: Monitoring equipment indicators Performing pre-operational checks Steel tube and pipe specifications Managing constraints Analysing process parameters Product changeovers Set up procedures Quality control procedures Health, safety and environmental procedures Welding parameters, specifically welding materials 4. Sensory cues Cues for different defects (visual, noise, smell, vibration) related to producing steel welded tube and pipe 5. Processes, events, causes and effects, implications: Temperature and state changes Pressure changes Oil temperature changes Equipment calibration process Impact of setting on product cost Things going wrong, e.g. accidents, power and service failure, wrong or poorly prepared materials, poor planning procedures, change of plan or schedules Impact of early diagnosis of equipment malfunctioning Product and shift changeover Causes and effects / implications of not managing constraints Implications of using incorrect or defective equipment Effects of welding current, electrode force, welding time and electrode material and design on weld quality Influence of metal characteristics and surface condition on welding parameters Implications of ignoring potential hazards Implications of not checking for welding defects Impact of waste on overall product and process cost 6. Procedures and techniques: Business procedures and policies Emergency procedures Company (worksite) and international procedures Safety, health and environmental Document processes Process controlling Manufacturing practices Product shape control Product rolling Material recycling Quality Worksite / standard operating procedures Problem solving and continuous improvement Product testing Analysing and interpreting test results and trends Installation and removal of equipment Shutting down Communication Team work Recording and reporting Procedures for reporting major problems with machinery and equipment Managing constraints Theory of constraints Product and shift changeover Set up procedures for range of product welding processes Applicable welding procedures Preparation for welding 7. Regulations, legislation, agreements, policies, standards: Regulations related to safety and health and environment Regulations appropriate to the product Provisions of applicable acts National and international tube and pipe manufacturing standards 8. Theory: rules, principles, laws: Metallurgical principles related to the product and the process, e.g. quality, grades, chemical composition of materials Fundamentals of Metallurgy Process principles, e.g. cooling, welding, forming and seam annealing Temperature, changes of state, melting properties Torque, viscosity, fluid dynamics Electricity, current, power, resistance, circuits, components Behaviour of gases, fluids and solids Pressure, vacuum Units of measure Welding of steel fundamentals / Steel fusion fundamentals Theory of constraints Statistical Process Control 9. Relationships, systems: Relationship between materials, equipment, process, product and customer Auxiliary services influences on quality Relationships between process set up and control and final product Impact of troubleshooting and diagnosing malfunctions on equipment on production efficiencies Preventative / predictive maintenance systems Quality, safety and environmental systems

UNIT STANDARD DEVELOPMENTAL OUTCOME

N/A

UNIT STANDARD LINKAGES

N/A

Critical Cross-field Outcomes (CCFO):

UNIT STANDARD CCFO IDENTIFYING

1. Identify and solve problems Identify process deviations and take appropriate corrective action Identify and correct conditions or practices which will damage or reduce the life of the machinery and equipment Identify conditions or practices that will impact on the properties of the material to be processed or the end product performance and correct.

UNIT STANDARD CCFO WORKING

2. Work effectively with others Interact with workgroup members to effect efficient and problem free manufacturing and changeovers Interact with maintenance specialists to troubleshoot and determine most effective ways of repairing problems / optimising manufacturing process Organise work teams

UNIT STANDARD CCFO ORGANISING

3. Organise and manage myself and my activities Acquire and follow appropriate production schedule Prepare, plan and sequence production events Demonstrate decision making Manage time effectively

UNIT STANDARD CCFO COLLECTING

4. Collect, analyse, organise and critically evaluate information Monitor process and interpret production schedule by comparing production data with specifications Record, categorise and explain problems, faults and down times related to process Collect data, analyse it for trends and identify opportunities for continuous improvement, then record changes to operational settings for repeatability

UNIT STANDARD CCFO COMMUNICATING

5. Communicate effectively Communicate with team members to ensure continuous production Request or instruct workgroup members and associated people to co-ordinate and effect process activities

UNIT STANDARD CCFO SCIENCE

6. Use science and technology effectively and critically Control the production process, monitor machine efficiency, identify and implement improvement techniques Explain metallurgical principles as they apply to the manufacturing process Use a methodical approach to analysing test results

UNIT STANDARD CCFO DEMONSTRATING

7. Demonstrate an understanding of the world as a set of related systems Understanding of the impact of own actions on total production process Solutions to problems reflect an awareness that process control forms the key to quality, output and cost effectiveness.

UNIT STANDARD ASSESSOR CRITERIA

N/A

REREGISTRATION HISTORY

As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015.

UNIT STANDARD NOTES

N/A

QUALIFICATIONS UTILISING THIS UNIT STANDARD:

	ID	QUALIFICATION TITLE	PRE-2009 NQF LEVEL	NQF LEVEL	STATUS	END DATE	PRIMARY OR DELEGATED QA FUNCTIONARY
Elective	49403	Further Education and Training Certificate: Steel Tube and Pipe Manufacturing (Seamless Hot-Finished OR Welded OR Cold-Formed)	Level 4	NQF Level 04	Passed the End Date - Status was "Reregistered"	2012-06-30	MERSETA

PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD:

This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.

NONE

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All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.