Improve Workforce Efficiency

Course #: 286025
Duration: 10 hours (includes 1 test)
Course Objectives:

• Introduction to Welding
• Definitions of Weld, Braze, and Braze Weld
• Oxyfuel Gas Welding (OFW)
• Arc Welding (AW)
• Resistance Welding (RW)
• Solid-State Welding (SSW)
• The Brazing Welding Process
• Soldering Process
• Other Welding Processes

• This updated course replaces course 6151.
• The entire course consists of study units 286025 and 286066.

Course #: 286066
Duration: 10 hours (includes 1 test)
Course Objectives:

• Recognize basic joint designs used in welding ­ Butt, Corner, "T", Lap, and Edge
• Selecting the best types of grooves for welding applications
• Proper procedures for working on various positions when welding joints on pipes
• Interpreting welding symbols, dimensions, and schematics

• The entire course consists of study units 286025 and 286066.

Course #: 186004
Course Objectives:

• Identify common welding gases and understand how they are used in welding operations.
• Point out the hazards associated with welding gases.
• Safely handle and store different types of gas cylinders.
• Safely operate a basic gas welding setup.
• Recognize the safety considerations involved in the setup and operation of electric arc welding equipment.
• Identify welding equipment malfunctions and take corrective action.
• Utilize fire prevention and protection methods specific to welding operations.
• Discuss the importance of the hot work permit program in your facility.
• Explain the correct use of protective clothing and equipment for welding.
• Utilize proper ventilation when welding.
• Effectively deal with confined spaces when performing welding operations.

Course #: 6272A-B
Duration: 20 hours (includes 2 tests)
Prerequisites:

• Fundamentals of Welding, Parts 1-2 (286025, 286066)

Part 1 (6272A). Source of Heat for Gas Welding; Gases Used in Welding: Oxygen, Acetylene, Hydrogen, Other Fuel Gases; Oxyacetylene-Welding Equipment; Regulators; Hoses and Hose Fittings; Check Valves; Welding Torches; Accessory Equipment.

Part 2 (6272B). Setting Up a Welding Outfit; Taking Down the Welding Outfit; Backfires and Flashbacks; Centralized Distribution of Oxygen; Centralized Fuel ­ Gas Distribution; Miscellaneous Welding Equipment.

Course #: 6276A-C
Duration: 30 hours (includes 3 tests)
Prerequisites:

• Fundamentals of Welding, Parts 1-2 (286025, 286066)
• Gas Welding Equipment (6272A-B)

Part 1 (6276A). Instructions for Practice Welds; Joint Preparation; Corner Joints, Butt Joints, Lap and Tee Joints, and Fillet Welds; Tests to Make on Practice Welds; Welding with Single and Two or More Weld Layers; Progress Tests and Supplementary Heating; Welding Production Data; Application to Estimating and Calculation of Costs.

Part 2 (6276B). Weight and Schedule Systems of Classifying Pipe; Positions in Which Pipe is Welded, the Joint Preparation, and the Techniques to Use; Changes in Direction with Commercial Fittings, by Bending, and with Fabricated Fittings; Stress Relieving Tests and Tables of Weld Requirements; Advantages and Disadvantages of Braze Welding; Filler Metals; Fluxes; Joint Preparations; Braze Welding Techniques; Groove Preparations; Fluxes; Heat Treatment; Joint Preparation; Estimating Requirements; Welding Cast Iron with Cast-Iron Welding Rods and Braze Welding Cast Iron; Malleable Iron Welding.

Part 3 (6276C). Welding Procedures for Medium Carbon, High Carbon, and Stainless Steels; Preheating and Supplementary Heating; Welding Rods, Fluxes, and Joint Designs for Copper and Copper Alloys; Using Oxyacetylene and Oxyhydrogen for Welding Aluminum and Aluminum Alloys; Welding Rods, Fluxes, Joint Designs, and Techniques; Welding Procedures, Joint Designs, Fluxes, Welding Rods, and Techniques of Welding Magnesium and Magnesium Alloys, Nickel and Nickel Alloys, and Lead; Weld Sequence; Jigs and Fixtures; Joint Design; Drum Heading; Pre-deforming to Control Distortion.

Course #: 286028
Duration: 10 hours (includes 1 test)
Prerequisites:

• Fundamentals of Welding, Parts 1-2 (286025, 286066)

• Introduces the Process of using Heat to Cut Metal and other Materials
• Describes the Common Thermal Cutting Processes used in Industry and the capabilities of each
• The Tables to use when Estimating Requirements for specific Cutting Operations
• Describe the types of Equipment used for Oxyfuel Gas Cutting
• Identify the appropriate Procedures used in Oxygen Cutting Processes

• This new course replaces courses 6275A-B.

Course #: Block A21
Duration: 30 hours (includes 6 tests)
Prerequisites:

• Basic Industrial Math (Block X21)

In this block consisting of six study units, the trainee will learn the basics of electrical theory. These units introduce electrical terms, symbols, and the operation of simple circuits. Ohm’s law receives extensive coverage including practical troubleshooting examples used to industry. A new unit specific to capacitors and inductors provides more in-depth coverage. Up-to-date information on conductors, insulation, and specialty batteries forms a revised study unit. Study units covering magnetism, electromagnetism, motors, and generators are included with industry related examples.

• This updated course replaces DC Principles, Block A01. Each study unit contains a progress exam.

• 086096 Nature of Electricity
• 086002 Circuit Analysis and Ohm’s Law
• 086003 Capacitors and Inductors
• 086004 Magnetism and Electromagnetism
• 086005 Conductors, Insulators, and Batteries
• 086006 DC Motors and Generator Theory

Course #: 086002
Course Objectives:

• Find the total resistance in series, parallel, and series-parallel circuits.
• Use Ohm’s law to calculate the current, voltage, or resistance in circuits.
• Calculate the amount of power supplied and dissipated in a DC circuit.
• List the steps for finding current, voltage, and resistance with a digital or analog meter.

Course #: 086003
Course Objectives:

• Explain how a capacitor holds a charge.
• Describe common types of capacitors.
• Identify common capacitor ratings.
• Calculate the total capacitance of a circuit containing capacitors in series or in parallel.
• Calculate the time constant of a resistance-capacitance or RC circuit.
• Explain how inductors are constructed.
• Describe the system used to rate inductors.
• Describe how an inductor regulates the flow of current in a DC circuit.
• Calculate the total inductance of series or parallel connected inductors.
• Calculate the time constant for a resistance-inductance or RL circuit.

Course #: 086004
Course Objectives:

• Identify the north and south poles of permanent magnets and electromagnets.
• Name magnetic and nonmagnetic materials.
• Describe how to magnetize a piece of steel by induction.
• Explain the difference between simple, compound, and closed magnetic circuits.
• Locate the direction of magnetic lines of force around a conductor (if the direction of current is known).
• Use the right-hand rule to locate the poles of a solenoid.
• Describe the operation of simple electromagnetic relays, buzzers, and stepping switches.
• Explain how a DC motor operates.
• Give a simplified explanation for generator action and motor action with electromagnetic induction.

Course #: 086005
Course Objectives:

• Describe the various types of conductors and discuss their conductivity.
• Explain the American Wire Gage System of sizing copper conductors.
• Determine the size of conductor needed for an application.
• Identify the various types of insulating materials and their temperature ratings.
• Explain the difference between a dry cell and a storage battery.
• How to connect cells together to obtain more voltage, more current, or more of both voltage and current.
• Describe the proper safety precautions used when working with storage batteries.
• Describe how to properly clean and care for storage batteries.
• Discuss the instruments used for testing storage batteries.
• Explain how NiCad, lithium, and other types of special batteries operate, and describe their ratings.

Course #: 086006
Course Objectives:

• Identify a series-, shunt-, and compound-wound motor and discuss their application.
• Explain how a permanent-magnet and stepper motor operate.
• List the steps to reversing a DC motor’s direction.
• Discuss how the speed of a DC motor can be controlled.
• Explain the basic principle for generating a direct current.
• Name the factors that affect the strength of the induced voltage.
• Describe the purpose of a commutator and brush assembly.
• Discuss the difference between the field connections of series-, shunt-, and compound-wound machines.
• Give the reason for shifting brushes.
• Discuss the use of commutating poles and compensating windings for better generator operation.
• List the various types of machine losses.

Course #: 086096
Course Objectives:

• Explain the operation of a simple circuit.
• Define the terms: conductor, insulator, and resistor.
• Demonstrate that unlike charges attract and like charges repel.
• List the dangers and benefits of static electricity.
• Define the terms: volt, ampere, and ohm.
• Describe common notations and prefixes used to identify electrical and electronic values.
• Identify carbon resistors, potentiometers, and rheostats, and explain how they work.
• Identify the common electrical symbols used in schematic diagrams.
• Explain the difference between a series and parallel circuit.

Course #: Block A22
Duration: 40 hours (includes 8 tests)
Prerequisites:

• Basic Industrial Math (Block X21)
• DC Principles (Block A21)

Alternating current is the form of current most often used to furnish electrical energy. Students receive a complete introduction to AC terminology and basic AC circuit configurations. Individual study units on the uses of capacitors and inductors in AC circuits underlines the importance of these components in AC theory. The generation, control, and distribution of AC power are highlighted in study units on alternators, transformers, and energy distribution. How electricity is generated at a power plant and sent to consumers is covered. The student will also be introduced to basic electronics through a study unit on rectification and basic electronic components.

• This updated course replaces AC Principles and Components, Block A02. Each study unit contains a progress exam.

• 086007 Alternating Current
• 086008 Alternating Current Circuits
• 086009 Inductors in AC Circuits
• 086010 Capacitors in AC Circuits
• 086011 Transformers
• 086012 Alternators
• 086013 Electrical Energy Distribution
• 086014 Rectification and Basic Electronic Devices

Course #: 086007
Course Objectives:

• Draw a graph of an AC voltage and describe how AC voltage is created.
• Explain AC cycle terms: "alternation," "peak," "positive," and "negative."
• Define the time period of an AC voltage as expressed in degrees.
• List the characteristic values of an AC cycle and describe the relationship between the values.
• Define phase angle and describe how it relates to reactive circuits.
• Calculate power for single-phase and three-phase circuits.
• Describe how a 220 VAC single-phase circuit operates.
• Illustrate the phase relationship of three-phase wave forms.
• Determine real power by reading a power factor meter.
• Describe delta and wye three-phase circuit connections.

Course #: 086008
Course Objectives:

• Identify electric circuits in terms of their circuit characteristics.
• List several circuit characteristics that are used to describe a circuit for a particular load application.
• Connect electrical components in series and parallel circuits.
• Control loads from one or two switch points.
• Describe how delta- and wye-connected three phase circuits are different.
• Explain how grounding a circuit increases its safety.
• Recognize the difference between control circuits and power circuits.

Course #: 086009
Course Objectives:

• Explain how an inductor is made and how it operates in a DC and AC circuit.
• Describe inductive reactance and impedance, and how AC frequency effects inductance.
• Use Ohm’s law in an AC circuit that includes an inductor.
• Calculate the impedance of a series RL circuit.
• Calculate the impedance of a parallel RL circuit.

Course #: 086010
Course Objectives:

• Describe how a capacitor stores a charge and how series connected and parallel connected capacitance values are calculated.
• Discuss capacitive reactance and use Ohm’s Law in AC circuits that contain a capacitor.
• Calculate the impedance of a series RC circuit.
• Explain how changing the frequency of an AC signal changes capacitive reactance.

Course #: 086011
Course Objectives:

• Explain what the main components of a transformer are.
• Tell how mutual inductance makes it possible to change an AC voltage from one value to another when using a transformer.
• Determine the turns ratio of a transformer when the primary and secondary voltages are known.
• Calculate primary or secondary voltages or current when either one of these and the turns ratio are known.
• Explain why transformers are laminated.
• Connect three single-phase transformers for three-phase operation.
• Calculate line current (if phase current is known) in delta-connected transformers.
• Explain the operating principles of an auto transformer.

Course #: 086012
Course Objectives:

• Explain how single- and three-phase alternators operate.
• List and describe the major components of an alternator.
• Discuss alternator ratings in terms of power, voltage, speed, and temperature.
• State the steps required for starting, stopping, and operating alternators.
• Describe the similarities and differences of the three main types of alternators.

Course #: 086013
Course Objectives:

• Explain the difference between feeder and branch circuits.
• Describe the different types of systems available for distributing power within a plant.
• Recognize and identify utilization equipment.
• Discuss the use of transformers in energy distribution.
• Identify by name and describe the uses of various types of raceways.
• Distinguish between panel boards and switchboards.
• Describe the electrical system of a power utility.
• Describe how electricity is generated at a power station or utility.

Course #: 086014
Course Objectives:

• Explain how diodes are used as rectifiers.
• Discuss the basic operation of a diode and a triode electron tube.
• Connect a PN junction for forward and reverse bias.
• Explain how a transistor operates as an amplifier.
• Recognize transistor input and output circuits.
• Compare rectifier circuits with and without filter circuits.
• Describe the operation of an SCR and a triac.
• Calculate the ripple frequency of a half-wave and full-wave single- phase and three-phase rectifier.

Course #: 086025
Course Objectives:

• How to use the multimeter (also known as a volt-ohm-milliammeter or VOM).
• Define the terms voltage, current and resistance, and explain their relationship in a circuit.
• Discuss how voltage, current and resistance is measured with a multimeter.
• Identify the schematic symbols used to represent various reactive devices.
• Describe the major features of analog and digital VOMs.
• Explain how to use both analog and digital VOMs to measure voltage, resistance and current in a circuit.
• Learn about the special probes used with a digital VOM.
• Discuss the important safety precautions you must take when using a multimeter.

Course #: 086026
Course Objectives:

• Review the functions of a multimeter.
• Name the safe practices you should use when troubleshooting with a VOM.
• How to measure circuit resistance.
• Learn the purpose of, and how to perform, tests for continuity and short circuits.
• Perform resistance tests on resistors, fuses, solenoids, relays, switches, transformers, motors and semiconductors.
• How to take basic current measurements on power supplies, AC feeder lines and other such circuit areas.
• Measure current by using a direct series connection or by using a clamp-type ammeter.
• How to take basic voltage measurements on both AC and DC systems.
• Measure the output voltage of a DC power supply and the voltage of an AC feeder line.
• Measure voltage at disconnect switches, circuit breakers, contactors and transformers.
• Perform voltage tests on circuit boards, PLC systems and motor circuits.

Course #: 186005
Course Objectives:

• Explain how electricity can harm you and your property.
• Discuss the importance of properly using quality electrical components.
• Follow the basic methods of protection when wiring electrical installations.
• Tell why it is important to ground electrical equipment and systems.
• Select the type of electrical equipment to use in a hazardous location.
• List the safety practices required in an electrical work area.
• Talk about the importance of a clear working space around electrical equipment.
• Educate your own level of safety training to be sure it matches the electrical work you are performing.

Course #: 286032
Duration: 10 hours (includes 1 test)
Prerequisites:

• Fundamentals of Welding, Parts 1-2 (286025, 286066)
• Electricity (4210A-C)

• Terminology and Processes
• Power Sources for Arc Welding
• Arc Welding Machines
• Transformer Types of Welding Power Source

• This updated course replaces course 6274A.
• The entire course consists of study units 286032, 286033, and 286053.

Course #: 286033
Duration: 10 hours (includes 1 test)
Prerequisites:

• Fundamentals of Welding, Parts 1-2 (286025, 286066)
• Electricity (4210A-C)

• Sources of DC Welding Power
• Sources of AC Welding Power
• Supplemental Arc Welding Equipment: Meters, Indicators, Cables, Electrode Holders
• Face Shields, Helmets, Goggles, Protective Clothing, Screens

• This updated course replaces course 6274B.
• The entire course consists of study units 286032, 286033, and 286053.

Course #: 286053
Duration: 10 hours (includes 1 test)
Prerequisites:

• Fundamentals of Welding, Parts 1-2 (286025, 286066)
• Electricity (4210A-C)

• Requirements for Mechanized, Semiautomatic, and Automatic Welding
• Submerged Arc Welding
• Robotic and Adaptive Control
• Electroslag Welding
• Tubular Filler Metals
• Gas Tungsten Arc Welding
• Gas Metal Arc Welding
• Spot Welding Equipment
• Electron Beam, Plasma Arc, Flux Cored Arc, and Laser Beam Welding, Equipment and Processes

• This updated course replaces course 6274C.
• The entire course consists of study units 286032, 286033, and 286053.

Course #: 286030
Duration: 10 hours (includes 1 test)
Prerequisites:

• Practical Measurements (Block X22)
• Fundamentals of Welding, Parts 1-2 (286025, 286066)
• Arc Welding Equipment, Parts 1-3 (286032-286033, 286053)

• Equipment and Materials
• Weld Metal Testing
• Welding Applications of Covered Mild-Steel Electrodes
• Basic Arc Welding Operations
• Single V- Groove Butt Welds

• This updated course replaces course 3536A.
• The entire course consists of study units 286030-286031.

Course #: 286031
Duration: 10 hours (includes 1 test)
Prerequisites:

• Practical Measurements (Block X22)
• Fundamentals of Welding, Parts 1-2 (286025, 286066)
• Arc Welding Equipment, Parts 1-3 (286032-286033, 286053)

• The Vertical Position
• The Horizontal Position
• The Overhead Position
• Fillet Welds: Welding Heavy Metal Plates
• Sheet Metal Welding

• This updated course replaces course 3536B.
• The entire course consists of study units 286030-286031.

Course #: 286059
Duration: 10 hours (includes 1 test)
Prerequisites:

• Fundamentals of Welding, Parts 1-2 (286025, 286066)
• Safety in Welding and Cutting (6154)

• Applications and Advantages of Gas Metal Arc Welding
• Identify the Variables involved in the GMAW process
• Explain the uses for Equipment and Supplies required for GMAW Applications
• The use of components such as GMAW Welding Guns and Shielding Gas
• How to select Welding Gun Positions for particular applications
• List the requirements for preparing Workpieces prior to welding
• Introduction to GMAW Welding Techniques and Practices
• Using Tables to select appropriate Operating Data for a particular Welding application

• This new course replaces course 6162.

Course #: 286035
Duration: 10 hours (includes 1 test)
Prerequisites:

• Fundamentals of Welding, Parts 1-2 (286025, 286066)
• Safety in Welding and Cutting (6154)

• Applications and Advantages of Gas Tungsten Arc Welding
• Identify the Variables involved in the GTAW process
• Explain the uses for Equipment and Supplies required for GTAW Applications
• Identify the different types of Tungsten Electrodes
• How to select, prepare and use Tungsten Electrodes
• List the requirements for preparing Workpieces prior to welding
• Introduction to GTAW Welding Techniques and Practices

• This new course replaces course 6161.

Course #: 286104
Duration: 10 hours (includes 1 test)
Course Objectives:

• Understand the terminology used to describe metals and their properties.
• Use physical, mechanical, and chemical properties to identify metals.
• Understand how materials deform and fracture under mechanical load.
• Apply your knowledge of metal properties to understand problems encountered during welding.
• Recognize differences in material processes and how processing can later change the behavior of metal during welding.

• This new course replaces Practical Metallurgy for Welders, Part 1, course 6152A.

Course #: 286105
Duration: 10 hours (includes 1 test)
Course Objectives:

• Understand the welding process in terms of heat transfer, melting, and solidification.
• Understand how electrode coatings and fluxes change the way molten metal behaves and the properties of the finished weld.
• Differentiate between ferrous metals based on chemistry, processing, and weldability.
• Identify general types of nonferrous metals and distinguish common alloys within each family.
• Recognize the causes and corrective actions for common welding defects.

• This new course replaces Practical Metallurgy for Welders, Part 2, course 6152B.

Course #: 5249A-B
Duration: 20 hours (includes 2 tests)
Prerequisites:

• Electricity (4210A-C)
• Fundamentals of Welding, Parts 1-2 (286025, 286066)
• Arc Welding Equipment, Parts 1-3 (286032-286033, 286053)

Part 1 (5249A). Welding Techniques; Joint Designs and Preparation; Steel Manufacture; Rimmed, Capped, Killed, and Semikilled Steels; Cast Steels; Specifications for Low Carbon Steel Electrodes; Electrode Classification; Electrode Groups; Chemical Composition of Electrodes; Electrode Coverings; Storage and Rebaking of Electrodes; Welding Current; Use of Low Hydrogen Electrodes; Electrode Tests; Welding Test Plates; Tension and Impact Tests; Fillet Weld Test; Establishment of Welding Procedures; Developing Welding Procedures; Identification of Welding Process, Base Metal, Filler Metal, and Supplementary Materials; Welding Position Qualifications; Arc Welding Single V-Groove Butt Joints, V-Groove with Backing Strip, Double V-Groove Butt Joints, and Fillet Welds; Application of Submerged Arc Welding; Classification of Submerged Arc Electrodes and Filler Metal; Submerged Arc Welding Fluxes; Submerged Arc Welding versus Metal Arc Welding; Selection of Submerged Arc Electrodes and Fluxes; Submerged Arc Welding Procedure; Electroslag Welding.

Part 2 (5249B). Gas Tungsten Arc (Tig) Welding; Application of Tig Welding; Filler Metals for Tig Welding; Tig Welding of Pipe; Techniques for Root Bead Welding; Gas Backup for Root Bead Welding; Volume of Backup Gas; Root Welding of Pipe; Pipe Welding involving Two Welding Procedures; Tig Spot Welding; Basic Features of Gas Metal Arc (Mig) Welding; Mig Shielding Gases; Mig Filler Metal; Drop and Short Circuiting Metal Transfer in Mig Welding; Current Effect on Mig Welding; Pulsed Spray Arc Welding; Electrodes for Mig Welding: Mig Welding Procedures; Linde Equipment; Hobart and Airco Operating Data; Flux Cored Welding; Flux Cored Welding Electrodes; Operating Data on Flux Cored Welding Electrodes.

Course #: 5250
Duration: 10 hours (includes 1 test)
Prerequisites:

• Electricity (4210A-C)
• Fundamentals of Welding, Parts 1-2 (286025, 286066)
• Arc Welding Equipment, Parts 1-3 (286032-286033, 286053)

• Alloy Steels
• Alloy Steel Electrodes
• Arc Welding of Stainless Steel
• Heat Treatment of Welded Stainless Steel
• Arc Welding of Manganese Steel, Silicon Steel, and High-Carbon Steels
• Welding Band and Circular Saws
• Arc Welding of Cast Iron
• Welding Wrought Iron
• Electric Welding in Ship Construction
• Repairing Wobblers and Coupling Boxes
• Welding of Rail Joints
• Building Up Rail Ends
• Welding Firebox Sheets, Locomotive Frames, Tanks, and Boilers
• Pipe Welding
• Welding of Structural Shapes
• Carbon Arc Cutting

Course #: 5251
Duration: 10 hours (includes 1 test)
Prerequisites:

• Electricity (4210A-C)
• Fundamentals of Welding, Parts 1-2 (286025, 286066)
• Arc Welding Equipment, Parts 1-3 (286032-286033, 286053)

• Metals considered: Aluminum, Copper, Nickel, Magnesium, and Their Various Alloys
• Metallic and Carbon Electrodes
• Welding Clad Metals
• Welding Galvanized Sheets
• Overlaying
• Soft Facing
• Hard Facing
• Electric Arc Cutting

Course #: 6278A-B
Duration: 20 hours (includes 2 tests)
Prerequisites:

• Fundamentals of Welding, Parts 1-2 (286025, 286066)

Part 1 (6278A). Uses of Welded Piping; Reliability; Effects of Pipe Threads; Determining Wall Thickness; Making Pipe by Piercing, Extrusion, Cupping and Drawing, and Welding; Compositions and Designations of Steel, Copper, Wrought Iron, Aluminum, Nickel, and Lead Pipe; Fabricated and Standard Fittings; Alignment of Pipes, Flanges, and Connections.

Part 2 (6278B). Applications, Advantages, Limitations of Each Welding Process Used in Fabrication of Pipe; Joint Design Backing Structures; Welding Steel, Wrought Iron, and Stainless Steel Pipe; Welding Copper, Aluminum, Nickel, Lead, and Titanium Piping.

Course #: 5160
Duration: 10 hours (includes 1 test)
Course Objectives:

• Inspection of Equipment
• Tests of Welders
• Inspection of Preparation for Welding
• Inspection of Structural Work, Tank Work
• Tacking, Seam Spacing, Pipe Work, Welding in Progress
• Visual Inspection of Completed Welds
• Gauging of Fillets
• Nondestructive Tests
• Tests with Air, Water, and Oil
• Magnetic and Sonic Tests
• Radiography in Examining Welds
• Polariscope Tests
• Destructive Tests
• Tests of Spot Welds
• Code Requirements for Fusion Welding
• Welding Symbols
• Protection of Welders