KSKV SVM 2017

MINISTRY OF EDUCATION, MALAYSIA

VOCATIONAL COLLEGE STANDARD CURRICULUM

COURSE INFORMATION

PROGRAMME : WELDING TECHNOLOGY

COURSE NAME : THERMAL CUTTING

COURSE CODE : MTK 2022

YEAR / SEMESTER : 1 SEMESTER 2

CREDIT UNIT : 2.0

CONTACT HOUR : FACE TO FACE : 4.0 HOURS / WEEK

NON FACE TO FACE :

COURSE TYPE : VOCATIONAL

PRE-REQUISITE : MTK 1033: MATERIAL AND CONSUMABLE

CORE REQUISITE : -

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COURSE OUTCOMES:

At the end of the course, the students should be able to:-

1. Identify Thermal cutting process

2. Cut materials using Oxy-acetylene cutting process
3. Cut material using Plasma cutting process

COURSE DESCRIPTION:

This unit identifies the competency required to set up oxy-acetylene and plasma cutting equipment and accessories, lay out material for
cutting processes, set up oxy-acetylene cutting flame and plasma cutting pressure to cut materials so that the materials are cut to the required
size, shape and dimensional accuracy as per drawing specification.

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CONTENT AND LEARNING STANDARDS

PROGRAMME : WELDING TECHNOLOGY

COURSE NAME : THERMAL CUTTING

COURSE CODE : MTK 2022

CONTACT HOURS
CONTENT
(TRAINING LEARNING STANDARD ASSESSMENT CRITERIA
DURATION) STANDARD

12 hours RELATED KNOWLEDGE ASSESSMENT CRITERIA

(3 weeks)
1. IDENTIFY 1.1 Identify various types of thermal 1.1.1 Identify various types of thermal cutting process applied
Lecture: 3 hours VARIOUS cutting process in different fields of mechanical engineering.
(1 hours x 3 TYPES OF 1.1.2 Describe the different categories of thermal cutting
weeks) THERMAL process
CUTTING 1.1.3 Explain different methods of thermal cutting process
Practical: 9 hours PROCESS such as with gas and by electrical gas discharge.
(3 hours x 3 1.1.4 Describe principle of oxy-acetylene cutting process in
weeks) accordance with application tasks, checked for
serviceability and any faults reported to the supervisor.
1.1.5 Describe principle of air plasma cutting process in
accordance with application tasks, checked for
serviceability and any faults reported to the supervisor

ATTITUDE / SAFETY / ENVIRONMENTAL

1. Demonstrate safe working habit

and consciousness in workshop
2. Adhere to worksite safety
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requirement, regulations
3. Alert in ensuring safe working
environment
4. Responsible and accountable in
performing welding task
5. Transparent in reporting to
relevant authority
6. Ensure housekeeping
7. Ensure proper PPE worn at work
site
8. Practice housekeeping

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CONTENT AND LEARNING STANDARDS

PROGRAMME : WELDING TECHNOLOGY

COURSE NAME : THERMAL CUTTING

COURSE CODE : MTK 2022

CONTACT HOURS
CONTENT
(TRAINING LEARNING STANDARD ASSESSMENT CRITERIA
DURATION) STANDARD

32 hours RELATED KNOWLEDGE ASSESSMENT CRITERIA

(8 weeks)
2. CUT 2.1 Identify oxy-acetylene cutting 2.1.1 Identify safety precaution related to handling and
Lecture: 8 hours MATERIALS equipment and accessories operating of oxy acetylene cutting equipment
(1 hours x 8 USING OXY- according to OSHA requirement / Identify type of
weeks) gas required and its application for cutting process.
ACETYLENE
2.1.2 Identify and choose oxy-acetylene cutting equipment
Practical: 24 hours CUTTING and accessories for the required cutting process.
(3 hours x 8 PROCESS 2.1.3 Practise cleanliness and tidiness throughout
weeks) cleaning process in accordance to standard safety
procedures.

RELATED SKILLS

2.2 Install oxy-acetylene cutting 2.2.1 Identify and perform correct procedure of installing
equipment and accessories including oxy-acetylene cutting equipment and accessories in
nozzle accordance to standard operational procedures.
2.2.2 Detect and set working oxy-acetylene gas pressure
in accordance with material to be cut, standards
operational procedures and OSHA regulations.
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2.3 Inspect leakage on installed
equipment
2.4 Identify measuring tools and
instrument, marking tools and
material
2.5 Construct cutting layout
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2.2.3 Practice safety precaution in compliance with work
safety requirement according to OSHA
2.3.1 Identify method of checking leakages according to
standards operational procedures.
2.3.2 Carry out leak test on defective parts according to
standards operational procedures.
2.3.3 Practise safety precaution in compliance with work
safety requirement in accordance to OSHA
regulations.
2.4.1 Identify safety precaution related to handling of
measuring tools, instrument and marking tools.
2.4.2 Identify type of measuring tools and instrument;
marking tools and materials according to work
requirement.
2.4.3 Identify basic geometrical construction for material
preparation
2.4.4 Describe technique for marking medium/material by
referring to engineering drawing.
2.5.1 Demonstrate technique of using measuring tools,
instrument and marking tools according to OSHA
2.5.2 Use engineering drawing for material preparation to
meet required cutting process.
2.5.3 Apply related mathematical calculation in metal
construction process.
2.5.4 Interpret drawing requirement for marking according
to work specifications.
2.5.5 Construct basic geometrical development according
to specific work instructional.
2.5.6 Use measuring and marking tools and instrument
according to manufacturer’s specifications and
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recommendations.
2.5.7 Identify cutting allowances for kerf and width for the
required cutting process.

2.6 Identify type of flame required 2.6.1 Apply safety precaution related to application of oxy-
acetylene flame according to manufacturer’s
recommendations.
2.6.2 Define principle of flame combustions and effect.
2.6.3 Identify type of flames used according to flame chart
characteristic given.
2.6.4 Set cutting flame according to cutting work
requirement.

2.7 Adjust gas pressure
2.7.1 Apply safety precaution related to handling and
adjusting of oxy-acetylene gas cutting equipment.
2.7.2 Identify correct procedures of adjusting gas.
2.7.3 Identify causes of back fire and flash back in oxy
acetylene cutting process
2.7.4 Demonstrate procedure to arrest back fire and flash
back according to standard operational procedures.

2.8 Clean surface of material 2.8.1 Apply safety precaution related to cleaning of
materials.
2.8.2 Identify and select tools for cleaning surface.
2.8.3 Apply correct methods of cleaning surfaces using
tools for cleaning.
2.8.4 Remove unwanted material from surface and
application according to correct technique of
cleaning surface.

2.9 Select cutting technique 2.9.1 Identify and demonstrate various cutting technique
according to standard operational procedures.
2.9.2 Identify appropriate cutting speeds in cutting
process.

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2.10 Cut material
2.11 Inspect work piece after cutting
2.12 Shut down equipment
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KSKV SVM 2017
2.9.3 Measure tip distance/gap and cutting angle for
cutting work.
2.9.4 Identify effect of drag and slag in cutting process.
2.9.5 Practice consciousness, cautious and proper
working etiquette accordance to standard safety
procedures
2.10.1 Apply safety precaution related to handling of hot
material and cutting material according to OSHA.
2.10.2 Identify and use various cutting guides in cutting
work according to standard operational procedures.
2.10.3 Determine cutting allowances for the cutting process
to meet specific work dimension.
2.10.4 Operate gas cutting equipment according to
standard operational procedures.
2.10.5 Demonstrate correct and safe cutting technique
according to standard operational procedures.
2.10.6 Handle hot metal safely in compliance with work
safety requirement
2.11.1 Apply post cutting process according to standard
operational procedures.
2.11.2 Use measuring tools and instrument to check work
piece after cutting.
2.12.1 Apply correct method to shutting down gas pressure
according to standard operational procedures.
2.12.2 Release gas in the hose and manifold according to
standard operational procedures
2.12.3 Release gas in hoses and regulators according to
standard operational procedures.
2.12.4 Practice consciousness, cautious and proper
working etiquette accordance to standard safety
procedures.
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ATTITUDE / SAFETY / ENVIRONMENTAL

1. Demonstrate safe working habit and

consciousness in workshop
2. Adhere to worksite safety
requirement, regulations
3. Alert in ensuring safe working
environment
4. Responsible and accountable in
performing welding task
5. Transparent in reporting to relevant
authority
6. Ensure good housekeeping
7. Ensure proper PPE worn at work
site
8. Practice good housekeeping

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CONTENT AND LEARNING STANDARDS

PROGRAMME : WELDING TECHNOLOGY

COURSE NAME : THERMAL CUTTING

COURSE CODE : MTK 2022

CONTACT HOURS
CONTENT
(TRAINING LEARNING STANDARD ASSESSMENT CRITERIA
DURATION) STANDARD

24 hours RELATED KNOWLEDGE ASSESSMENT CRITERIA

(6 weeks)
3 CUT 3.1 Identify air plasma cutting equipment. 3.1.1 Apply safety precaution related to handling and
Lecture: 6 hours MATERIAL operating air plasma cutting equipment according to
(1 hours x 6 USING AIR standard operating procedure.
weeks) PLASMA 3.1.2 Identify capacity and performance of machine
CUTTING according to manufacturer specification.
Practical: 18 hours PROCESS 3.1.3 Define principle of air plasma cutting process and
(3 hours x 6 application in accordance to manufacturer’s
weeks) specifications.

RELATED SKILLS

3.2 Set compressed air pressure 3.2.1 Apply safety precaution related to handling and
operating of compressed air according to OSHA.
3.2.2 Identify compressor operating procedure according to
manufacturer specifications.
3.2.3 Set pressure and flow rate of air according to
manufacturer specifications.
3.2.4 Choose type of torch-transfer arc and non-transfer arc
for require cutting process.
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3.2.5 Set gauge regulators according to manufacturer’s

specifications and recommendations
3.2.6 Prepare cutting and cooling pressures according to
manufacturer’s specifications and recommendations

3.3 Identify and select cutting torch
and consumable (tungsten
electrode, air nozzle, skirt, collet
etc)
3.3.1 Identify cutting torch accessories (air nozzle, electrode,
skirt, collect etc.) for require cutting process according
to manufacturer’s specifications and recommendations.
3.3.2 Select nozzle and tungsten electrode for require cutting
process according to manufacturer’s specifications and
recommendations.

3.4 Cut work piece 3.4.1 Apply safety precaution related to cutting process
according to Standard operational procedures.
3.4.2 Set air pressure, flow rate and cutting speed for cutting
following standard instruction of cutting process
according to manufacturer’s specifications and
recommendations
3.4.3 Operate plasma cutting machine according to standard
operating procedures.
3.4.4 Demonstrate correct cutting technique to produce metal
as required by instructional given

3.5 Clean work piece after cutting. 3.5.1 Apply correct technique of cleaning work piece after
cutting.
3.5.2 Detect and check for contamination due to cutting
process according to specific instructional given.
3.5.3 Practise cleanliness and tidiness throughout cleaning
process accordance to standard operational
procedures.

3.6 Inspect work piece. 3.6.1 Use measuring tools and instrument correctly to check
work piece after cutting according to standard operating
procedures.

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3.6.2 Practice consciousness, cautious and proper working

etiquette accordance standard safety procedures.

ATTITUDE / SAFETY / ENVIRONMENTAL

1. Demonstrate safe working habit and

consciousness in workshop
2. Adhere to worksite safety
requirement, regulations
3. Alert in ensuring safe working
environment
4. Responsible and accountable in
performing welding task
5. Transparent in reporting to relevant
authority
6. Ensure good housekeeping
7. Ensure proper PPE worn at work
site
8. Practice good housekeeping

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CORE ABILITY

CORE ABILITY

SILA RUJUK LAMPIRAN A : JADUAL PEMETAAN NOSS DAN KSKV

SILA RUJUK LAMPIRAN B : JADUAL PEMETAAN NOSS DAN CORE ABILITY

Tools, Equipment and Materials (TEM)

ITEMS RATIO (TEM : Trainees)

1 Base metal plate 1 : 1

2 Base metal pipe 1 : 1
3 Safety shoe 1 : 1
4 Leather gloves 1 : 1
5 Fire extinguisher 1 : 5
6 Muffler / ear plug 1 : 1
7 First aid kit 1 : 5
8 Marking tools and hand tools 1 : 1
9 Jig & fixture fit-up clamp 1 : 1
10 Grinding machine 1 : 1
11 Spark lighter 1 : 1
12 Plasma cutting (for stainless steel) 1 : 15
13 Oxy-acetylene gas cutting (manual) and accessories with flash back 1 : 15
arrester
14 Oxy-acetylene gas cutting machine (semi-auto) and accessories 1 : 15
with flash back arrester
15 Oxy-acetylene pipe cutting machine and accessories with flash back 1 : 15
arrester
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ITEMS RATIO (TEM : Trainees)

16 Air compressor and receiver 1 : 15

REFERENCES

1 Sacks & Bohnart,2007,Welding Principles & Practices,3rd edition, 1221, Avenue of the Americas, New York, NY 10020 USA, Mc Graw Hill, ISBN:
978-0077238773
2 James F. Lincoln, Arc Welding Foundation, 2002, The Procedure Handbook of Arc Welding, 14th Edition, 22801 St. Clair Avenue, Cleveland, Ohio,
44117 USA, Lincoln Electric Company, ISBN: 978- 9993897302
3 Robert L. O'Brien, 1997, Jefferson's Welding Encyclopaedia, 18th Edition, 550 N.W. Lejeune Road, Miami, Florida, 33126 USA, American Welding
Society, ISBN: 978-0871715067
4 Joseph W. Giachino, William, Weeks, 1985, Welding Skills & Practices, 6th edition, Western Michigan University, Kalmazoo, Michigan, Chicago,
60637, USA, American Technical Society, ISBN:978-0826930019
5 Griffin, Roden, Briggs, 1985, Pipe Welding Techniques, 4th edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-0827322486
6 Ivan H. Griffin, Edward M. Roden and Charles W. Briggs, 1984, Basic Arc Welding 4th edition, Albany, New York, 12205 USA, Delmar
Publishers, ISBN: 978-0827321311
7 ASM International, 1983, Metal Reference Book, 2nd edition, Material Park, Ohio, 44073 USA, American Society For Metals, ISBN:978-
0871701565
8 Gower A. Kennedy, 1982, Welding Technology - Student's Manual, 2nd edition, Indianapolis, USA, A Howard W. Sams Book, Bobbs- Merill

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REFERENCES

Educational Publishing, ISBN:978-0672971099

9 Gower A. Kennedy, 1982, Welding Technology, 2nd edition, Lethbridge Community College, Alberta, New York, USA, Howard W. Sams & Son
Inc., ISBN: 978-0672979903
10 Frank R. Schell, 1977, Welding Procedures: Electric Arc, 1st edition, Albany, New York, 12205 USA, Delmar Publishers, ISBN: 978-0827316034
11 Giachino, Weeks, Johnson, 1974, Welding Technology, 2nd edition, Chicago, 60637 USA, American Technical Society, ISBN: 978-0826930637

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