Upon successful completion of this course, the student should be able to identify currently used types and sizes of rail, frogs, switch points and insulated joints. The student should be able to locate operation procedures in an approved manual and apply them to the appropriate component. In addition, the student should be able to describe the proper application of oxygen fuel cutting (OFC), oxy-fuel heating, shielded metal arc welding (SMAW), flux core arch welding (FCAW), carbon arc cutting with air (CAC-A), thermite welding (TW) and grinding procedures. 3 hrs. lecture/wk.
Prerequisites: Approval of BNSF manager of engineering maintenance training and the JCCC department approval
Refer to the instructor's course syllabus for details about any supplies that may be required.
Upon successful completion of this course, the student should be able to:
- Demonstrate safety at all times, to include: follow all safety rules and all safety procedures, wear personal protective equipment (PPE) when using SMAW, FCAW, CAC-A, TW, OF Processes, grinding equipment, and apparatus of all types.
- Locate, identify and select controls, switches, dials, levers, buttons, guards, and operating devices related to welding power supplies, oxy-fuel equipment, and grinders.
- Demonstrate knowledge of proper procedures and terminology from current manuals, and according to industry standards.
- Demonstrate procedures for the preparation, welding, and grinding of mild steel, rail steel, switch points, frogs, and thermite welds.
- Identify metallurgical effects that take place in low and medium carbon steels, rail steel, and frogs.
- Explain and demonstrate the methods used to test and inspect welds and welding repairs made to rail steel and manganese steel.
Content Outline and Competencies:
I. Demonstrate safety at all times, to include: follow all safety rules and all safety procedures, wear personal protective equipment (PPE) when using SMAW, FCAW, CAC-A, TW, OF Processes, grinding equipment, and apparatus of all types. A. Follows the correct and approved safety rules and procedures according to the JCCC and company safety policies. B. Wear proper PPE when welding, cutting, sawing, grinding, heating, and performing testing procedures. C. Demonstrate correct and safe methods to set up and shut down the OFC and Oxy-Fuel heating apparatus. D. Performs accurate cuts using the OFC process. E. Demonstrate safety procedures when using various welding processes. F. Follow proper procedures when operating rail saws and grinding equipment. G. Identify safety rules for heating, welding and cutting. II. Locate, identify and select controls, switches, dials, levers, buttons, guards, and operating devices related to welding power supplies, oxy-fuel equipment, and grinders. A. Selects correct amperage and voltage required for the operation of welding power supplies. B. Describe the correct start up and shut down procedures for operating gas and /or hydraulic rail saws. C. Demonstrate the correct method to set up and shut down grinding and shearing equipment. D. Identify general safety and operating rules and procedures for the operation of power supplies, grinders, and gauging devices. III. Demonstrate knowledge of proper procedures and terminology from current manuals, and according to industry standards. A. Use current welding repair manual to apply correct repair procedures for mild steel, rail steel, and manganese steel. B. Select and review SMAW, FCAW, OF Heating, OFC and grinding process for the correct repair of rail steel. C. List current industry standards for the repair of mild steel. D. Identify proper terms as applied to rail, frogs, and thermite welds. IV. Demonstrate procedures for the preparation, welding, and grinding of steel, rail steel, switch points, frogs, and thermite welds. A. Review mild steel and rail steel welding with SMAW and FCAW. B. Review SMAW and FCAW when welding manganese steel. C. Review the thermite welding processes. D. Apply correct welding procedures for SMAW on rail steel and frogs. E. Apply correct welding procedures for FCAW on steel, rail steel, and frogs. F. Apply correct welding procedures for thermite welding. V. Identify metallurgical effects that take place in low and medium carbon steels, rail steel, and frogs. A. Explain why rail steel is preheated. B. Explain why manganese frog are not preheated. C. Explain why work hardness should be removed prior to welding. VI. Explain and demonstrate the methods used to test and inspect welds and welding repairs made to rail steel and manganese steel. A. Demonstrate straight edging and gauging techniques on finish ground welds on rail steel and frogs. B. Properly perform die penetrant testing on rail steel and frogs.
Method of Evaluation and Competencies:
Evaluation of student mastery of course competencies will be accomplished using the following methods:
Classwork and lab competencies include some subjective evaluations on the part of the instructor(s). Lab competencies will be assigned a level of competency on a scale of 1-10 with 10 being highest. Semester grades will be determined as follows: Frog 33 1/3% of grade Rail 33 1/3% of grade Thermite 33 1/3% of grade TOTAL 100%
- Students will be penalized one letter grade for each day missed unless excused by employer.
- Students need to be prepared to work in bad weather conditions. Lab activities are out-of-doors. Students must wear proper safety equipment as required, with no exceptions.
- Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. Note: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1) provide evidence that existing eyewear meets ANSI Z87.1, or 2) wear cover goggles (if allowable), or 3) purchase and wear ANSI Z87.1 prescription eyewear.
If you are a student with a disability, and if you will be requesting accommodations, it is your responsibility to contact Access Services. Access Services will recommend any appropriate accommodations to your professor and his/her director. The professor and director will identify for you which accommodations will be arranged.
JCCC provides a range of services to allow persons with disabilities to participate in educational programs and activities. If you desire support services, contact the office of Access Services for Students With Disabilities (913) 469-8500, ext. 3521 or TDD (913) 469-3885. The Access Services office is located in the Success Center on the second floor of the Student Center.