About this module
Level 2 made you good at welding. Level 3 makes you trusted: by inspectors, by oil and gas companies, and by customers who need machines that work safely for years.
Who it is for. People who have finished Welding and Fabrication Level 2, or who can show the same skills. In Ghana's framework, National Proficiency II leads to National Certificate I, which covers complex work with minimum supervision. This module sits at about that level.
CTVET status. CTVET has an approved Welding and Fabrication Technology programme at several levels, but its unit list was not found online. This module is not that curriculum, and it does not certify you as a coded welder, inspector or engineer.
Bridge from Level 2: what you already know
- Gas cylinder storage and leak tests; fume control on galvanised steel; hearing protection; two-person lifts
- Weld symbols; square, single-V and double-V preparation
- Oxy-acetylene and plasma cutting; the 30-minute fire watch
- Fillet and V-butt welds horizontal, vertical-up and overhead; storing E7018; hydrogen cracking
- MIG on thin sheet; galvanised steel and zinc-rich repaint
- Visual inspection and defect causes; distortion control with jigs and weld order
- Costing, quoting and contracts; the Ghana Welding Bureau route
Level 2 did not cover written procedures and qualification, pipe positions, TIG, stainless or aluminium, testing beyond visual inspection, production planning, machine drives, permits, lockout or supervising others. This manual does. For general bookkeeping and business skills, see the Hub's Money Skills Level 2 and Entrepreneurial Thinking Level 2.
How the module works
Each unit has learning outcomes, performance criteria, the range and the evidence your assessor needs. You are judged Competent or Not Yet Competent. About 70% of the time is practical, following CTVET's Oil Palm programme split of about 30% school and 70% workplace.
Safety first
- Hot-work permit: written permit after an area check; combustibles moved about 11 m away or covered; fire watch during the work and at least 30 minutes after; the welder is never their own fire watch.
- Confined spaces such as tanks and manholes can hold toxic, flammable or oxygen-poor air. Keep cylinders and the welding machine outside, use a lifeline and an attendant, ventilate, and never ventilate with oxygen.
- Lockout before repair: announce, find every energy source, isolate, lock and tag, then test that it is dead; each worker fits their own padlock.
- Fume: welding fume can cause cancer; use extraction at the weld.
- Engineer sign-off: anything load-bearing, pressure-retaining or carrying people needs an engineer's design and coded welders.
Unit 1 · Weld to a procedure and prepare for qualification
Coded work means doing it the written way, every time, and proving you can.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 1.1 Follow a WPS | reads and follows a welding procedure specification; explains how a PQR supports it |
| 1.2 Weld a test coupon | welds a qualification-style coupon and prepares it for examination |
| 1.3 Keep records | keeps qualification records and a continuity log; plans a certification route |
Range. Two procedures on plate. Evidence. Coupons; procedure sheets followed; log.
Procedures and qualification
- A welding procedure specification (WPS) is a written document telling welders how to make code-compliant welds. It is backed by a procedure qualification record (PQR) of a test weld and its results. Common codes include ASME IX, AWS D1.1 for structural steel, ISO 15614 and API 1104 for pipelines.
- Welders are certified by welding test coupons that are then examined. The certificate covers a process, metal, thickness, joint and position. Europe uses ISO 9606. Qualifications usually last about two years and may lapse if the welder stops doing that work, so keep a log.
The route in Ghana
- The Ghana Welding Bureau is the professional body for welding under the Ministry of Energy and Petroleum Commission, focused on oil and gas; it trains and certifies welders. Its website does not list levels or fees: contact them.
- Under a Petroleum Commission agreement, Takoradi Technical University is to train and certify 100 welders, and Canadian-certified welders now train others in Ghana.
- In March 2026 Regional Maritime University signed an agreement with the Canadian Welding Bureau and CPI Training, reported as the only accredited test centre of its kind in Africa.
Codes and positions. Welders worldwide describe positions with two systems. In the American (AWS/ASME) system the number is the position (1 flat, 2 horizontal, 3 vertical, 4 overhead; 5 and 6 are fixed pipe) and the letter is the joint (G groove, F fillet). The international ISO 6947 system uses letters: PA = 1G/1F (flat), PB = 2F, PC = 2G, PD = 4F, PE = 4G (overhead), PF = 3G uphill, PG = 3G downhill, PH = 5G uphill, PJ = 5G downhill, and H-L045 / J-L045 = 6G (pipe fixed at 45°), the hardest test. Bend-test rules and code editions (AWS D1.1, ASME IX, ISO 9606) were not read for this manual: your trainer and the certifying body set the test.
Weld to procedure
- Read a sample WPS and list every variable it controls.
- Weld a coupon exactly to the procedure.
- Prepare it for examination and record the result.
- Start a continuity log of every coded weld you do.
Certification
Contact the Ghana Welding Bureau and ask about its certification route and costs.
Unit 2 · Pipe welding and TIG on stainless steel and aluminium
Clean, precise welds on pipe and stainless steel open the door to oil and gas and food machinery work.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 2.1 Weld pipe | fits up and welds pipe with root, hot, fill and cap passes in fixed positions |
| 2.2 Use TIG | sets polarity, gas and tungsten and welds thin stainless and aluminium |
| 2.3 Protect stainless | prevents contamination and corrosion on stainless steel |
Range. Pipe offcuts; 304 stainless and aluminium sheet. Evidence. Pipe joints; TIG samples.
TIG basics
- TIG uses DC with the tungsten negative for steels, and AC for aluminium to break the oxide layer. Argon is the usual gas.
- Thoriated tungsten is mildly radioactive when ground; ceriated, lanthanated and zirconiated tungsten are alternatives.
- TIG gives a much brighter arc and more UV than stick and forms ozone: cover all skin and ventilate.
Stainless steel
304 stainless (18–20% chromium, 8–11% nickel) is widely used for food equipment. It pits in warm salty conditions, so 316 is used for salt water and oil rigs. 304L limits corrosion problems caused by welding heat. Keep stainless away from carbon-steel brushes and grinding dust.
Ghana examples
ENI and partners trained 17 young people from Ellembelle in argon (TIG) welding with international certification. TIG machines were advertised in Ghana from about GH¢3,500 for small units.
Pipe and TIG
- Fit up and weld a pipe joint with root and cap passes in a fixed position.
- TIG-weld 1.5 mm stainless sheet and aluminium sheet.
- Inspect each and record defects.
Tungsten
Check which tungsten your workshop uses and how it is ground and disposed of.
Unit 3 · Manage fabrication production and quality
Plan the steel, plan the steps, plan the checks. Quality is built in, not inspected in.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 3.1 Plan production | does a material take-off, cutting list and nesting; plans jigs and fixtures |
| 3.2 Plan quality | writes a simple quality plan and inspection and test plan with hold points |
| 3.3 Know testing methods | explains penetrant, magnetic and ultrasonic testing and when to call a certified inspector |
Range. One multi-part job. Evidence. Take-off; nesting plan; ITP.
Cutting waste
Nesting means laying parts out on sheet or plate to reduce scrap, often with software. A take-off lists every part; a cutting list groups them by material and length.
Inspection and test plan (ITP)
- Each step of the job in order
- What is checked, by whom, with what method
- Hold points where work stops until checked
- Acceptance standard
- Record and signature
Testing beyond the eye
- Dye penetrant: clean, apply penetrant, wait 5–30 minutes, remove excess, apply developer, inspect. It finds surface cracks only, and rough welds give false signs.
- Magnetic particle: finds flaws at or just below the surface of magnetic steels only.
- Ultrasonic: finds internal flaws with sound waves; results depend on trained technicians.
Use the Level 2 defect table and distortion controls. Acceptance reports must come from certified inspectors.
Plan a job
- Do a take-off and cutting list for a gate or machine frame.
- Draw a nesting plan to reduce waste.
- Write an ITP with hold points.
- Do a dye penetrant test on a practice weld.
Waste
How much steel did your nesting plan save compared with cutting in any order?
Unit 4 · Build machines to drawings and lead safe work
A machine must work, last and never hurt the person using it.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 4.1 Build to drawings | sizes belt and gear drives, chooses food-contact materials and fits guards |
| 4.2 Run safe systems | runs hot-work permits, confined-space controls and lockout |
| 4.3 Supervise | leads toolbox talks, PPE checks and quality sign-off; refers load-bearing work to an engineer |
Range. One agro-processing machine or frame. Evidence. Drawings; drive calculations; permits; finished machine.
Drives
- Belts: pulley speeds are inversely proportional to diameter: speed 1 × diameter 1 = speed 2 × diameter 2. Real speeds are slightly lower due to slip.
- Gears: ratio = teeth on the driven gear ÷ teeth on the driver = input speed ÷ output speed.
Drive sum
A motor runs at 1,450 rpm with a 100 mm pulley. The grater needs about 725 rpm. What size pulley on the grater shaft?
Guards
Enclose belts, pulleys, gears and chains within about 2.1 m of the floor; guards can be expanded metal, perforated sheet or mesh on a frame. Interlocked guards should work with lockout.
Food machines
Use 304 stainless for parts that touch food. Ask the FDA about rules for food-processing equipment.
Market
Cassava graters were advertised from about GH¢1,300 to GH¢6,800 and corn mills from GH¢2,800 to GH¢27,000.
Build and lead
- Build a small machine or frame from a drawing with guarded drives.
- Issue a hot-work permit and run the fire watch.
- Lock out a machine for maintenance with a multi-lock hasp.
- Lead a toolbox talk and sign off the quality check.
Guard audit
Check three machines in workshops near you. Are the belts and gears guarded?
Unit 5 · Establish your fabrication business
Oil and gas work needs a registered company and a Petroleum Commission permit. Every workshop needs an Assembly permit and insurance.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 5.1 Choose a legal form | compares business types and registers one |
| 5.2 Meet tax and permit duties | lists tax, VAT, Assembly, Petroleum Commission and export duties |
| 5.3 Employ fairly | applies SSNIT, PAYE and Labour Act basics |
Range. Own business plan. Evidence. Registration checklist with costs; payroll sheet.
Choose a legal form
| Type | ORC fee (2026) | Notes |
|---|---|---|
| Business name (sole proprietor) | GH¢130; GH¢70 renewal | Most workshops start here |
| Partnership | GH¢270; GH¢100 renewal | 2–20 partners |
| Company limited by shares | GH¢585 + capital duty | Needed for Petroleum Commission work; yearly returns |
| Company limited by guarantee | GH¢490 | Non-profit training workshops |
Companies file annual returns with financial statements.
Tax and permits
- Your Ghana Card number is your tax number. Sole traders may use the Modified Taxation Scheme. Companies pay 25%, or 18.5% for manufacturers in a regional capital such as Takoradi.
- VAT is 20% in total from 2026; a business selling goods registers once turnover passes GH¢750,000.
- In Sekondi-Takoradi, a metal fabricator pays GH¢200 a year and an auto arc welder GH¢550.
- Petroleum Commission permit: application pack GH¢100; needs incorporation, tax and SSNIT clearance, VAT certificate, a health and safety policy, business plan and financials; renewed every year.
- Export: register with GEPA through the government portal; get a rules-of-origin certificate from Customs for African free trade.
- Insurance only from licensed insurers.
Employing welders
- Pay at least GH¢21.77 a day.
- SSNIT: worker 5.5% plus employer 13%, paid by the 14th; register workers on hiring.
- PAYE: the first GH¢588 a month is tax-free; pay by the 15th.
- Written contract for six months or more; 15 working days' paid leave.
Accessibility
The Disability Act bans job discrimination. Planning, nesting, ITP writing and test reporting are desk work and suit wheelchair users. Deaf welders need visual hot-work and lockout signals and written permits. The Assemblies' disability fund now supports skills and assistive devices.
Register
- Choose a legal form and explain why.
- Make a registration and permit checklist with costs.
- Work out one month's payroll for two welders.
Petroleum Commission
List the documents you would need for a Petroleum Commission permit.
Unit 6 · Bookkeeping and accounting for a fabrication workshop
Every job uses steel, gas, rods and hours. Cost each job, or you will not know which work pays.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 6.1 Keep daily books | keeps cash, MoMo/bank, job cards, purchases and stock records |
| 6.2 Produce statements | prepares a monthly profit and loss and balance sheet, and profit per job |
| 6.3 Control cash | reconciles MoMo and bank, and forecasts cash |
Range. One month of real or example jobs. Evidence. Books; statements; reconciliation; forecast.
The records
| Record | What it shows |
|---|---|
| Job cards | Materials, hours, deposits and balance for each job |
| Purchases book | Steel, rods, wire, gas, paint |
| Stock sheet | Steel lengths and consumables in store |
| Cash book and MoMo book | Every cedi in and out |
| Asset register | Machines and their depreciation |
Keep records for at least 6 years.
Assets = liabilities + owner's equity. Depreciation = (cost − end value) ÷ years of use.
Worked example (all figures are examples)
Yaw's fabrication shop, August
- Yaw puts in GH¢25,000.
- Buys a TIG machine for GH¢8,400 (4 years, no end value).
- Job 1: two cassava graters sold at GH¢4,500 each = GH¢9,000 cash. Materials GH¢3,200.
- Job 2: gates for an estate, GH¢12,000; deposit GH¢6,000 received, GH¢6,000 owed. Materials GH¢5,500.
- Steel left in stock at month-end: GH¢800 (included in purchases of GH¢9,500).
- Rent GH¢600, power GH¢900, one welder GH¢2,000, gas and rods GH¢700.
- Yaw takes GH¢1,500 (drawings).
Work out: (1) cash at the end of August; (2) net profit; (3) the balance sheet; (4) gross profit on each job.
Reconciliation and forecast
Match MoMo and bank books to statements each month. Large jobs are paid in stages, so forecast when deposits and balances arrive and when steel must be bought.
Software and the calendar
Use a spreadsheet, or a free plan such as Zoho Books or Wave.
| When | What |
|---|---|
| 14th | SSNIT |
| 15th | PAYE and withholding tax |
| Last working day | VAT (if registered) |
| Within 4 months of year-end | Annual income tax return |
| Yearly | Petroleum Commission permit renewal; Assembly permit by 31 March |
Month-end close
- Keep job cards and books for one month.
- Reconcile MoMo and bank.
- Prepare a profit and loss, balance sheet and profit per job.
- Forecast cash for three months.
Steel prices
Collect steel prices from two Takoradi dealers and update your job costing.
Unit 7 · Grow and sustain the business
Grow on certified skills, documented quality and a reputation for safe machines.
Competency standard
| Learning outcome | Performance criteria — the trainee… |
|---|---|
| 7.1 Find finance and markets | identifies finance, support and markets |
| 7.2 Lead people and quality | develops welders and keeps quality records |
| 7.3 Plan and pitch | presents a one-page plan with a 12-month cash forecast |
Range. Own business plan. Evidence. Business plan; cash forecast; pitch.
Finance and support
- The Ghana Enterprises Agency has Business Advisory Centres in Takoradi and nearby districts.
- Ghana EXIM supports SMEs and exporters and has a Takoradi office.
- The Bank of Ghana policy rate was 14%.
Markets
- The Jubilee oil field lies about 60 km off the Western Region coast, and the Ghana Local Content Conference runs 10–13 November 2026 in Takoradi.
- Suame Magazine in Kumasi and Kokompe in Accra are large metal clusters where machining can be subcontracted.
Location settings that give good returns
- Near the Petroleum Commission office and oil and gas service companies in Takoradi
- Near the port for marine repair work
- On a busy road where finished machines are seen
- Near steel and gas suppliers
- Three-phase power or a safe generator area
Business ideas and ingenuity
- Stainless food-processing machines with guards
- Batch production of solar frames with jigs
- Pipe spools and skids as a subcontractor to permitted firms
- Penetrant testing service after certified training
- Maintenance contracts that include lockout
Market yourself
- Show qualification certificates and continuity logs.
- Give a sample ITP with every quote.
- Register with the Petroleum Commission and attend local content events.
Capstone
Present to a panel: a one-page business plan and a 12-month cash forecast.
Pitch
- Write a one-page plan.
- Build a 12-month cash forecast.
- Pitch to a panel for ten minutes.
Local content
Find out how to register for the next local content event.
Glossary
| Term | Meaning |
|---|---|
| Continuity log | A record that keeps a welder's qualification valid |
| ITP | Inspection and test plan |
| Lockout | Locking off energy before work |
| Nesting | Arranging parts to cut waste |
| PQR | Procedure qualification record |
| TIG | Welding with a tungsten electrode and argon gas |
| WPS | Welding procedure specification |
Logbook
- Safety: hot-work permits; lockout records
- Unit 1: coupons; procedure sheets; continuity log
- Unit 2: pipe and TIG samples
- Unit 3: take-off; nesting plan; ITP; penetrant test
- Unit 4: drawings; drive sums; finished machine
- Unit 5: registration checklist; payroll
- Unit 6: books; statements; forecast
- Unit 7: business plan; pitch
- Every homework, dated
Self-check quiz
- What is a WPS, and what backs it up?
- Why keep a continuity log?
- Which polarity does TIG use for steel and for aluminium?
- Why avoid grinding thoriated tungsten?
- Why use 316 rather than 304 near salt water?
- What does nesting do?
- What can dye penetrant not find?
- Write the pulley speed rule.
- Who can never be the fire watch?
- Name the five lockout steps.
- Why form a company for oil and gas work?
- Write the accounting equation.
Further reading and sources
Best next reads: your Level 2 manual; TWI job knowledge articles; the Ghana Welding Bureau; the Hub's Money Skills Level 2 and Entrepreneurial Thinking Level 2.
What this module does not cover: coded welder certification tests, certified NDT inspection, pressure vessel and structural design (engineers only).
Every source used in this manual is listed, with links, in the Teacher Copy.