This is an archived copy of the 2023-24 Catalog. To access the most recent version of the catalog, please visit http://catalog.jccc.edu/.

Courses

RRIT 132 Thermite Welding* (3 Hours)

Prerequisites : Department approval.

Upon successful completion of this course, the student should be able to produce in a safe manner high-quality, sound thermite welds on standard rail and mismatched rail. This course is intended for people who are employed in the railroad industry. It will include specific in-depth industrial training. Students will be required to make various rail alignments and to grind various new and worn rails.

RRIT 136 Rail and Switch Point Repair Welding* (3 Hours)

Prerequisites : BNSF Railway Training Director approval and JCCC department approval.

Upon successful completion of this course, the student should be able to identify and/or produce in a safe manner high-quality welding repairs and correct welding techniques to railroad track components to include maintenance, grinding, welding and repairs of switches, track rail ends, track wheel burns, battered welds, rail transition ramp building methods, Pandrol weld on shoulders, proper placement of work piece connections, and approved switch point welding procedures, as specified by the Burlington Northern Santa Fe Railway. This course will involve the study of different welding processes, welding safety, proper grounding techniques, rail heater and metallurgy. The effects of heat in relationship to specific rail steel components will be discussed. Students will be required to experience all appropriate methods and processes including welding, cutting, grinding, straight edging rail steel and preparing switch points for proper mating surface according to current industry standards. Evaluation will be in a classroom and laboratory setting.

RRIT 142 Structural Pile Welding* (3 Hours)

Prerequisites : BNSF Railway Training Director approval and JCCC department approval.

Upon successful completion of this course, the student should be able to splice pipe and H-beam piling and install cap plate gussets according to Burlington Northern Santa Fe (BNSF) standard blueprints. This course shall make use of oxy-fuel cutting (OFC), grinding, shielded metal arc welding (SMAW), and flux cored arc welding (FCAW) to prepare, fit and weld piling. Selected welds will have test strips bent to check for soundness of welds. These strips should meet basic American Welding Society (AWS) test standards. Basic metallurgy will be discussed as it applies to the need for preheat and post heat in the building of railroad bridges.

RRIT 145 Frog Welding* (3 Hours)

Prerequisites : BNSF Railway Training Director approval and JCCC department approval.

Upon successful completion of this course, the student should be able to repair by welding a manganese frog casting according to Burlington Northern Santa Fe Railway standards. This course will involve the study of different welding and cutting processes, with emphasis on the FCAW process. Metallurgy and the effects of heat in relationship to austenitic manganese steel will be discussed. Students will be required to cut, grind, straight edge, dye penetrant test, weld and monitor heat input during the repair process on austenitic steel frog casting for evaluation in an actual laboratory setting.

RRIT 160 Basic Welding* (3 Hours)

Prerequisites : BNSF Railway Training Director approval and JCCC department approval.

Upon successful completion of this course, the student should be able to properly use oxyfuel cutting (OFC), plasma arc cutting (PAC), plasma arc gouging, air carbon arc cutting (CAC-A), shielded metal arc welding (SMAW), and flux core arc welding (FCAW) equipment. The SMAW and FCAW portion of the course will concentrate on flat groove welds (1G) and horizontal fillet welds (2F). The student is required to pass welding tests in accordance with the Railroad Welding Specification for Cars and Locomotives (AWS D15.1).

RRIT 162 Structural Stick Welding* (3 Hours)

Prerequisites : BNSF Railway Training Director approval and JCCC department approval.

Upon successful completion of this course, the student should be able to properly use the shielded metal arc welding (SMAW) process on multi-pass groove welds in the horizontal (2G), vertical up (3G), and overhead (4G) positions. The student is required to pass welding tests in accordance with the Railroad Welding Specification for Cars and Locomotives (AWS D15.1).

RRIT 164 Structural Wire Welding* (3 Hours)

Prerequisites : BNSF Railway Training Director approval and JCCC department approval.

Upon successful completion of this course, the student should be able to properly use the flux core arc welding (FCAW) process on multi-pass groove welds in the horizontal (2G), vertical up (3G), and overhead (4G) positions. The student is required to pass welding tests in accordance with the Railroad Welding Specification for Cars and Locomotives (AWS D15.1).

RRIT 166 Mechanical Welding Air Brake Pipe* (3 Hours)

Prerequisites : Department approval.

Upon successful completion of this course, the student should be able to properly use the shielded metal arc welding (SMAW) and flux cored arc welding (FCAW) processes on pipe welds. The student is required to pass welding tests in accordance with the Railroad Welding Specification for Cars and Locomotives (AWS D15.1).

RRIT 168 Sheet Metal Welding* (3 Hours)

Prerequisites : BNSF Railway Training Director approval and JCCC department approval.

Upon successful completion of this course, the student should be able to properly use the gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) processes on sheet metal. The student is required to pass welding tests in accordance with the Railroad Welding Specification for Cars and Locomotives (AWS D15.1).

RRIT 132

Title: Thermite Welding*
Number: RRIT 132
Effective Term: 2023-24
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Requirements:

Prerequisites: Department approval.

Description:

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Explain the basic process and chemical reaction.
Identify and practice appropriate safety practices and rules in the performance of a Thermite weld.
Analyze and explain quality assurance or quality control measures and documentation required for proper completion of welding various sizes of rail.
Align various profiles of track using wedges and alignment frames.
Explain the proper procedure for sawing, cleaning, cutting, trimming and preparing rail ends.
Produce as welder in-charge, multiple Rail Tech and Orgo Therm or comparable welds.
Align, assemble, fit and pack Orgo Therm and Rail Tech or comparable molds on new to new, head worn to new, gauge face worn to gauge face worn and transposed rail.
Describe the safe use and use torches in a safe manner.
Describe various terms related to metallurgy and relate them to the use of temperature indicating devices.
Tear down or remove the ’hot’ mold and weld in a safe manner.
Perform the rough and finish grinding operations correctly and in a safe manner.
Explain and apply procedures and rules as listed in the BNSF Orgo Therm and the BNSF Rail Tech manuals.

Content Outline and Competencies:

I. An Overview of the Basic Thermite Process
   A. Explain the chemical reaction of Thermite steel.
   B. Check the temperature at various points in time and location.
   C. Describe the effect of moisture on slag and Thermite steel.
   D. Describe the recommended disposal of unused Thermite.
II. Safety
   A. Identify BNSF and JCCC safety rules.
   B. Answer questions about commonly used safety rules in industry.
   C. Identify and select proper personal protective equipment for
Thermite welding and grinding.
   D. List the parts of the fire triangle.
   E. Complete statements concerning eye protection.
   F. Complete statements concerning basic safety rules for oxy-fuel
cylinders and associated gases.
   G. Complete a list of safety rules for the thermite work area.
   H. Select true statements concerning environmental safety
requirements.
   I. Liquid oxygen safety
      1. Describe the construction of the GP-22 or GP-45.
      2. Explain the operation and purpose of safety valves.
      3. Explain the gas use valve.
      4. Explain the liquid valve.
      5. Explain the pressure building valve.
      6. Demonstrate the safe set-up and operation of liquid oxygen used
with a fuel gas.
   J. Propane safety
      1. Describe the construction of the propane cylinder.
      2. Describe the safety valve.
      3. Describe the use valve.
   K. Regulator and torch safety
      1. Describe single stage regulators.
      2. Describe flow check valves vs. flashback arrestors.
      3. Explain types and uses of hoses.
      4. Select and use the proper torch handle.
      5. Select and use the proper cutting attachment.
      6. Select and use the proper torch tip.
   L. Grinder and saw safety
      1. Check rpm of equipment.
      2. Check condition of blades and stones.
      3. Wear proper protective equipment.
      4. Operate grinders and saws safely.
   M. Personal safety
      1. Wear approved hard hat.
      2. Wear approved safety glasses.
      3. Wear approved shaded eye protection.
      4. Wear approved boots.
      5. Wear approved gloves.
      6. Wear approved goggles.
      7. Wear approved face shield.
   N. Demonstrate the proper use of measuring tools, specialized Thermite
tools, hand tools, shearing tools, jacks and other tools and supplies
associated with welding rail with the Thermite welding process in a safe
manner.
III. Quality
   A. Complete a production welding report.
   B. Complete a quality welding report.
   C. Document adding or subtracting rail.
IV. Alignment Procedures
   A. Preparation – general restrictions/limitations
      1. Remove spikes or clips
      2. Saw joint or plug to fit the crib
      3. Square ends
      4. Document addition or subtraction of rail
      5. Clean rail ends
      6. Torch clean rails
      7. Document rail height
      8. Review temperature and weather conditions
      9. Examine rail requirements
     10. Observe rail movement/traffic restrictions
     11. Review track work preparation
     12. Review track concrete and wood tie requirements
     13. Review rail end preparation
     14. Explain alignment of 115#, 132#, 136# and 141#
   B. Rough crown
      1. Use a 36" steel straight edge
      2. Use a magnetic straight edge
      3. Eyeball the track
      4. Set correct dimensions
      5. Check elevation of mismatch
      6. Use the taper gage
      7. Offset vertical mismatch in the base only
   C. Base
      1. Use a 36", 1 meter or 18" straight edge
      2. Align gage side base whenever possible
   D. Ball
      1. Use a 36" or 1 meter straight edge
      2. Align gage side ball whenever possible
   E. Final alignment
      1. Check web
      2. On mismatched rail check field side alignments, as a reference
      3. Set final crown
      4. Recheck all
V. Rail Cutting
   A. Use rail saws in a safe manner
   B. Use oxyfuel cutting torch to cut rail as required to remove
expansion
   C. Clean rail ends as needed
VI. Complete Welds
   A. Perform a Rail Tech weld from start to finish
   B. Perform an Orgo Therm weld from start to finish
   C. Perform a third weld from start to finish
   D. The welder’s responsibility
      1. Insure rail end preparation is done correctly
      2. Insure proper alignment is done correctly
      3. Check mold installation
      4. Check mold packing
      5. Keep track of all times and temperatures
      6. Insure grinding is done properly
      7. Insure quality documentation is recorded
      8. Insure sawing and grinding are done properly
E. The grinder’s or helper’s responsibilities
      1. Perform or assist welder with sawing and grinding operations
      2. Assist the welder in the performance of his/her duties
VII. Mold Application
   A. Arrange for the preparation to apply the molds
   B. Complete and check the packing of molds
   C. Do filing as required
   D. Complete and check the installation of the molds and hardware
VIII. Current Brand of Torch
   A. Explain the operation of the Victor brand
   B. Explain the operation and use the Hesa/SkV brand as needed.
IX. Metallurgy
   A. Describe head hardened rail
   B. Describe standard carbon rail
   C. Describe time at temperature
   D. Describe preheat
   E. Describe postheat
   F. Describe a rail end that is too cold and too hot during preheating
X. Mold Tear Down or Removal
   A. Remove hardware
   B. Crop the top of the mold
   C. Use shear or hot-cut only when needed
   D. Cover the weld according to conditions
XI. Grinding
   A. Rough grind the weld
   B. Finish grind the weld
   C. Use a 36" or 1 meter straight edge during finish grinding
XII. Process Rules and Procedures
   A. Review Rail Tech procedures
   B. Review Orgo Therm procedures

Method of Evaluation and Competencies:

Multiple Thermite welds will be assigned a score of 1-10. Check-off
sheets used in the welding area are the student's responsibility. 
The final grade will be calculated as follows:
Participation         10% of grade
Lab competencies      60% of grade
Two quizzes           10% of grade
Final test            20% of grade
TOTAL                100%
The lab competencies grade (60%) will be a composite of multiple
welding/grinding grades, additional comments recorded on lab sheets
following the procedures, the overall use of time, the completion of lab
work and successfully completing your own work.

Grade Criteria:

90 – 100% = A
80 – 89% = B
70 – 79% = C
60 – 69% = D
0 – 59% = F

Caveats:

Students need to be prepared to work in bad weather conditions. Lab activity is out-of-doors.
Students must wear proper safety equipment, 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.

Student Responsibilities:

Disabilities:

JCCC provides a range of services to allow persons with disabilities to participate in educational programs and activities. If you are a student with a disability and if you are in need of accommodations or services, it is your responsibility to contact Access Services and make a formal request. To schedule an appointment with an Access Advisor or for additional information, you may send an email or call Access Services at (913)469-3521. Access Services is located on the 2nd floor of the Student Center (SC 202).

RRIT 136

Title: Rail and Switch Point Repair Welding*
Number: RRIT 136
Effective Term: 2023-24
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Requirements:

Prerequisites: BNSF Railway Training Director approval and JCCC department approval.

Description:

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate safety at all times, to include: follow all safety rules and all safety procedures using related cutting, welding and grinding processes; oxy-propane heating; SMAW and FCAW processes; hydraulic rail saws and grinding equipment; personal protective equipment (PPE) and apparatus of all types.
Locate, identify and select controls, switches, dials, levers, buttons, guards, and operating and grounding devices related to welding power supplies, hydraulic rail saws, grinders, electrical test meters and manual gauging devices.
Prepare rail steel and switch points for welding by performing correct grinding and heating procedures according to current industry standards and welding repair manuals.
Identify metallurgical effects that take place in carbon and high carbon steel as the steel is heated and cooled.
Select correct current when operating welding machines (power supplies), i.e., Constant Current (CC) or Constant Voltage (CV).
Select the approved electrode type, size and parameters for the process being used for the repair of rail and switch point steel.
Perform maintenance and repairs on rail steel, switch points, and related cutting and grinding equipment according to the current welding repair manual.
Demonstrate the ability to successfully contour rail steel using the approved grinding techniques and gauging tools.
Describe several styles and sizes of formerly used and currently used switch points.
Use the approved dye penetration methods and gauging tools used to test welded repairs made to the surface of the rail steel and switch points after welding and grinding.

Content Outline and Competencies:

I. Safety

A. Follow correct and approved safety rules and procedures according to JCCC and BNSF safety sheets.

B. Use PPE when welding, cutting, sawing, grinding and testing procedures on rail steel and switch points.

C. Demonstrate correct and safe methods to set up, use and shut down the hydraulic power units, and the tools associated with the equipment.

D. Demonstrate correct and safe methods to set up and shut down the oxy-propane torch.

E. Demonstrate safety procedures when operating hydraulic rail saws and grinding equipment.

F. Demonstrate proper procedures when operating welding equipment.

G. Demonstrate the correct and safe method to set up and shut down the SMAW and FCAW equipment.

H. List safety rules for welding, cutting, hydraulic rail saws and grinding equipment.

II. Rail steel and switch point controls identification

A. Select correct amperage and voltage required for the operation of welding power supplies.

B. Use a multi-meter to accurately measure welding voltages and welding amperage at the welding arc.

C. Demonstrate the appropriate, correct and safe method of installing the (ground clamp) work piece connection.

D. Perform accurate cuts using a hydraulic rail saw.

E. Perform accurate grinding on rail steel and switch points using appropriate grinding stones to contour rail steel and mating surfaces of switch points to meet industry standards.

III. Rail steel and switch points preparation

A. Use current welding repair manual to select correct repair procedures.

B. Demonstrate correct methods to repair rail steel and switch points by welding and grinding.

C. Select the correct process, SMAW or FCAW, for the repair of rail steel and/or switch points according to the current welding repair manual.

D. List current industry standards for the repair of rail steel and switch points.

IV. Metallurgical effects identification

A. Explain the purpose for preheat, interpass temperature and post heat.

B. Explain selected metallurgical terms.

C. Explain the approved electrode composition for the SMAW and FCAW processes.

D. Demonstrate the proper use of temperature sensing devices.

E. List and define metallurgical effects of welds made when repair welding rail steel and switch points.

V. Welding power supplies current

A. Identify the correct welding electrode type for SMAW of rail steel and switch points.

B. Identify the correct welding electrode type for FCAW of rail steel and switch points.

C. Select the correct parameters (amps) for the SMAW process when welding on rail steel and switch points.

D. Select the correct parameters (volts) for the SMAW process when welding on rail steel and switch points.

E. List factors that determine the type, size and parameters when selecting electrodes.

VI. Electrode selection for (Pandrol Plates) repair

A. Identify the correct electrode type for the FCAW process.

B. Select the correct parameters (volts) for FCAW electrodes.

C. List factors that determine the type, size and parameters when using FCAW.

VII. Rail steel, switch points, and Pandrol welds

A. Perform minor maintenance on welding equipment, e.g., power supplies, hydraulic units, work piece connections, hydraulic rail saws and grinders, cables, electrode holders, wire feed units and wire feed guns, oxy-propane equipment.

B. Demonstrate by welding to industry standards, Pandrol (weld-on-shoulder) with the FCAW process.

C. List steps and/or methods used when making minor repairs to equipment used to maintain rail steel and switch points.

VIII. Contour radius and straight edge rail steel and switch point mating techniques

A. Select correct hydraulic grinding equipment.

B. Perform grinding techniques and procedures according to current welding manual.

C. List tools required to check contour, straight edge, radius and mating surface for rail steel and switch points.

D. Use correct technique and approved gauges to verify and conform radius and running surface of repaired rail and mating surfaces for switch points.

IX. Switch point styles and sizes

A. Follow approved practices and the current welding repair manual to identify switch point types and sizes.

B. Explain reasons for preventive grinding of switch points.

C. Identify general requirements for the repair of switch points

D. Define common sizes of selected switch points to include:

1. Knife Point switch point

2. Samson switch point

E. Demonstrate switch point preparation for grinding.

F. Demonstrate switch point welding repair.

G. Demonstrate switch point finish grinding.

H. Demonstrate switch point mating surface check

I. List essentials needed when determining if repairs are required.

X. Dye penetration procedures

A. Select approved dye penetrant solution.

B. Apply dye penetrant in a safe and correct manner.

C. Inspect rail and switch point surface for flaws or defects.

D. List steps to successfully perform the dye penetrant test on rail steel and/or switch points.

Method of Evaluation and Competencies:

Note: Lab competencies will be assigned a level of competency of 0-10,10 being high.

Demonstrate by achieving 100% on a safety test.
Demonstrate by achieving a minimum of 90% each on two quizzes.

50-60% Lab competencies
10-15% Participation
25-40% Written exams
Total: 100%

Grade Criteria:

95 – 100% = A
90 – 94% = B
80 – 89% = C
70 – 79% = D
0 – 69% = F

Caveats:

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 eye-wear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1) provide evidence that existing eye-wear meets ANSI Z87.1, or 2) wear cover goggles (if allowable), or 3) purchase and wear ANSI Z87.1 prescription eye-wear.

Student Responsibilities:

Disabilities:

RRIT 142

Title: Structural Pile Welding*
Number: RRIT 142
Effective Term: 2023-24
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Requirements:

Prerequisites: BNSF Railway Training Director approval and JCCC department approval.

Description:

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Identify and practice appropriate shop safety rules.
Explain a variety of testing and inspection methods and why they are used.
Perform weld tests and evaluate according to given standard or code.
Compare and contrast different welding processes and procedures.
Explain the reasons for pre and post heat when welding.
Demonstrate a basic understanding of blueprint reading.
Discuss and demonstrate correct pipe and H-beam preparation and fit up techniques.
Demonstrate skill in welding pipe and H-beam in the 2G position using both SMAW and FCAW.

Content Outline and Competencies:

I. Shop Safety Rules

A. Identify BNSF and JCCC safety rules. Select true statements concerning safe clothing requirements.

B. Identify statements concerning basic safety rules for oxyacetylene cylinder and gases.

C. Complete statements concerning eye protection.

D. Demonstrate the safe way of setting up oxyacetylene equipment.

E. Define SMAW an FCAW safety terms.

F. Complete statements concerning important rules for safe handling of welding cables.

G. Compare and contrast different types of welding hoods.

H. Determine steps in selecting a safe lens shade.

I. Select true statements concerning environmental safety requirements.

II. Testing and Inspection

A. Describe the difference between mechanical and non-destruction (NDT) testing.

B. List the twelve cost common discontinuities and the methods used to locate them.

C. Explain why welds are tested.

D. List the four most common root defects and the causes of each defect.

E. Discuss qualification standards for welding according to the AWS D1.1.96 code.

F. Evaluate a weld according to AWS D1.1.96 code parameters.

III. Welding Processes and Procedures

A. Describe the advantages of using different electrodes.

B. Compare and contrast the advantages and disadvantages of SMAW and FCAW for pile welding.

C. Describe the advantages and disadvantages of stringer and weave beads.

D. Discuss reasons for pre and post heat.

IV. Joint Preparation and Fit Up

A. Properly interpret blueprints to obtain proper joint fabrication and tolerances.

B. List the basic piling joints.

C. Compare and contrast an open joint to using a chill ring.

D. Discuss fish plating.

E. List causes and cures of fit up problems.

F. Explain lands and root openings.

G. Prepare pipe joints and H-beam joints for welding using a torch and grinder.

H. Align, fit up, and tack straight joints for welding in the 2G position.

I. Demonstrate the ability to prepare and tack weld fish plates on piling.

J. Prepare and fit up gussets on cap plates.

V. Pile Welding

A. Demonstrate ability to run root passes in the 2G.

B. Display the ability to run hot passes in the 2G.

C. Exhibit expertise in running filler and cover passes in the 2G position.

D. Demonstrate the ability to weld fish plate on H-beam piling.

E. Weld gussets onto cap plates and piling.

Method of Evaluation and Competencies:

15-25% Bend Test
50-70% Lab
5-15% Participation
3-7% Mid Term
3-7% Final Exam

Total: 100%

Grade Criteria:

95 – 100% = A
90 – 94% = B
80 – 89% = C
70 – 79% = D
0 – 69% = F

Caveats:

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.

Student Responsibilities:

Disabilities:

RRIT 145

Title: Frog Welding*
Number: RRIT 145
Effective Term: 2023-24
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Requirements:

Prerequisites: BNSF Railway Training Director approval and JCCC department approval.

Description:

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate safety at all times, to include: follow all safety rules and all safety procedures using carbon arc cutting with air (CAC-A), SMAW, FCAW processes, rail saws, and grinding equipment, personal protective equipment (PPE) and apparatus of all types.
Locate, identify and select controls, switches, dials, levers, buttons, guards and operating devices related to welding power supplies, carbon arc cutting with air equipment, grinders, test meters and gauging devices.
Repair austenitic manganese steel castings (frogs) for welding by performing correct procedures according to current industry standards and welding repair manuals.
Identify metallurgical effects that take place in austenitic manganese steel as the steel is heated and cooled.
Select correct current when operating welding machines (power supplies), i.e., constant current (CC) or constant voltage (CV).
Select the approved electrode type, size and parameters for the process being used for the repair of austenitic manganese steel.
Perform maintenance and repairs on austenitic manganese steel railroad frog castings and related equipment according to the welding repair manual with selected welding and cutting processes.
Demonstrate the ability to successfully contour austenitic manganese steel to railroad standards using the approved grinding techniques and gauging tools.
Use the approved dye penetration methods to test welded repairs made to the surface of the austenitic manganese steel castings before, during and after welding and grinding is completed.

Content Outline and Competencies:

I. Safety

A. Follow the correct and approved safety rules and procedures according to JCCC and BNSF safety sheets.

B. Use PPE when welding, cutting, grinding and testing procedures on rail steel.

C. Demonstrate correct and safe methods to set up and shut down the CAC-A cutting process.

D. Perform accurate cuts using the CAC-A process.

E. Demonstrate safety procedures when operating welding equipment.

F. Demonstrate proper procedures when operating grinding equipment.

G. List safety rules for welding and cutting austenitic manganese steel.

II. Austenitic Manganese Steel Castings

A. Select correct amperage and voltage required for the operation of welding power supplies.

B. Use a multi-meter to accurately measure welding voltages and welding amperage at the welding arc.

C. Demonstrate the correct method to set up and shut down grinding equipment.

D. Perform accurate grinding on austenitic manganese steel castings using appropriate grinding stones to contour rail steel to meet industry standards.

III. Austenitic manganese steel

A. Use current welding repair manual to select correct repair procedures for austenitic manganese steel.

B. Select SMAW or FCAW process for the correct industry standard for the repair of manganese steel castings.

C. Demonstrate correct methods for the welding repair of austenitic manganese steel.

D. List current industry standards for the repair of austenitic manganese steel.

IV. Austenitic manganese steel frog casting repair

A. Explain the term interpass temperature.

B. Interpret hardness levels of austenitic manganese steel.

C. List and define metallurgical terms associated with austenitic manganese steel welding.

V. SMAW, FCAW power supply operation

A. Explain the term SMAW as related to austenitic manganese steel.

B. Explain the term FCAW as related to austenitic manganese steel.

C. Demonstrate correct and safe methods to set up and shut down CC and CV power supplies.

D. Use a CC power supply to successfully weld austenitic manganese steel frog castings using the correct SMAW techniques.

E. Use a CV power supply to successfully weld austenitic manganese steel frog castings using the correct FCAW techniques.

F. List correct welding procedures for SMAW.

G. List correct welding procedures for FCAW.

VI. Rail Steel repair

A. Identify the correct electrode types for the SMAW process.

B. Identify the correct electrode type for the FCAW process.

C. Select the correct parameters (amps) for SMAW electrodes.

D. Select the correct parameters (volts) for FCAW electrodes.

E. List factors that determine the type, size and parameters when selecting electrodes.

VII. Austenitic manganese steel maintenance and repair

A. Use the current welding repair manual to locate correct procedures.

B. Perform minor maintenance on welding equipment, e.g., power supplies, cables, electrode holders, wire feed units and wire feed guns, CAC-A equipment.

C. List steps and/or methods used to make minor repairs to equipment used to maintain austenitic manganese steel.

VIII. Austenitic manganese steel frog castings

A. Select appropriate grinding equipment when working on an austenitic manganese steel railroad frog casting.

B. Perform grinding procedures according to current welding manual.

C. List correct gauging tools required to check contour and straight edging of austenitic manganese steel frogs.

D. Use correct technique and approved gauges to verify and confirm radius and running surface of repaired austenitic manganese steel railroad frog casting.

IX. Railroad frogs surface defects inspection

A. Select approved dye penetrant solution.

B. Apply dye penetrant in a safe and correct manner.

C. Inspect austenitic manganese steel frog surface for flaws or defects.

D. List steps to successfully perform the dye penetrant test on austenitic manganese steel frogs.

Method of Evaluation and Competencies:

Note: Lab competencies will be assigned a level of competency of 0-10, 10 being high.

Demonstrate by achieving 100% on a safety test.
Demonstrate by achieving a minimum of 80% each on two tests.

5-15% Participation
40-60% Classroom and Lab competencies
5-15% Midterm exam
25-35% Written final exam

Total: 100%

Grade Criteria:

95 –100% = A
90 – 95% = B
80 – 89% = C
70 – 79% = D
0 – 69% = F

Caveats:

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 Statute(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:

provide evidence that existing eyewear meets ANSI Z87.1, or
wear cover goggles (if allowable), or
purchase and wear ANSI Z87.1 prescription eye-wear.

Student Responsibilities:

Disabilities:

RRIT 160

Title: Basic Welding*
Number: RRIT 160
Effective Term: 2023-24
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Requirements:

Prerequisites: BNSF Railway Training Director approval and JCCC department approval.

Description:

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate shop safety and the safety rules required when using various welding and cutting processes.
Demonstrate the shielded metal arc welding (SMAW) process.
Demonstrate the flux core arc welding (FCAW) process.
Demonstrate the oxy-propane cutting (OPC) or oxyfuel cutting (OFC) process.
Demonstrate the plasma arc cutting (PAC) and plasma arc gouging processes.
Demonstrate the air carbon arc cutting (CAC-A) process.
Demonstrate the ability to weld selected lab projects.
Demonstrate the ability to set up, weld and test v-groove welds.
Demonstrate the ability to visually inspect welds in accordance with the AWS D15.1 code.
Pass an AWS D15.1 code test.

Content Outline and Competencies:

I. Safety Rules and Procedures

A. Follow safety rules and procedures at all times.

B. Demonstrate the appropriate use of personal protective equipment (PPE).

C. Describe safety hazards associated with cutting and welding.

II. Oxyfuel Cutting

A. Demonstrate the set up and breakdown of oxyfuel cutting equipment.

B. Demonstrate straight cuts on steel plate.

III. Plasma Arc Cutting and Gouging

A. Demonstrate the setup and breakdown of plasma arc cutting and gouging equipment.

B. Demonstrate straight cuts on steel plate.

C. Gouge the backing strips off the 1 1/2" test coupons.

IV. Air Carbon Arc Cutting

A. Demonstrate the set up and breakdown of air carbon arc cutting equipment.

B. Remove 1/4" backing plate from the single-v-groove test plate.

V. SMAW Fillet Welds in Selected Positions

A. Demonstrate proper PPE.

B. Demonstrate correct base metal preparation.

C. Demonstrate proper electrode selection.

D. Demonstrate proper welding techniques.

E. Successfully complete selected quality fillet welds.

VI. SMAW Groove Welds in Selected Positions

A. Demonstrate proper PPE.

B. Demonstrate correct base metal preparation.

C. Demonstrate proper electrode selection.

D. Demonstrate proper welding techniques.

E. Successfully complete selected quality groove welds.

F. Demonstrate correct heat control techniques.

G. Pass an AWS D15.1 groove weld test.

V. FCAW Fillet Welds in Selected Positions

A. Demonstrate proper PPE.

B. Demonstrate correct base metal preparation.

C. Demonstrate proper electrode selection.

D. Demonstrate proper welding techniques.

E. Successfully complete selected quality fillet welds.

VI. FCAW Groove Welds in Selected Positions

A. Demonstrate proper PPE.

B. Demonstrate correct base metal preparation.

C. Demonstrate proper electrode selection.

D. Demonstrate proper welding techniques.

E. Successfully complete selected quality groove welds.

F. Demonstrate correct heat control techniques.

G. Pass an AWS D15.1 groove weld test.

VII. Visual Inspection of Welds

A. Identify common visual discontinuities and defects on welds.

B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.

C. Use appropriate inspection tools.

VIII. Destructive Inspection of Welds

A. Perform face and root bends in accordance with AWS D15.1.

B. Inspect face and root bends in accordance with AWS D15.1.

Method of Evaluation and Competencies:

30-40% Lab Competencies
5-15% Classroom/Lab Participation
3-7% Midterm Test
5-15% Final Test
35-45% Code Weld Tests

Total: 100%

Grade Criteria:

95 – 100% = A
90 – 94% = B
80 – 89% = C
70 – 79% = D
0 – 69% = F

Caveats:

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. Students who wear prescription glasses must: a) provide evidence that existing eyewear meets ANSI Z87.1, or b) wear cover goggles (if allowable), or c) purchase and wear ANSI Z87.1 prescription eyewear.
Face Shield and Goggles: When grinding with a hand grinder, BNSF requires that students wear approved face shield and goggles.
Boots: BNSF approved footwear is required.
Welding Helmet: BNSF approved welding helmet is supplied for students.
Welding Gloves and Jacket: BNSF approved welding gloves and jackets are supplied for students.
Ear Plugs: BNSF approved ear plugs are supplied for students.

Student Responsibilities:

Disabilities:

RRIT 162

Title: Structural Stick Welding*
Number: RRIT 162
Effective Term: 2023-24
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Requirements:

Prerequisites: BNSF Railway Training Director approval and JCCC department approval.

Description:

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate shop safety and the safety rules required when using various welding and cutting processes.
Demonstrate the ability to weld selected lab projects.
Demonstrate proper weld bead sequencing on multi-pass groove welds using shielded metal arc welding (SMAW).
Demonstrate the shielded metal arc welding (SMAW) process in the horizontal (2G), vertical up (3G), and overhead (4G) positions.
Demonstrate the ability to set up, weld and test v-groove welds in the horizontal (2G), vertical up (3G), and overhead (4G) positions.
Demonstrate the ability to visually inspect welds in accordance with the AWS D15.1 code.
Pass AWS D15.1 test plates for unlimited thickness in the horizontal (2G), vertical up (3G), and overhead (4G) positions.

Content Outline and Competencies:

I. Safety Rules and Procedures

A. Follow safety rules and procedures at all times.

B. Demonstrate the appropriate use of personal protective equipment (PPE).

C. Describe safety hazards associated with cutting and welding.

II. SMAW Fillet Welds in Selected Positions

A. Demonstrate proper PPE.

B. Demonstrate correct base metal preparation.

C. Demonstrate proper electrode selection.

D. Demonstrate proper welding techniques.

E. Complete selected quality fillet welds.

III. SMAW Groove Welds in Selected Positions

A. Demonstrate proper PPE.

B. Demonstrate correct base metal preparation.

C. Demonstrate proper electrode selection.

D. Demonstrate proper welding techniques.

E. Successfully complete selected quality groove welds.

F. Demonstrate correct heat control techniques.

G. Pass an AWS D15.1 groove weld tests in the horizontal, vertical up, and overhead positions.

IV. Visual Inspection of Welds

A. Identify common visual discontinuities and defects on welds.

B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.

C. Use appropriate inspection tools.

V. Destructive Inspection of Welds

A. Perform side bends in accordance with AWS D15.1.

B. Inspect side bends in accordance with AWS D15.1.

Method of Evaluation and Competencies:

5-15% Lab Competencies
5-15% Classroom/Lab Participation
3-7% Midterm Test
10-20% Final Test
15-25% 2G Code Test
15-25% 3G Code Test
15-25% 4G Code Test

Total: 100%

Grade Criteria:
A = 95 - 100%
B = 90 - 94%
C = 80 - 89%
D = 70 - 79%
F = 0 - 69%

Grade Criteria:

95 – 100% = A
90 – 94% = B
80 – 89% = C
70 – 79% = D
0 – 69% = F

Caveats:

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. Students who wear prescription glasses must: a) provide evidence that existing eyewear meets ANSI Z87.1, or b) wear cover goggles (if allowable), or c) purchase and wear ANSI Z87.1 prescription eyewear.
Face Shield and Goggles: When grinding with a hand grinder, BNSF requires that students wear approved face shield and goggles.
Boots: BNSF approved footwear is required.
Welding Helmet: BNSF approved welding helmet is supplied for students.
Welding Gloves and Jacket: BNSF approved welding gloves and jackets are supplied for students.
Ear Plugs: BNSF approved ear plugs are supplied for students.

Student Responsibilities:

Disabilities:

RRIT 164

Title: Structural Wire Welding*
Number: RRIT 164
Effective Term: 2023-24
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Requirements:

Prerequisites: BNSF Railway Training Director approval and JCCC department approval.

Description:

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate shop safety and the safety rules required when using various welding and cutting processes.
Demonstrate the ability to weld selected lab projects.
Demonstrate proper weld bead sequencing on multi-pass groove welds using flux core arc welding (FCAW).
Demonstrate the flux core arc welding (FCAW) process in the horizontal (2G), vertical up (3G), and overhead (4G) positions.
Demonstrate the ability to set up, weld and test v-groove welds in the horizontal (2G), vertical up (3G), and overhead (4G) positions.
Demonstrate the ability to visually inspect welds in accordance with the AWS D15.1 code.
Pass AWS D15.1 test plates for unlimited thickness in the horizontal (2G), vertical up (3G), and overhead (4G) positions.

Content Outline and Competencies:

I. Safety Rules and Procedures

A. Follow safety rules and procedures at all times.

B. Demonstrate the appropriate use of personal protective equipment (PPE).

C. Describe safety hazards associated with cutting and welding.

II. FCAW Fillet Welds in Selected Positions

A. Demonstrate proper PPE.

B. Demonstrate correct base metal preparation.

C. Demonstrate proper equipment set up for the FCAW process.

D. Demonstrate proper welding techniques.

E. Successfully complete selected quality fillet welds.

III. FCAW Groove Welds in Selected Positions

A. Demonstrate proper PPE.

B. Demonstrate correct base metal preparation.

C. Demonstrate proper equipment set up for the FCAW process.

D. Demonstrate proper welding techniques.

E. Successfully complete selected quality groove welds.

F. Demonstrate correct heat control techniques.

G. Pass an AWS D15.1 groove weld tests in the horizontal, vertical up, and overhead positions.

IV. Visual Inspection of Welds

A. Identify common visual discontinuities and defects on welds.

B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.

C. Use appropriate inspection tools.

V. Destructive Inspection of Welds

A. Perform side bends in accordance with AWS D15.1.

B. Inspect side bends in accordance with AWS D15.1.

Method of Evaluation and Competencies:

5-15% Lab Competencies
5-15% Classroom/Lab Participation
3-7% Midterm Test
10-20% Final Test
15-25% 2G Code Test
15-25% 3G Code Test
15-25% 4G Code Test

Total: 100%

Grade Criteria:

95 – 100% = A
90 – 94% = B
80 – 89% = C
70 – 79% = D
0 – 69% = F

Caveats:

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. Students who wear prescription glasses must: a) provide evidence that existing eyewear meets ANSI Z87.1, or b) wear cover goggles (if allowable), or c) purchase and wear ANSI Z87.1 prescription eyewear.
Face Shield and Goggles: When grinding with a hand grinder, BNSF requires that students wear approved face shield and goggles.
Boots: BNSF approved footwear is required.
Welding Helmet: BNSF approved welding helmet is supplied for students.
Welding Gloves and Jacket: BNSF approved welding gloves and jackets are supplied for students.
Ear Plugs: BNSF approved ear plugs are supplied for students.

Student Responsibilities:

Disabilities:

RRIT 166

Title: Mechanical Welding Air Brake Pipe*
Number: RRIT 166
Effective Term: 2023-24
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Requirements:

Prerequisites: Department approval.

Description:

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate and describe shop safety.
Demonstrate the ability to weld selected lab projects.
Demonstrate proper welding techniques using shielded metal arc welding and flux core arc welding.
Demonstrate the shielded metal arc welding and flux core arc welding processes on various pipe welds.
Demonstrate the ability to visually inspect welds.
Demonstrate the ability to conduct visual and destructive inspections of welds in accordance with the AWS D15.1 code.
Pass AWS D15.1 pipe tests.

Content Outline and Competencies:

I. Safety Rules and Procedures
  A. Follow safety rules and procedures at all times.
  B. Demonstrate the appropriate use of personal protective equipment (PPE).
  C. Describe safety hazards associated with cutting and welding.

II. SMAW and FCAW Fillet Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality fillet welds.

III. SMAW and FCAW Groove Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Complete selected quality groove welds.
  F. Demonstrate correct heat control techniques.
  G. Pass an AWS D15.1 pipe tests.

IV. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.
  C. Use appropriate inspection tools.

V. Destructive Inspection of Welds
  A. Perform face and root bends in accordance with AWS D15.1.
  B. Inspect face and root bends in accordance with AWS D15.1.

Method of Evaluation and Competencies:

Lab Competencies 10%
Classroom/Lab Participation 10%
Midterm Test 5%
Final Test 15%
Pipe Code Tests 60%
TOTAL 100%

Grade Criteria:

A = 95 - 100%
B = 90 - 94%
C = 80 - 89%
D = 70 - 79%
F = 0 - 69%

Grade Criteria:

Caveats:

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. Students who wear prescription glasses must: a) provide evidence that existing eyewear meets ANSI Z87.1, or b) wear cover goggles (if allowable), or c) purchase and wear ANSI Z87.1 prescription eyewear.
Face Shield and Goggles: When grinding with a hand grinder, BNSF requires that students wear approved face shield and goggles.
Boots: BNSF approved footwear is required.
Welding Helmet: BNSF approved welding helmet is supplied for students.
Welding Gloves and Jacket: BNSF approved welding gloves and jackets are supplied for students.
Ear Plugs: BNSF approved ear plugs are supplied for students.

Student Responsibilities:

Disabilities:

RRIT 168

Title: Sheet Metal Welding*
Number: RRIT 168
Effective Term: 2023-24
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Requirements:

Prerequisites: BNSF Railway Training Director approval and JCCC department approval.

Description:

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate shop safety and the safety rules required when using various welding and cutting processes.
Demonstrate the ability to weld selected lab projects.
Demonstrate proper welding techniques required for groove, flare-bevel, and fillet welding sheet metal using the gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) processes.
Demonstrate the ability to set up, weld and test sheet metal welds.
Demonstrate the ability to visually inspect welds in accordance with the AWS D15.1 code.
Pass AWS D15.1 sheet metal tests.

Content Outline and Competencies:

I. Safety Rules and Procedures

A. Follow safety rules and procedures at all times.

B. Demonstrate the appropriate use of personal protective equipment (PPE).

C. Describe safety hazards associated with cutting and welding.

II. GMAW and GTAW Fillet Welds in Selected Positions

A. Demonstrate proper PPE.

B. Demonstrate correct base metal preparation.

C. Demonstrate proper electrode and filler metal selection.

D. Demonstrate proper welding techniques.

E. Successfully complete selected quality fillet welds.

F. Pass an AWS D15.1 sheet metal fillet weld tests.

III. GMAW and GTAW Groove Welds in Selected Positions

A. Demonstrate proper PPE.

B. Demonstrate correct sheet metal preparation.

C. Demonstrate proper electrode and filler metal selection.

D. Demonstrate proper welding techniques.

E. Successfully complete selected quality groove and flare-bevel welds.

F. Pass an AWS D15.1 sheet metal groove and flare-bevel tests.

IV. Visual Inspection of Welds

A. Identify common visual discontinuities and defects on welds.

B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.

C. Use appropriate inspection tools.

V. Destructive Inspection of Welds

A. Perform sheet metal tests in accordance with AWS D15.1.

B. Inspect sheet metal tests in accordance with AWS D15.1.

Method of Evaluation and Competencies:

5-15% Classroom/Lab Participation
3-7% Midterm Test
5-15% Final Test
70-80% Sheet Metal Code Tests

Total: 100%

Grade Criteria:

95 – 100% = A
90 – 94% = B
80 – 89% = C
70 – 79% = D
0 – 69% = F

Caveats:

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. Students who wear prescription glasses must: a) provide evidence that existing eyewear meets ANSI Z87.1, or b) wear cover goggles (if allowable), or c) purchase and wear ANSI Z87.1 prescription eyewear.
Face Shield and Goggles: When grinding with a hand grinder, BNSF requires that students wear approved face shield and goggles.
Boots: BNSF approved footwear is required.
Welding Helmet: BNSF approved welding helmet is supplied for students.
Welding Gloves and Jacket: BNSF approved welding gloves and jackets are supplied for students.
Ear Plugs: BNSF approved ear plugs are supplied for students.