Piping Fabrication Operation Level 2

STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN (NATIONAL OCCUPATIONAL SKILLS STANDARD)

PIPING FABRICATION OPERATION (OIL, GAS AND PETROCHEMICAL) LEVEL 2

JABATAN PEMBANGUNAN KEMAHIRAN KEMENTERIAN SUMBER MANUSIA, MALAYSIA

0

TABLE OF CONTENTS

No.

Pages

Contents

1.

Introduction

1

2.

Occupational Structure

2

3.

Definition Of Competency Levels

3

4.

Malaysian Skill Certification

4

5.

Job Competencies

4

6.

Working Conditions

4

7.

Employment Prospects

5

8.

Sources Of Additional Information

6

9.

Approval Date

6

10. Acknowledgement

6

11. Committee Members for Development of Standard Practice (SP), Job

7

Profile Chart (JPC) And Competency Profile (CP) 12. Committee Members for Development Curriculum of Competency

8

Unit (CoCu) 13. Job Profile Chart (JPC)

9

14. Competency Profile (CP)

10-19

15. Curriculum of Competency Unit (CoCu): Piping Fabrication Material

20-27

Preparation 16. Curriculum of Competency Unit (CoCu): Pipe Cutting Work Handling

28-35

17. Curriculum of Competency Unit (CoCu): Pipe Jointing (Fit Up)

36-42

18. Curriculum of Competency Unit (CoCu): Pipe Support Fabrication

43-50

19.

51

Summary of Training Duration

i

STANDARD PRACTICE NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR PIPING FABRICATION OPERATION LEVEL 2

1. INTRODUCTION Pipe fabrication is the process of manufacturing and fabricating predesigned piping systems for various uses. Though plumber and piping fabrication are same in dealing with pipes, Piping Fabrication usually used in large sectors and consumptions such as in oil refineries,

residential irrigation, HVAC

1

(Heating, Ventilation & Air Conditioning), fire fighting pipelines, mechanical

construction firms, chemical plant, nuclear power plant, gas plant, hospitals, pharmaceutical companies, shipyards, semiconductor plant and etc. The Piping Fabrication personnel are very important precisely in oil and gas companies for pipe installation and maintenance. They are part of a piping crew in the oil and gas company which is responsible in ensuring and inspecting damages or breakdowns of the pipe systems. Nowadays, Globalisation helps us in the diversity of world economy. It reduced firm barrier and make the international economy’s unification. People during these days are free to market or commercialize themselves in terms of skills, knowledge, experiences, products and services they had. Thus, Piping Fabrication personnel have opportunity to work abroad when they are gradually trained and excellent with their skills. Since Malaysia is also producing oils and gasses, many companies and organization are currently active in oil exploration, R&D (Research & Development), extraction and operation. There are also actively support personnel who are inspired and interested to work in piping fabrication (Pipefitter). Therefore, this National Occupational Skills Standard (NOSS) document is arranged and developed in order to be used for generating skilful and experience personnel in this specified occupation or competency. 1

Pipe Fitting, http://en.wikipedia.org/wiki/Pipe_fitting (November 2011)

1

2. OCCUPATIONAL STRUCTURE Piping Fabrication personnel come under the Sector of oil and gas and SubSector of oil, gas and petrochemical. Figure 1.1 and Figure 1.2 show the structured career path of piping fabrication personnel. SECTOR

OIL and GAS

SUB

OIL, GAS AND PETROCHEMICAL

TECHNICAL

Level 5

TECHNICAL ENGINEER

level 4

TECHNICAL SUPERVISOR

level 3

DRAFTSMAN

level 2

No Level

level 1

No Level

METAL STRUCTURE FABRICATION STRUCTURE FABRICATION ENGINEER STRUCTURE FABRICATION SUPERVISOR METAL STRUCTURE FABRICATION FOREMAN METAL STRUCTURE FABRICATION TRADESMAN

PIPING FABRICATION

QUALITY ASSURANC E

PIPING SUPPORT

PIPING

PROJECT COORDINATOR

QA/QC MANAGER/E NGINEER

PIPING SUPERVISOR

SUPERVISOR SUPPORT

QA INSPECTOR

PIPING FOREMEN

FOREMEN SUPPORT

QC INSPECTOR

PIPE FITTER

FITTER SUPPORT

No Level

No Level

No Level

Figure 1.1 Occupational Profile Chart for Piping Fabrication Personnel

SECTOR

OIL AND GAS

SUBSECTOR


AREA

PIPING

L5

PIPING FABRICATION MANAGEMENT

L4

PIPING FABRICATION SUPERVISION

L3

PIPING FABRICATION OPERATION

L2


L1

No Level

Figure 1.2 Occupational Area Analysis (OAA) Chart for Piping Fabrication Personnel

2

-

3. DEFINITION OF COMPETENCY LEVEL The NOSS is developed for various occupational areas. Candidates for certification must be assessed and trained at certain levels to substantiate competencies. Below is a guideline of each NOSS Level as defined by the Department of Skills Development, Ministry of Human Resources, Malaysia. Malaysia Skills Certificate Level 1: (Operation Level)

Competent in performing a range of varied work activities, most of which are routine and predictable. Competent in performing a significant range of varied work activities, performed in a variety of contexts. Some of the activities are non-routine and required individual responsibility and autonomy. Competent in performing a broad range of varied work activities, performed in a variety of contexts, most of which are complex and non-routine. There is considerable responsibility and autonomy and control or guidance of others is often required. Competent in performing a broad range of complex technical or professional work activities performed in a wide variety of contexts and with a substantial degree of personal responsibility and autonomy. Responsibility for the work of others and allocation of resources is often present. Competent in applying a significant range of fundamental principles and complex techniques across a wide and often unpredictable variety of contexts. Very substantial personal autonomy and often significant responsibility for the work of others and for the allocation of substantial resources features strongly, as do personal accountabilities for analysis, diagnosis, planning, execution and evaluation.

Malaysia Skills Certificate Level 2: (Operation Level)

Malaysia Skills Certificate Level 3: (Supervisory Level)

Malaysia Skills Diploma Level 4: (Executive Level)

Malaysia Skills Advanced Diploma Level 5: (Managerial Level)

3

4. MALAYSIAN SKILL CERTIFICATION Candidates after being assessed and verified and fulfilled Malaysian Skill Certification requirements shall be awarded with Malaysia Skills Certificate (SKM) for Level 2. Pre-requisite The minimum requirements proposed by the industrial experts for those interested to enrol this course are as follows: •

Possesses minimum PMR certificate

•

Good eye-sight

•

Medically fit

•

Knowledge in English would be advantage.

5. JOB COMPETENCIES: Piping Fabrication Operation Personnel (Level 3) is designated to carry out the necessary operations to produce pipe spools. Tasks include: •

Performing Piping Fabrication Material Preparation

•

Performing Pipe Cutting Work Handling

•

Performing Pipe Jointing (Fit Up)

•

Performing Pipe Support Preparation

6. WORKING CONDITIONS Piping Fabrication (Pipe Fitter) personnel usually work in large industry and various sectors in which they are often deal with their supervisors, co-workers and subordinate in completing piping fabrication project.

Piping fabrication personnel usually work in groups and sometimes working in workshop environment. Personnel should be competent and machine aptitude in preparing, installation and maintenance of the pipe systems.

4

They also need to be particular in tools and equipment preparation before piping installation and maintenance activity starts. On the other hand, they also need to have knowledge in precaution and safety for safe working condition.

Through gradual training in piping fabrication, they may encounter skills and experiences to be used for domestic and commercial business purposes. Consequently, they will also have opportunity to work abroad and the remuneration is also enormous. 7. EMPLOYMENT PROSPECTS Malaysia is rich with both renewable and non-renewable sources of energy. One of the non-renewable sources of energy is petroleum (oil). The oil exploration started in the beginning of 20th century in Sarawak, where the oils was first discovered in 1909 and first produced in 19102. Thus, many companies and organization are involved into this industry as it was examined would be the most valuable and profitable for business and country's revenues. This industry started to be more focuses in various activities such as exploration, R&D (Research & Development), extraction and operation. Those activities are supporting by numerous government and related agencies. As consequence, there are plenty of job opportunities offered and available. The industry currently have less skilful and experience workforce or personnel in piping fabrication. Piping Fabrication personnel would be hired in many sectors such as HVAC construction firms, fire fighting pipelines, mechanical construction firms, oil refineries, chemical plants, pharmaceutical companies, semiconductor plants and many more. Therefore, industry is encouraging personnel who are inspired and interested to be one of the skilful and expert in oil & gas industry. 2

Jurutera; The Malaysian Oil and Gas Industry: An Overview,http://myiem.org.my/assets/download/JanBul05.pdf (November 2011)

5

8. SOURCES OF ADDITIONAL INFORMATION LOCAL SOURCES •

Offshore Structure Fabricators Association of Malaysia (OSFAM) B-2-05, Jalan SS6/20, Dataran Glomac Kelana Jaya Business Centre 47301 Petaling Jaya, Selangor Malaysia Phone

: +603 78046502

Email : [email protected] URL

: www.osfam.org.my

INTERNATIONAL SOURCES •

National Association of Pipe Fabricators URL: www.napf.com

9.

APPROVAL DATE The National Skills Development Board (MPKK), Ministry of Human Resources has agreed and endorsed this Standard on ………………………………….

10.

ACKNOWLEDGEMENT The Director General of DSD would like to extend his gratitude to the organisations and individuals who have been involved in developing this standard.

6

11. COMMITTEE MEMBERS FOR DEVELOPMENT OF STANDARD PRACTICE (SP), JOB PROFILE CHART (JPC) AND COMPETENCY PROFILE (CP) PIPING FABRICATION OPERATION

LEVEL 2

PANEL 1.

MOHD SABRI BIN IDRIS

SUPERVISOR HYUNDAI ENGINEERING PFCE

2.

MOKHTAR BIN MAT

FOREMEN NEWWIN ENGINEERING

3.

RUSLAN ABD RAHIM

FOREMEN MUSHTARI ENGINEERING

4.

KHAIRUAZUAN BIN MAT NARASIK HYUNDAI ENGINEERING PFCE

5.

SAIMI BIN A. RAHIM

PIPE FITTER NEWWIN ENGINEERING

6.

AFFENDY BIN MOHAMAD

PIPE FITTER AQEEL ENGINEERING

7.

HAMAD HASSAN BIN KASIM


8.

SHAHIMI BIN SULONG

PIPE FITTER MUSHTARI ENGINEERING

PIPE FITTER

FACILITATOR 1.

TRAINING CONSULTANT IDAMAN JAUHARI SDN BHD

MOHD KHAIRULLAH BIN AB MANAF

CO-FASILITATOR 1.

NABLAN BIN YUSOFF

DIRECTOR IDAMAN JAUHARI SDN BHD

2.

NOORPAZURA BAHARUDDIN

TRAINING EXECUTIVE IDAMAN JAUHARI SDN BHD

7

12.

COMMITTEE MEMBERS FOR DEVELOPMENT COMPETENCY UNIT (CoCU) PIPING FABRICATION OPERATION

OF

CURRICULUM

LEVEL 2

PANEL 1. MOHD SABRI BIN IDRIS

SUPERVISOR HYUNDAI ENGINEERING PFCE

2. MOKHTAR BIN MAT

FOREMEN NEWWIN ENGINEERING

3. RUSLAN ABD RAHIM

FOREMEN MUSHTARI ENGINEERING

4. KHAIRUAZUAN BIN MAT NARASIK

PIPE FITTER HYUNDAI ENGINEERING PFCE

5. SAIMI BIN A. RAHIM

PIPE FITTER NEWWIN ENGINEERING

6. AFFENDY BIN MOHAMAD


7. HAMAD HASSAN BIN KASIM


8. SHAHIMI BIN SULONG

PIPE FITTER MUSHTARI ENGINEERING

9. KAMAL BAHRIN BIN OMAR

INSTRUCTOR AKADEMIK BINAAN MALAYSIA

10. MOHD NORDIN BIN MOHAMED

INSTRUCTOR AKADEMIK BINAAN MALAYSIA

11. ZAIHAN BIN HASAN

INSTRUCTOR INSTITUT LATIHAN PERINDUSTRIAN FACILITATOR

1.

TRAINING CONSULTANT IDAMAN JAUHARI SDN BHD

MOHD KHAIRULLAH BIN AB MANAF

CO-FASILITATOR 1.

NABLAN BIN YUSOFF

2.

NOORPAZURA BAHARUDDIN

DIRECTOR IDAMAN JAUHARI SDN BHD TRAINING EXECUTIVE IDAMAN JAUHARI SDN BHD

8

of

JOB PROFILE CHART (JPC) SECTOR

OIL AND GAS

SUB SECTOR


JOB AREA


JOB LEVEL

TWO (2)

JOB AREA CODE

COMPETENCY

CORE

COMPETENCY UNIT PIPING FABRICATION MATERIAL PREPARATION

PIPE CUTTING WORK HANDLING

9

PIPE JOINTING (FIT UP)

PIPE SUPPORT FABRICATION

COMPETENCY PROFILE (CP) Sub Sector


Job Area


Level

TWO (2) CU Title

1. Pipe Fabrication Material Preparation

CU Code

CU Descriptor Pipe

Fabrication

CU Work Activities

Material

Preparation is a process to prepare

material

1. Identify piping material dimension

including

Performance Criteria 1.1 Isometric drawing interpreted 1.2 Isometric drawing symbol

tools and equipment starting

determined

from interpretation of isometric

1.3 Pipe spool number

drawing to determine required

determined

material specification until the

1.4 Isometric drawing symbol to

required material, tools and

pipe fabrication material

equipment

matched

ready

for

fabrication work.

1.5 Material dimension confirmed 2. Identify material heat number

2.1 Piping colour coding determined 2.2 Pipe fabrication work specification determined 2.3 Material code number

10

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria determined 2.4 Heat number confirmed

3. Perform pipe fabrication material preparation

3.1 Pipe fabrication work material specification confirmed 3.2 Pipe fabrication work material quantity confirmed 3.3 Pipe length calculate 3.4 Calculated pipe length reviewed 3.5 Calculated pipe length confirmed

4. Perform prepared piping material arrangement at workplace

4.1 Allocated workplace determined 4.2 Transportation methodology determined 4.3 Prepared material checked 4.4 Prepared material to workplace delivered

11

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria 4.5 Material at workplace arrange

5. Perform pipe fabrication

5.1 Types of tools and

work hand tools and

equipment for pipe

equipment preparation

fabrication work determined 5.2 Fabrication work equipment consumable determined 5.3 Suitable tools, equipment and consumables for pipe fabrication work selected 5.4 Selected tools and equipment for pipe fabrication work suitability confirmed

2. Pipe Cutting Work Handling

Pipe Cutting Work Handling is a 1. Perform cutting equipment process to cut piping material

condition checking

1.1 Cutting equipment set obtained

starting from ensuring cutting

1.2 Cutting equipment set

equipment in good condition

accessories condition

until piping material cut into

checked

required length and size based

12

1.3 Cutting equipment condition

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria ensured

on Isometric Drawing

1.4 Hot cutting equipment checking procedure followed

2. Perform pipe marking

2.1 Pipe colour coding confirmed 2.2 Required length confirmed 2.3 Pipe marked for cutting 2.4 Marked pipe punched 2.5 Pipe marking confirmed

3. Perform pipe cutting

3.1 Material marking point confirmed 3.2 Cutting technique determined 3.3 Suitable cutting tools, equipment & consumable selected 3.4 Pipe cut and bevelled 3.5 Cut pipe to fabrication

13

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria workplace delivered

4. Perform pipe edge preparation

4.1 Grinding equipment identified 4.2 Grinding technique identified 4.3 Suitable grinding equipment selected 4.4 Pipe grinding executed 4.5 Pipe bevelling accuracy confirmed

5. Perform pipe cutting area housekeeping

5.1 Types of pipe determined fabrication work material waste 5.2 Pipe fabrication workplace housekeeping procedure determined 5.3 Unused pipe to storage area returned 5.4 Cutting material waste

14

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria disposal technique applied 5.5 Pipe cutting area housekeeping completion confirmed

3. Pipe Jointing (Fit Up)

a 1. Perform pipe alignment for fit 1.1 Fitting requirement

Pipe Jointing (Fit Up) is

process to fit up pipe starting

up

determined 1.2 Piping gap for welding

from pipe alignment until pipe

ensured

spool produced according to Isometric drawing requirement

1.3 Pipe stability ensured

and ready for welding

1.4 Pipe for fit up aligned 1.5 Pipe hi-low checked 1.6 Pipe dimension checked 1.7 Pipe alignment for fit up confirmed

2. Perform pipe jointing (fit-up)

2.1 Isometric drawing requirement confirmed 2.2 Pipe alignment confirmed 2.3 Pipe dimension confirmed 2.4 Pipe gap confirmed

15

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria 2.5 Fit up pipe checked 2.6 Pipe fit up ready for tack weld ensured

3. Perform joint number recording on pipe

3.1 Pipe fit up completion confirmed 3.2 Joint number and drawing number determined 3.3 Pipe joint number on pipe recorded 3.4 Pipe joint report prepared 3.5 Recorded pipe joint number checked 3.6 Pipe joint report reviewed 3.7 Pipe joint report and record completion confirmed 3.8 Pipe joint report and record to foremen submitted

16

CU Title 4. Pipe Support Fabrication

CU Code

CU Descriptor

CU Work Activities

Pipe Support Fabrication is a process to fabricate pipe support

1. Perform pipe support material preparation

Performance Criteria 1.1 Template isometric drawing for pipe support preparation interpreted

starting from material preparation, marking and cutting

1.2 Support detail drawing for

until complete pipe support

pipe support preparation

produced as per pipe support

interpreted 1.3 Isometric drawing symbol

drawing

to pipe support material matched 1.4 Material dimension confirmed 1.5 Pipe support fabrication work material specification confirmed 1.6 Pipe support fabrication work material quantity confirmed 1.7 Pipe support length calculated

17

CU Title

CU Code

CU Descriptor

CU Work Activities 2. Perform pipe support

material marking

Performance Criteria 2.1 Pipe support size confirmed 2.2 Pipe support material required length confirmed 2.3 Pipe support material for cutting marked 2.4 Marked pipe support template punched 2.5 Pipe support template marking confirmed

3. Perform pipe support material cutting

3.1 Pipe support material marking point confirmed 3.2 Pipe support material cutting technique determined 3.3 Suitable cutting tools, equipment & consumable selected 3.4 Pipe support material cut and bevelled

18

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria 3.5 Cut pipe support material to installation workplace delivered

4. Perform pipe support material grinding

4.1 Grinding equipment determined 4.2 Grinding technique determined 4.3 Suitable grinding equipment selected 4.4 Pipe support material grinding executed 4.5 Pipe support bevelling accuracy confirmed 4.6 Pipe support fit up ready for tack weld ensured

19

CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector


Job Area


Competency Unit Title

PIPING FABRICATION MATERIAL PREPARATION

Competency Unit Descriptor Competency Unit ID

Work Activities

1. Identify piping material dimension

Pipe Fabrication Material Preparation is a process to prepare material including tools and equipment starting from interpretation of isometric drawing to determine required material specification until the required material, tools and equipment ready for fabrication work. Training 137 Level 2 Credit Hours Duration Hours

Related Knowledge

Applied Skills

i. ii. iii. iv. v.

Isometric drawing Piping material Piping size Piping schedule Types of drawing symbol • Joint such as: o Butt weld o Socket Weld o Thread • Valve vi. Pipe fittings such as • Flange • Elbow • Lateral • Tee • Concentric Reducer

Attitude / Safety / Environmental

Training Hours 12 Hours

Delivery Mode Lecture

• • •

•

•

•

20

Assessment Criteria Pipe size determined Pipe schedule determined Piping material quantity determined Isometric drawing symbol differentiated Pipe spool number recognised Isometric drawing symbol to pipe Fabrication material compared

Work Activities

Related Knowledge • Eccentric Reducer • ‘O’ lets vii. Pipe spool number

Applied Skills

i. Interpret Isometric ii. iii. iv. v.

vi. 2. Identify material heat number



Delivery Mode Demonstration

drawing Determine Isometric drawing symbol Determine pipe spool number Determine required pipe fittings Match Isometric drawing symbol to Pipe Fabrication material Confirm material dimension

i. Piping colour coding such as: • Red-Low Temperature • Yellow-Carbon • Blue-Stainless Steel ii. Pipe Fabrication work specification iii. Piping material code number iv. Piping Material Mill Certificate

Assessment Criteria

• Required pipe fittings confirmed

8 Hours

Lecture

• Piping colour coding differentiated • Pipe Fabrication work specification described clearly • Material code number differentiated • Piping material to prepare finalised

21

Work Activities

Related Knowledge

Applied Skills

i. ii.

iii. iv. v.

3. Perform pipe fabrication material preparation

Determine piping colour coding Determine pipe Fabrication work specification Determine material code number Interpret Mill Certificate Confirm heat number refer to Piping Material Mill Certificate

i.

Pipe cutting calculation using formula ii. Pipe Fabrication work material specification iii. Piping material code number

22




Assessment Criteria

12 Hours

Lecture

• Pipe fabrication work material specification finalised • Pipe fabrication work material quantity finalised • Calculate pipe length • Review calculated

Work Activities

Related Knowledge

Applied Skills

i.

ii.

iii.

iv. v. vi. 4. Perform piping material arrangement at workplace




i. Adhere to safety procedure and regulation

6 Hours

Lecture

Confirm pipe Fabrication work material specification Confirm pipe Fabrication work material quantity Calculate pipe length as per drawing and pipe fabrication requirement Review calculated pipe length Confirm calculated pipe length Confirm pipe quantity

i.

Material location at workplace ii. Types of transportation such as: • Crane • Forklift • Lorry • Trolley iii. Material transportation

23

Assessment Criteria pipe length • Confirm calculated pipe length

• Allocated workplace availability confirmed based on job order • Transportation methodology selected • Prepared material

Work Activities

Related Knowledge procedure iv. Occupational Safety and Health Act (OSHA)

5. Perform pipe Fabrication work hand tools and equipment preparation

Applied Skills


i.

Confirm material location at workplace ii. Determine suitable transportation method iii. Check material receiving at work place iv. Arrange material at workplace

i. Types of tools and equipment for pipe Fabrication work such as: • Cutting torch (1 set) • Grinder • Die pinch grinder • Measuring Tape • Grinder • Centre punch • Water Level • Square L (12”) (24”) • Spark Lighter • Cooper hammer • Clamp • Adjustable Spanner • Screw Driver

i. Adhere to safety procedure and regulation

24



Assessment Criteria transported to correct allocated workplace • Material arrangement at workplace complied to organization standard operating procedure

3 Hours

Lecture

• Types of tools and equipment for pipe fabrication work distinguished • Fabrication work equipment consumable recognised • Tools, equipment and consumables selection for

Work Activities

Related Knowledge

Applied Skills


Training Hours

Delivery Mode

i. Personal Protective Equipment (PPE) ii. Adhere to safety procedure and regulation

8 Hours

Demonstration

• PPE ii. Types of Fabrication work equipment consumable such as: • Grinding disk • Cutting disk • Mountain Stone • Chalk iii. Pipe Fabrication work equipment operation manual i.

Determine types of tools and equipment for pipe Fabrication work ii. Determine Fabrication work equipment consumable iii. Select suitable tools, equipment and consumables for pipe Fabrication work iv. Confirm selected tools and equipment are in good working condition

25

Assessment Criteria pipe fabrication work complied to specific works

Employability Skills Core Abilities 04.07 04.09 05.03 05.04

Social Skills

Negotiate acceptance and support for objectives and strategies Prepare project/work plans Allocate and record usage of financial and physical resources Delegate responsibilities and/or authority

1. 2. 3. 4. 5. 6. 7. 8.

Communication skills Teamwork Learning skills Conceptual skills Interpersonal skills Self-discipline Multitasking Leadership skills

Tools, Equipment and Materials (TEM) ITEMS

RATIO (TEM : Trainees)

1. Cutting torch (1 set) 2. Hand Grinder 3. Die pinch grinder 4. Measuring Tape 5. Centre punch 6. Water Level 7. Square L (12”) (24”) 8. Spark Lighter 9. Copper hammer 10. Clamp 11. Adjustable Spanner 12. Screw Driver

1:4 1:1 1:3 1:1 1:1 1:2 1:2 1:1 1:1 1:2 1:1 1:1

26

References REFERENCES 1. 2.

Peter Smith, Gulf Professional Publishing; 1 edition (2005); Piping Materials Guide; ISBN-13: 978-0750677431 Noel P. O'Dowd, Amer Society of Mechanical (2008); Proceedings of the ASME Pressure Vessels and Piping Conference 2008: Materials and Fabrication; ISBN-13: 978-0791848296

27



Job Area



PIPE CUTTING WORK HANDLING


Work Activities

1. Perform cutting

Pipe Cutting Work Handling is a process to cut piping material starting from ensuring cutting equipment in good condition until piping material cut into required length and size based on Isometric Drawing Training Level 2 195 Hours Credit Hours Duration

Related Knowledge i.

equipment condition checking ii.

iii. iv.

v. vi.

Applied Skills

Types of cutting such as: • Hot cutting • Cold cutting Cutting equipment specification Cutting equipment functionality Cutting equipment accessories condition Cutting equipment operation manual Cutting equipment checking procedure




•

•

•

•

28

Assessment Criteria Suitable hot cutting equipment acquired Hot cutting equipment set regulator functionality tested Hot cutting equipment set flash back arrestor functionality tested Hot cutting

Work Activities

Related Knowledge

Applied Skills i. ii. iii.

iv. v.

Determine types of cutting Obtain cutting equipment set Check cutting equipment set accessories condition Ensure cutting equipment condition Apply cutting equipment checking procedure

29




Assessment Criteria equipment set O2 and acetylene gas cylinder confirmed in good condition • Hot cutting equipment set pipe cutter chain, rail and nozzle confirmed in good condition • Hot cutting equipment set extension wire confirmed in good condition • Hot cutting equipment checking process complied to equipment checking procedure

Work Activities

2. Perform pipe marking

Related Knowledge

Applied Skills


i. Pipe drawing ii. Pipe marking for edge preparation: • Flat • Bevel iii. Pipe identification such as: • Colour Coding • Pipe Schedule • Size • Material iv. Marking tools such as • Chalk • Centre Punch • Measuring tape • Pipe Strap



•

•

•

•

i. Interpret isometric drawing ii. Confirm pipe colour coding iii. Confirm required length iv. Mark pipe for cutting v. Punch marked pipe vi. Confirm pipe marking

30

i. Adhere to Safety and ergonomic procedure

48 Hours

Demonstration

Assessment Criteria Pipe colour coding differentiated Required length confirmed as per requirement Pipe marking process complied to pipe marking technique Marking point punched clearly for cutting

Work Activities

3. Perform pipe cutting

Related Knowledge

Applied Skills


i.

Pipe cutting technique • Flat • Bevel ii. Piping material marking point iii. Pipe cutting tools, equipment & consumables iv. Cutting procedure include: • Hot work permit • OSHA requirement • Standard Operating procedure (SOP) v. Personal Protective Equipment (PPE)



•

•

•

•

i. ii. iii.

iv.

v.

Confirm material marking point Determine cutting technique Select suitable cutting tools, equipment & consumable Carry out pipe cutting according to procedure Carry out piping cutting quality check

31

i. Wear Personal Protective Equipment (PPE) ii. Adhere to Safety and ergonomic procedure

50 Hours

Demonstration •

Assessment Criteria Correct material marking point ensured Available cutting technique recognised Selected cutting tools, equipment & consumable suitability confirmed Pipe Cutting and bevelling process complied to Pipe cutting technique Cut pipe sent to allocated fabrication workplace

Work Activities

4. Perform pipe edge preparation

Related Knowledge

Applied Skills


i.

Types of grinding equipment ii. Personal Protective Equipment (PPE) iii. Grinding technique



•

•

i. ii. iii. iv. v.

Identify grinding equipment Identify grinding technique Select suitable grinding equipment Execute pipe grinding Confirm pipe bevelling accuracy

i. Wear Personal Protective Equipment (PPE) ii. Adhere to safety procedure

24 Hours

Demonstration

•

•

•

32

Assessment Criteria Grinding equipment suitability differentiated Grinding technique determined Selected grinding equipment suitability confirmed Pipe grinding process complied to grinding technique Pipe bevelling accuracy ensured

Work Activities

5. Perform pipe cutting area housekeeping

Related Knowledge

Applied Skills


i.

Types of pipe fabrication work material waste ii. pipe fabrication Workplace housekeeping procedure iii. Cutting material waste disposal procedure iv. Housekeeping material, tools and equipment



•

•

• i.

ii.

iii. iv.

v.

Determine types of pipe fabrication work material waste Carry out housekeeping work according to procedure Return unused pipe to storage area Dispose waste according to procedure Confirm pipe cutting area housekeeping completion

33

i. Adhere to safety procedure

10 Hours

Demonstration •

•

•

Assessment Criteria Types of pipe fabrication work material waste differentiated Pipe fabrication workplace housekeeping procedure recognised Unused pipe returned to storage area Types of pipe fabrication work material waste segregated Pipe cutting area housekeeping process complied to pipe fabrication workplace housekeeping procedure Pipe cutting area housekeeping completion ensured

Employability Skills Core Abilities 04.07 04.09 04.10 05.03 05.04

Negotiate acceptance and support for objectives and strategies Prepare project/work plans Utilize science and technology to achieve goals Allocate and record usage of financial and physical resources Delegate responsibilities and/or authority

Social Skills 1. 2. 3. 4. 5. 6. 7. 8.




1. Cutting torch (1 set) 2. Hand Grinder 3. Die pinch grinder 4. Measuring Tape 5. Centre punch 6. Water Level 7. 12” and 24” L Square 8. Spark Lighter 9. Copper hammer 10. Clamp 11. Adjustable Spanner 12. Screw Driver 13. Brush 14. Rubbish Bank

1:4 1:1 1:2 1:1 1:1 1:2 1:2 1:1 1:1 1:1 1:1 1:1 1:4 1:10

34

References REFERENCES 1. 2.

C.L. Hart, Construction Trades Press; Rev edition (2006); Pipe Layout Helps: For the Pipefitter and Welder; ISBN-13: 978-0962419744 S. D. Bowman; Claitors Pub Div; 12 edition (2002);Modern Methods of Pipe Fabrication ; ISBN-13: 978-0875110080

35



Job Area



PIPE JOINTING (FIT UP)


Pipe Jointing (Fit Up) is a process to fit up pipe starting from pipe alignment until pipe spool produced according to Isometric drawing requirement and ready for welding Training Level 2 122 Hours Credit Hours Duration

Work Activities

Related Knowledge

1. Perform pipe alignment for fit up

i.

Applied Skills

Types of Alignment tools such as: • 12” and 24” L Square • Water level • Flat screw driver • Pipe Clamp • Tapper gauge • Theodolite ii. Pipe alignment technique iii. Pipe fabrication work specification iv. Pipe fittings such as • Flange • Elbow • Lateral




•

•

• •

• •

36

Assessment Criteria Fitting requirement recognised Piping gap preserved for welding Pipe stability confirmed Pipe alignment for fit up ensured Pipe hi-low ensured Pipe dimension confirmed as per isometric

Work Activities

Related Knowledge • Tee • Concentric Reducer • Eccentric Reducer • ‘O’ lets

2. Perform pipe jointing (FitUp)

Applied Skills i.

Determine fitting requirement ii. Prepare root gap for welding iii. Ensure pipe stability iv. Align pipe for fit up v. Check pipe hi-low vi. Check pipe dimension vii. Check fitting alignment viii. Confirm pipe alignment for fit up

i.

Pipe Fit up technique ii. Pipe alignment technique iii. Pipe fabrication work specification

37

Attitude / Safety / Environmental i. Adhere to Safety and ergonomic procedure



Assessment Criteria drawing

6 Hours

Lecture

• Isometric drawing requirement recognised • Pipe alignment re-checked • Pipe dimension viewed • Pipe gap preservation for welding

Work Activities

Related Knowledge

Applied Skills i.

Confirm isometric drawing requirement ii. Confirm pipe alignment iii. Confirm pipe dimension iv. Confirm pipe gap v. Fit up pipe vi. Check fit up pipe vii. Ensure pipe fit up ready for tack weld

3. Perform joint number recording on pipe

i. Isometric drawing ii. Pipe joint number recording procedure iii. Joint number record format iv. Pipe Tagging information such as • Pipe spool number • Drawing number

38

Attitude / Safety / Environmental i. Wear Personal Protective Equipment (PPE) ii. Adhere to safety procedure



2 Hours

Lecture

Assessment Criteria availability ensured • Pipe fit up process complied to pipe fit up technique • Completed fit up pipe confirmed • Pipe fit up readiness for tack weld confirmed • Pipe fit up process completion ensured • Joint number and drawing number differentiated • Pipe joint number on pipe wrote

Work Activities

Related Knowledge

Applied Skills i. ii.

iii. iv.

v. vi.

vii.

4. Perform pipe fit up area housekeeping

Confirm pipe fit up completion Determine joint number and drawing number Mark pipe joint number on pipe Prepare pipe joint report Check pipe joint report Confirm pipe joint report and record completion Prepare pipe joint report and record for endorsement

i.

Types of pipe fit up work material waste ii. Pipe fit up workplace housekeeping procedure iii. Pipe fit up material waste disposal procedure iv. Housekeeping material, tools and equipment



• •

• •

•

3 Hours

39


Lecture

Assessment Criteria Pipe joint report produced Recorded pipe joint number confirmed Pipe joint report re-checked Pipe joint report and record completion ensured Pipe joint report and record submitted to foremen

• Types of pipe fit up work material waste differentiated • Pipe fit up workplace housekeeping procedure recognised • Unused pipe and fittings

Work Activities

Related Knowledge

Applied Skills i.

ii.

iii.

iv.

v.

Determine types of pipe fit up work material waste Carry out housekeeping work according to procedure Return unused pipe and fittings to storage area Dispose waste according to procedure Confirm pipe fit up area housekeeping completion

40




Assessment Criteria returned to storage area • Types of pipe fit up work material waste segregated • Pipe fit up area housekeeping process complied to pipe fabrication workplace housekeeping procedure • Pipe fit up area housekeeping completion ensured

Employability Skills Core Abilities 04.07 04.09 04.10 05.03 05.04 06.08

Negotiate acceptance and support for objectives and strategies Prepare project/work plans Utilize science and technology to achieve goals Allocate and record usage of financial and physical resources Delegate responsibilities and/or authority Identify and analyse effect of technology on the environment

Social Skills 1. 2. 3. 4. 5. 6. 7. 8.




1. Cutting torch (Complete set) 2. Hand Grinder 3. Die pinch grinder (Straight Grinder) 4. Measuring Tape 5. Centre punch 6. Water Level 7. 12” and 24” L Square 8. Spark Lighter 9. Copper hammer 10. Clamp 11. Adjustable Spanner 12. Screw Driver (Flat) 13. Water Level Degree (if required)

1:4 1:2 1:2 1:1 1:1 1:2 1:2 1:1 1:1 1:1 1:1 1:1 1:25

41

References REFERENCES 1.

S. D. Bowman; Claitors Pub Div; 12 edition (2002);Modern Methods of Pipe Fabrication ; ISBN-13: 978-0875110080

42



Job Area



PIPE SUPPORT FABRICATION


Work Activities 1. Perform pipe support material preparation

Pipe Support Fabrication is a process to fabricate pipe support starting from material preparation, marking and cutting until complete pipe support produced as per pipe support drawing Training 220 Level 2 Credit Hours Duration Hours

Related Knowledge

Applied Skills

i. Pipe support detail drawing ii. Types of pipe support such as: • Trunnion (Dummy) support • Spring support • Hanging support • Shoe support • Clamp support • Cradle block support iii. Pipe support template for • Bolting • Stiffener iv. Pipe support material specification

43




Assessment Criteria • Template isometric drawing for pipe support preparation comprehended • Support detail drawing for pipe support preparation comprehended • Isometric drawing symbol to pipe support material compared for confirmation • Pipe material

Work Activities

Related Knowledge

Applied Skills i. ii.

iii. iv.

v.

Interpret pipe support drawing Interpret detail drawing for pipe support preparation Calculate pipe support length Confirm pipe support material dimension and quantity Confirm pipe support material specification

44




Assessment Criteria dimension ensured • Pipe support fabrication work material specification authenticated • Pipe support fabrication work material quantity ensured • Calculated pipe support length complied to pipe fabrication work specification • Pipe support length recalculated

Work Activities

Related Knowledge

2. Perform pipe support template preparation

i. Pipe support template

Applied Skills




Assessment Criteria

• Pipe support

dimension ii. Pipe support template marking iii. Pipe support template material such as: • Manila Card • Galvanised iron sheet • Tin plate iv. Template cutting tools such as • Scissor • Snip

•

•

i. Confirm pipe support

i. Wear

template dimension ii. Mark and trace pipe support template material for cutting iii. Confirm pipe support template marking iv. Punch marked pipe support template v. Cut pipe support template

Personal Protective Equipment (PPE) ii. Adhere to safety procedure

45

48 Hours

Practical

•

•

size finalised Pipe support material required length finalised Pipe support material marking point complied to required length Pipe support material marking point punched clearly for cutting Pipe support template marking correctness ensured

Work Activities

Related Knowledge

3. Perform pipe support fabrication

i. Pipe support material Marking ii. Pipe support material cutting technique • Flat • Bevel iii. Cutting tools, equipment & consumables iv. Basic welding operation • Shielded metal arc • v.

Applied Skills




•

•

•

welding (SMAW) Gas Tungsten Arc. Welding (GTAW).

Personal Protective Equipment (PPE)

•

i. Obtain pipe support ii.

iii.

iv.

v.

template Mark pipe support material based on template Confirm Pipe support material marking location Select suitable cutting tools, equipment & consumable Cut pipe support material

46


48 Hours

Demonstration

•

Assessment Criteria Pipe support material marking point complied to required length Pipe support material cutting technique selected Selected cutting tools, equipment & consumable suitability confirmed Pipe support cutting and bevelling process complied to cutting technique Cut pipe support material sent to installation workplace

Work Activities

4. Perform pipe support material grinding

Related Knowledge

Applied Skills


i.

Types of grinding equipment and consumables ii. Grinding technique iii. Safety Procedures iv. Personal Protective Equipment (PPE)



•

•

•

i. ii. iii. iv.

v.

vi.

5. Perform pipe support fabrication workplace housekeeping

Determine grinding equipment Determine grinding technique Select suitable grinding equipment Carry out pipe support material grinding Confirm pipe support edge accuracy Carry out pipe support tack weld

i.

Types of pipe support fabrication work material waste ii. Pipe support fabrication workplace housekeeping


48 Hours

•

•

3 Hours

47

Demonstration

Lecture

Assessment Criteria Grinding equipment suitability differentiated Grinding technique determined Selected grinding equipment suitability confirmed Pipe support material grinding process complied to grinding technique Pipe support bevelling accuracy ensured

• Types of pipe support fabrication work material waste differentiated

Work Activities

Related Knowledge

Applied Skills


Training Hours

Delivery Mode

procedure iii. Pipe support fabrication waste disposal procedure iv. Housekeeping material, tools and equipment

•

i.

ii.

iii.

iv.

v.

Determine types of pipe support fabrication work material waste Carry out housekeeping work according to procedure Return unused pipe support material to storage area Dispose waste according to procedure Confirm pipe support fabrication area housekeeping completion

48


10 Hours

Demonstration

•

•

•

Assessment Criteria Pipe support fabrication workplace housekeeping procedure recognised Unused pipe support material returned to storage area Types of pipe support fabrication work material waste segregated Pipe support fabrication area housekeeping process complied to workplace housekeeping procedure

Employability Skills Core Abilities 04.07 04.09 04.10 05.03 05.04 06.08

Social Skills

Negotiate acceptance and support for objectives and strategies Prepare project/work plans Utilize science and technology to achieve goals Allocate and record usage of financial and physical resources Delegate responsibilities and/or authority Identify and analyse effect of technology on the environment

1. 2. 3. 4. 5. 6. 7. 8.




1. Cutting torch (Complete set) 2. Hand Grinder 3. Die pinch grinder (Straight Grinder) 4. Measuring Tape 5. Centre punch 6. Water Level 7. 12” and 24” L Square 8. Spark Lighter 9. Copper hammer 10. Clamp 11. Adjustable Spanner 12. Screw Driver (Flat) 13. Water Level Degree (if required)

1:4 1:2 1:2 1:1 1:1 1:2 1:2 1:1 1:1 1:1 1:1 1:1 1:25

49

References REFERENCES 1.

S. D. Bowman; Claitors Pub Div; 12 edition (2002);Modern Methods of Pipe Fabrication ; ISBN-13: 978-0875110080Quebec; Montreal,

50

Summary of Training Duration

NO.

COMPETENCY UNIT TITLE

RELATED KNOWLEDGE

APPLIED SKILLS

HOURS

12

24

36

8

16

24

Perform pipe fabrication material preparation

12

36

48

Perform prepared piping material arrangement at workplace

6

12

18

3

8

11

12

24

36

12

48

60

Perform pipe cutting

6

50

56

Perform pipe edge preparation

6

24

30

Perform pipe cutting area housekeeping

3

10

13

Perform pipe alignment for fit up

6

54

60

Perform pipe jointing (fit-up)

6

48

54

Perform joint number recording on pipe

2

6

8

3

10

13

8

48

56

6

48

54

WORK ACTIVITIES Identify piping material dimension Identify material heat number

1

Pipe Fabrication Material Preparation

Perform pipe fabrication work hand tools and equipment preparation Perform cutting equipment condition checking Perform pipe marking 2

3

4

Pipe Cutting Work Handling

Pipe Jointing (Fit Up)

Pipe Support Fabrication

Perform pipe pipe fit up area housekeeping Perform pipe support material preparation

ASSESSMENT (KA & PA)

TOTAL (Hours)

137

195

122

220

Perform pipe support material marking

51

NO.

COMPETENCY UNIT TITLE

RELATED KNOWLEDGE

APPLIED SKILLS

HOURS

Perform pipe support material cutting

8

48

56

Perform pipe support material grinding

6

48

54

Perform Pipe Support Fabrication area housekeeping

3

10

13

128

548

700

WORK ACTIVITIES

TOTAL HOURS (CORE Competency + Elective Competency)

52

ASSESSMENT (KA & PA)

TOTAL (Hours)

700

Piping Fabrication Operation Level 2

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