piping fabrication operation level 2

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STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN (NATIONAL OCCUPATIONAL SKILLS STANDARD)

PIPING FABRICATION OPERATION (OIL, GAS AND PETROCHEMICAL)

LEVEL 2

JABATAN PEMBANGUNAN KEMAHIRAN

KEMENTERIAN SUMBER MANUSIA, MALAYSIA

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TABLE OF CONTENTS

No. Contents Pages

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 Profile Chart (JPC) And Competency Profile (CP)

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12. Committee Members for Development Curriculum of Competency Unit (CoCu)

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13. Job Profile Chart (JPC) 9 14. Competency Profile (CP) 10-19 15. Curriculum of Competency Unit (CoCu): Piping Fabrication Material

Preparation

20-27

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. Summary of Training Duration 51

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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 economys 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.

1Pipe Fitting, http://en.wikipedia.org/wiki/Pipe_fitting (November 2011)

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2. OCCUPATIONAL STRUCTURE

Piping Fabrication personnel come under the Sector of oil and gas and Sub-Sector 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 METAL

STRUCTURE FABRICATION

PIPING FABRICATION QUALITY ASSURANC

E PIPING PIPING

SUPPORT

Level 5 TECHNICAL ENGINEER STRUCTURE

FABRICATION ENGINEER

PROJECT COORDINATOR QA/QC

MANAGER/ENGINEER

level 4 TECHNICAL SUPERVISOR STRUCTURE

FABRICATION SUPERVISOR

PIPING SUPERVISOR

SUPERVISOR SUPPORT

QA INSPECTOR

level 3 DRAFTSMAN METAL

STRUCTURE FABRICATION

FOREMAN

PIPING FOREMEN

FOREMEN SUPPORT

QC INSPECTOR

level 2 No Level METAL

STRUCTURE FABRICATION TRADESMAN

PIPE FITTER FITTER SUPPORT No Level

level 1 No Level No Level No Level -

Figure 1.1 Occupational Profile Chart for Piping Fabrication Personnel

SECTOR OIL AND GAS

SUB-

SECTOR OIL, GAS AND PETROCHEMICAL

AREA PIPING

L5 PIPING FABRICATION MANAGEMENT L4 PIPING FABRICATION SUPERVISION L3 PIPING FABRICATION OPERATION L2 PIPING FABRICATION OPERATION L1 No Level

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

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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.

Malaysia Skills Certificate Level 2: (Operation Level)

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.

Malaysia Skills Certificate Level 3: (Supervisory Level)

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.

Malaysia Skills Diploma Level 4: (Executive Level)

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.

Malaysia Skills Advanced Diploma Level 5: (Managerial Level)

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.

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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.

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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)

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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.

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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 PIPE FITTER 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 PIPE FITTER AQEEL ENGINEERING

8. SHAHIMI BIN SULONG PIPE FITTER MUSHTARI ENGINEERING

FACILITATOR

1. MOHD KHAIRULLAH BIN AB MANAF TRAINING CONSULTANT IDAMAN JAUHARI SDN BHD

CO-FASILITATOR

1. NABLAN BIN YUSOFF DIRECTOR IDAMAN JAUHARI SDN BHD

2. NOORPAZURA BAHARUDDIN TRAINING EXECUTIVE IDAMAN JAUHARI SDN BHD

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12. COMMITTEE MEMBERS FOR DEVELOPMENT OF CURRICULUM of COMPETENCY UNIT (CoCU)

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 PIPE FITTER 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 PIPE FITTER AQEEL ENGINEERING

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. MOHD KHAIRULLAH BIN AB MANAF TRAINING CONSULTANT IDAMAN JAUHARI SDN BHD CO-FASILITATOR

1. NABLAN BIN YUSOFF DIRECTOR IDAMAN JAUHARI SDN BHD

2. NOORPAZURA BAHARUDDIN TRAINING EXECUTIVE IDAMAN JAUHARI SDN BHD

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COMPETENCY

COMPETENCY UNIT

CORE

PIPING FABRICATION

MATERIAL PREPARATION

PIPE CUTTING WORK HANDLING

PIPE JOINTING (FIT UP)

PIPE SUPPORT FABRICATION

JOB PROFILE CHART (JPC)

SECTOR OIL AND GAS

SUB SECTOR OIL, GAS AND PETROCHEMICAL

JOB AREA PIPING FABRICATION OPERATION

JOB LEVEL TWO (2) JOB AREA CODE

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COMPETENCY PROFILE (CP)

Sub Sector OIL, GAS AND PETROCHEMICAL Job Area PIPING FABRICATION OPERATION Level TWO (2)

CU Title CU Code CU Descriptor CU Work Activities Performance Criteria

1. Pipe Fabrication Material Preparation

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.

1. Identify piping material dimension

2. Identify material heat number

1.1 Isometric drawing interpreted

1.2 Isometric drawing symbol determined

1.3 Pipe spool number determined

1.4 Isometric drawing symbol to pipe fabrication material matched

1.5 Material dimension confirmed

2.1 Piping colour coding determined

2.2 Pipe fabrication work specification determined

2.3 Material code number

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3. Perform pipe fabrication material preparation

4. Perform prepared piping material arrangement at workplace

determined 2.4 Heat number confirmed

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

4.1 Allocated workplace determined

4.2 Transportation methodology determined

4.3 Prepared material checked 4.4 Prepared material to

workplace delivered

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5. Perform pipe fabrication work hand tools and equipment preparation

4.5 Material at workplace arrange

5.1 Types of tools and equipment for pipe 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 process to cut piping material starting from ensuring cutting equipment in good condition until piping material cut into required length and size based

1. Perform cutting equipment condition checking

1.1 Cutting equipment set obtained

1.2 Cutting equipment set accessories condition checked

1.3 Cutting equipment condition

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on Isometric Drawing

2. Perform pipe marking

3. Perform pipe cutting

ensured 1.4 Hot cutting equipment

checking procedure followed

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

3.1 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

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4. Perform pipe edge preparation

5. Perform pipe cutting area housekeeping

workplace delivered

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

5.1 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

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disposal technique applied 5.5 Pipe cutting area

housekeeping completion confirmed

3. 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

1. Perform pipe alignment for fit up

2. Perform pipe jointing (fit-up)

1.1 Fitting requirement determined

1.2 Piping gap for welding ensured

1.3 Pipe stability ensured 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

2.1 Isometric drawing requirement confirmed

2.2 Pipe alignment confirmed 2.3 Pipe dimension confirmed 2.4 Pipe gap confirmed

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3. Perform joint number recording on pipe

2.5 Fit up pipe checked 2.6 Pipe fit up ready for tack

weld ensured

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

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4. Pipe Support Fabrication

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

1. Perform pipe support material preparation

1.1 Template isometric drawing for pipe support preparation interpreted

1.2 Support detail drawing for pipe support preparation interpreted

1.3 Isometric drawing symbol 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

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2. Perform pipe support material marking

3. Perform pipe support material cutting

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

3.1 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

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4. Perform pipe support material grinding

3.5 Cut pipe support material to installation workplace delivered

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

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CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector OIL, GAS AND PETROCHEMICAL

Job Area PIPING FABRICATION OPERATION

Competency Unit Title PIPING FABRICATION MATERIAL PREPARATION

Competency Unit Descriptor 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.

Competency Unit ID

Level 2 Training Duration 137

Hours Credit Hours

Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours

Delivery Mode

Assessment Criteria

1. Identify piping material dimension

i. Isometric drawing ii. Piping material iii. Piping size iv. Piping schedule v. 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

12 Hours Lecture 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

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Delivery Mode

Assessment Criteria

Eccentric Reducer O lets

vii. Pipe spool number

i. Interpret Isometric drawing

ii. Determine Isometric drawing symbol

iii. Determine pipe spool number

iv. Determine required pipe fittings

v. Match Isometric drawing symbol to Pipe Fabrication material

vi. Confirm material dimension

24 Hours Demonstration

Required pipe fittings confirmed

2. Identify material heat number

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

8 Hours Lecture Piping colour coding differentiated

Pipe Fabrication work specification described clearly

Material code number differentiated

Piping material to prepare finalised

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Delivery Mode

Assessment Criteria

i. Determine piping colour coding

ii. Determine pipe Fabrication work specification

iii. Determine material code number

iv. Interpret Mill Certificate

v. Confirm heat number refer to Piping Material Mill Certificate


3. Perform pipe fabrication material preparation

i. Pipe cutting calculation using formula

ii. Pipe Fabrication work material specification

iii. Piping material code number

12 Hours Lecture Pipe fabrication work material specification finalised

Pipe fabrication work material quantity finalised

Calculate pipe length

Review calculated

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Delivery Mode

Assessment Criteria

i. Confirm pipe Fabrication work material specification

ii. Confirm pipe Fabrication work material quantity

iii. Calculate pipe length as per drawing and pipe fabrication requirement

iv. Review calculated pipe length

v. Confirm calculated pipe length

vi. Confirm pipe quantity


pipe length Confirm

calculated pipe length

4. Perform piping material arrangement at workplace

i. Material location at workplace

ii. Types of transportation such as:

Crane Forklift Lorry Trolley

iii. Material transportation

i. Adhere to safety procedure and regulation

6 Hours Lecture Allocated workplace availability confirmed based on job order

Transportation methodology selected

Prepared material

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Delivery Mode

Assessment Criteria

procedure iv. Occupational Safety

and Health Act (OSHA)

i. Confirm material location at workplace

ii. Determine suitable transportation method

iii. Check material receiving at work place

iv. Arrange material at workplace


transported to correct allocated workplace

Material arrangement at workplace complied to organization standard operating procedure

5. Perform pipe Fabrication work hand tools and equipment preparation

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

3 Hours Lecture Types of tools and equipment for pipe fabrication work distinguished

Fabrication work equipment consumable recognised

Tools, equipment and consumables selection for

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Delivery Mode

Assessment Criteria

PPE ii. Types of Fabrication

work equipment consumable such as: Grinding disk Cutting disk Mountain Stone Chalk

iii. Pipe Fabrication work equipment operation manual

pipe fabrication work complied to specific works

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

i. Personal Protective Equipment (PPE)

ii. Adhere to safety procedure and regulation


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Employability Skills

Core Abilities Social Skills

04.07 Negotiate acceptance and support for objectives and strategies

04.09 Prepare project/work plans 05.03 Allocate and record usage of financial and physical

resources 05.04 Delegate responsibilities and/or authority

1. Communication skills 2. Teamwork 3. Learning skills 4. Conceptual skills 5. Interpersonal skills 6. Self-discipline 7. Multitasking 8. 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

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References

REFERENCES

1. Peter Smith, Gulf Professional Publishing; 1 edition (2005); Piping Materials Guide; ISBN-13: 978-0750677431 2. 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

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Competency Unit Title PIPE CUTTING WORK HANDLING

Competency Unit Descriptor 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

Competency Unit ID Level 2 Training Duration 195 Hours Credit Hours


Delivery Mode

Assessment Criteria

1. Perform cutting equipment condition checking

i. Types of cutting such as: Hot cutting Cold cutting

ii. Cutting equipment specification

iii. Cutting equipment functionality

iv. Cutting equipment accessories condition

v. Cutting equipment operation manual

vi. Cutting equipment checking procedure

12 Hours Lecture Suitable hot cutting equipment acquired

Hot cutting equipment set regulator functionality tested

Hot cutting equipment set flash back arrestor functionality tested

Hot cutting

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Delivery Mode

Assessment Criteria

i. Determine types of cutting

ii. Obtain cutting equipment set

iii. Check cutting equipment set accessories condition

iv. Ensure cutting equipment condition

v. Apply cutting equipment checking procedure


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

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Delivery Mode

Assessment Criteria

2. Perform pipe marking

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

12 Hours Lecture Pipe colour coding differentiated

Required length confirmed as per requirement

Pipe marking process complied to pipe marking technique

Marking point punched clearly for cutting

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

i. Adhere to Safety and ergonomic procedure


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Delivery Mode

Assessment Criteria

3. Perform pipe cutting

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)

6 Hours Lecture 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

i. Confirm material marking point

ii. Determine cutting technique

iii. Select suitable cutting tools, equipment & consumable

iv. Carry out pipe cutting according to procedure

v. Carry out piping cutting quality check

i. Wear Personal Protective Equipment (PPE)

ii. Adhere to Safety and ergonomic procedure


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Delivery Mode

Assessment Criteria

4. Perform pipe edge preparation

i. Types of grinding equipment

ii. Personal Protective Equipment (PPE)

iii. Grinding technique

6 Hours Lecture Grinding equipment suitability differentiated

Grinding technique determined

Selected grinding equipment suitability confirmed

Pipe grinding process complied to grinding technique

Pipe bevelling accuracy ensured

i. Identify grinding equipment

ii. Identify grinding technique

iii. Select suitable grinding equipment

iv. Execute pipe grinding

v. Confirm pipe bevelling accuracy


ii. Adhere to safety procedure


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Delivery Mode

Assessment Criteria

5. Perform pipe cutting area housekeeping

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

3 Hours Lecture 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

i. Determine types of pipe fabrication work material waste

ii. Carry out housekeeping work according to procedure

iii. Return unused pipe to storage area

iv. Dispose waste according to procedure

v. Confirm pipe cutting area housekeeping completion

i. Adhere to safety procedure


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04.09 Prepare project/work plans 04.10 Utilize science and technology to achieve goals

05.03 Allocate and record usage of financial and physical resources

05.04 Delegate responsibilities and/or authority



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. 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

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References

REFERENCES

1. C.L. Hart, Construction Trades Press; Rev edition (2006); Pipe Layout Helps: For the Pipefitter and Welder; ISBN-13: 978-0962419744 2. S. D. Bowman; Claitors Pub Div; 12 edition (2002);Modern Methods of Pipe Fabrication ; ISBN-13: 978-0875110080

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Competency Unit Title PIPE JOINTING (FIT UP) Competency Unit Descriptor 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 Competency Unit ID Level 2 Training Duration 122 Hours Credit Hours


Delivery Mode

Assessment Criteria

1. Perform pipe alignment for fit up

i. 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

6 Hours Lecture 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

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Delivery Mode

Assessment Criteria

Tee Concentric

Reducer Eccentric

Reducer O lets

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. Adhere to Safety and ergonomic procedure


drawing

2. Perform pipe jointing (Fit-Up)

i. Pipe Fit up technique ii. Pipe alignment

technique iii. Pipe fabrication work

specification

6 Hours Lecture Isometric drawing requirement recognised

Pipe alignment re-checked

Pipe dimension viewed

Pipe gap preservation for welding

38


Delivery Mode

Assessment Criteria

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




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

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

2 Hours Lecture Pipe fit up process completion ensured

Joint number and drawing number differentiated

Pipe joint number on pipe wrote

39


Delivery Mode

Assessment Criteria

i. Confirm pipe fit up completion

ii. Determine joint number and drawing number

iii. Mark pipe joint number on pipe

iv. Prepare pipe joint report

v. Check pipe joint report

vi. Confirm pipe joint report and record completion

vii. Prepare pipe joint report and record for endorsement


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

4. Perform pipe fit up area housekeeping

i. Types of pipe fit up work material waste

ii. Pipe fit up workplace housekeeping procedure

iii. Pipe fit up material waste disposal procedure


3 Hours Lecture Types of pipe fit up work material waste differentiated

Pipe fit up workplace housekeeping procedure recognised

Unused pipe and fittings

40


Delivery Mode

Assessment Criteria

i. Determine types of pipe fit up work material waste


iii. Return unused pipe and fittings to storage area


v. Confirm pipe fit up area housekeeping completion



10 Hours Demonstration 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

41







06.08 Identify and analyse effect of technology on the environment



ITEMS RATIO (TEM : Trainees) 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

42

References

REFERENCES

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

43



Competency Unit Title PIPE SUPPORT FABRICATION

Competency Unit Descriptor 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

Competency Unit ID Level 2 Training Duration 220

Hours Credit Hours


Delivery Mode

Assessment Criteria

1. Perform pipe support material preparation

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

8 Hours Lecture 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

44


Delivery Mode

Assessment Criteria

i. Interpret pipe support drawing

ii. Interpret detail drawing for pipe support preparation

iii. Calculate pipe support length

iv. Confirm pipe support material dimension and quantity

v. Confirm pipe support material specification




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 re-calculated

45


Delivery Mode

Assessment Criteria

2. Perform pipe support template preparation

i. Pipe support template 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

6 Hours Lecture Pipe support 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

i. Confirm pipe support 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



48 Hours Practical

46


Delivery Mode

Assessment Criteria

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

welding (SMAW) Gas Tungsten Arc.

Welding (GTAW). v. Personal Protective

Equipment (PPE)

8 Hours Lecture 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

i. Obtain pipe support template

ii. Mark pipe support material based on template

iii. Confirm Pipe support material marking location

iv. Select suitable cutting tools, equipment & consumable

v. Cut pipe support material




47


Delivery Mode

Assessment Criteria

4. Perform pipe support material grinding

i. Types of grinding equipment and consumables

ii. Grinding technique iii. Safety Procedures iv. Personal Protective

Equipment (PPE)

6 Hours Lecture

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

i. Determine grinding equipment

ii. Determine grinding technique

iii. Select suitable grinding equipment

iv. Carry out pipe support material grinding

v. Confirm pipe support edge accuracy

vi. Carry out pipe support tack weld




5. Perform pipe support fabrication workplace housekeeping

i. Types of pipe support fabrication work material waste

ii. Pipe support fabrication workplace housekeeping

3 Hours Lecture

48


Delivery Mode

Assessment Criteria

procedure iii. Pipe support fabrication

waste disposal procedure


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

i. Determine types of pipe support fabrication work material waste


iii. Return unused pipe support material to storage area


v. Confirm pipe support fabrication area housekeeping completion




49







06.08 Identify and analyse effect of technology on the environment



ITEMS RATIO (TEM : Trainees) 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

50

References

REFERENCES

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

51

Summary of Training Duration

NO. COMPETENCY UNIT TITLE WORK ACTIVITIES RELATED

KNOWLEDGE APPLIED SKILLS HOURS

ASSESSMENT (KA & PA)

TOTAL (Hours)

1 Pipe Fabrication Material Preparation

Identify piping material dimension 12 24 36

137

Identify material heat number 8 16 24 Perform pipe fabrication material preparation 12 36 48

Perform prepared piping material arrangement at workplace 6 12 18

Perform pipe fabrication work hand tools and equipment preparation 3 8 11

2 Pipe Cutting Work Handling

Perform cutting equipment condition checking 12 24 36

195

Perform pipe marking 12 48 60

Perform pipe cutting 6 50 56

Perform pipe edge preparation 6 24 30

Perform pipe cutting area housekeeping 3 10 13

3 Pipe Jointing (Fit Up)

Perform pipe alignment for fit up 6 54 60

122 Perform pipe jointing (fit-up) 6 48 54 Perform joint number recording on pipe 2 6 8 Perform pipe pipe fit up area housekeeping 3 10 13

4 Pipe Support Fabrication

Perform pipe support material preparation 8 48 56

220 Perform pipe support material marking 6 48 54

52

NO. COMPETENCY UNIT TITLE WORK ACTIVITIES RELATED

KNOWLEDGE APPLIED SKILLS HOURS

ASSESSMENT (KA & PA)

TOTAL (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

TOTAL HOURS (CORE Competency + Elective Competency) 128 548 700

700

piping fabrication operation level 2

Documents