LEARNER’S GUIDE



LEARNER’S GUIDE

PREPARE FOR PIPING AND TUBING INSTALLATION

Published by

HEART TRUST/NATIONAL TRAINING AGENCY

Produced by

Learning Management Services Department

Gordon Town Road

Kingston 7

Jamaica W.I.

This material is protected by copyright. Copying this material or any part of it by any means, including digital or in any form is prohibited unless prior written permission is obtained from the HEART Trust/NTA.

*** 2003***

TABLE OF CONTENTS

PAGE

Introduction 1

Welcome 1

This Competency Unit 1

Before You Start 2

Planning Your Learning Programme 2

Self-Assessment Checklist 3

How To Use This Learner’s Guide 6

Using the Computer and other Resources 7

Method of Assessment 7

Element 1: Plan for Installation Process 8

Self-Assessment Checklist 16

Element 2: Prepare Materials Selected for Installation Process 18

Self-Assessment Checklist 22

Element 3: Prepare Work Area Suitable for Installation Process 23

Self-Assessment Checklist 25

Element 4: Use Tools, Plant and Equipment Appropriate for Installation Process 26

Self-Assessment Checklist 30

Element 5: Prepare Background of Surfaces/Environment for Piping

and Tubing Installation 31

Self-Assessment Checklist 35

Element 6: Select Materials and Cut Components 36

Self-Assessment Checklist 43

Element 7 & 8: Distribute Components and Clean Up 44

Self-Assessment Checklist 47

INTRODUCTION

Welcome

Welcome to the Learner’s Guide for Unit of Competency “Prepare for Piping and Tubing Installation”. This is just one of a number of Learner’s Guides produced for the Plumbing stream of the Metal Engineering and Maintenance Industry, and it is designed to guide you, the learner, through a series of learning processes and activities that will enable you to achieve the specified learning outcomes for the competency unit.

The content of this guide was developed from the Competency Standard MEMINS0061A, which is one of the basic building blocks for the National Vocational Qualification of Jamaica (NVQ-J) certification within the industry. Please refer to your Learner’s Handbook for a thorough explanation of standards and competencies, and how these relate to the NVQ-J certification.

You are also advised to consult the Competency Standard and assessment instrument for a better understanding of what is required to master the competency.

This Competency Unit

“Prepare for Piping and Tubing Installation” addresses the knowledge and skills requirements for effectively prepare for piping and tubing installation. There are eight main areas or elements:

Element 1: Plan a for Installation Process

Element 2: Prepare Materials Selected for Installation Process

Element 3: Prepare Work Area Suitable for Installation Process

Element 4: Use Tools, Plant and Equipment Appropriate for Installation Process

Element 5: Prepare Background of Surfaces/Environment for Piping and Tubing

Installation

Element 6: Select Materials and Cut Components

Element 7: Distribute Components

Element 8: Clean Up

As you go through each element, you will find critical information relating to each one. You are advised to study them carefully so that you will be able to develop the necessary knowledge, skills and attitudes for preparing for piping and tubing installation.

Before you start

Before you start this Learner’s Guide, you need to:

a. Obtain a Learner’s Logbook that you will use to record evidence of your new skills/competence. As you demonstrate your new skills, record your activities and have your learning facilitator sign off on them. This will allow you to provide evidence of your competence when you are being assessed against the competency standard.

b. Ensure that you have access to the facilities and equipment necessary for learning.

c. Ensure that your learning resources are available.

d. Ensure that you are wearing suitable clothing, that tools and equipment are safe, and that the correct safety equipment is used.

e. Plan your learning programme (see below)

f. Understand how to use this Learner’s Guide (see below)

Planning your learning programme

The self-assessment checklist on the following page will assist you in planning your training programme as it will help you to think about the knowledge and skills needed to demonstrate competency in this unit. As you go through the checklist you will be able to find out what elements you have already mastered and which ones you will need to pay more attention to as you go through the learning process.

To complete the self-assessment checklist, simply read the statements and tick the ‘Yes’ or ‘No’ box. You should do this exercise now.

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Element 1 Plan for Installation Process Yes No

1. I can recognize and adhere to Quality Assurance requirements

of engineering/maintenance operations ( ) ( )

2. I can identify preparation and planning requirements from

drawings/work location and/or supervisor’s instructions ( ) ( )

3. I can identify and adhere to OH&S requirements in

accordance with application tasks and workplace environment ( ) ( )

4. I can identify safety hazards and adopt correct procedures

to minimize risk to self and others ( ) ( )

5. I can select materials according to supervisor’s instructions

safely handle and store/locate ready for application ( ) ( )

6. I can select, fit correctly and use appropriate personal

protective equipment ( ) ( )

7. I can select tools and equipment consistent with the job

requirements, check for serviceability and report any

faults to supervisor ( ) ( )

8. I can select materials/components consistent with the job

requirements where applicable and check for damage ( ) ( )

Element 2 Prepare Materials Selected for Installation Process Yes No

1. I can identify activities for material preparation from

specifications or supervisor’s instructions ( ) ( )

2. I can carry out material preparation to satisfy requirements

of installation process ( ) ( )

Element 3 Prepare Work Area Suitable for Installation Process Yes No

1. I can identify activities to be carried out in work area from

installation technique, method of installation and access to area ( ) ( )

2. I can prepare work for installation process according to

supervisor’s instructions ( ) ( )

Element 4 Use Tools, Plant and Equipment Appropriate for

Installation Process Yes No

1. I can identify regular tools/measuring devices suitable for

application process to job requirements ( ) ( )

2. I can use regular tools/measuring devices safely and

effectively to carry out processes where applicable ( ) ( )

Element 5 Prepare Background of Surfaces/Environment for Piping

And Tubing Installation Yes No

1. I can identify surfaces/environment for preparation ( ) ( )

2. I can chase/chop/prepare surface where appropriate ( ) ( )

3. I can carry out excavations where appropriate ( ) ( )

Element 6 Select Materials and Cut Components Yes No

1. I can obtain material as per instruction ( ) ( )

2. I can use correct manual handling techniques to move

and place materials ( ) ( )

3. I can move materials safely to work area ( ) ( )

4. I can use techniques to accurately cut/bend/fabricate/secure

components to same length to given instruction ( ) ( )

Element 7 Distribute Components Yes No

1. I can distribute and stack components to suit job location

and sequence ( ) ( )

Element 8 Clean Up Yes No

1. I can stack/store materials for re-use or dispose of materials ( ) ( )

2. I can clear work area ( ) ( )

3. I can clean, maintain and store tools and equipment ( ) ( )

How did you do?

If you ticked all or most of the ‘Yes’ boxes then you might not need to go through the entire guide. Ask your learning facilitator to assist you in determining the most appropriate action you should take.

If you ticked a few of the ‘Yes’ boxes or none at all then you should work through all of the guide, even though some of the material my be familiar to you.

Plan your learning based on your answers. Be sure to involve your learning facilitator in the planning process.

How to use this Learner’s Guide

This Learner’s Guide is designed to assist you in working and learning at your own pace.

We suggest that you:

Go through the sections/elements as they are presented (starting at Section 1)

Check your progress at each checkpoint to ensure that you have understood the material

Observe the icons and special graphics used throughout this guide to remind you of what you have to do and to enhance your learning. The icons and their meanings are as follows:

Complete Assessment Exercise

This exercise requires you to think about the knowledge and skills

that you have or will develop in this competency unit.

Definition Box

Words/phases are defined or explained in this box. The words/phases being explained are in bold print.

Checkpoint

This denotes a brain teaser and is used to check your

understanding of the materials presented. No answers are

provided for the questions asked.

Activity

This denotes something for you to do either alone or with

the assistance of your learning facilitator.

Reference

Points you to the reference materials and other support

documents or resources used in compiling the unit content.

Ask your learning facilitator for help if you have any problems with the interpretation of the contents, the procedures, or the availability of resources.

Complete each activity as you come to it. If the activity requires you perform an actual task, be sure to tell your learning facilitator when you get to that activity so that he/she can make any arrangements, if necessary.

• Get your learning facilitator to sign and date the Learner Logbook when you have completed an activity.

• Complete the self-assessment checklist at the end of each section or element.

When you have worked through all elements of the guide, and when you can tick every ‘Yes’ box, you are ready for assessment and should ask your learning facilitator to assist you in making the arrangements to have your performance assessed.

Using the Computer and Other Resources

Where your activities refer you to the library, computer and Internet resources, ask your learning facilitator to assist you with locating these resources. If you are getting your training in an institution, there may be a library and a computer laboratory. If this is not the case, visit the local library and find out what resources are available.

If you are new to the computer and the Internet, someone in the computer room should be able to show you how to use these resources.

Please note that in many of your activities you have been referred to information on the Internet. This is because the Internet has a vast amount of information that can help you in acquiring the particular competencies. We would like to advise you, however, that we cannot guarantee that all the sites will be available when you need them. If this happens, ask your learning facilitator to assist you with locating other sites that have the information you require.

Method of Assessment

Competency will be assessed while you are actually performing the tasks related to this competency, this may be in a real workplace or a simulated situation that accurately relates to the work situation. You are advised to consult the associated competency standard for further details relating to the assessment strategies.

You may now start your learning. Have fun while you work!

ELEMENT 1: PLAN FOR INSTALLATION PROCESS

LEARNING OUTCOMES

As you go through this element you need to ensure that you acquire the knowledge, skills and attitudes required to plan for installation process. Your learning facilitator is there to assist you through the various activities so that upon completion you should be able to:

1. Recognize and adhere to the Quality Assurance requirements of engineering/maintenance operations

2. Identify preparation and planning requirement from drawings/ work location and or supervisor’s instructions

3. Identify and adhere to OH&S requirements in accordance with application tasks and workplace environment

4. Identify safety hazards and adopt correct procedures to minimize risk to self and others

5. Select materials according to supervisor’s instruction and safely handle and store them.

6. Select, fit and use appropriate personal protective equipment

7. Select tools and equipment consistent with the job, check for serviceability and faults, and report same to supervisor

QUALITY ASSURANCE

Like any other occupation in the metal engineering and maintenance industry, plumbing installation is governed by certain codes /standards with which you must comply if quality assurance is to be maintained. Do you know what quality assurance is? Are you aware of the level of responsibility that you will have to display to ensure that quality assurance is adhered to? Before you attempt to answer these questions, you need to ensure that you understand what quality assurance is and how that level of understanding will enhance your performance.

Simply put, quality assurance is the ability to demonstrate consistent compliance with requirements. It is repeating good performance on every contract by the use of a system of documented procedures which are known and operated by you, your workmates/team as well as your learning facilitator. Quality Assurance ensures that at each stage of the process control is offered so that it will be very difficult for you to create a product or service that will be rejected. Remember now, this need not be an expensive way of doing things. For example it can take the form of a simple checklist.

Here are some of the advantages that can be gained from strict adherence to, and application of Quality Assurance measures. Quality Assurance:

▪ Identifies everything that can have an impact on quality

▪ Defines and conveys the company’s quality objectives, policies, procedures (what the company stands for, what it does, and how it does things)

▪ Makes sure that everything is done consistently

▪ Provides an assurance to customers that controls are in place

▪ Helps identify and ensure ‘Best Practices’

▪ Provides objective evidence for determining causes of poor quality

▪ Provides foundation for improvement

▪ Improves productivity by ‘Doing it Right the First Time’

▪ Places emphasis on problem prevention rather that dependence on detection after occurrence (Prevention is better than cure)

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PLANNING REQUIREMENTS FROM DRAWINGS

If you will be working from blueprints, symbols are likely to show up. Common symbols used in reference to plumbing fixture:

▪ Scales used for building plans

▪ Scales used for site plans

▪ Symbols for various materials

[pic]Refer to: Blankenbaker, Keith, E., Modern Plumbing; Pgs. 107-109

Woodson, Dodge R., Plumber’s Quick Reference Manual; Pgs. 189-19

[pic]

PLUMBING SAFETY

Don’t take safety for granted. Always comply with safety requirements set forth on your job.

Here are some general safe working habits you should cultivate:

1. Wear safety equipment

2. Observe all safety rules at the particular location

3. Be aware of any potential dangers in the specific situation

4. Keep tools in good condition

Personal Protective Equipment

Clothing: You should always dress appropriately to reduce the possibility of accidents or injury. Clothing and equipment should include:

• Overalls

• Waterproof pants and jacket

• Boots

• Water boots

• Gloves

• Respirators

• Hard hat

• Safety gloves

[pic]

[pic]

Identifying Safety Hazards

As a plumber you will be exposed to a number of safety hazards at the worksite. You must do all you can to minimize risk to yourself and others. If you are working in ditches of trenches:

- Be careful of underground utilities when digging.

- Do not allow people to stand on the top edge of the ditch while workers are in the ditch.

- Be sure to throw the dirt away from the ditch walls when digging a trench

- Be especially careful in areas with a high water table. Water in a trench can easily undermine the trench walls and lead to a cave in.

- Never work in a trench alone.

- Always have someone nearby, someone who can help you and locate additional help.

- Always keep a ladder nearby so you can leave the trench quickly if you have to.

- Be aware of any potentially dangerous situation

Safety on Rolling Scaffolds

- Do not lay tools or other materials on the floor of a scaffold. They can easily move and you can trip over them, or they might fall, hitting someone on the ground.

- Do not move a scaffold while you are on it.

- Always lock the wheels when the scaffold is positioned and you are using it.

- Always keep the scaffolds level to maintain a steady platform on which to work

- Take no shortcuts. Be watchful at all times and be prepared for any emergencies.

When working from a ladder:

- Use a solid and level footing to set up the ladder.

- Use a ladder in good condition.

- Be sure step ladders are opened fully and locked.

- When using an extension ladder, place it at least ¼ of its length away from the base of the building.

- Keep both hands free when climbing a ladder

- Do not carry tools in your pocket when climbing a ladder.

- Do not allow 2 people on a ladder designed for the use by 1 person.

- Keep ladder clean from mud, Grease etc. in order to avoid falls.

Try to prevent fires by:

- Keeping fire extinguishers handy; and ensuring that it is full and you know how to use it.

- Ensuring that you disconnect and bleed all hoses and regulators used in welding, brazing and soldering.

- Storing cylinders and acetylene, propane, oxygen and similar substances in an upright position in a well-vented area.

- Operating all welding, soldering and air acetylene equipment according to the manufactures directions.

- Not using propane torches or other similar equipment near materials that can easily catch fire

- Being careful at all times and being prepared for the worst situation.

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it is your responsibility to ensure that safety tips for the plumbing shop are adhered to. This will surely help to minimize safety hazards at the worksite

- Pick up objects with the knees bent and back straight.

- Clean up after completing a job.

- Obtain help to move a length of pipe

- Use tools only for the purpose intended

- Ensure tools are in good working condition

- Report all injuries no matter how small.

- Secure all ladders both at top and bottom.

- Know where ire equipment is.

- Never run in the shop.

- Never move things by throwing the.

- Do not carry tools in back pocket.

[pic]

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[pic]Refer to: Learning Guide BCGCOR0011A Carry Out OH&S Requirements

Plumbing Level 1 Curriculum and Student Manual

(Ask your learning facilitator how to access these)

TOOLS AND EQUIPMENT

Simple plumbing jobs will require only a few tools. However, to perform all operations that are part of plumbing work you will require a considerable number of various types of tools.

Measuring and Laying Out Tools

Instruments that measure length, height, diameter, levelness, or plumb are classified as measuring tools. Those that are used to produce accurate lines, circles or any other marking are called layout tools.

• Tapes

• Rules

• Squares

• Levels

• Transits

• Plumb bobs

• Chalk lines

• Compasses

• Dividers

Cutting Tools

Plumbing will require that you make some alterations to the structure so that pipes can be passed into walls and through roofs and floors. This calls for cutting tools.

• Hacksaws

• Saber saw

• Reamers

• Files

• Hole cutters

• Compass saw

• Threading machines

• Stock and dies

Smooth- edge cutting tools: produce polished edges and remove any remains of burr, often formed during operation.

• Cold chisel

• Aviation snips

• Pipe cutter

• Soil pipe cutter

Bending Tools

Most bends or changes in direction of pipework can be done using special purpose fittings and joints.

• Steel pipe

• Copper pipe

• Bending spring

Drilling and Boring Tools

Boring tools are useful for making holes in wooden structural parts where plumbing is being installed.

• Ratchet Brace

• Portable electric drills

• Auger bits

Tools for Assembling and Holding

These are used for tightening or loosening fittings and pipes.

• Wrenches

• Spanners/swaging tools

• Caulking tools

• Blowlamps

• Screwdrivers

• Ballistic

• Fixing gun

• Pliers and pincers

• Hammers

• Testing pump

• Vices

[pic]

[pic]Refer to: Smith, C. J. and Curry, B.,(1998) The Motivate Series: Practical Plumbing

ARE YOU READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, see if you have fully grasped all the components by doing the following the self-assessment.

Checklist 1 Yes No

1. I know how to identify and adhere to quality assurance

requirements ( ) ( )

2. I understand how to identify preparation and planning

requirements from drawings/work location and supervisor’s

instructions ( ) ( )

3. I know how to recognize OH&S requirements and respond

in accordance to workplace environment ( ) ( )

4. I know how to identify safety hazards and understand how

to adopt procedures to minimize risks to self and others ( ) ( )

5. I can demonstrate how to select, handle safely and store

materials in accordance with supervisor’s instructions ( ) ( )

6. I know how to select appropriate personal protective

equipment and can demonstrate how to fit and use them ( ) ( )

7. I understand how to select tools and equipment in accordance

with job requirements, demonstrate how to check for

serviceability and report faults (if any) to supervisor ( ) ( )

Checklist 2 Yes No

1. Quality assurance requirements identified and adhered to ( ) ( )

2. Preparation and planning requirements identified from

drawings/work location and supervisor’s instructions ( ) ( )

3. OH&S requirements recognized and adhered to ( ) ( )

4. Safety hazards identified and procedures adopted to

minimize risks to self and others ( ) ( )

5. Materials selected, safely handled and stored in accordance

with supervisor’s instructions ( ) ( )

6. Personal protective equipment selected correctly fitted

and used ( ) ( )

7. Tools and equipment selected, checked for serviceability

and faults (where they exist) reported to supervisor ( ) ( )

8. Materials/components checked for damage (where applicable) ( ) ( )

ELEMENT 2: PREPARE MATERIALS SELECTED FOR INSTALLATION

PROCESS

LEARNING OUTCOMES

As you go through this element it will provide you with the knowledge, skills and attitudes required to prepare materials selected for installation process. Your learning facilitator is there to assist you through the various activities so on completion you should be able to:

1. Identify activities for material preparation from specifications or from supervisor’s instructions.

2. Prepare materials to satisfy requirements of installation process

MATERIAL PREPARATION

Activities for material preparation include:

▪ Measuring

▪ Cutting

▪ Cementing

▪ Bending

▪ Joining

▪ Soldering

▪ Welding

▪ Threading

Measuring: When a measurement is taken from a blueprint it should be checked from both ends of the building to ensure accuracy. Before any cutting is done, be sure all your measurements are exact. You will need to determine the face-to-face distance between new fittings, then add the distance the pipe will extend into the fitting.

Cutting: It is important to cut the pipe square so that it butts up exactly to the pipe stop in the joint. This will ensure that the pipe is seated squarely in the fitting. This is very essential for making a watertight seal.

Tip for cutting Pipe squarely

• For a perfect fit, pipe ends must be cut square. If you are using a hacksaw, hold a strip of paper round the pipe so its edges align and saw parallel to the paper edge. Use the same trick if you have to file an inaccurate cut end

If you are cutting copper pipe here are some factors you should consider:

1. Ensure an accurate measurement of the proposed pipe run is done. Don’t forget to allow extra for the pipe that will fit inside the joints.

2. Use a simple paper template to help you to cut pipe squarely. Wrap the paper around the pipe and align the edges.

3. Use the flat side of your file to clean any burr from the outside of the pipe. The curved side of the file can be used to clean the inside.

4. When using a wheel tube cutter make sure you position the cutting mark on the pipe against the edge of the cutting wheel, then tighten the control knob before you begin to work

5. be sure you know how to rotate the cutter so it makes an even cut. The rollers on the tool will keep the blade square of the pipe.

6. A wheel tube cutter leaves a clean cut on the outside of the pipe, but any burr on the inside can be removed with a reamer.

[pic]

Joining: Before you join pipes, check that the ends are circular and have not been distorted. If they have been dented, cut back to an undamaged section of the pipe using a hacksaw with sharp blade or a wheel tube cutter.

Bending: If a lot of changes of direction are necessary in a pipe run, it is cheaper and quicker to bend the pipe rather than use fittings. This also makes the neatest finish particularly if the pipe-work is going to be exposed.

Note: Do not bend chromium-plated tubes, the plating will crack and the tube may break

When bending copper pipe, remember the following:

1. Use a bending spring, which is compatible in size with the pipe.

2. Over-bend the pipe slightly, and then bend it back to the required angle.

3. Put a screwdriver through the ring at the end of the spring. Twist it, then pull the spring out.

4. Open the leaver and position the pipe, then slide the straight former on top, when using a bending machine.

5. Raise the leaver so the wheel runs along the straight edge and the pipe is forced round the circular former.

6. Bend the pipe to the required angle, and then remove by opening the levers, and taking out the straight former.

Note: Your learning facilitator will demonstrate the bending technique using a bending machine

[pic]

Cementing: Before cementing the pipe and fitting together you should know exactly how the finished run will line up. It is a good idea to mark the pipe and the fitting beforehand and line up the two marks when cementing.

Threading: Galvanized pipe is connected to fitting by means of threads. To thread pipe you’ll need two pieces of equipment.

- A pipe vise to hold the pipe steady

- A threader with a head of the same nominal diameter as the pipe

How It’s Done

To thread the pipe exert force toward the body of the pipe while rotating the handle clockwise. When the head of the threader bites into the metal, stop pushing and simply continue the clockwise rotation. Apply generous amounts of cutting oil as you turn the threader. If the threader sticks, some metal chips are probably in the way; back the tools off slightly and blow the chips off. Continue threading until the pipes extends about one thread beyond the ends of the threader. head. Remove the threader from the pipe and clean off the newly cut threads with a stiff wire brush.

[pic]

Soldering procedure requires that you know how to:

1. Cut the copper properly with a tubing cutter

2. Ream the ends of each pipe to remove metals burrs

3. Clean copper pipe ends and the socket or cup of the fitting using abrasive paper, emery cloth or steel wool

4. Apply the proper flux to all pipe and joint areas with a clean brush

4. Assemble the fluxed pipes into the fitting

5. Select the proper solder

6. Light a small portable propane gas torch for heating the pipe and fitting

7. Direct the heat on the copper pipe before heating the fitting

8. Touch the ends of the solder wire to the joint area to check for proper temperature and feed the solder into the joint as you move the torch flame to the center of the fitting

9. To produce a joint that is smooth and neat, wipe with a burlap or denim cloth while still hot

10. Secure propane torch and other equipment

Note: You must ensure that all safety measures are in place before you attempt to do

soldering. As a matter of fact, your learning facilitator MUST be there to ensure

safety measures are observed.

[pic]Refer to: Plumbing Curriculum Level 1 (1999) 3rd Edition Modules 3-5

Plumbing Student Manual Level 1

[pic]

ARE YOU READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, see if you have fully grasped all the components by doing the following the self-assessment.

Checklist 1 Yes No

1. I know how to identify activities for material preparation

from specifications or supervisor’s instructions ( ) ( )

2. I can demonstrate how to prepare material to satisfy

requirements of installation process ( ) ( )

Checklist 2 Yes No

1. Activities for material preparation are identified ( ) ( )

2. Materials for installation area satisfactorily prepared ( ) ( )

ELEMENT 3: PREPARE WORK AREA SUITABLE FOR INSTALLATION

PROCESS

LEARNING OUTCOMES

As you go through this element it will provide you with the knowledge, skills and attitude required to prepare work area suitable for installation process. Your learning facilitator is there to assist you through the various activities so on completion you should be able to:

1. Identify from installation technique, activities to be carried out in the work are for

installation technique

2. Prepare work area for installation process according to your supervisor’s instruction

IDENTIFY INSTALLATION TECHNIQUE

Your work area is the immediate surroundings where the work will be carried out. In order to have your installation process going smoothly you will need to consider the following:

Housekeeping- means keeping your work area clean and orderly.

General lighting in the work area is required for a safe working environment. As a plumber

you may need a flashlight to illuminate confined works areas.

Check your clothing to see that it meets the standards established.

Check all portable electric tools in the shop to see that that are grounded.

Tools and equipment should be at a central location where they can be easily reached during

installation.

• Identify tools for each process

- Surface preparation- sandpaper, dusk mask

- Earth moving/wall chopping- pickaxes, shovel, pry bar, wheelbarrow

- Cleanup- brooms, vacuum

• Gather all material needed, first write down what you have, then what you need get from your supervisor

• Ensure work area is well ventilated away from heat and flames before using plastic solvent cement. These solvent products are flammable and toxic to varying degrees.

• If you are using scaffolding on jobs be sure it is anchored secure and able to support the intended load.

Earth Moving

• Where excavating and trenching must be performed by the plumber, underground utilities, if any, should be located and protected

• Dig trenches to adequate depth using correct tools

• Level soil or other surface before laying pipes

Remember, the activities to be carried out will give you most, if not all the information you will need in order to do your preparation. If you are not sure about the processes involved, ask your learning facilitator. That is the only way your preparation will be correct. Ask yourself:

What will be done?

How will it be done?

What kind of tools and equipment will be used?

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ARE YOU READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, see if you have fully grasped all the components by doing the following the self-assessment.

Checklist 1 Yes No

1. I know how to identify the different activities to be carried

out in the work area for installation ( ) ( )

2. I can demonstrate how to prepare a work area for installations ( ) ( )

Checklist 2 Yes No

1. Different activities to be carried out are identified ( ) ( )

2. Work area for installations is prepared ( ) ( )

ELEMENT 4: USE TOOLS, PLANT AND EQUIPMENT APPROPRIATE

FOR INSTALLATION PROCESS

LEARNING OUTCOMES

As you go through this element it will provide you with the knowledge, skills and attitudes required to use tools, plant and equipment appropriate for installation process. Your learning facilitator is there to assist you through the various activities so on completion you should be able to:

1. Identify regular tools/measuring devices suitable for application process to job requirements.

2. Use measuring tools safety and effectively to carry out processes where applicable.

IDENTIFY REGULAR TOOLS/MEASURING DEVICES

As a plumber you will use a number of tools in your job

- rules

- tapes

- squares

- levels

- transits

- plumb bob

- chalk lines

- compasses and dividers

You will need these to help you with accurate measurements. There are many variations to each tool/equipment.

Rules

A plumbers’ rule is a special type of folding rule. It has vertical marking on one side and a 45 degree scale on the other.

Care of Rule

Avoid dropping a folding rule on its end

Tapes

Steel tapes in 25, 50 and 100 foot lengths are desirable for locating terminal points for pipe or for measuring the lengths of pipe required for long runs. You will prefer the 100 foot size because of its greater capacity. Some steel tapes are marked in both English and metric.

Uses of Tapes

1. To measure irregular shapes as well as regular shapes.

2. To make accurate inside measurements.

Care of Tapes

If your tape is to work properly, it must be kept clean, dry and free from kinks. During the process of winding and unwinding the tape, dirt, sand, or other abrasive materials tend to wear away the numbers. A bent tape is difficult to rewind and will not lie straight when extended. These problems can be prevented if you take care when the tape is extended and wipe away water and dirt before rewinding.

[pic]

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Squares

▪ Try square

▪ Combination square

▪ Framing square

When are squares useful?

• When locating the position of fixtures.

• When marking framing members for cuts that will permit plumbing installation.

• When testing a level or plumb surface.

The type of square selected depends on the type of work being done

Care of Squares

Avoid dropping or hitting the square, this could change the angle between the blade, head and tongue. Protect the blade from rusting so that the scales remain readable.

Uses of a Chalk Line

• For laying out lines on ceilings.

• For laying out grid and wall lines on the floor in toilet rooms so that the plumber may accurately install his pipe before the walls are constructed.

Uses of Plumb Bob

• A plumb bob can be used to center opening for pipes from one floor to the next.

• Can be used to mark openings so that accurate measurements can be taken of the line for cutting pipe.

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Level

▪ Line level

▪ Builders level

▪ Water level

A good general purpose level has at least 3 vials. One vial tests levelness when a parallel edge of the level is against the part. A second vial tests levelness when the other parallel edge of the level is against the objects. The remaining vial tests plumbness of an object regardless of which end of the level is up.

Care of Level

Levels should be handled carefully to prevent the vial from breaking. When not in use, it can be stored where they will not be twisted, bent or forced from their own shape.

Compasses and Dividers

Laying out circles and arcs requires a compass or divider. The divider also step off measurements and divides distances along a straight line.

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ARE YOU READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, see if you have fully grasped all the components by doing the following the self-assessment.

Checklist 1 Yes No

1. I know how to identify regular tools, measuring devices suitable

for application in a specific job application ( ) ( )

2. I understand how to use measuring tools effectively to carry out

process where applicable ( ) ( )

Checklist 1 Yes No

1. Regular tools and measuring devices identified ( ) ( )

2. Measuring tools safely and effectively used ( ) ( )

ELEMENT 5: PREPARE BACKGROUND OF SURFACES/

ENVIRONMENT FOR PIPING AND TUBING INSTALLATION

LEARNING OUTCOMES

As you go through this element it will provide you with the knowledge, skills and attitudes required to prepare background of surfaces/environment for piping and tubing installation. Your learning facilitator is there to assist you through the various activities so on completion you should be able to:

1. Identify surfaces for preparation for installation of piping and tubing.

2. Chase, chop and prepare surface for piping and tubing installation.

3. Excavate surfaces where appropriate for piping and tubing installation.

IDENTIFY AND PREPARE SURFACES

Surfaces

Piping and tubing may be installed in surfaces such as:

1. Concrete

2. Concrete block work

3. Brick work/Stone work

4. Pavements

5. Underground

These surfaces are normally prepared by excavating, chopping and chasing.

Concrete surfaces are a combination of Portland cement and water paste with some type of aggregate. The paste surrounds the aggregate particles and as it sets, binds them solidly together. A solid concrete has voids between particles filled with paste. In order to break such material extensive chopping may be required.

Excavations are done underground, normally made slightly deeper than the bottom of the pipe to allow gravel to be used as a base for the pipe. Gravel will not compact, and it is easier to obtain full support for the pipe by filling around it with gravel, than it is to very carefully level the bottom of the trench. Also, gravel over pipe protects it from damage that could be caused by larger rocks during the backfilling operation.

▪ Use heavy equipment to dig trenches and provide access to sewer and water mains. Trenching is done with a backhoe or trencher.

▪ Extended sewer lines into a basement before the concrete is placed, saves considerable amount of hand digging.

▪ Before digging determine if other utilities are buried in the path of the water main or sewer.

▪ It is a good idea to check electrical company, Cable Television Company and storm sewer utility to ensure that excavations for the water and sewer piping will not disturb any of the other installations.

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Excavating and Trenching

Where excavation and trenching must be performed by the plumber, underground utilities should be located and protected. Utility companies and other regulatory agencies must be contacted. The necessary permit and approval must be obtained before excavating begins.

▪ Walls and faces of excavation and trenches over 5 feet, that expose workers to danger, must be guarded with shoring, sloping off the ground or some other equally effective means. Trenches less than 5 feet deep may require shoring or sloping if hazardous soil conditions are present. Trench boxes or shields may be used in place of shoring or sloping

▪ Tools, equipment and excavated soil must be kept 2 feet away from the lip of the trench.

▪ Runways, pavements and side walks must be kept free of debris. If you are unsure, they must be shored to prevent cave-ins. Barricades and warnings signs must be used.

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To cut into gypsum wallboard:

▪ To cut into gypsum wallboard, drill small pilot holes at the floor corners of your outline, then use a keyhole saw to cut along the lines you marked.

▪ If there are tiles along a wall or floor where you will be working, chip them out. Remove the tile and plaster or wallboard from the wall. There may be nails or screws holding old fixtures/ piping in place, remove then before installing new piping.

▪ Layout and dig trenches- starting with wooden stakes hammered into the ground at each location. To guide your digging, stretch a line between steaks. Then dig trenches with a shovel, gentle work the shovel beneath the layers.

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Choosing Excavation Equipment

Some plumbing jobs will require the use of large equipment. Many factors have a bearing on the type and size of machine that will be considered. The major considerations are:

1. The type of soil to be excavated

2. Site condition

3. Distance of haul

4. Time allowed for job completion

5. Contract price

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Rock Excavation

Excavating sometimes include the removal of solid rock, and this involves blasting, a job that is normally carried out by specialists, it is important that the basic principles of rock removal by blasting be understood by those involved with the construction job. A plumber would not have the responsibility of blasting.

ARE YOU READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, see if you have fully grasped all the components by doing the following the self-assessment.

Checklist 1 Yes No

1. I can identify surfaces for preparation ( ) ( )

2. I can identify surfaces suitable for chopping, chasing and

excavating ( ) ( )

Checklist 2 Yes No

1. Gypsum wallboard is cut ( ) ( )

2. Excavation is shored ( ) ( )

3. Work area is prepared for piping installation ( ) ( )

ELEMENT 6: SELECT MATERIALS AND CUT COMPONENTS

LEARNING OUTCOMES

As you go through this element it will provide you with the knowledge, skills and attitude required to select materials and cut components. Your learning facilitator is there to assist you through the various activities so on completion you should be able to:

1. Select materials to be cut as per instruction.

2. Demonstrate correct manual techniques used to move and place materials.

3. Move materials safely to work area.

4. Cut/ bend/ fabricate, secure component to the same length as given instruction, using proper techniques.

SELECTING MATERIALS

During your plumbing jobs, you will find that the local plumbing code for your area will specify the type of piping materials that may be used for each particular piping system. Plumbing codes takes into consideration such local conditions as soil type, ground conditions, local rainfall etc. all of which can affect the choice of a piping material. The local plumbing code must be consulted to see that the material to be used is the code approved material for the system being piped.

Characteristics of Plumbing Material

It is important for you to be familiar with the characteristics of the various piping materials. You may need to use them in your laboratory or in the field.

Tools Used for Cutting

It is important for you to note the best tool for cutting each material. This will make your job easier and you will become more efficient in the technique of cutting piping materials.

Below is a list of commonly used materials, the best tool for cutting each material is also highlighted.

Piping Materials

Cast Iron- is very strong, but is difficult to cut and fit. Repairs and replacements should be made with plastic pipe, if allowed by local code.

• Tools for cutting: Cast iron or hacksaw

Acrylonitrile-Butadiene-Styrene (ABS) - was the first rigid plastic approved for the use in home drain system. Some local plumbing codes now restrict the use of ABS in new installations.

• Tools for cutting: Tubing cutter, miter box, or hacksaw

Poly-Vinyl-Chloride (PVC) - is a modern rigid plastic that is highly resistant to damage by heat or chemicals. It is the best material for drain waste vent pipes.

• Tools for cutting: Tubing cutter, miter box, or hacksaw

Galvanized iron- is very strong, but gradually will corrode. Not advised for new installation. Because galvanized iron is difficult to cut and fit, large jobs are best left to a professional.

• Tools for cutting: Hacksaw or reciprocating saw

Chlorinated- Ploy-Vinyl Chloride (CPVC) – rigid plastic is chemically formulated to withstand the high temperatures and pressures of water supply systems. Pipes and fittings are inexpensive.

• Tools for cutting: Tubing cutter, miter box, or hacksaw

Poly Butylenes (PB) - flexible plastic is easy to fit. It bends easily around corners and requires fewer fittings than CPVC. Not all local codes have been updated to permit use of PB pipe.

• Tools for cutting: Flexible plastic tubing cutter, sharp knife, or miter box

Rigid Copper is the best material for water supply pipes. It resists corrosion and has a smooth surface that provides good water flow. Soldered copper joints are very durable.

• Tools for cutting: Tubing cutter, hacksaw, or jig saw

Chromed copper has an attractive shiny surface, and is used where appearance is important. Chromed copper is durable and easy to bend and fit.

• Tools for cutting: Tubing cutter or hacksaw

Flexible copper tubing is easy to shape, and will withstand a slight frost without rupturing. Flexible copper bends easily around corners, so it requires fewer fittings than rigid copper.

• Tools for cutting: Tubing cutter or hacksaw

Chromed brass has an attractive shiny surface and is used for drain traps where appearance is important.

• Tools for cutting: Tubing cutter, hacksaw, or reciprocating saw

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MOVING MATERIALS SAFELY TO WORK AREA

It is important that you as a plumber handle, lift, move and fix materials with care. Protective measures have already been mentioned in previous elements, in relation to protecting the hands against injury from handling hot, oily or sharp materials. Great care should be taken when lifting, carrying and putting down heavy objects. Apart from crush injuries, the biggest cause of injury associated with handling and lifting is back injury. This results from lifting too heavy a load. You should ask for help when lifting heavy materials and long pieces of pipes.

Lifting Materials

1. Check that there are no obstacles in your pathway.

2. Try not to lift with your fingers under the load. If unavoidable, it is safer to lever the edges up and place wedges or spacers underneath so that you can get a better grip.

3. Never overestimate your strength. Get help or use mechanical equipment.

4. When carrying long objects like pipes and ladders, be careful when going around corners.

TECHNIQUE IN BENDING PIPING AND TUBING

The method of bending varies according both to the material from which the pipe is manufactured and to the size of pipe as well as the thickness of the pipe wall. When pipes are subjected to the process of bending, particularly with small radius bends, tremendous stresses are set up in the material. The stresses will be either compression or tension, depending upon where the stress reading is taken.

Methods of bending are classified as:

Loaded

In this method a steel or rubber insert or loose fill material is used. Air pressure is also used for certain pipes.

Mechanical

The use of bending machines is a commonly accepted method of bending. They are either manual or hydraulic.

Machine Bending

Bending machines are supplied in various forms suitable for bending all types of metal pipes both ferrous and non-ferrous, thin and thick walled varieties. They come under one of the following headings:

1. Compression bending- this method is used when bending thin- walled pipes as it gives the greatest support to the pipe at the point of bending

2. Draw bending- although very effective, the type of machine used for draw bending is of a more specialist nature. It can produce bends to a much smaller radius than those required in normal domestic work.

3. Push bending- this type of bending is the simplest and requires the least skill or knowledge of pipe bending on the part of the operator. It is sometimes called ‘center point’ bending because the bending pressure is applied at a single point in the center of the bend.

Bending Technique

If you use the knee method, you actually bend the pipe over your knee, supporting the pipe internally with a bending spring. You will over bend the pipe slightly and bring it back to the required angle. The spring will be fixed tightly in the pipe and you will not be able to pull it out. The removal is quite simple, insert a bar or screwdriver through the ring at the end of the spring and twist it. This reduces the spring’s diameter and will enable you to withdraw it. Greasing the spring before you insert it will make pulling it out much easier. Wrinkles may form on the inside of the bend, but these can be tapped out by gentle hammering. It’s wise not to attempt this before taking out the spring. If you do so you’ll never be able to remove it.

Bending springs are suitable for 15mm and 22mm diameter pipe. It can also bend 28mm pipes but it’s advisable to use a bending machine instead.

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A Bending Machine

This consists of a semi-circular former that supports the pipe externally during the bending operation and a roller that forces the pipe round the curve when the levers of the machine are brought together. The degree of bend depends on how far you move the handles.

Using the bending machine

1. Position the piping tube under the tube stop so that the marked spot for the start of the bend is at the leading edge of the curved former.

2. Fit the straight former in position under the roller and along the section of tube to be bent. You should still insert a bending spring into the tube; make sure this is in the correct position.

Disadvantage of spring bending:

1. It is not possible to make tight radius bends

2. There is no control over working the lead to the heel of the bend

3. There is more tendency to thin the lead at the heel of the bend

You may want to practice bending using the “wooden bobbin method.”

Bending using wooden bobbin

1. Straighten the pipe and true the bore by driving a wooden mandrel of the appropriate size through the pipe.

2. Set out the required bend. Mark the beginning and the end of the bend.

3. Dress the lead from the inside of the bend to the back of the bend, making it slightly oval in cross section.

4. Place your knee on the throat of the bend. Pull the pipe evenly; apply support on the throat of the bend.

5. Repeat steps 3 & 4 until the required angle is obtained.

6. Drive wooden bobbins through pipe, restoring the bend to the same uniform diameter as before.

7. The finish bend should be free of tool marks. These can be removed with the aid of a wooden dresser and a lead flapper.

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NOTE: The plumbing books in your library will give you additional information

[pic]Refer to: Blankenbaker, Keith E, Modern Plumbing

Woodson, Dodge R., Plumber’s Quick Reference Manual

The Complete Home Plumber

ARE YOU READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, see if you have fully grasped all the components by doing the following the self-assessment.

Checklist 1 Yes No

1. I can identify the various piping materials ( ) ( )

2. I am familiar with the characteristics of each piping material ( ) ( )

3. I can move and place material using correct handling technique ( ) ( )

4. I have grasped the technique to accurately cut/bend/fabricate/

secure components ( ) ( )

Checklist 2 Yes No

1. Piping materials safely moved to work area ( ) ( )

3. Material cut and bent to given instruction

4.

5.

6.

7.

8.

9. ( ) ( )

ELEMENT 7 & 8: DISTRIBUTE COMPONENTS AND CLEAN UP

LEARNING OUTCOMES

As you go through this element it will provide you with the knowledge, skills and attitude required to distribute components and clean up after work. Your learning facilitator is there to assist you through the various activities so on completion you should be able to:

1. Distribute and stack components to suit job location and sequence.

2. Stack and store materials for re-use or disposal

3. Clear work area

4. Clean, maintain and store tools and equipment

ORGANIZATION

As a plumber it is imperative that you organize your tools and equipment that will be used for any job. In your plumbing workshop all the tools, materials and fittings should have a special storage space. Hand tools should have special cupboards, fitting and other small items should be stored together. A first aid kit should also be stored in the lab in the case of an emergency. Power tools and long pieces of piping materials and ladders should also have their special storage area.

On site organization

It is important to note that the proper storage of each item allows you to locate them when they are ready to be used. It is no different on a job sites. On a job site all your materials, fittings and tools should be placed in a storage location to facilitate the flow of your performance.

Tools and materials for techniques that would be done first should be stored together in one area. The tools and materials for the second procedure should be placed in an area where that operation would take place. Operations and techniques that would be performed last would have a separate location for those materials storage. The nature of the job would determine how to layout your tools and materials for each step.

You will need to gather all the materials that will be used in whatever process is taking place. These materials will include: copper pipe, tubing ,soldering, steel wool, fittings. These components will be stored in one location.

The same idea of grouping tools will occur in a cutting procedure. You would gather, pipe, hacksaw, file and vise. You may find that the uses of some tools are used for many operations.

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CLEANING UP

When you are working in your workshop or on a building site, it is essential to keep the working area tidy. This will ensure that jobs are carried out safely and more efficiently. Accidents can be avoided if you take care to replace tools and materials when you are not using them.

Reminder:

Never allow obstacles and hazards to build up by leaving tools and materials lying around.

When tools in your work area are not packed away, accidents may be caused by tripping over materials or trailing cables. Kneeling on or putting hands on small fittings, screws can also cause painful injury.

When tools are not in use

Return them to the toolbox or bag. The same applies to fittings and materials. Only keep at hand those materials that are immediately needed.

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STORAGE

Store materials off cuttings, fittings and scraps inside a material box. Make sure the lids are put back on tins of flux, jointing materials or adhesives immediately after use to reduce the possibility of spillage.

CLEAN UP

• Sweep floors and workbenches to remove dust/shaving, metal off cuts and dispose of, or use a shop vacuum.

• Clean up work area from all tools and materials

• Clean tools to keep them new and in the best condition.

• Store left over material in a cupboard. They can be used for another job.

• Dispose of debris that is cut offs and scraps.

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Remove all combustible material such as timber, paper and cardboard packaging, because they can be a fire hazard if left around a workshop. Check benches to make sure that there are no protruding nails, screws or splinter that could cause injury. Check to see if vises are secure.

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ARE YOU READY TO PROVE YOUR COMPETENCY?

Now that you have completed this element, see if you have fully grasped all the components by doing the following the self-assessment.

Checklist 1 Yes No

1. I know how to distribute and stack components to suit

job location ( ) ( )

2. I can demonstrate how to stack/store materials for re-use or

disposal ( ) ( )

3. I know how to clear work area ( ) ( )

4. I can demonstrate how to clean maintain and store tools ( ) ( )

Checklist 2 Yes No

1. Components are distributed and stacked ( ) ( )

2. Materials are stacked/stored for re-use/disposal ( ) ( )

3. Work area is cleared ( ) ( )

4. Tools are cleaned, maintained and stored ( ) ( )

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LG-MEMINS0061A:

PREPARE FOR PIPING AND

TUBING INSTALLATION

Self-Assessment Checklist

Prepare for Piping and Tubing Installation

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Quality Assurance means all those

planned and systematic actions

necessary to provide adequate

confidence that a product or service will satisfy given requirements for quality.

ACTIVITY

Prepare a scrapbook with symbols for; bidet, toilet, floor drain, lavatory, laundry tub, kitchen suite, water heater, dishwasher.

ACTIVITY

Demonstrate the correct way to fit each piece of protective equipment listed.

CHECKPOINT

Are you familiar with general safe working habits on the worksite?

ACTIVITY

Demonstrate how to use a fire extinguisher.

Burr: A sharp rough edge on a piece of pipe or tubing as a result of being cut.

ACTIVITY

Make a floor plan (drawing) of your workshop showing the location of all fire extinguishers, fire doors and power cut- off locations.

CHECKPOINT

How do you work safely on a ladder or a scaffold when using cutting tools?

ACTIVITY

1. Check all the tools in your workshop to ensure that they are in good working order. Demonstrate how to change blades and sharpen tools. If you are not sure, ask your learning facilitator to help you or do a demonstration.

2. During your checking of tools in the workshop, you discovered that some tools needed servicing. Write a short report on your findings to your learning facilitator.

ACTIVITY

Practise cutting pieces of pipe putting special emphasis on accuracy.

CHECKPOINT

What are some of the activities for preparing materials for installation?

ACTIVITY

Practice joining two pieces of plastic pipes together.

ACTIVITY

1. Discuss with your learning facilitator some of the factors considered in the different activities for material preparation

2. Demonstrate for your learning facilitator how to join two pieces of pipe by welding.

ACTIVITY

Prepare your work area suitable for a simple piping and tubing installation. Ask your supervisor for specific instruction.

ACTIVITY

Use your tape and ruler to measure a length of pipe work to be cut. Remember to allow for depth of socket on fittings. Ask your supervisor for specific instructions.

ACTIVITY

Practice using your square, chalk line and plumb bob in your workshop. Your supervisor will give you specific instructions on the step to be taken and the care of these tools/equipment.

CHECKPOINT

Can you demonstrate how to use a square? A plumb bob?

ACTIVITY

Discuss with your learning facilitator the use of the tools mentioned in your notes.

Demonstrate for your learning facilitator how to use one of each type of tool: measuring tools, cutting tools/reaming tools

CHECKPOINT

What are some of the surfaces identified for preparation to accommodate piping and tubing installation?

CHECKPOINT

Describe the tools a plumber uses and say for what each tool is used.

Chase- (a pipe chase) A space or recess in the walls of a building where pipes are run.

Excavation lines- lines laid out on the job site to indicate where digging for foundation and piping is to be done.

ACTIVITY

Dig a trench in your school yard and practice shoring the sides of the excavation. Your learning facilitator will supervise and give you specific instructions.

CHECKPOINT

What are some of the utilities that should be located and protected before excavation?

ACTIVITY

Follow the instruction to cut into gypsum wallboard and practice cutting into gypsum wallboard. Your learning facilitator will guide you.

CHECKPOINT

What are the two methods of bending?

ACTIVITY

Check machines in your workshop to see that all parts are clean and in good working condition. Clean all the parts on machines and remember to lubricate where needed.

ACTIVITY

Gather the small tools in your workshop and clean them. Replace blades if they need to be changed. Your supervisor will help you to maintain each tool.

CHECKPOINT

When is compression bending used?

ACTIVITY

1. Bend a given length of pipe to a required angle. Ask your learning facilitator to help you.

ACTIVITY

Cutting Copper Pipe

1. Make an accurate measurement of the proposed pipe run. Don’t forget to allow extra for the pipe that will fit inside the joints.

ACTIVITY

1. Gather the necessary tools for cutting copper pipe in your workshop. Remember these tools will include measuring tools, cutting tools and a paper template. Group the tools according to their use, example tools for cutting. Your supervisor will give you other instructions.

2. Do the same for materials to be used.

CHECKPOINT

What are some of the piping materials used in plumbing?

CHECKPOINT

What is Quality Assurance? What can you gain by adhering to Quality Assurance measures?

CHECKPOINT

Why is it essential to keep working area tidy?

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