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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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CU Title CU Code CU Descriptor CU Work Activities Performance Criteria
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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CU Title CU Code CU Descriptor CU Work Activities Performance Criteria
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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CU Title CU Code CU Descriptor CU Work Activities Performance Criteria
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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CU Title CU Code CU Descriptor CU Work Activities Performance Criteria
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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CU Title CU Code CU Descriptor CU Work Activities Performance Criteria
disposal technique applied 5.5 Pipe cutting area
housekeeping completion confirmed
3. Pipe Jointing (Fit Up) 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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CU Title CU Code CU Descriptor CU Work Activities Performance Criteria
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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CU Title CU Code CU Descriptor CU Work Activities Performance Criteria
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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CU Title CU Code CU Descriptor CU Work Activities Performance Criteria
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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CU Title CU Code CU Descriptor CU Work Activities Performance Criteria
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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Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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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Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
16 Hours Demonstration
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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Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
36 Hours Demonstration
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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Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
12 Hours Demonstration
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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Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
8 Hours Demonstration
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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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CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector OIL, GAS AND PETROCHEMICAL
Job Area PIPING FABRICATION OPERATION
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
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training 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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Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
24 Hours Demonstration
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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Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
48 Hours Demonstration
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Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
50 Hours Demonstration
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Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
i. Wear Personal Protective Equipment (PPE)
ii. Adhere to safety procedure
24 Hours Demonstration
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Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
10 Hours Demonstration
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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 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
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. 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
35
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
36
CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector OIL, GAS AND PETROCHEMICAL
Job Area PIPING FABRICATION OPERATION
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
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training 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
37
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
54 Hours Demonstration
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
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
i. Wear Personal Protective Equipment (PPE)
ii. Adhere to safety procedure
48 Hours Demonstration
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
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
6 Hours Demonstration
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
iv. Housekeeping material, tools and equipment
3 Hours Lecture Types of pipe fit up work material waste differentiated
Pipe fit up workplace housekeeping procedure recognised
Unused pipe and fittings
40
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
Delivery Mode
Assessment Criteria
i. Determine types of pipe fit up work material waste
ii. Carry out housekeeping work according to procedure
iii. Return unused pipe and fittings to storage area
iv. Dispose waste according to procedure
v. Confirm pipe fit up area housekeeping completion
i. Wear Personal Protective Equipment (PPE)
ii. Adhere to safety procedure
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
Employability Skills
Core Abilities Social Skills
04.07 Negotiate acceptance and support for objectives and strategies
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
06.08 Identify and analyse effect of technology on the environment
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 (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
CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector OIL, GAS AND PETROCHEMICAL
Job Area PIPING FABRICATION OPERATION
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
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training 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
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
i. Wear Personal Protective Equipment (PPE)
ii. Adhere to safety procedure
48 Hours Demonstration
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
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
i. Wear Personal Protective Equipment (PPE)
ii. Adhere to safety procedure
48 Hours Practical
46
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
i. Wear Personal Protective Equipment (PPE)
ii. Adhere to safety procedure
48 Hours Demonstration
47
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
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
i. Wear Personal Protective Equipment (PPE)
ii. Adhere to safety procedure
48 Hours Demonstration
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
Work Activities Related Knowledge Applied Skills Attitude / Safety / Environmental Training Hours
Delivery Mode
Assessment Criteria
procedure iii. Pipe support fabrication
waste disposal procedure
iv. Housekeeping material, tools and equipment
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
ii. Carry out housekeeping work according to procedure
iii. Return unused pipe support material to storage area
iv. Dispose waste according to procedure
v. Confirm pipe support fabrication area housekeeping completion
i. Wear Personal Protective Equipment (PPE)
ii. Adhere to safety procedure
10 Hours Demonstration
49
Employability Skills
Core Abilities Social Skills
04.07 Negotiate acceptance and support for objectives and strategies
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
06.08 Identify and analyse effect of technology on the environment
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 (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