COMPETENCY - BASED LEARNING MATERIALS

Sector:
METALS AND ENGINEERING

Qualification:
Pipefitting (Metallic) NCII

Unit of Competency:

Module Title:

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

 Welcome

The unit of competency Maintain tools and equipment is one of the

competencies of Pipefitting (Metallic) NCII. This module covers the
knowledge, skills and attitudes required for TVET trainee to possess.

The module on, Maintaining tools and equipment contains training

materials and activities related to identifying learner’s requirement.

In this module you are required to go through a series of learning

activities in order to complete each learning outcome such as Information-
Sheets, Self-checks, Operation Sheets and Task/Job Sheets. Follow and
perform the activities on your own. If you have questions do not hesitate to
ask for assistance from your trainer.

Remember to:
 Work through all the information and complete the activities in each
section.

Read information sheets and complete the self-check. Suggested references

are included to supplement the materials provided in this module.

 Most probably, your trainer will also your supervisor or manage. he is

there to support you and show you the correct way to do things.

 You will be given plenty of opportunities to ask questions and practice

on the job make sure you practice your new skills during regular work
shifts. This way you will improve your speed, memory and your
confidence.

 Use the self-check, Operation Sheets and Task/job Sheets at the end of
each section to test your own progress. Use the Performance Criteria
Checklist or Procedural Checklist located after the sheet to check your
own performance.

 When you feel confident that you have sufficient practice, ask your
trainer to evaluate you. The result of your assessment will be recorded
in your Progress Chart and Accomplishment Chart.

 You need to complete this module before you can perform the next module

LIST OF COMPETENCIES
No. Unit of Competency Module Title Code
Prepare construction Preparing construction
1. materials and tools materials and tools
CON931201
Observe procedures, Observing procedures,
2. specifications and specifications and manuals CON311201
manuals of instruction of instruction
Perform mensurations Performing mensurations
3. and calculations and calculations
CON311203
Maintain tools and Maintaining tools and
4. equipment equipment
CON311204
 MODULE CONTENT

QUALIFICATION: Pipefitting (Metallic) NCII

UNIT OF COMPETENCY: Maintain tools and equipment

MODULE TITLE: Maintaining tools and equipment

MODULE DESCRIPTION: This unit covers the knowledge, skills and attitudes on checking
condition, performing preventive maintenance and storing of
construction painting tools and equipment..

NOMINAL DURATION: Hrs.

LEARNING OUTCOMES:
LO1. Check condition of tools and equipment
LO2. . Perform basic preventive maintenance
LO3. Store tools and equipment

DETAILS OF LEARNING OUTCOME

LEARNING OUTCOME 1: Check condition of tools and equipment
CONTENTS:
 Check condition of tools and equipment

ASSESSMENT CRITERIA:
 1.1 Materials, tools and equipment are identified according to
classification and job requirements
 1.2 Non-functional tools and equipment are segregated and
labeled according to classification
 1.3 Safety of tools and equipment are observed in accordance
with manufacturer’s instructions
 1.4 Condition of Personal Protective Equipment (PPE) are
checked in accordance with manufacturer’s instructions
CONDITIONS:(Tools, equipment, s/m, references/materials)
 Equipment
- SMAW Welding machine (AC/DC)
- Training Materials
- SMAW welding manuals
- Welding procedures specifications (WPS)
- Welding standards

METHODOLOGIES:
 Lecture/demonstration
 Self-paced learning
 Guided demonstration
ASSESSMENT METHODS:
 Written test
 Demonstration with oral questioning
 LEARNING EXPERIENCE

LEARNING OUTCOME 1: Perform single pass fillet weld in flat position (1F)

Learning Activities Special Instructions

1. Read Information sheet 4.1.1

Compare your answers to

2. Answer Self-Check 4.1.1 Answer Key 4.1.1
 INFORMATION SHEET 4.1.1
Check condition of tools and equipment

Water leaks can cause all kinds of damage. Pipefitters are the people who keep
them from happening. There is a wide variety of tools that pipefitters need to have
before going out to fit or fix pipes. We are supplying you with a list of what those
tools are and what they are used for. Precise measurements are so important in pipe
fitting that no one tool is really more important than the next. They are all important
to getting the pipes to fit together.

1. Quality Control Welder’s Gauge

Pipefitters have a hard job. Their job requires knowing what kind of material is
needed for each individual job, the exact dimensions of the pipes, and the precise
angle at which the pipe should be bent. Any little errors can cause leakage issues.
After the pipe has been fitted and welded together at its source, it is double-checked
to make sure the angles are exactly right and that everything is aligned correctly.
The quality control welder’s gauge is the tool that pipefitters use to check the quality
of pipes, before they are fitted, to make sure that they can handle the job at hand.

2. Pipefitter’s Square
The standard angle that pipes are usually bent to at their source is either 45° or 90°.
There are some jobs that require different angles, though. That is where the
pipefitter’s square comes in. The square is used to make sure that the pipe is
properly aligned.
3. Fitter Grips
Fitter grips are used to lock two pipes together while they are being welded one to
the other. They are also used when welding a pipe to a joint.

4. Two Hole Pin Pipe Fitting Tool

Two hole pins are used to make sure two bolt holes are aligned to one another at the
exact same height. The pins are lined up with the middle of the bolt holes. After they
have been tightened down, the pipefitter will lay a level across the pins to make sure
they are perfectly aligned.
5. Pipe Wraps
Pipe wraps are used to mark pipes before cutting. The wrap is put around the pipe,
making sure that all edges are perfectly aligned where the wrap overlaps itself.
Pipefitters then draw a line around the pipe with a sharp piece of soapstone. This
ensures a straight cut on the pipe.

6. Magnetic Centering Heads

Magnetic centering heads are used to find the center line at any angle and mark it
around the inside and the outside of a pipe.
7. Flange Aligners
Flange aligners are used to align joints before they are welded together. They are
also used during routine maintenance to realign any joints that have somehow
become misaligned. The tool is attached at the point of misalignment. It has vertical
and horizontal level vial markers that show whether the pipes are properly aligned
when workers are making adjustments.

8. Magnetic Flange Aligners

Magnetic flange aligners do the same job as flange aligners, but they are held in
place by strong magnets.

9. Magnetic Pocket Level

The magnetic pocket level is a two-vial bubble tool that is attached to a pipe by
magnets. The bubbles will show you whether the pipes are level before they are
welded together.
10. Miter Marker Pipe Layout Tool
The miter marker pipe layout tool is magnetically attached to a pipe. There is a knob
to adjust the angle at which to cut the pipe. There is a sharp piece of soapstone
attached to the end of a long arm that swings down, marking one side of the pipe at
the appropriate angle. The tool is then flipped over to mark the other side at the
same angle without being moved. The miter marker will fit pipes from 1 ½ inches up
to 18 inches.

11. Master Marker Pipe Layout Tool

The master marker pipe layout tool is the same as the miter marker, except that it
will fit pipes up to 48 inches. The two different-sized arms will fit into the same body,
so pipefitters don’t have to purchase two completely different tools.

12. Multi-Hole Imager

The multi-hole imager is a different arm that fits into the same base as the marker
layout tools. It is used to mark where to cut holes. There is a long arm that slides up
and down on a rod. There is a piece of soapstone on the end of the rod. Pipefitters
set the angle that they want the hole cut at, then lift the soapstone to the top of the
pipe and let it fall, marking the pipe where they want to cut.
 HAND TOOLS INSPECTION PROCESSES
Every manufacturer knows the importance of providing quality product to each
consumer worldwide. If consumers like the product, it is safe to expect that the
consumer would be a repeat-customer. In order to obtain high quality products all the
time, it is very important to perform different tests and inspection process to ensure
product reliability, safety and ease of use.
This article will cover the standard inspection processes being done on various hand
tools available in the market today:
PRE-PRODUCTION INSPECTION
The purpose of this inspection process is to verify that all of the needed tools for
hand tool production are free from any damage, defects or any loose joints to ensure
proper and consistent production when the operation starts. Any devices that show
any defects should be repaired or replaced as soon as possible to avoid the risks of
creating defective products.
RAW MATERIALS INSPECTION
The purpose of this inspection process is to thoroughly inspect and verify that all of
the needed materials for molding, hardening, cooling, and assembling are in
complete and good order to ensure that all of the materials to be used are free from
any damages or defects prior to initiating the production process. Any component
that is proven to show defects will be labeled “DEFECTIVE” and will be re-assigned
to a different queue for repairs or refurbishment.
ASSEMBLY INSPECTION
The purpose of this inspection process is to verify that all of the specifications under
the assembly queue meet the initial requirements in order for it to be considered in
the next production queue. Items that have the following will be labeled as
“DEFECTIVE” and will be reassigned to a different queue according to its defective
state.
Defective list:

 Deformations (for steel-based tools)

 Visual Damage
 Loose components
 Pre-production anomalies

COATING INSPECTION
The purpose of this inspection process is to verify that all of the hand tools that
require metal coating are properly coated evenly on all the needed surface of the
hand tool to ensure that all of the products in need of coating are properly checked.
Each hand tool that has missed spots during the coating process will be re-coated to
save on production time.
VISUAL INSPECTION
The purpose of this inspection process is to thoroughly inspect all of the hand tools,
regardless of the type, for any visible damages, dents, cracks, chips, or any known
production anomalies to ensure that all of the hand tools on the queue are ready for
the next set of inspection processes. Should there be any items that show poor
craftsmanship and functionality, these will be labeled “DEFECTIVE” and should be
reconfigured to pass the quality control and safety guidelines.
WEIGHT AND MEASUREMENT INSPECTION
The purpose of this inspection process is to accurately measure the different hand
tools under the same category to ensure that all of the tools are uniform in height,
weight, size and diameter. This process is important to assure the right number of
components used under the same queue is in check.
For the actual measurements, each hand tool will undergo a machine that will
accurately measure each dimension of the hand tool to ensure proper ergonometric
features that is both safe and reliable for everyday use (if applicable). Any hand tool
that have a different specification as provided will be labeled as “DEFECTIVE” and
will be re-assessed accordingly.
HANDS ON/QUALITY CONTROL INSPECTION
The purpose of this inspection process is to thoroughly test and inspect the
behaviors of the different hand tools when being used to raise awareness of how
certain items can break and cause unwanted accidents. Each hand tool will be
inspected and tested using different sets of tests that would fit the hand tool on the
current queue.
The main focus of this inspection is to verify that there are no hand tools that have
poor-quality plating and grinding capabilities all the time to keep the quality of
excellence seal for all the hand tools being tested. By performing efficiency testing
on all hand tools, inspectors will be able to accurately pin-point the maximum
capabilities of these hand tools by battery testing and other hands-on exercises.
Any items that fail the hands-on inspection will automatically be labeled as
“DEFECTIVE” and will be thrown away to avoid the risk of reconditioning defective
equipment.
Electrical Hand Tools: Each electrical hand tool (drills, screwdrivers, polishers etc…)
will undergo battery tests and efficiency tests to properly measure the performance
and capabilities of each electrical tool to ensure safe, efficient and reliable use prior
to shipping and distribution.
 Self Check 4.1-1

Name 5 pipefitting tools?

 Answer Key 4.1-1

 Fitter Grips
 Two Hole Pin Pipe Fitting Tool
 Pipe Wraps
 Magnetic Centering Heads
 Magnetic Flange Aligners
 DETAILS OF LEARNING OUTCOME

LEARNING OUTCOME 2: Perform basic preventive maintenance

CONTENTS:
 Perform basic preventive maintenance

ASSESSMENT CRITERIA:
2.1 Appropriate lubricants are identified according to types of
equipment
2.2 Tools and equipment are lubricated according to preventive
maintenance schedule or manufacturer's specifications
2.3 Measuring instruments are checked and calibrated in accordance
with manufacturer’s instructions
2.4 Tools are cleaned and lubricated according to standard
procedures
2.5 Defective instruments, equipment and accessories are inspected
and replaced according to manufacturer’s specifications
2.6 Tools are inspected, repaired and replaced after use
2.7 Work place is cleaned and kept in safe state in line with
Occupational Safety and Health (OSHS)
CONDITIONS:(Tools, equipment, s/m, references/materials)
PPE
Pipefitting Tools

METHODOLOGIES:
 Lecture/demonstration
 Self-paced learning
 Guided demonstration
ASSESSMENT METHODS:
 Written test
 Demonstration with oral questioning
 LEARNING EXPERIENCE

LEARNING OUTCOME 2:

Learning Activities Special Instructions

1. Read Information sheet 4.2.1

Compare your answers to

2. Answer Self-Check 4.2.1 Answer Key 4.2.1
 Information Sheet 4.2.1
Preventive maintenance

Preventive maintenance (or preventative maintenance) is maintenance that is

regularly performed on a piece of equipment to lessen the likelihood of it failing. It is
performed while the equipment is still working so that it does not break down
unexpectedly. In terms of the complexity of this maintenance strategy, it falls
between reactive (or run-to-failure) maintenance and predictive maintenance.

TYPES OF PREVENTIVE MAINTENANCE

Preventive maintenance can be scheduled on a time or usage based trigger. Let’s

look at an example for each.

Time-based preventive maintenance

A typical example of a time-based preventive maintenance trigger is a regular
inspection on a critical piece of equipment that would severely impact production in
the event of a breakdown.

Usage-based preventive maintenance

Usage-based triggers fire after a certain amount of kilometres, hours, or production
cycles. An example of this trigger is a motor-vehicle which might be scheduled for
service every 10,000km.

When is it suitable to use preventive maintenance?

Suitable preventive maintenance applications

Assets suitable for preventive maintenance include those that:

 Have a critical operational function

 Have failure modes that can be prevented (and not increased) with regular
maintenance

 Have a likelihood of failure that increases with time or use

 Unsuitable preventive maintenance applications

Unsuitable applications for preventive maintenance include those that:

 Have random failures that are unrelated to maintenance (such as circuit

boards)

 Do not serve a critical function

PROPER TOOL MAINTENANCE

If you take care of your tools, they will return the favor. Proper care and routine
maintenance of your hand tools and power tools makes any home improvement or
repair project easier, safer and more successful. Proper tool care also saves you
money because the better they’re cared for, the longer they’ll last.

HAND TOOLS
Hand tools such as screwdrivers, wrenches, hammers, pliers, levels, and wire
cutters are examples of common household tools that are often left out in places
such as basements, garages and tool sheds. Tools are tough, but they are not
indestructible and exposure to the elements can take its toll.

Below are some tips on how to take care of your tools and store them properly so
that you get optimum use out of them.

 Clean, Inspect and Care for Tools

Make it a habit to clean tools after each use before you return them to storage.
Wipe them down with a rag or old towel and be sure they are free of dust, grease
and debris before you put them into their proper places. This is also an opportunity
to look for any damage or defects. Check your tools' handles for splinters, breaks
and cracks. Also, make sure that metal parts show no signs of corrosion or rust.
Repair or replace any tools that show signs of damage.
 Cold chisels, log-splitting wedges and other striking tools can be very dangerous if
they are not maintained properly. Because these types of tools are used for
repeated striking, the surface of the metal head eventually mushrooms out and
spreads to form a lip or ridge around the edge. With continued use, there is more
spreading and the metal lip may continue to thin, split or curl until it finally breaks. If
the metal head separates from the handle while in use, this could result in a
dangerous projectile. To prevent this hazard, just grind off the metal edges with a
powered grinder on a regular basis.

 Don’t use tools that need repair or replacement. Broken tools can cause
injury.
 Don’t use tools inappropriately; you risk injury to yourself, others and
damage to the tools.

After cleaning, use an all-purpose oil, such as WD-40® to lubricate tools with
adjustable parts. Lightly spray other metal tool parts as well (avoid getting oil on
handles), such as screwdrivers and bladed lawn and garden tools. Wipe away any
excess with a rag before storing. This will help fight corrosion and rust.

If your tools already show signs of rust, there are a number of rust removers
available at True Value, such as Evapo-Rust Rust Remover. You can also try
spraying tools with WD-40® and then scrubbing them with steel wool or a stiff wire
brush. Afterwards, wash them with warm, soapy water and scrub them again with a
cloth or rag until all signs of rust are gone. Then dry them thoroughly with a clean,
dry rag. Apply a light coat of WD-40® and wipe away excess oil before storing.

POWER TOOLS
Power tools such as electric drills, saws, sanders and nailers need routine
maintenance just like your hand tools. Because of their mechanical and electrical
parts, power tools are more susceptible to problems caused by poor maintenance,
dust and debris accumulation and general malfunction. The following are some
helpful tips on how to clean and properly store your tools.

 Keep Power Tools Clean

Dust and grime can bring your power tools to a grinding halt if left unchecked over
time. Wipe them clean with a rag after every job has been completed and then store
them. Deep clean periodically by using a damp cloth. Get into exhausts and intakes
and other hard-to-clean areas with lightly oiled cotton swabs or other slender tools.

Inspect for Wear or Damage

Periodically inspect power tools for any signs of wear or damage. Pay special
attention to power cords. If you see frayed insulation or exposed wires, have the cord
repaired or replaced immediately by a professional, unless you have the expertise to
do it yourself. Damaged power cords can potentially lead to injury from electric shock
or can cause a fire. Also, check the cord’s prongs to see if they are bent or loose. If
any are, repair or replace.

Lubricate Moving Parts

Keep moving parts lubricated for premium performance. Not only does it keep the
mechanics of a tool running smoothly, it also decreases the chance of rust
developing. While common machine oil is a good choice, consult your owner’s
manual to see if the manufacturer recommends or requires a specific type of oil.

Keep Batteries in Shape

Cordless, battery-powered tools are convenient and portable and have become very
popular for contractors and homeowners alike. To keep them running efficiently and
effectively, it is essential for their batteries to be maintained.

Batteries remain working at peak level by fully charging and then fully discharging
their power once every couple of weeks. Don’t let batteries sit unused for extended
periods of time. Try to use batteries once every two weeks.

Care for batteries by cleaning contacts with cotton swabs and alcohol. Store
batteries you won’t be using for a while in a dry, clean place away from excessive
heat.

That’s it! Follow these general steps and your tools should last for years.
 Self Check 4.2-1
Name 2 types of preventive maintenance?
 Answer Key 4.2-1

Time-based preventive maintenance

A typical example of a time-based preventive maintenance trigger is a regular

inspection on a critical piece of equipment that would severely impact production in
the event of a breakdown.

Usage-based preventive maintenance

Usage-based triggers fire after a certain amount of kilometres, hours, or production

cycles. An example of this trigger is a motor-vehicle which might be scheduled for
service every 10,000km.
 DETAILS OF LEARNING OUTCOME

LEARNING OUTCOME 3: Store tools and equipment

CONTENTS:
 Store tools and equipment

ASSESSMENT CRITERIA:
3.1 Inventory of tools, instruments and equipment are conducted and
recorded as per company practices
3.2 Tools and equipment are stored safely in appropriate locations in
accordance with manufacturer's specifications or company
procedures
CONDITIONS:(Tools, equipment, s/m, references/materials)
PPE
Pipefitting Tools
Store Area

METHODOLOGIES:
 Lecture/demonstration
 Self-paced learning
 Guided demonstration
ASSESSMENT METHODS:
 Written test
 Demonstration with oral questioning
 LEARNING EXPERIENCE

LEARNING OUTCOME 3:

Learning Activities Special Instructions

1. Read Information sheet 4.3.1

Compare your answers to

2. Answer Self-Check 4.3.1 Answer Key 4.3.1
 Information Sheet 4.3-1

Store tools and equipment

If you take care of your tools, they will return the favor. Proper care and routine
maintenance of your hand tools and power tools makes any home improvement or
repair project easier, safer and more successful. Proper tool care also saves you
money because the better they’re cared for, the longer they’ll last.

Hand Tools

Store Tools Properly

A proper storage system is a must for hand tools. A toolbox, storage container,
shelving unit, or a combination of all of these can be used to keep your tools
protected and in peak condition. Ideally, your storage units should be kept
somewhere with minimal exposure to moisture and temperature changes.
Remember to keep tools in their respective places or hung on designated hangers
when a job has been completed.

Helpful Tips

Use a small tool bag for the tools you use most often such as tools for simple
jobs around the house. The rest of your tool arsenal can remain in your main
toolbox.

You should have a space where you can inspect your tools and perform
necessary maintenance tasks, such as a worktable. Cover it with newspaper or
plastic sheeting to protect the table and make it easier to clean up after you're
done with the job.

Hang lawn and garden tools, such as shovels and rakes, on a wall to get them
off of the ground and to protect them from moisture.

Power Tools
Store Power Tools Correctly

Keep your power tools protected from dust, moisture and other adverse conditions
by storing them properly after use. Keep them in their original cases if possible, or
tuck them away in storage drawers or tool chests, preferably in a garage or
basement with a moderately controlled climate. This not only protects them, it also
keeps them organized so you can easily find the tool you need when you need it.

Helpful Tip

Remember to keep instruction manuals for all of your tools. They are provided to
you by the manufacturer so that you can safely and competently operate your
tools. They’ll also have valuable information on how to care for the tool, find
replacement parts and other important pieces of information. Store manuals
either in a toolbox drawer or a cabinet in your workspace/storage area so that
they are readily available.

IMPORTANCE OF PROPER STORAGE OF TOOLS AND EQUIPMENT

The proper care and storage of tools and equipment are not only the concern of the
management but of the workers who use the equipment.
Importance of proper storage of tools and equipment

1. It is an important factor for safety and health as well as good business.

2. Improves appearance of general-shop and construction areas.
3. Reduces overall tool cost through maintenance.
4. This also ensures that tools are in good repair at hand.
5. Teaches workers principles of (tool) accountability.
Pointers to follow in storing tools and equipment:
1. Have a designated place for each kind of tools.
2. Label the storage cabinet or place correctly for immediate finding.
3. Store them near the point of use.
4. Wash and dry properly before storing.
5. Store knives properly when not in use with sharp edge down.
6. Put frequently used items in conveniently accessible locations.
7. Gather and secure electrical cords to prevent entanglement or snagging.
8. Cutting boards should be stored vertically to avoid moisture collection.
9. Metal equipment can be stacked on one another after drying such as storage
dishes and
bowls.
10. Make sure the areas where you are storing the equipment are clean, dry and not
overcrowded.

Self Check 4.3-1

Name 10 importance of storing tools properly?

 Answer Key 4.3-1

1. It is an important factor for safety and health as well as good business.

2. Improves appearance of general-shop and construction areas.
3. Reduces overall tool cost through maintenance.
4. This also ensures that tools are in good repair at hand.
5. Teaches workers principles of (tool) accountability.
Pointers to follow in storing tools and equipment:
1. Have a designated place for each kind of tools.
2. Label the storage cabinet or place correctly for immediate finding.
3. Store them near the point of use.
4. Wash and dry properly before storing.
5. Store knives properly when not in use with sharp edge down.
6. Put frequently used items in conveniently accessible locations.
7. Gather and secure electrical cords to prevent entanglement or snagging.
8. Cutting boards should be stored vertically to avoid moisture collection.
9. Metal equipment can be stacked on one another after drying such as storage
dishes and
bowls.
10. Make sure the areas where you are storing the equipment are clean, dry and not
overcrowded.