CBLM

COMPETENCY BASED LEARNING MATERIALS
Sector: CONSTRUCTION SECTOR
Qualification Title: PIPE FITTING NC II
Unit of Competency: CUT, BEVEL AND THREAD PIPES
Module Title: CUTTING, BEVELLING AND THREADING PIPES

Technical Education and Skills Development Authority
CABUGAO SCHOOL OF HANDICRAFT AND COTTAGE INDUSTRY
Cabugao, Bato, Catanduanes
Date Developed: Document No. CSHCI-CSS

June 2019
Trainers Methodology Level I Issued by: Page:
Developed by: CSHCI
PIPE FITTING NC II
ALEX A. ANGELES Revision #
00
PIPE FITTING NC II
COMPETENCY –BASED LEARNING MATERIALS
List of Competencies
BASIC COMPETENCIES
Unit of Competency Module Title Code
Participate in workplace Participating in workplace
500311105
communication communication
Working in a team
Work in a team environment 500311106
environment
Practicing career
Practice career professionalism 500311107
professionalism
Practice occupational health Practicing occupational
500311108
and safety procedures health and safety procedures
COMMON COMPETENCIES
Prepare construction materials Prepare construction
CON931201
and tools materials and tools
Observe procedures, Observe procedures,
specifications and manuals of specifications and manuals of CON931201
instruction instruction
Interpret technical drawings and Interpret technical drawings
CON931202
plans and plans
Perform mensuration and Perform mensuration and
CON931203
calculations calculations
Maintain tools and
Maintain tools and equipment CON931204
equipment
CORE COMPETENCIES
Cut, bevel and / or thread
Cut, bevel and / or thread pipes CON713340
pipes
Install overhead piping

Install overhead piping system CON713341
system
Install underground piping Install underground piping CON713342

system system
CON713343
Perform tack welding Perform tack welding

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ALEX A. ANGELES
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HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIAL
Welcome!
The unit of competency, “CUT, BEVEL AND THREAD PIPES”, is one

of competencies of PIPE FITTING NC II, a course which comprises the
knowledge, skills and attitudes required for a TVET trainer to possess.
The module, Setting-up Computer Servers, contains training materials

and activities related in identifying learner’s requirements, preparing session
plan, preparing basic instructional materials and organizing learning and
teaching activities for you to complete.
In this module you are required to go through the series of learning

activities in order to complete each learning outcome. In each learning
outcome are Information Sheets, Self-Checks, and Task or Job Sheet. Follow
and perform the activities on your own. If you have questions, do not
hesitate to ask for assistance from your facilitator.
Remember to:
 Work through all the information and complete the activities in each
section.
 Read information sheets and complete the Self-checks, suggested
references are included to supplement the materials provided in this
module.
 Most probably, your trainer will also be your supervisor or manager.
He is there to support you and show you the correct way to do things.
 You will be given plenty of opportunities to ask question and practice
on the job. Make sure you practice your new skills during the regular
work shifts. This way, you will improve your speed, memory and your
confidence.
 Use the self-check, Operation sheet or Job/task sheet 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 had sufficient practice, ask
your Trainer to evaluate you. The results 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, Facilitate Training Facilities.

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MODULE CONTENT
QUALIFICATION TITLE : NC II
UNIT OF COMPETENCY : Pipe Fitting
MODULE TITLE : Cutting, Beveling and Threading Pipes
MODULE DESCRIPTOR : This module covers the knowledge,
skill and attitudes required to cut, bevel and thread pipes in
preparation for Pipe Fitting.
NOMINAL DURATION: 48 hours
LEARNING OUTCOMES:
At the end of this module you MUST be able to:

1. Plan and prepare for work
2. Prepare materials, tools and equipment
3. Cut, bevel and thread pipes
4. Perform housekeeping
ASSESSMENT CRITERIA:
1. Wrap around procedure is performed following job requirements

2. Pipes are measured and marked according job specifications
3. Pipes are cut following job specifications
4. Pipe fitting tools and equipment are used as following manufacturer’s
instructions.
5. Beveling and grinding procedure is performed following job
specifications
6. Threading of pipe is performed as per specification
7. Joint preparation is performed following job requirements

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LEARNING OUTCOME SUMMARY
Learning Outcome No. 3 :

CUT, BEVEL AND THREAD PIPES
CONTENTS:
1. Plan and prepare for work
2. Prepare materials, tools and equipment
3. Cut, bevel and thread pipes
4. Perform housekeeping
ASSESSMENT CRITERIA:
1. Cutting procedure is performed following job specifications
2. Bevelling and grinding procedure is performed following job
specifications
3. Threading of pipe is performed, as specified
4. Joint preparation procedure is performed following job requirements
CONDITIONS:
Students/ Trainees must be provided with the following:
 Job specifications/plan
 Pipes
 Pipe wrap around
 Marking tools/equipment
 Pipe cutting equipment/ oxyfuel cutting set
 Beveling/grinding tools and equipment
 Working bench
 Pipe wrenches
 Tubing water level/spirit level
 Pipe threader
 Learning materials
 Workplace or simulated environment
ASSESSMENT METHODS:
1. Demonstration/observation
2. Written Test

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LEARNING EXPERIENCE
Learning Outcome #3
CUT, BEVEL AND THREAD PIPE
Learning Activities Special Instruction

1. Read Information Sheet 1.3-1 Read and understand the
on Procedures on Cutting Information Sheet and check your-
Pipes self by answering the self-check. You
2. Answer Self-check 1.3-1 on must answer all questions correctly
Procedures on Cutting Pipes before proceeding to the next activity
3. Compare Answers to Answer
Key 3.1-1
4. Perform Task Sheet 1.3-1 on
Cut Pipes
5. Evaluate your Performance
Using Performance Criteria
Checklist 1.3-1
6. Read Information Sheet 1.3-2 Read and understand the
on Procedures on Beveling and Information Sheet and check your-
Grinding of Pipes self by answering the self-check. You
7. Answer Self-check 1.3-2 on must answer all questions correctly
Procedures on Beveling and before proceeding to the next activity
Grinding of Pipes
8. Compare Answer to Answer
Key 1.3-2
9. Perform Task Sheet 1.3-2 on
Bevel and Grind Pipes
10. Evaluate your
Performance Using
Performance Criteria Checklist
1.3-2
11. Read Information Sheet Read and understand the
1.3-3 on Threading of Pipes Information Sheet and check your-
12. Answer Self-check 1.3-3 self by answering the self-check. You
on Threading of Pipes must answer all questions correctly
13. Compare Answer to before proceeding to the next activity
Answer Key 1.3-3
14. Perform Task Sheet 1.3-
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3 on Threading of Pipes
15. Evaluate your
Performance Using
1.3-3
16. Read Information Sheet Read and understand the
1.3-4 on Joint Preparation Information Sheet and check your-
Procedure self by answering the self-check. You
17. Answer Self-check 1.3-4 must answer all questions correctly
on Joint Preparation Procedure before proceeding to the next activity
18. Compare Answer to
Answer Key 1.3-4
19. Perform Task Sheet 1.3-
4 on Joint Preparation
Procedure
20. Evaluate your
Performance Using
1.3-4

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INFORMATION SHEET 1.3-3
PIPE FABRICATION
Learning Objectives:
After reading this INFORMATION SHEET, you must be able to:
1. Define briefly what piping fabrication system is.
2. Identify the different types of pipe cutter.
3. Operate the different types of pipe cutter.
Introduction
Pipe fabrication
Pipelines are used to transport fluids, including vapours, gases, slurries and
powders which flow through pipes at various pressures and temperatures.
The transmission of these materials invariably subjects the pipe to intense
stresses and strains and this demands the highest possible performance
from the pipe. All pipework must be designed and fabricated in a way that
ensures the safety of plant operators, the plant, the public and the
environment.

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The fabricator is responsible for the quality of the pipework and pipe
fabrication must be carried out in accordance with all relevant standards
and specifications. One faulty weld could lead to damage costing millions of
dollars, personal injury and in serious cases even death. Welded pipe
systems demand the highest degree of excellence in materials and quality of
work. Because high standards are required, the cost of pipework is
extremely high.
Typical costs for pipework in a manufacturing plant are shown in Table 1.1.
It is essential that pipework is fabricated by suitably trained and competent

trade persons.
Codes and standards
To ensure the highest standards of uniformity, safety and work quality,

most piping systems are designed, welded, installed and tested to rigid
specifications or codes. The most commonly used codes for welded pipework
in Australia are as follows.
Standards Australia International Limited (SAI)

● AS/NZS 3992:1998/Amdt 1:2000 Pressure equipment – Welding and
brazing qualification
● AS/NZS 4645.2:2008 Gas distribution networks - Steel pipe systems
● AS 2885.4-2010 Pipelines - Gas and liquid petroleum - Submarine
pipeline systems
● AS 1796-2001 Certification of welders and welding supervisors
● AS 1074-1989 Steel tubes and tubulars for ordinary service
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● AS 4458-1997 Pressure equipment – Manufacture
● AS 4041-2006 Pressure piping
American Society of Mechanical Engineers (ASME)

● ASME IX Piping systems in connection with power boilers, nuclear vessels
and unfired pressure vessels
American Petroleum Institute (API)

● API Std 1104 (R2010) Welding of Pipelines and Related Facilities – 20th
Edition, includes Errata 1 (2007) and 2 (2008)
American National Standards Institute (ANSI)

● ANSI/ASME B31.3 Chemical plant and petroleum refinery piping
● ASME B36.10M-2004 Welded and Seamless Wrought Steel Pipe
Some insurance companies, manufacturers and the military forces set up

their own codes to cover the fabrication and welding of pipeline systems.
All codes are developed to establish uniform minimum standards for:
● piping material
● fabrication and welding procedures
● quality of work
● qualification of personnel
● inspection and testing.
These standards ensure that there is maximum protection against accidents

occurring when the piping is in service.
Approval of piping systems
There must be a high degree of quality control when high-pressure pipe

systems are being fabricated to ensure that they meet the specifications of
the relevant codes.
The inspecting authority may be the machinery inspection branch of the

state or territory government, the insurance company underwriting the job
or the representatives of the client for whom the pipework is being
fabricated.
The quality control program includes the following steps.
1. Approval of the design of the pipe system.

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2. Approval of the fabricator who may have to prove that there is adequate
equipment and expert personnel to successfully meet the requirements of
the relevant code(s).
3. Frequent checks to ensure that the specified material is being used.
4. Approval of welding procedures and regular inspections to ensure that
these procedures are being followed.
5. Qualification of welders who are tested to ensure that they are capable of
carrying out the approved procedures successfully.
6. Non-destructive testing as required by the code(s).
7. Post-weld heat treatment as required by the code(s).
8. Final hydrostatic testing or alternative testing method.
Fabricators are responsible for the quality of the work they perform and for
the coordination of all inspection and testing procedures as required by the
relevant code(s).
Materials
Pipe
Pipe is specified by stating its nominal size (NS), which is only approximate.
Nominal size is neither the inside nor the outside diameter and it is
necessary to use standard tables or manufacturers’ tables to ascertain these
two dimensions exactly.
Pipe thicknesses are often described as ‘standard’ (STD), ‘extra strong’ (XS)
and ‘double extra strong’ (XXS). However, most manufacturers have adopted
the American piping code classification which classifies pipes into a
schedule system. The mass of the pipe is referred to as the schedule of pipe,
and may vary from Schedule 10 to Schedule 160.
As the schedule number increases so does the wall thickness, and as a

consequence the inside diameter reduces. The outside diameters remain
constant enabling standardisation of pipe brackets or threading. The exact
wall thickness can be determined from standard tables.

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Pipes are sometimes referred to as tubes. The primary difference is in how
they are measured, Boiler tubes and tubing are known by their outside
diameter and their wall thickness. Both dimensions are required when
ordering.
Carbon steel pipe
Carbon steel (CS) pipe is by far the most common pipe used and it is
supplied to strict specifications.
Straight seam-welded and spiral-welded pipe is made from plate, and

seamless pipe is made by piercing solid billets.
CS pipe is strong, weldable, durable, ductile, machinable and cheaper than

most other materials.
If CS pipe can meet the requirements of pressure, temperature, corrosion,

resistance and hygiene, it is a cost effective choice.
CS pipes in common use are manufactured to the following standards:
● ASME B36.10M-2004 Welded and Seamless Wrought Steel Pipe

● AS 1074-1989 Steel tubes and tubulars for ordinary service

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● BS 1387:1985 Specification for screwed and socketed steel tubes and
tubulars and for plain end steel tubes suitable for welding or for screwing to
BS 21 pipe threads.
Dimensions for pipes covered by these standards are, for practical purposes,
the same.
Cutting the pipe
The process by which pipe is cut is determined by its ferrous or non-ferrous

nature. There are several types of cutting machines available, both hand
and mechanical. Tools such as pipe cutters, joint profile machines, oxy and
plasma cutting tools are all appropriate for cutting pipe
To ensure accuracy of cut, a scribed line should be centre punched every 10

mm.
Different Types of Pipe Cutting Equipment
1. Mechanical Oxy Acetylene
2. Manual Oxy Acetylene

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3. Pipe Cold Cutting Machine
4. Electro Gas Pipe Cutter

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5. Improvised Plasma Pipe Cutter
6. Transportable by Truck Pipe Cutter
7. Chain Type Pipe Cutter

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8. Portable Angle Grinder
9. Single Wheel Pipe Cutter & Bench Top Chop Saw
COMMONLY TOOL USED IN PIPE CUTTING
Portable Angle Grinder

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Angle Grinder
An angle or hand grinder is a power tools regularly used by construction

worker and contractors. However, it’s also an invaluable tool in the home
workshop or round the house, with a multitude of uses. As the name
suggests, it can be used for grinding and cutting but also sanding and wire
brushing. But like any power tools, grinder can be dangerous if used
incorrectly. This guide shows you what safety precautions to take before and
during cutting and how to cut properly.
What are Angle Grinder used for?
A grinder is useful for cutting and grinding

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Iron, steel and other metals
Metal roof cladding, corrugated iron and other steel sheeting
Brick, stone and concrete
PVC waste pipe
Rebar in concrete
Grinding and sharpening tools
Safety Precaution when using an Angle Grinder
1. Make your work environment safe
All work environments need to be safe, but when using power tools, a trip or
fall can result in serious accident. Tools are often driven by power motors or
engines and the business end of the machine can be an abrasive cutting
disk, a blade with sharp teeth or a sharp drill bit.as the saying goes “flesh is
no match for steel”, so safe is paramount.
2. Use Personal Protective Equipment

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Eye protection – safety goggles need to be worn to protect eyes from
flying particles and spark.
Ear Protection – Muffs or ear plugs will lessen the risk of hearing
damage.
Hand Protection – Gloves provide protection from sparks, and small

fragment of disk and waste metal thrown out by the disk.
Breathing Protection – Use a suitable dust mask to protect against

fumes and dust particles.
Footwear – Wear steel toe cap shoe or boots with good grips. If you
are working with heavy items which could drop when cut up, this will
protect your toe.
Overalls and/or Leader Apron – These protect clothes from sparks.

Watch out for sparks falling into pockets or turn-ups.
3. Check your Grinder is in good condition and safe to use
An angle grinder like any power toll should be maintained in good

condition are given a quick inspection before use. Check out following:
Flex and Plug – The Flex should be securely attached to the tool and
plug.
Check the Guard – the guard on an angle grinder is an essential

component which should be place at all times.
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It protects the user from sparks
A secondary but equally important function of the guard is to shield
the back of the disk from making contact with your hand, potentially
causing a serious injury.
Side Handle – This should be tightly screwed into the tool.
Ventilation Slots – These should be regularly cleaned to prevent

overheating of motor.
4. Choose the right disc for the job
 Use the proper disk for material being Cut (e.g. masonry or
metal)

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 Check the disk for defects – Cracks, missing chunks or other
defects in a disk are potentially hazard.
 Never use a Cutting disk for grinding – Cutting disks are thin
and not design to withstand side pressure, unlike disks used for
grinding.
 Disk should never be used at a Rotational Speed Greater than

they were designed – Disk are marked with the maximum RPM
(Revolution Per Minute) specification. The
 Disk should never be used at a Rotational Speed Greater than

they were designed – Disk are marked with the maximum RPM
(Revolution Per Minute) specification. The large the disk, the
lower the maximum speed it can rotate at. This means that you
shouldn’t use a worn-down 9-inch disk on a 4 1/2 inch grinder.
 Make sure the Flange nut is suitable for the disk and tightened
fully
 Make sure the disk is seated properly before tightening

 Don’t use a disk after the use by date
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5. Use the Grinder correctly
PIPE CUTTING PROCEDURES
The fabricator is required to follow these four steps to achieve this.
1. Wrap a strip of paper around the pipe.

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3. Place the paper around the pipe.
4. Mark the pipe with engineer’s chalk at each crease and where the two
ends meet.
5. Using push pull rule check the mark to make sure before cutting
operation

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6. Used appropriate PPE, before starting the portable angle grinder
7. Switch on to run the machine and slowly move down to reach the pipe
mark line
8. While the disc start cutting slowly move forward the cutting disc to
reach the full circle line

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9. After done cutting remove the excess or scrap cut pipe
10. Using pencil grinder clean the inside edged of cut pipe
11. Again, using pencil grinder clean the outside edged of cut pipe
12. Finished product

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Self-Check 1.3-1
Multiple Choices:
Instructions: Choose the letter with the correct answer. Write the letter of
your choice on your answer sheet.
1.
2.
3.
4.
5.

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ANSWER KEY
1.
2.
3.
4.
5.

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TASK SHEET 1.3-1
Title: Cut Pipes using Portable Angle Grinder

Performance Objectives: Given the needed materials, you should be able to
cut pipes using portable angle grinder within 1 hour in accordance with the
industry standard.
Supplies/Materials: Portable Angle Grinder, 1 meter Carbon steel pipe and

pipe cutting disc.
Equipment:
Steps/Procedure:
1. Prepare your supplies/materials needed
Assessment Method:
Use of Performance Criteria Checklist 3.1-1

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PERFORMANCE CRITERIA CHECKLIST 3.1-1
Criteria
Did you….? YES NO

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BEVELING AND GRINDING OF PIPES
1.
2.
3.
Pipe Beveling
Beveling is the process in whch we
form an angle between the edge of
of a pipe and plane perpendicular
to the suface to a certain degree,
most commonly used to prepare
the ends of pipes for welding. Beve-
ling can also be used deburring the
cut tends for safety and aesthetic
reasons. We can apply any type of
bevel to any degree required. Bevel-
ling can be applied to the face of
any size or diameter of a pipe.

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Preparation for butt welds
Unless the piping system is of a large enough diameter to permit

internal access, butt welds must possess sound and smooth root
penetration when welded from the outside. To achieve this, the
weld preparation requires careful attention and the root face, root
gap and root alignment are all critical. A single-Vee preparation is
most common with the dimensions as shown in Figure 1.1.
Fig 1.1: Preparation for butt weld

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Pipe Threading
1. Identify and explain the materials used in threaded piping
systems.
2. Identify and explain pipe fittings.
3. Read and interpret screwed fitting joint drawings.
4. Identify and explain types of threads
Introduction to Pipe Threads
A pipe thread is a spiral ridge on the end of a pipe that enables pipes to be
joined together. For male fittings, pipe thread appears on the outer diameter
of the pipe; if female, the pipe thread appears on the inner diameter. By
rotating a male pipe end into a female pipe thread, the two fittings become
joined. Since male and female pipe thread must align successfully to form a
connection, manufacturers follow pipe thread industry standards.
The two main pipe thread standards are as follows:

 The British Standard Pipe thread (BSP)
 The American National Pipe Thread (NPT)
Types of Pipe Threads
Pipe threads are used to make not only a mechanical joint but also a leak
proof liquid seal. This is accomplished by machining the thread form on a
taper and using pipe sealant to fill any voids between the two threads which
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could cause a spiral leak. In both thread standards there are 2 different
types of threads:
 Parallel ('straight') threads, BSPP (British Standard Pipe Parallel

Thread), which have a constant diameter; denoted by the letter G.
 Taper threads, BSPT (British Standard Pipe Taper Thread), whose
diameter increases or decreases along the length of the thread;
denoted by the letter R.
A parallel pipe thread only forms a mechanical seal and is not used for
liquid seal applications. While a tapered pipe thread that can make a close-
fitting wet seal. Pipe threads used for liquid joints can be divided into two
types:
 Jointing threads: These are pipe threads where pressure-tightness is

made through the mating of two threads together. They always use a
taper male thread, but can have either parallel or taper female threads
and the seal is usually secured with a sealant compound. (In Europe,
taper female pipe threads are not commonly used.)
 Fastening threads: These are parallel pipe threads used where a
pressure-tight joint is achieved by the compression of a soft material
(such as an o-ring seal, gasket or a washer) between the end face of
the male thread and a socket or nipple face, with the tightening of a
backnut.
British Standard Pipe (BSP) Thread
In the nineteenth century, many different types of screw threads were

required for hydraulic and pneumatic circuits as well as fastening
components. As a result, manufacturers started to devise their own
fastening systems. This resulted in compatibility problems. The English
mechanical engineer and inventor, Sir Joseph Whitworth devised a uniform
threading system in 1841 to address the incompatibility problem. The
Whitworth thread form is based on a 55 degree thread angle with rounded
roots and crests. The joint is made self-sealing by cutting at least one of the
threads on a taper (usually the male thread). This became known as the
British Standard Pipe thread has been adopted internationally for
interconnecting and sealing pipe ends. The image below shows a BSPT (BSP
Taper) male thread sealing in BSPP (BSP Parallel) female coupling.

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To achieve the taper the bottoms of the threads aren't on a cylinder, but on
a cone; with a taper which is 1⁄16 inch in an inch, which is the same as 3/4
inch in a foot. The taper divided by a centre line yields an angle 1° 47' 24"
or 1.7899° as measured from the centre axis. Commonly-used sizes are ⅛,
¼, ⅜, ½, ¾, 1, 1¼, 1½, and 2”, available at most suppliers. Larger sizes are
used less frequently because other methods of joining are more practical for
3” and above in most applications.
The most important point to understand about pipe threads is that their size
refers to the diameter of the hole going through the fitting (i.e. where the
media travels such as air or oil, etc), and not the diameter of the thread
itself.
National Pipe Thread (NPT)
In America, William Sellers set the standard for nuts, bolts, and screws
which became the National Pipe Tapered Thread (NPT) in 1864. His 60
degree thread angle with flat crests and roots is the American standard for
tapered threads used to join pipes and fittings. The ANSI/ASME standard
B1.20.1 covers threads of 60-degree form in sizes from 1/16” to 24” Nominal
Pipe Size (NPS).
The taper rate for NPT threads is the same as BSPT (3/4” per foot) measured
by the change of diameter (of the pipe thread) over distance. Sometimes
NPT threads are referred to as MPT ('Male Pipe Thread'), MNPT, or NPT (M)
for male (external) threads; and FPT ('Female Pipe Thread'), FNPT, or NPT(F)
for female (internal) threads.

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Sealing a Tapered Thread
Because of the taper, a pipe thread can only screw into a fitting a certain
distance before it jams. The standard specifies this distance as the length of
hand tight engagement, the distance the pipe thread can be screwed in by
hand. It also specifies another distance – the effective thread, this is the
length of the thread which makes the seal on a conventional machined pipe
thread. For pipefitters, instead of these distances, it is more convenient to
know how many turns to make by hand and how many with a wrench. A
simple rule of thumb for installing tapered pipe threads, both metal and
plastic, is finger tight plus one to two turns with a wrench. Torque
installation values can be determined per application, but due to the
variations involved in pipe joints such as dissimilar materials of male and
female threads, type of sealants used, and internal variations in product
wall thickness, a standard torque specification cannot be generically
applied. The table below compares the critical dimensions of BSP and NPT
threads and gives the number of turns to hand tighten.
British BSP American NPT

Nominal Actual Threads Actual Threads Turns for a
Size OD per inch OD per inch hand tight joint
1/8" 0.383” 28 0.405” 27 ≈ 3.3 turns
1/4" 0.518” 19 0.540” 18 ≈ 3.1 turns
3/8" 0.656” 19 0.675” 18 ≈ 3.3 turns
1/2" 0.825” 14 0.840” 14 ≈ 3.4 turns
3/4" 1.041” 14 1.050” 14 ≈ 3.7 turns
1" 1.309” 11 1.315” 11.3 ≈ 3.7 turns
1 1/4" 1.650” 11 1.660” 11.5 ≈ 3.8 turns
1 1/2" 1.882” 11 1.900” 11.5 ≈ 3.8 turns
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2" 2.347” 11 2.375” 11.5 ≈ 3.8 turns
Comparison of BSP v NPT threads and turns to hand tighten
Pipe Threading Equipment
Hand Held Threading Handle
A hand held threading handle is made up of a stock to which the handles

are attached and to which the cutting die is inserted in. There are two sets
of set screws on the stock, one set for holding the dies in place and the other
set for adjusting the dies. On the stock there is a deep mark to correspond
with the standard thread mark on the dies. On the opposite side of the stock
there is a place for the follower which helps to guide the cutting dies onto
the pipe that is to be threaded. The photos below are typically representative
of manual threading handles.
Manual threading handles, ratchets and cutting dies
A threading ratchet has only one handle and a ratchet action which allows it
to be used in confined spaces. Their size and convenience makes it possible
for pipefitters to cut a section of pipe and add the right configuration of
threads to pipes while at the job site or clean up an existing thread which
had become damaged.
Threading Dies
A full set of stocks and dies is composed of right and left dies from 1⁄8” up to
1”, with a guide for each size. The dies will have marked on them 1" R
which will cut a 1” right handed thread, (if 1-inch left were wanted, the
mark would be 1" L).
Die

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Die head and set of universal cutting dies for a range of thread sizes
A threading machine uses a set of universal machine dies which are fixed in
the die head and are numbered to be inserted in the correct sequence. One
set of these dies can cut a range of pipe sizes usually from 1” to 2” threads
and 2½” to 4” threads. The photos above show a die head with the positions
numbered and a set of universal dies for cutting threads on 1” to 2” pipe
Hand Held Threading Machine
Portable handheld electric units are relatively inexpensive, lightweight and

are ideal for maintenance and repair workers, as well as service plumbers.
They can thread pipe from 1/8” to 2" in diameter and usually come in a
durable carrying case with a set of 6 right hand dies to cover all common
pipe sizes in this range
Hand held threading machine for light work 1/8” to 2”
Threading Machine
At one time, pipe threading machines were the province of large scale
manufactures and tended to focus on the mass production of threaded steel
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pipes. Along with machining the specified thread design, the machines
would also cut the pipe into workable sections, as well as ream out the pipe
to ensure there were no defects in the pipe proper. Over time, the process for
pipe threading and pipe cutting was refined, making it possible to produce
completed goods for sale in a very short period of time. The uses of
machines allow the threading process to produce uniform pipe threads that
are uniform in nature.
Workshop threading machine with foot pedal control
For heavier duty or high volume repetitive work a pipe fitter would typical
use a power threading machine. This type of machine can thread a wide
range of pipe including black, galvanized and plastic-coated pipe, together
with stainless steel and heavy-wall conduit, as well as rod up to 30 Rockwell
C. These types of units typically operate at 36 RPM for 1/4" to 2" pipe and
at 12 RPM for 2 1/2" to 4" pipes. There is constant and proper lubrication
of dies and the work piece with through-head oiling and a universal receding
die head allows cutting of tapered or straight BSPT/BSPP or NPT/NPSM
threads. Motor control Reverse/Off/Forward, is achieved with a heavy-duty
rotary-type integral foot switch which allows the pipe fitter have both hands
free for the work piece.
Along with increased efficiency and lower maintenance costs, there are pipe
threading machines that are designed to work with materials other than
metal. Pipes made with various types of plastic or resin materials can now
be ran through pipe threading machines with no fear of overheating and
thus damaging the finished product. There are many manufactures who use
these machines to prepare low cost plastic piping making use of universally
recognized thread configurations.
Threading Oils

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Threading oils are used to cool and lubricate the cutting die and work piece.
The use of threading oils assists the threading process for the following
reasons:
 They keep the threading dies and the work piece at a stable
temperature (critical when working to close tolerances) and therefore
improves thread quality.
 Maximize the life of the cutting dies by lubricating the working edge
and reducing die ware.
 Reduces threading torque and speeds metal removal.
 Prevent rust on the threading dies and on the machined threads.
There are various kinds of cutting fluids specially formulated to maximize

wear resistance and can increases die life up to 60% and significantly
reduce operating costs by up to 30%. Like thread sealants they should be
selected depending on the piping service being installed and the pipe
material being threaded.
General Safety Precautions for Pipe Threading Equipment
When operating pipe threading equipment the operator should be properly

trained and supervised and observe all the general safe working procedures
required for the threading processes. While this is not meant to be an
exhaustive list some specific points to note for pipe threading are as follows:
Always -
 Comply with the prescribed safety precautions and fire-prevention

guidelines for the workshop.
 Ensure the threading machine is in sound condition and good working
order. Take action for immediate repair or replacement of damaged

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parts. Use recommended parts only. The use of improper parts may be
dangerous and will invalidate the machine warranty.
 Ensure that all dies are in good condition with no worn edged or have
points missing.
 Ensure that there is a sufficient supply of clean coolant and that all
filters are clean and functioning.
 Do not assemble when tired or when under the influence of drugs or
medication.
 DO NOT allow untrained persons to operate threading equipment.
 Keep threading machine and associated parts clean for best and safest
performance.
 Wear ANSI-approved safety goggles and heavy-duty work gloves
during use.
 As with any machining process, there is a significant pinch hazard
created. Keep hands, fingers, feet, and any item which may be injured
or damaged away from the threading machine during operation.
 Ensure that there are no loose clothes to snag on rotating parts, that
long hair is tied up and all jewelry is removed before commencing
work.
 Locate the threading machine in a suitable, well lit working area.
 Keep working area clean, tidy and free from unrelated materials.
 Key Learning Points
 Identify specific hazards pertinent to pipe threading
 Identify how these hazards are eliminated or minimized
 Identify how hazards towards others are minimized
 Identify safety precautions to be observed while threading pipe.
 Use on level and solid ground, preferably concrete.
 Ensure all non-essential persons keep a safe distance whilst the
threading machine is in use.
 When threading pipe the equipment should be in a horizontal position
with sufficient clear space to insert and withdraw the end of the pipe
for threading.
 Ensure that the threading machine is set-up with the correct
parameters for the pipe material being threaded as brass and cast
iron are dry cut without coolant.
Pipe threaded Machine Operation
1. Transportation Fig.2
When moving or transporting the machine, remove the oil pan. There
is no need to drain off the cutting oil in the tank.

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 Manual open die head˴ Chuck a piece of pipe securely, loosen the
lever nut on the die head and open the dies. (So that the dies do not
drop out, place the eccentric handle in the thread cutting position.)
Lower the pipe cutter, fix the pipe with the cutter roller sand blade,
and then move the machine.
 NV-auto die head, Self-opening die head and Uni-auto die head
(OPTIONAL)˴ Before moving the machine, chuck a piece of pipe
securely and fix the pipe with the cutter.
1. Setting up Fig.3
 Place the machine on a flat surface. Even when placed on a flat

surface, the machine is designed to be in as lightly raised position.
 Once the machine is setup, be sure to place the oil pan in its correct
position

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2. Cutting oil Fig.4
Fill the tank with the cutting oil that is supplied with the machine. Use only
the cutting oil that comes as a Standard Accessory or REX cutting oil
(Option).
 For stainless steel pipe only "Miyagawa100SW-R"Blackcan

 Water soluble "Miyagawa 50W-R"Bluecan”
 Standard "Miyagawa 246-R" “Redcan”

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3. Attaching the Die head Fig.5
Attach the die head that matches the size of pipe to be threaded to the
machine.
Attach the die head to the machine
Align the die head post to the carriage fitting hole, and push it until it
contacts the carriage while moving the die head up and down a little.
Lower the die head and check it is positioned correctly.

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4. Operating the Die Head
Manual-open Die Head

(There is no need to remove the die head from the machine)
Removing the dies Fig.6
 Knock the eccentric hand let other right, loosen the lever nut and
push the eccentric handle over to the far left. In this position, dies
No.3 and No.4 can then be removed.
 Raise the die head and you can remove dies No.1 and No.2.
˴

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Replacing the dies Fig.7
 Ensure the number on the dies corresponds with the number of the slot on the die
head. Insert each die until the notch is engaged.
 Pull the eccentric handle back in the opposite direction left of the arrow; (Fig.6) The
dies will move towards the centre of die head.
If the eccentric handle does not move in to position properly, move the dies up and down a
little while pushing and pulling the eccentric handle gently and try again.
Dies are made as a matched set off our, so be sure to use the mas such and replace the mall at
the same time. Do not attempt to replace just one or two of the set, as cutting will be
adversely affected.

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NV-auto Die Head: Option
There is no need to remove the die head from the machine.
Removing the dies (Fig.8)

 Open the die head. (i.e. Pull the open lever as shown by the arrow
marked "Open" in Fig.8)
 Loosen the lever nut (Fig.8), pull the cam plate as far as it will go in
the direction of the arrow, and lightly tighten the lever nut.
DiesNo.3andNo.4canbethenberemoved. Fig.9
RaisethedieheadandyoucanremovediesNo.1andNo.2.

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Replacing the dies
 Match the number on the die to the corresponding number on the die
head. Insert the die until the notch click sin to position.
 Push the cam plate back; the dies will move towards the centre of the
die head.
If the dies do not move in to position properly, move them up and down a
little and try again.
Dies are made as a matched set off our, so be sure to use them as such and
replace the mall at the same time. Do not attempt to replace just one or two
of the set, as cutting will be adversely affected.

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5. Setting up the pipe
 Removing the pipe (ig.10)

 Open the hammer chuck and rear chuck wider than the size of the
pipe to be threaded and insert the pipe from the rear chuck side
where possible. In the case of a short pipe, insert a pipe from the
chuck side.)
 Close the rear chuck and, holding the pipe in your right hand, close
the hammer chuck lightly with your left hand to place a grip on the
pipe and make sure the chuck jaw inserts engage the pipe properly.
Pull the hand-wheel sharply towards you to lock.
 A sharp jerk in the opposite direction will release the pipe once you
have finished threading. Next, remove the pipe after releasing the rear
chuck.

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Suggestions for short pipes (Fig.11)
 Lightly grip the pipe with the chuck, gently engage the dies with the
end of the pipe to be threaded, and then tighten the hammer chuck
again. Note: Chuck the pipe with the pipe protruding at least 90mm
from the edge of the chuck jaw insert.(Fig.11)

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Suggestions for long pipes (Fig.12)
 When threading long pipes, use a pipe support to avoid excessive
vibration etc. while the pipe is rotating, and to prevent the machine
from becoming unstable under the weight of the work piece.

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Caution! Not using a pipe support may result in irregular threads, damage
to the machine, and/or accident or injury.

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6. Power supply (ig.14)
 Before using the unit, check the voltage on the nameplate. Use only
an AC power supply. If an extension cord is used, it must be as short
as possible and of sufficient capacity for the power supplied
(atleast2mm2 cabtyrecable10Afor220-230V).
WARNING! Before connecting the plug to the socket, check that the machine
switch is turned OFF to prevent abrupt movements that could lead to
accident or injury.
7. Checks before starting (Fig.15)

1. Turn on the machine to set the main shaft in motion.
 Check there are no abnormal sounds or odours coming from the
motor.

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 Check the pipe you installed does not vibrate abnormally. If it does,
install it again.
 Check that cutting oil flows as it should from the die head. Confirm
that there is at least 1 liter of cutting oil in the tank. (tank capacity:
1.3L)
2. Allow the machine to rotate without any load for several minutes.
 Check the motor does not become abnormally hot, etc.
3. Turn the machine off and allow it to stop rotating.

 Check that the motor stops rotating right away.
The unit uses a motor equipped with brakes for improved safety. Make sure
you read and understand the points below relating to the use and
performance of the brake system.

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8. Cutting pipes (Fig.16)
 Raise the die head and reamer.

 Position the pipe so that it is ready for cutting and fasten the pipe
securely with the hammer chuck.
 Open the pipe cutter wider than the diameter of the pipe, lower it into
position and turn the cutter handle, bringing the cutter close to the
position where the blade and roller lightly press against the pipe.
 Switch the machine on and turn the cutter handle up to ½ a turn for
each rotation of the pipe.
Note: If the cutter handle is turned too quickly, it will affect the shape and
finish of the thread.
CAUTION
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Be sure to position the cutter correctly before the pipe starts rotating. If it is
not in the correct position it could damage the pipe or the machine.
 Special Precautions when you cut a pipe with another cutter We

strongly recommend that only the pipe cutter attached to the machine
be used to cut pipes.
If another cutter is used, ensure that the pipe end is at right angles to
the axis of the pipe. (Fig. 17-A)
If the pipe is not square on, as in Fig17-Band C, threads may be
defective. Band C may be the result of the following: Fig.17-B
 The bearing or chucking of the cutter is unstable.
 When a grinder is used with excessive force (especially in the
case of large diameter pipes.)
 When the pipe is engaged at an angle when cutting. Fig.17-C
 When you have cut a large diameter pipe 2 or 3 times with a
small grinder.
CAUTION
If the end of the pipe is slanted (Fig. B) or has steps in it (Fig. C), it is not
only impossible to make a perfect thread, but may even result in damage to
the machine, accident or injury.

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9. Reaming (Figs.18,19)
 After cutting the pipe with the pipe cutter, be sure to use the reamer
to chamfer the inside of the pipe before making a thread.
 Lift the die head and cutter out of the way.
 Reamers without a shaft.

 Move the reamer over and set it in position on the carriage.(Fig.18)
 Turn the machine on to start the pipe rotating. Then, turn the
carriage handle to the right to move the reamer forward to engage
the pipe. Allowthepipetorotateatleast1/2 a turn, then remove the
reamer from the pipe. That completes the reaming process. (Fig.19)

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CAUTION
 Do not use excessive force when pressing the reamer against the pipe
as this may scratch the pipe or even damage the machine.
 The reamer blade is extremely sharp. NEVER touch it with your bare
hands as you could be seriously injured.
 Points to Watch During Threading
 Manual-open Die Head
1) Before adjusting the size of the thread to be cut, bring the eccentric
handle towards you, until it is in the position indicated. (Fig.20-1)
2) Tighten the lever nut securely by hand.
3) Thread size can be simply adjusted with the lever nut. Move it towards
you to increase, and away to decrease the thread size. (Fig.20-2)

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 NV-auto Die Head (Option) (Fig.21)

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Precautions when Threading (Fig.22)
 Care when the dies come in to contact with the pipe Engage the
cutting edge of the dies very lightly with the end of the pipe. Bringing
the dies too forcefully in to contact with the pipe will resulting damage
to the dies and shorten their working life. Once the dies engage the
end of the pipe, apply light pressure to the carriage handle in a clock
wise direction and then gradually increase the pressure. As the dies
cutting to the pipe, it is no longer necessary to apply pressure to the
carriage handle as the carriage will move on its own.
10. Cutting threads with the NT50A (Manual-open Die Head)

The NT50A comes with the Manual-open Die Head (1/2-2"), and 2sets of dies
(1/2-3/4") (1-2") as standard accessories, check that the die head an dies you are
using are suitable for the pipe you are working on.
CAUTION
Start the thread cutting process with the carriage to the right of the red line on
the front support bar. Failure to do so could lead to accident or damage to the
unit.
 To match the size of the thread, align the scale on the Eccentric link
(Fig.20-1) with the thread size on the size scale on the die head, and then
tighten and fix the lever nut in position (Fig.23).
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 Turn the machine on and oil will automatically flow from the die head.
 Turn the carriage handle to the right to engage the pipe with the dies. Cut
3 or 4 threads and threading will then be performed automatically. The
unit uses a series motor whose rotation speed automatically varies
according to the load. (Fig.24)

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 When the thread has been cut other prescribed dimensions, slowly raise
the eccentric handle in the direction of the arrow and release the dies to
complete the threading process. (Note: If you release the dies too abruptly,
it may result in an imperfect finish such as a step-edged thread). (Fig.25)

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 Finally, complete the process by releasing the die head from the pipe by
turning the carriage handle to the left. If you place the die head in the
raised position, the flow of oil will stop. (Fig.25)
11. Adjusting the oil flow (Fig.26)

You can adjust the oil flow from the die head.
 With the die head in threading mode, remove the oil pan and check the
discharge of the oil.
 Turn the relief valve to adjust to the most suitable amount of oil needed.

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Depending on the load when threading, the amount of oil will vary according to
the speed the machine rotates.
12. Cutting threads with the REXNT50A OPTION:NV-auto Die Head)

When using an NV-auto die head 1/2-2" check that the dies you use match the
size of pipe you are working on.
CAUTION!
To avoid accident or injury, always start the thread cutting process with the
carriage to the right of the red line on the front support bar.
 Loosen the lever nut on the die head and match the marking on the cam
plate fixing pin with the pipe size on the size plate; then retighten the
lever nut. (Fig.27)

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Press down on the Open lever to put it in to the 'Set' position. (Fig28)
 Switch the machine on and oil will start flowing automatically from the die
head.

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 Turn the carriage handle to the right to engage the pipe with the dies. Cut
3 or 4 threads and threading will then be performed automatically. (Fig.29)

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When the prescribed length of thread has been cut, the dies will automatically be
released by the auto-open lever.
 Finally, release the die head from the pipe by turning the carriage handle
to the left
(Measuring Threads with a gauge)

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WARNING!
Threads may be affected by the condition of the dies (blades), cutting oil etc.,
so be sure to use a thread gauge to check the thread. This is especially
important after you have changed the die set.
13. Measuring threads with a gauge
 Confirming the thread diameter
 Use a thread gauge to confirm the diameter is as it should be.

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 Confirming the number of threads
 Confirm whether the thread length is as it should be according to the
number of threads as shown in Fig.34below.
CAUTION!
Choose an appropriate method for checking the threads on joints and other
connections, such as using sealants, washing the joint, checking the torque
etc.
 Unacceptable threads
 Irregular shaped threads (Fig.35-) ˴Recognising irregular shaped
threads C Visually inspect the thread after wiping off any oil or dirt
with a rag; you will find a wave-like formation. D Gently check the
surface of the thread with your fingers, feeling for any irregularity.
Check if bits of scrap are produced when cutting.
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 The diameter of the
thread is too small or
too large Fig.35- Check
with a thread gauge
 Distorted threads in the
case of manual die
heads Fig.35-Ԛ When
cutting threads that are
wider than the width of
the dies, you can
gradually open up the
eccentric handle; but
then if you leave the
eccentric handle in the
same position and cut
a thread longer than
the width of the dies,
the taper will remain
the same width as the
die and the rest of the
thread will be straight.
 Threads are too small
Fig.35-ԛ
 The thread is chipped
Fig.35-Ԝ
 Thread with uneven thickness Fig.35-ԝ

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JOINT PREPARATION
1. Identify butt weld piping materials and fittings.
2. Read and interpret butt weld piping drawings.
3. Prepare pipe ends for fit-up.
4. Determine pipe lengths between fittings.
5. Select and install backing rings.
6. Perform alignment procedures for various types of fittings.
Introduction
Pipe fabrication
Pipe fabrication involves assembling pieces such as elbows, tees

and flanges into sections which, along with the pipe and all other
equipment, can be accurately fitted together into the plant.
Because of the cost and importance of such lines, pipe

fabricators must assemble and weld pipes together with a high
degree of precision. This requires careful thought and planning,
accurate layout of work and control of welding operations as well
as the competent use of jigs, templates and other precision tools.
Carbon steel pipe
Carbon steel (CS) pipe is by far the most common pipe used and
it is supplied to strict specifications.
Straight seam-welded and spiral-welded pipe is made from plate,
and seamless pipe is made by piercing solid billets.
CS pipe is strong, weldable, durable, ductile, machinable and
cheaper than most other materials.
If CS pipe can meet the requirements of pressure, temperature,
corrosion, resistance and hygiene, it is a cost effective choice.

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CS pipes in common use are manufactured to the following
standards:
●● ASME B36.10M-2004 Welded and Seamless Wrought Steel
Pipe
●● AS 1074-1989 Steel tubes and tubulars for ordinary service
●● BS 1387:1985 Specification for screwed and socketed steel
tubes and tubulars and for plain end steel tubes suitable for
welding or for screwing to BS 21 pipe threads.
Dimensions for pipes covered by these standards are, for
practical purposes, the same.
Different types of Piping System
There are three common methods of joining piping, each with its
own advantages and disadvantages.
Butt welded piping systems are used for most process, utility or
service piping. Butt welding is the most practicable way of
obtaining strong, leak-proof joints; especially on larger piping.
The pipe and fitting used have, or are prepared with, standard
weld preparation. They require high levels of workmanship in
their assembly and welding.

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Socket-welded piping systems are used for lines of small
diameter which carry flammable, toxic or expensive materials
where no leakage is permitted. They are easier to assemble and
weld than butt welds and no weld metal can enter the bore. The
pipe end is finished square and fitted into the fittings, usually
with a 1.5 mm gap. This gap sometimes pockets liquids and is
not recommended if severe erosion of crevice corrosion is
anticipated.

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Screwed piping systems are used for small lines, usually of 50
mm diameter and are easily assembled using standard fittings.
The removal of metal to create the thread is a disadvantage and
fatigue strength is poor. There is no need for coded welders when
a screwed pipe system is used except where seal welding is
undertaken. Only butt welded and socket welded systems will be
dealt with in this text.

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Pipe fittings
A pipe fitting may be defined as any type of pipe connector that is
used to:
● make a connection
● change the size or direction of pipes or
● change the pipe specification from one material to another.
Fittings are classified by the method of end fixing, eg. Butt-
welding, socket-welding, screwed or flanged and by name, eg. 90°
and 45° elbows, reducing elbows, short and long radius bends,
equal and unequal tees, concentric and eccentric reducers and
stub ends.

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Butt welded fittings
Butt welded fittings have a 37.5° truncated edge with a designed

weld preparation consisting of a root gap and landing that is
welded. Types in common use are shown in Figure 2.5.
Butt weld Fittings are normally used for pipe size 2” and above.
In ASME B16.9, Long Radius Elbows, 3D Bends, Straight Tees
and Crosses, Reducing Tees and Crosses, Caps and Reducers are
available up to 48”. In ASME B16.9, Short radius elbows, Long
Radius Returns, Short Radius Return, Lap joint stubs ends are
available up to 24” They are Factory Made Wrought Steel Fittings.
(Works)
Dimension Standards
1. ASME B16.9: Factory-Made Wrought Butt welding Fittings.
2. MSS-SP-97: Integrally Reinforced Forged Branch Outlet
Fittings – Socket Welding, Threaded, and Butt welding
Ends.

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Fittings
Butt Weld Long Radius 90 Degrees Elbow
Butt weld long radius 90 degree elbow is used for 90 degree turn
on piping in butt weld piping system. Long radius elbows are
preferred due to their low pressure drop. They can also be cut at
lesser degree if required in piping layout. Their centreline radius
is 1.5 times the nominal pipe diameter. 90-Degree elbows with a
straight extension at one end (long tangent) are still available in
STD weight if required.
Butt Weld Short Radius 90 Degree Elbow
Butt weld sort radius 90 degree elbows are used where space is
limited. They are available only in 90 degree but they can be cut
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to lesser degree if required as per piping layout. Centreline radius
of short radius elbows is same as its nominal pipe diameter.
Butt Weld Long Radius 45 Degree Elbow
Butt weld long radius 45 degree elbow is used for 45 degree turn
on piping in butt weld piping system. Long radius elbows are
preferred due to their low pressure drop. They can also be cut at
lesser degree if required in piping layout. Their centreline radius
is 1.5 times the nominal pipe diameter. Only long radius 45
degree elbows are available.
Butt Weld Long Radius Reducing Elbow

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Only long radius reducing elbows are available. They are
sparingly used where is a space constraint. Normally a straight
elbow with butt elbow reducer is used.
Butt Weld Long Radius 180 Degree Return
180 degree turns are to construct heating coils, vents on tanks

etc. Long radius returns provide minimum pressure drop.
Butt Weld Straight Crosses
For economy, availability and to minimize the number of items in

inventory, it is preferred to use tees etc. and not crosses except
where space is restricted, as in marine piping or revamp work.

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Butt Weld Reducing Crosses
For economy, availability and to minimize the number of items in

inventory, it is preferred to use tees etc. and crosses except where
space is restricted, as in marine or revamp work.
Butt Weld Straight Tee

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Butt weld straight tees are used for branch connection of same
size that of header. These are one of the widely used butt welding
fittings.
Butt Weld Reducing Tee
Butt weld reducing tees are used for branch connection of

smaller size than that of header. These are one of the widely used
butt welding fittings.
Butt Weld Concentric Reducer

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These are used preferably in vertical piping. Placing them in
horizontal piping changes elevation of piping which can be
detrimental. These are normally avoided to reduce inventory and
eccentric reducers are used as much as possible.
Butt Weld Eccentric Reducers
These are mostly used in place of eccentric reducers as they keep

bottom of pipe unchanged in horizontal piping. To reduce
inventory, eccentric reducers are preferred in place of concentric
reducers.

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Butt Weld Caps
These are used to close the pipe ends on pipe racks. Are also
used at the bottom of condensate drip legs. Holes can be drilled
on their head and drain connections can be added in case if drip
legs.
Butt Weld Short Radius Returns
180 degree returns are used to construct heating coils, vents on

tank etc. Long radius returns provide minimum pressure drop.

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Pipe Bends: 3D, 4D, 5D etc.
Bends are made from straight pipe. Common bending radii are 3
and 5 times the pipe size (3R and 5R bends, where R=Nominal
Pipe Size – nominal diameter – not radius). 3D bends are
available from stock. Larger bends can be custom made,
preferably by hot bending. Only seamless or electric resistant-
welded pipe is suitable for bending.
Lap Joint Stub End

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These are used when piping is made of a costly material such as
stainless steel. Thick flange slip on this stub end. Flange can
made of a cheaper material like carbon steel.
Stub in is a term for a branch pipe welded directly into the side of
the main pipe run – it is not a fitting. This is the commonest and
least expensive method of welding a full-size or reducing branch
for pipe 2-inch and larger. A stub-in can be reinforced.
Reducing Laterals
Reducing laterals are ordered similarly to butt-welding tees,

except that the angle between branch and run is also started.
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Piping Flanges
Flanges are widely used in piping network for removable

connections to various piping components like valves, special
items as well for connection to equipment. They are normally
made by forging process. Only in few cases it can be fabricated
rom plates.
In ASME B16.5 only Blind flange and reducing flange can be
fabricated from a weldable quality plates.
Materials of Construction
Flanges are made by forging process. So Materials of

Construction are as follows.
1. A105 : Standard Specification for Carbon Steel Forgings for

Piping Applications.
2. A181 : Standard Specification for Carbon Steel Pipe
Forgings, for General-Purpose Piping.
3. A182 : Standard Specification for Forged or Rolled Alloy and
Stainless Steel Pipe Flanges, Forged Fittings, and Valves
and Parts for High-Temperature Service.
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4. A350 : Standard Specification for Carbon and Low-Alloy
Steel Forgings, Requiring Notch Toughness Testing for
Piping Components.
Applicable Standards
Flanges are made internationally according to following

standards:
1. ASME B16.1 : Cast Iron Flanges and Flanges Fittings:

Classes 25, 125, and 250
2. ASME B16.5 : Pipe Flanges and Flanged Fittings NPS ½
Through NPS 24 Metric/Inch Standard
3. ASME B16.47 : Large Diameter Steel Flanges (NPS 26
Through NPS 60)
4. DIN EN 1092-1 : Forged Stainless or Steel Flanges
Types of Flanges
1. Slip on Flanges
2. Socket Weld Flanges
3. Threaded Flanges
4. Welding Neck Flanges
5. Reducing Flanges
6. Blind Flanges
7. Lap Joint Flanges
Slip on Flanges
1. Slip on Flanges are generally forged with a hub.

2. When they are made from plates they do not have hub.
3. Slip on flanges are more economics than weld neck flanges.
4. They are used in non-critical applications above 2” npd.

5. Slip on flanges are welded to pipe both inside and outside.
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Socket Welding Flanges
1. Socket weld flanges are used in socket welding small bore

piping.
2. They are welded only on outside of the pipe.
3. There is small pocket after pipe to accommodate thermal
expansion of pipe, which stagnates fluid and can corrosion
if fluid is highly corrosive.
4. Socket welded flanges shall be specified with connection
pipe thickness to ensure proper bore dimensions.
Threaded Flanges
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1. Threaded Flanges are used for small bore threaded piping.
2. They are also used at locations where welding is not
allowed.
3. Threaded flanges are used in temperature range of 25 Deg C
to 450 Deg C.
4. The treaded can be NPT (Nominal Pipe Threads) or BSPT
(British Standard Pipe Threads) as required in the Piping
specification.
Welding Neck Flanges
1. Welding Neck Flanges are butt welded to the pipe.

2. As Radiography is required for all welds in critical services,
welding neck flanges are majorly used in such locations.
3. The thickness of welding neck flanges needs to be specified
for procurement which is generally same as the pipe
thickness of same size.
4. Welding neck flanges are more expensive and used in high
temperature, flammable, toxic etc. services.

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Lap Joint Flanges
1. Lap Joints flanges are used along with stub end which is
butt weld to pipe.
2. It is used where pipe is of higher grade or exotic material.
3. Loose flange is mostly carbon steel.
4. The inside diameter of lap joint flanges are machine to fit
onto the radius of stub end.

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Blind Flanges
Blind Flanges are used to close the end of the pipe and are bolted
on the other flange. In few locations, blind flanges are procured
with tapped holes for instruments or drain connection.
Reducing Flanges
Reducing flanges are used to connect the pipes of different

diameter without the use of a reducer. The dimensions and
thickness of the reducing flange should be of the larger diameter
pipe but the inside diameter is to suit the smaller diameter pipe.

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Available Flange Ratings
1. For Flange up to 24”, available Rating are: 150#, 300#,

400#, 600#, 900#, 1500# and 2500#.
2. For Type A Flanges, 26” to 60#, available rating are 150#,
300#, 400#, 600# and 26” to 48” for 900#.
3. For Type B Flanges, 26” to 60”, available rating are 75#,
150#, 300#. Sizes 26” to 36# for 400#, 600# and 900#.
Flange Facings
1. Flat Face
2. Raised Face
3. Male-Female
4. Tongue-Groove
5. Ring Type Joint
Flat Face flanges are used when the counter flanges are flat face.

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Raised Face Flanges
Raised Face pipe flanges are the most commonly used flanges.
The raised face thickness for 150# and 300# are include in the
specified flange thickness and for higher rating they are not
included in the flange thickness.
Male and Female Pipe Flanges

Male and Female pipe flanges are better version of Raised face
flanges.
Tongue-Groove Flanges
Tongue and Groove pipe joint but are costlier than the other
types of flanges.

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Ring Type Joint Flanges
The Ring Type Joint flanges are generally used in high pressure
(Class 600 and higher rating) and/or high temperature services
above 800ᵒF (427ᵒC).
Flange Face Finishes
1. Available Face Finishes are Stock Finish, Smooth/Serrated

Finish and Extra Smooth Finish.
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2. Stock Finish flanges are used with non-metal gaskets.
3. Type of flanges face serrations are Concentric and Spiral.
4. Concentric serrations are used where the conveying fluid is
highly flammable or toxic or lower molecular weight gas.
Torque Wrench
This tool is used to tighten the bolts s per specified torque
in project specification.

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Internal Flange Alignment Tool
Internal flange Alignment Tool is used to align flange and
pipe to each other before welding them together.
Flange Alignment Pins

This tool is used to exactly align flanges to each other before
bolting.
Water Hose Level

This tool is use to align level of two piping or structure parts
exactly same elevation.

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1. Welding machine is used to weld two piping parts together
using high ampere electric current and welding sticks.
A Frame
“A Frame” is used to lift and transport very heavy pipes and

fittings from one place to another.

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Pneumatic Pipe Cutting Machine
Pneumatic pipe cutting machine is an orbital pipe cutter
working on air pressure.

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Adjustable Wrench
Adjustable Wrench has adjusting wheel which changes
distance between jaws so that different sizes of nuts can be
removed.
C Clamp
C Clamp is used to hold and align different piping parts
together for welding
Center Punch
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Center Punch is used to make markings along cutting line
for welding pupose.
Chain Block
Chain block can lift weight 30 times of pulling force applied
on lifting chain with help of internal gears.
Chalk Line
Chalk line is used to mark long straight lines on pipes or
metal plates.

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Combination Wrench
Combination Wrench have one end open and other box or
circular type and are used to loosen or tighten the nuts.
Come Along Tool

A come-along (comealong, come-a-long, poer puller) is a
hand operated winch with a ratchet used to pull objects.

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Compass or Divider
Compass or Divider can be used for inscribing circle or arcs.
As divider, they can also be used as tools to measure
distances.
Contour Marker
Contour Marker is used to mark circular marking on pipe
periphery at various angles for cutting purpose.

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Flange Two-Hole Pins
Flange two-hole pins are used to make sure that any two
flange holes are perfectly aligned to horizontal.
Various Shape Files

Files of various shapes are used to remove burrs from cut
edges of pipes and fittings. Can be also used to rust from
small places.
Flat Screw Driver

Flat screw driver is used to multiple purposes apart from
using to tighten/loosen screws.

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Fork Lift
Fork lifts are used to lift and transport heavy piping items
from one place to another in workshop.
Grinder
Grinder are used to remove rust from pipes and fittings
ends before welding so that no defects occur in welds.
Hammer Wrench
Hammer Wrench has thick heavy end which can be
hammered to provide extra force to loosen bolts if they
stuck.

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Hydraulic Crane
Hydraulic Cranes are used to lift and move heavy piping
items from one pace to other in a workshop.
Nylon String
Nylon String can be used to do various long markings on
pipes and any other markings.
Oxyacetylene Cutting Kit

Oxyacetylene Cutting Kits is used to cut large size pipes,
elbows and steel plates using oxyacetylene flame.

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Pencil Grinder
Pencil Grinder is used to clean surfaces off rust in tight
places such as inside small pipes or holes.
Pipe Clamp
Pipe clamps are used to hold pipes tightly for various
purposes like cutting, threading or welding.

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Pipe Stand
Pipe Stands are used to arrange pipe at required elevation
during welding to each other or to fittings.
Pipe Threader
Pipe Threader is used to make threads a pipe fittings for

threaded piping specification.

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Pipe Vise
Pipe vise is used to hold small size pipes tightly for various
purposes like threading, cutting welding etc.
Pipe Wrap
Pipe wraps used to make markings on pipes for cutting
them to various shapes.

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Pipe Wrench
Pipe Wrench is an adjustable wrench/spanner used for
turning soft iron pipes and fittings with a rounded surface.
Plumb Bob
A plumb bob, or plummet, is a weight, usually with a
pointed tip on the bottom, suspended from a string and used as a
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vertical reference line, or plumb line. It is essentially the vertical
equivalent of a “water level”.
Protractor
Protractor is used to measure or mark required angles
during piping fabrication.
Sledge Hammer
Sledge Hammer is used to apply forces to wrenches or to
align things.

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Spirit Level
Spirit Level is used to ensure that piping is perfectly
horizontal or vertical as required by piping layout.
Stud Wrench
This tool is used to align flange bolt holes together as well as
tighten the bolts.

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Steel Square
This tool is used to align two parts at right angle before
welding.
Steel Tape
Most commonly used tools to measure length of various
piping items and other purposes.
TiRfor Winch
Tirfor Winch are used to lift to lift, pull and position loads
over great distances depending on the rope length.

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Tower Crane
Tower is crane is used to lift heavy piping and equipment to
high elevation.

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COMPETENCY BASED LEARNING MATERIALS

Sector: CONSTRUCTION SECTOR

Qualification Title: PIPE FITTING NC II

Unit of Competency: CUT, BEVEL AND THREAD PIPES

Module Title: CUTTING, BEVELLING AND THREADING PIPES

Date Developed: Document No. CSHCI-CSS

Install overhead piping

Install underground piping Install underground piping CON713342

Date Developed: Document No. CSHCI-CSS

The unit of competency, “CUT, BEVEL AND THREAD PIPES”, is one

The module, Setting-up Computer Servers, contains training materials

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

Date Developed: Document No. CSHCI-CSS

NOMINAL DURATION: 48 hours

At the end of this module you MUST be able to:

1. Wrap around procedure is performed following job requirements

Date Developed: Document No. CSHCI-CSS

Learning Outcome No. 3 :

Date Developed: Document No. CSHCI-CSS

Learning Activities Special Instruction

Date Developed: Document No. CSHCI-CSS

Date Developed: Document No. CSHCI-CSS

It is essential that pipework is fabricated by suitably trained and competent

To ensure the highest standards of uniformity, safety and work quality,

Standards Australia International Limited (SAI)

American Society of Mechanical Engineers (ASME)

American Petroleum Institute (API)

American National Standards Institute (ANSI)

Some insurance companies, manufacturers and the military forces set up

All codes are developed to establish uniform minimum standards for:

These standards ensure that there is maximum protection against accidents

Approval of piping systems

There must be a high degree of quality control when high-pressure pipe

The inspecting authority may be the machinery inspection branch of the

The quality control program includes the following steps.

1. Approval of the design of the pipe system.

Date Developed: Document No. CSHCI-CSS

As the schedule number increases so does the wall thickness, and as a

Date Developed: Document No. CSHCI-CSS

Carbon steel pipe

Straight seam-welded and spiral-welded pipe is made from plate, and

CS pipe is strong, weldable, durable, ductile, machinable and cheaper than

If CS pipe can meet the requirements of pressure, temperature, corrosion,

CS pipes in common use are manufactured to the following standards:

● ASME B36.10M-2004 Welded and Seamless Wrought Steel Pipe

Date Developed: Document No. CSHCI-CSS

Cutting the pipe

The process by which pipe is cut is determined by its ferrous or non-ferrous

To ensure accuracy of cut, a scribed line should be centre punched every 10

Different Types of Pipe Cutting Equipment

1. Mechanical Oxy Acetylene

2. Manual Oxy Acetylene

Date Developed: Document No. CSHCI-CSS

4. Electro Gas Pipe Cutter

Date Developed: Document No. CSHCI-CSS

6. Transportable by Truck Pipe Cutter

7. Chain Type Pipe Cutter

Date Developed: Document No. CSHCI-CSS

9. Single Wheel Pipe Cutter & Bench Top Chop Saw

COMMONLY TOOL USED IN PIPE CUTTING

Portable Angle Grinder

Date Developed: Document No. CSHCI-CSS