Facilities Standards - Pipefitting

NATIONAL COUNCIL ON TECHNICAL AND VOCATIONAL
EDUCATION AND TRAINING

(NCTVET)
FACILITIES STANDARDS FOR

TRAINING
IN
PIPEFITTING
Version 1
Prepared by the
Standards and Assessment Development Unit, NCTVET
Gordon Town Road, Kingston 6, Jamaica, West Indies
Facilities Standards for Pipefitting
Table of Contents
PREFACE ............................................................................................................................................................ 4
DESCRIPTION OF PROGRAMME .......................................................................................................................... 4
FACILITIES STANDARDS OBJECTIVES ................................................................................................................... 5
ASSUMPTIONS REGARDING SIZE OF TRAINING GROUP ....................................................................................... 5
BASIC DESIGN CONCEPT ..................................................................................................................................... 6
PROGRAMME LIMITATIONS ............................................................................................................................... 6
NON‐TRADITIONAL TRAINING PROGRAMME ...................................................................................................... 7
PROGRAMME LEVEL ........................................................................................................................................... 8
WORKSHOP LAYOUT .......................................................................................................................................... 8
STORAGE REQUIREMENTS .................................................................................................................................. 9
ELECTRICAL‐CIRCUIT DETAILS ............................................................................................................................. 9
VISUAL COMFORT ............................................................................................................................................. 10
VENTILATION .................................................................................................................................................... 10
PLUMBING REQUIREMENTS .............................................................................................................................. 11
GENERAL SAFETY AND FIRST AID ....................................................................................................................... 11
FIRE EXTINGUISHERS ...................................................................................................................................................... 11
SAFETY RULES .............................................................................................................................................................. 11
HOUSEKEEPING ............................................................................................................................................................ 12
FIRST AID .................................................................................................................................................................... 12
OUTDOOR TRAINING SITE............................................................................................................................................... 12
FACILITIES, ACTIVITIES, EQUIPMENT, TOOLS AND RESOURCE REQUIREMENTS CHECKLIST .................................. 12
1. PLANT SPACE SPECIFICATIONS ................................................................................................................................. 13
Shop Space ........................................................................................................................................................... 13
Floor Space per Trainee ....................................................................................................................................... 13
Classroom Space .................................................................................................................................................. 13
Office Space ......................................................................................................................................................... 13
Floor Space ........................................................................................................................................................... 13
Standards for Doors ............................................................................................................................................. 13
2. ELECTRICAL‐CIRCUIT DETAILS .................................................................................................................................. 13
3. STORAGE AND SPECIAL AREAS ................................................................................................................................. 14
4. VISUAL COMFORT ................................................................................................................................................. 14
Light‐Reflection Value .......................................................................................................................................... 15
Illumination Level ................................................................................................................................................. 15
5. VENTILATION ....................................................................................................................................................... 15
6. PLUMBING FACILITIES ............................................................................................................................................ 15
7. GENERAL SAFETY .................................................................................................................................................. 16
Colour code for safety .......................................................................................................................................... 16
Areas/items for written safety rules .................................................................................................................... 16
Safety and Health Protection Equipment ............................................................................................................. 16
SAU-FSMEM 1.0/ Facilities Standards for Pipefitting
Standards and Assessment Development Unit, NCTVET March. 2016 Page 2 of 32
Copyright  2015 National Council on Technical & Vocational Education & Training (NCTVET)
All rights reserved. No part of this document may be reproduced in any form or by any means without the prior permission of the
publishers
8. MISCELLANEOUS STANDARDS .................................................................................................................................. 17
Fire extinguishers ................................................................................................................................................. 17
First‐aid facilities .................................................................................................................................................. 17
TOOLS & EQUIPMENT REQUIREMENTS FOR THE PIPEFITTING TRAINING PROGRAMME ..................................... 18
FLOOR PLAN OF OVAL CONFERENCE LAYOUT TRAINING SPACE FOR 20 TRAINEES .............................................. 23
FACILITY SUITABLE FOR MODIFICATION AND ADOPTION AS PIPEFITTING WORKSHOP ....................................... 24
VIDEO OF A PIPEFITTING WORKSHOP IN OPERATION ........................................................................................ 24
PICTORIAL LAYOUT OF OVAL CONFERENCE ARRANGEMENT .............................................................................. 25
U SHAPE TRAINING SPACE FOR 20 TRAINEES ..................................................................................................... 26
U SHAPE PICTURE OF TRAINING SPACE FOR 20 TRAINEE .................................................................................... 27
PIPEFITTING TOOLS/ACCESSORIES ..................................................................................................................... 27
STURDI JACK II PIPE STAND............................................................................................................................................. 27
INDUSTRIAL WORKER USING A MECHANICAL DRILL MACHINE, IN AN INDUSTRIAL ENVIRONMENT .................................................... 27
LARGE INDUSTRIAL PIPEFITTING WORKSHOP ...................................................................................................................... 28
METAL WORK TOOLS .................................................................................................................................................... 28
WORKER USING THE HOLD DOWN CLAMP IN THE PIPEFITTING WORKSHOP ............................................................................... 28
INTERNAL FLANGE ALIGNMENT TOOL ............................................................................................................................... 29
WORKER DEMONSTRATING THE USE OF A DISC GRINDER ....................................................................................................... 29
FLANGE ALIGNMENT PINS .............................................................................................................................................. 29
MECHANICAL FLANGE SPREADER ..................................................................................................................................... 29
COUPON CUTTER .......................................................................................................................................................... 30
FRAMING SQUARES ....................................................................................................................................................... 30
PROTRACTORS ............................................................................................................................................................. 30
PIPEFITTER’S SQUARE .................................................................................................................................................... 30
SPACING WEDGES ........................................................................................................................................................ 31
USING THE PIPE WRAP (WRAP AROUND) ......................................................................................................................... 31
CENTERING HEAD ......................................................................................................................................................... 31
REFERENCES ...................................................................................................................................................... 32

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Preface
The Standards for the physical facilities, machines, tools and other equipment for the Pipefitting
Training Programme are derived from the work functions and tasks generated from a
comprehensive study of the occupational area.
The work functions and tasks were obtained from:
i. worker behavior
ii. facilities, machines, tools, equipment, and materials used to complete the job
iii. knowledge and skills required to perform the job
The goals of this training programme would best be realized at the workplace, but in order to
meet the need for timely and efficient training, while avoiding costly disruptions and the
installation of non-productive facilities, training is mainly conducted outside of the workplace.
It is therefore the responsibility of programme sponsors and facilitators to ensure that:
i. the physical facilities are retrofitted with the necessary equipment to provide training to
meet the quality standards at industry levels
ii. the physical facilities and equipment provided for training closely match that which
obtains in an effective and efficient work environment
Within this Pipefitting Training Programme, a current list of functions which represent the duties
and tasks of this occupational area is used as the basis for determining the facilities, equipment
and work environment. This information also provides the standards for developing the criteria
for the assessment of learner performances.
Description of Programme
The specifications outlined within the facilities standards, provide guidelines which various
constituents will be able to use as a benchmark to determine the required standards for skills
development in the Pipefitting Training Programme. The standards specifications provide
information on the basic physical requirements of the workshop, machines, tools, and general
equipment necessary to facilitate the effective implementation of the programme and the
operational support entities which include lighting, ventilation, safety, electricity and water.

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Facilities Standards Objectives

The objectives for the Metal Work Engineering Facilities Standards are as follow:
 Provide the criteria that will facilitate the evaluation process for workshop tools and
other equipment; the support facilities and the operational requirements that will allow
for safe and effective performance by learners.
 Provide a guide for facilities planners, designers and builders to design facilities,
construct buildings, and install equipment in accordance with established standards that
will allow for safe and effective operation of the workshop.
 Provide a guide for curriculum planners and programme instructors to design learning
activities that are consistent with the standards established for the physical facilities and
equipment.
 Provide administrators with a guide for identifying areas of deficiencies and strengths of
the training area.
 Provide a basis for standardizing the physical facilities, machines, tools and other
equipment that facilitate the training/learning process.
 Provide a basis for evaluating instructors' management and care of the workshop,
physical facilities, machines, tools and other equipment.
Assumptions Regarding Size of Training Group

 Learners assigned to work station will require machines, tools and equipment to perform
training activities
 Hand tools and portable equipment can be shared among learners at a work station, even
if they are assigned to work on different types of projects at the same time
 Learners do not all work at the same rate or pace, therefore, the need to have the same
number of commonly used tools for each person is unnecessary
 Learners are better able to share ideas and correct errors among themselves when
working as work-units or as a team
 Six work stations placed 45cm apart will allow for increased interchange among learners

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Assumptions Regarding Size of Training Group (Cont’d.)
 A maximum of four trainees will function more effectively as a work group or team
because research and experience have demonstrated that this size is consistent with the
most productive teams in a working or learning situation
Basic Design Concept

The approach to training for the Pipefitting Programme will be based on the work station
concept. The essential idea is that a maximum of four (4) trainees will be located around a
workbench or work station. The main benefit of the work station or team approach to training is
that it emphasizes and supports the principles of cooperation, leadership, sharing responsibilities
and tasks, among others. It is these qualities that are essential to the workforce and enable the
worker to contribute positively and at a high standard of performance.
In order to maximize the benefits of the work station concept, trainees will be required to work in
teams in order to accomplish critical tasks and at the same time build as a cohesive work team.
In doing so the trainee will be able to demonstrate the critical employability skills requirements
outlined on the Competency Standards which would include:
 the planning and ordering of tools and materials from stores

 working with others by sharing the use of tools and equipment
 the assigning of job responsibilities
 sharing of ideas in regards to learning activities and problem solving
These are the practices and behaviors which closely reflect the workplace.
Another advantage of assigning trainees to work stations is that it fosters a more efficient use of
tools and equipment, so that the tools and equipment used regularly will be provided based on
the size and needs of the work station, and not based on the number of individuals in the group.
In fact, the tools and equipment needs will be reduced by approximately 30% or 40%, which
would support the efforts of administrators and planners to increase the benefits from our
training programmes with reduced resources.
Programme Limitations
At present, some facilities and equipment for the Pipefitting Programme are already in place in
the schools, training centres and academies. The majority of these training institutions may not
be able to meet the approved facilities and equipment standards specifications at this time unless
there is significant redesign or modification.

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Programme Limitations (Cont’d.)

Nevertheless, specific changes can be made in order to meet certain requirements such as
lighting, ventilation, machine placement, tools, material storage, and other emerging
technologies. It is envisaged that given a specific plan of action to meet the required standards,
most programmes would be able to comply within a reasonable period of time.
The purchasing and assigning of tools and other equipment based on the work station concept
would maximize the availability of these items for activities such as internal or external
examination. In addition, tools are constantly stolen; lost and damaged, therefore a replacement
policy has to be implemented. A 10% inventory of the basic hand tools and other equipment
would adequately address this deficiency.
Non-Traditional Training Programme

Pipefitting Training Programmes that are conducted in some production oriented work
environment may lack appropriate machines, tools, equipment and the emerging technologies
that are vital for the purpose of accreditation. In that regards, a needs assessment should be
conducted to identify the gaps. Every effort should be made to rectify the lack of resources at
the facilities, or alternative arrangements should be made for learners to acquire the relevant
experience with the appropriate resources at a suitable location through a partnership
arrangement.
Full permission may be granted for training and assessment if the following can be
demonstrated:
a) facilities and equipment requirements satisfy the conditions established for training and
assessment
b) facilities or equipment are located close to the training workshop, and they are available
to the training programme
c) facilities or equipment are located outside the immediate work environment, but are
available for training upon request
d) proof that the skills can be acquired without the use of the machine or facilities that are
not in place
e) facilities or equipment will be installed within a specific time period

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Programme Level
The basic physical facilities, tools and other equipment will essentially remain the same for all
levels of the Pipefitting Training Programme. Nevertheless, a limited number of specialized
tools will be required for the higher levels. In addition, the workshop machines and other
training equipment may have to be re-oriented in order to facilitate production type learning
activities.
In order to achieve greater skills development at the advanced levels of the programme, a
demonstrable increase in efficiency, quality management and overall production planning must
be the central focus of the training process.
Utilizing the work station concept as a basis for training will be reduced for learners at the
advanced levels, and individualized project activities would be emphasized. It is expected that
training groups would become smaller as learners pursue higher programme levels. Work
stations could then facilitate two trainees instead of the recommended four per work station.
Based on programme level, the following training group size is recommended:
Levels Training Group Size

1. Level I 12 to 20 trainees
2. Level II 10 to 18 trainees
3. Level III 10 to 15 trainees
It should be noted that as the size of the training group becomes smaller, even for higher levels
of training, the cost of delivering this and similar programmes becomes prohibitive. It is
therefore suggested that class size should be no less than ten trainees.
Workshop Layout
The workshop layout provides one approach for installing machines and other equipment for the
Pipefitting Programme. It emphasizes the basic principles of shop layout such as:
I. adequate walking area

II. working space between equipment
III. storage facilities for tools, materials, and waste
IV. properly positioned machines
This layout is designed to accommodate twenty (20) trainees, and will operate on the work
station or team basis. The space requirements will remain basically the same for all groups.
Therefore, to achieve the space requirement for smaller groups, contraction has to take place in
the storage areas and the number of work stations.

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Workshop Layout (Cont’d.)

One of the safety requirements for the workshop is the proper positioning and spacing of
machines and workbenches in order to ensure unobstructed working conditions for the learners.
Additionally, when long pieces of materials will be worked on, enough space has to be provided
for unimpeded movement, especially if machining will be carried out, The areas between the
broken lines and the machines or workbenches represent the space that should be free of
obstructions at all times.
Storage Requirements
The planning of storage facilities for tools, materials, projects, and trainees’ personal items is an
integral part of the physical layout and programme organization. Carefully planned storage
should emphasize:
a) safety
b) conservation
c) effective use of space
In addition, considerations should also be given to the programme levels and the number of
learners that will be accommodated, which in turn will determine the space requirements of each
storage unit.
Electrical-Circuit Details
The electrical installation for the training area should be done in accordance with established
safety procedures, and only qualified personnel should be used to maintain the electrical circuits
and components.
Electrical circuits and outlets should be properly labelled and switches should be enclosed and
protected from traffic. For each stationary machine, the isolator may be located on the wall and
properly labelled. This improves on the aesthetic of the installation. In some cases the isolators
are affixed to the machines. Portable power equipment has a ground wire which prevents
electrical shock and the mechanical grounds are provided for all stationery equipment.
Emergency stop buttons, which shut down the power to all machines, should be placed at
strategic locations. This will allow easy access during emergency situations.
Only authorized persons should be allowed access to the circuit breaker panels. Each panel
should be equipped with a lock on the outer door in order to restrict access by unauthorized
persons.

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Visual Comfort
Proper lighting is one of the elements which assists in ameliorating the learning environment.
With an abundance of sunlight, every effort should be made to combine the use of natural and
artificial light. In situations when natural light is absent from the workshop, adequate artificial
lighting must be provided.
The main factors which determine the lighting requirements are:
i. how much natural light is to be utilized

ii. the type and arrangement of the electric light
iii. the characteristics of the luminous patterns, such as illumination level, brightness and
glare
The use of fluorescent fixtures for artificial lighting has proven to be cost effective and should be
installed in workshops in order to provide the visual comfort for learning. Steps must be taken,
however, to eliminate, or at the least minimize the risk of light flicker. Most people cannot notice
the flicker in fluorescent lights that have a flicker rate of 100 cycles per second (or 100 Hz). The
light flicker may be detected by its stroboscopic effect. When objects move or rotate rapidly,
they may be lit at or about the same position during each cycle or rotation. This makes objects
look as if they are moving more slowly than their actual speeds - they may even appear
stationary if the object is moving at the same rate as the flicker frequency (or a multiple of it).
This fact is the principle behind a strobe light but it is not the desired effect in general lighting. In
fact, it could be a safety hazard if someone mistakenly thought that some equipment was
stationary or was moving slowly.
Ventilation
In a climatic region where the normal temperature ranges between the upper 20 and lower 30
degree Celsius, proper ventilation becomes an important condition to ensure a safe and
comfortable learning environment. In fact because little attention has been given to the design of
ceilings which minimize the level of heat absorption in the workshops, the temperature
sometimes reaches as high as 35 degree Celsius, especially during the summer.
Every effort must be made to seal roofs which are constructed of metals with materials that will
prevent the easy absorption of the heat from the sunlight. In addition, enough windows should
be installed in order to allow for the free flow of air through the workshop. Adequate ceiling or
standing fans could assist in reducing the impact of excess heat during the learning process.

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Plumbing Requirements
The plumbing facilities should cater for both trainees and instructors, and the cleaning and
maintenance schedule should be based on the frequency and level of use and not necessarily on
normal maintenance schedule for all facilities in the school or training environment. Adequate
toilets, urinals, showers, and wash basins should be provided for all users of the workshop, but
separate facilities must be provided for female learners. A wash basin should be installed in the
workshop for the washing of hands, etc., and a water cooler installed outside the main door of the
workshop.
General Safety and First Aid

The organization of the training facilities should be based on sound safety principles. This
should allow for proper material flow, proper spacing between machines, and the installation of
safety guards on the machines. Promoting personal safety by requiring the wearing of
appropriate safety glasses, boots and clothing is essential for developing proper safety attitudes.
Fire extinguishers
The training area should have fire extinguishers placed at strategic locations, and learners should
be instructed in their use, both in and out of the shop area. This equipment should be provided in
the workshop to extinguish minor fires only. If there is any risk from the fire, the building should
be evacuated. Before using a fire extinguisher the instructions should be read to ensure that it is
appropriate to the type of fire.
Safety rules
Learners should be presented with the safety rule handbook which outlines all general and
specific safety rules for the workshop and equipment. It is the responsibility of learners and staff
undertaking work in shops to take reasonable care of their own health and safety, and the health
and safety of others by:
i. taking action to avoid, minimize or eliminate known hazards

ii. ensuring that the appropriate personal protective equipment are worn
iii. using the approved safety devices
iv. seeking proper instructions before conducting unfamiliar work
v. maintaining the appropriate dress codes
vi. being familiar with emergency evacuation procedures
vii. reporting near-miss and hazards appropriately
All learners should be tested to determine their knowledge of the safety rules and a pass mark of
80% or above should be achieved before they are permitted to use the physical facilities and
equipment.
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General Safety and First Aid (Cont’d.)

Housekeeping
Housekeeping is an important component in the workshop to ensure risks of injury from

potential hazards in the environment are controlled. The following precautions should be taken to
ensure the safety of personnel within workshop:
•
i. floors are to be kept tidy and dry
ii. work benches should be kept clean and free from chemicals and anything that is not
being used
iii. aisles and exits are to be kept free from obstructions
iv. access to all emergency equipment (fire extinguishers, first aid kits) is to be kept free
from obstruction
v. work areas and equipment are to be thoroughly cleaned after use
vi. if last to leave the workshop, one should ensure all equipment is turned off
First Aid
For the purpose of minor accidents, a first-aid kit should be located in the workshop and both
instructors and learners should be aware of its contents and proper usage.
Outdoor Training Site
In order to gain practical experience in construction and installation, an appropriate site may be
prepared outside of the workshop. This will allow the trainees to conduct assembly and
disassembly, repair and modification in order to acquire applicable and operational skills in an
environment similar to that which obtains at a real worksite.
Facilities, Activities, Equipment, Tools and Resource Requirements Checklist

The purpose of the check list is to determine, by a team approach, the extent to which the
training facilities, machines, tools and other equipment have met the specifications which are
incorporated in the standards. The aim of the standards is to ensure that the facilities and
equipment provide the conditions for training to be conducted successfully. This aim is
accomplished by ensuring that:
a) the safety, visual, and physical comfort of the users meet the specifications
b) characteristics such as flexibility, accessibility, and efficiency are demonstrated by the
organization and management of the facilities.

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(Cont’d.)
Specific Requirements Recommended Features
1. Plant Space Specifications
Shop Space
- Training group size - 20
- Height of workshop - 3.65m minimum
- Width of workshop - 12m minimum
- Length of workshop - 19m minimum
- Total sq. metre - 228m minimum
- Walking Space unobstructed - Arrange machines and workbenches so that
unobstructed walking area is available
Floor Space per Trainee - 9.3sq. metre per trainee
Classroom Space - Separate location or locate stool/chair

around workbenches.
Office Space - Located in position that provides

full view of workshop
Floor Space
- Thickness - 17.8cm, 3000psi concrete
- Finish - Non-slip rendered concrete
Standards for Doors

- Main entrance - Door of adequate size and strength
- Emergency doors - Located towards back or side of workshop
- Operating conditions - Free of obstacles before and behind doors
and open readily in case of emergency.
Opens outwardly with ‘panic bar’.
- Width of corridor to workshop - 1.5m
2. Electrical-Circuit Details
- Power circuits - Four wire, three-phase (4w 3Ø)

- Branch power circuits - One per machine installed on wall
- Spare power circuits - One for every four active circuit
- Spare light circuits - One for every five active circuit
- Overload protection on power circuits - Circuit breakers (cb)
- Power circuit installation - Installed in cable trunkings and pvc or
galvanized conduits

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(Cont’d.)

2. Electrical-Circuit Details (Cont’d.)
- Installation of lighting circuits - Installed in cable conduits

Outlets (Js21.1992) Installed on wall at intervals of 3m
- Power cut-off safety buttons Standard - 10m
3. Storage and Special Areas
- Location of waste area - Wooden container in activity area size

between 1.50 and 2.0 cu.m. (discreetly located)
- Learners’ changing room - Approximately 20 sq. metres with wall mirror,

shelves and clothes hangers
- Space for storing learners’ property - 4 sq. metre with 1 double locker per 2 trainees
- Location of display area - Near to instructor’s desk
- Space for display area - Approximately 1 cu. metre
- Location area for instructor - Near entrance door or position that allows full view
of workshop
- Space for instructor - Approximately 5 sq. metre
- Location of open areas - Entrance way, tool and equipment area, around
wash basins, around water cooler and around
instructors’ area
- Width of aisle and travel areas - Minimum of 1.3m
- Location of supply and material storage - Within shop or storage centrally located for
several shops.
- Space for supply and materials storage - Approximately 28 cu. metre
- Space for equipment (tools, machine
accessories, etc.)
- Storage - Between 6.0 and 9.0 cu. metre
- Chalkboard - Between 2.4 and 2.8 metre
- Notice board - Between 1.5 and 2.4 metre
4. Visual Comfort
- Window area in shop - Approximately 25%

- Window arrangement - Windows on both walls (lengthwise)
- Height of windows - Ceiling height
- Window glass - Clear shade
- Control of natural light - Light coloured defused shade
- Artificial light sources - 1.5m fluorescent lamps
- General lighting system - Semi-direct (25% upward, 75% downward)

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(Cont’d.)
4. Visual Comfort (Cont’d.)
Light-Reflection Value Minimum Maximum
- Ceiling - 50% - 90%

- Wall - 50% - 70%
- Workbench top - 30% - 50%
- Furniture - 30% - 50%
- Chalkboard - 15% - 25%
- Equipment - 30% - 50%
- Floor - 20% - 30%
Illumination Level for the Following Equipment
- Workbench - 538 lumens/m2

- Lathe - 538 lumens/m2
- Soldering station - 538 lumens/m2
- Drill press - 538 lumens/m2
- Floor grinder - 538 lumens/m2
- Drafting table - 538 lumens/m2
General illumination level in service 80cm from floor - 323 lumens/m2
5. Ventilation
- Ceiling - It should reduce the impact of direct sunlight on the

users of the facilities
- Heat extraction - Install extractor fan system
- Air circulation - Windows should allow for the free flow of natural
air
6. Plumbing Facilities
- Drinking water - Water cooler per 25 students to be located outside

workshop
- Sanitary facilities - Separate for male and female learners

- 1 toilet per 25 learners
- 1 urinal per 25 male-learners

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(Cont’d.)
6. Plumbing Facilities (Cont’d.)

- Sanitary facilities (Cont’d.) - 1 toilet each for male and female staff
- 4 showers per 100 learners
- 1 shower each for male and female staff
- 6 face basins per 100 learners
- 1 basin each for male and female staff
7. General Safety
Colour code for safety

- Safe conditions - Green
- Traffic & housekeeping - White and black
- Caution & physical hazards - Yellow
- Dangerous parts of machines - Orange
or energized equipment
- Danger, emergency stop on - Red
Machine or fire equipment
Areas/items for written safety rules - Flammable liquid

- General physical equipment
- Housekeeping
- Use of machines, tools and other
equipment
- Handling of materials
- Storage of materials
- Disposal of waste
- Personal protection
- Electrical installation
- Fire protection
- Applying first aid procedures
Safety and Health Protection Equipment
- Head protection - Hard hats

- Face and eye protection - Goggles, face shields, safety
glasses
- Respiratory equipment - Respirators, dust masks
- Protective foot wear - Solid work shoes with steel box, oil
resistant and non-skid sole

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(Cont’d.)
8. Miscellaneous Standards

Fire extinguishers - Select two types -foam, dry chemical or carbon dioxide
- Located on fixed wall where they are readily accessible
and ready for immediate use
Inspect every two months to ensure good operating
condition
First-aid facilities - 2.54cm, 5.08 and 7.7cm bandage rolls

- Gauze and cotton
- Waterproof adhesive
- Mercurochrome or Gentian Violet 1% Paint B.P.C.
- Aromatic ammonia
- Analgesic balm
- Scissors, tweezers and cotton wound
- Applicators
- Steripads
- Waterproof Band-Aid
- Tourniquet
- Boric acid solution
- Pain killing tablets
- Eye drop lotion
- Zinc ointment
- Burn ointment
- Eye wash lotion

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Tools & Equipment Requirements for the Pipefitting Training Programme
PIPEFITTING
NUMBER OT ITEMS PER SIZE

ITEM DESCRIPTION OF TRAINING GROUP
24 22 20 18 16 14 12 10 8
1. Work table – (6’ x 4’) 4 4 4 3 3 3 2 2 1
2. No. 7 Utility vice 2 2 2 2 2 1 1 1 1
3. Spirit level (18’) 3 3 3 2 2 2 1 1 1
4. 900 try square (12” x 24”) 2 2 2 2 2 1 1 1 1
5. 900 try square (6” x 12”) 6 6 5 5 4 4 3 3 2
6. Portable electric grinder 2 2 2 2 1 1 1 1 1
7. Steel tape measure (6m) 6 6 5 5 4 4 3 3 2
8. Eclipse hack saw frames 12 11 10 9 8 7 6 5 4
9. Hack saw blades (24 teeth– 2.54cm) 24 22 20 18 16 14 12 10 8
10. Pedestal drill press (2cm) 1 1 1 1 1 1 1 1 1
11. Single wheel pipe cutter (0 – 5cm) 1 1 1 1 1 1 1 1 1
12. Single wheel pipe cutter (5 – 10cm) 1 1 1 1 1 1 1 1 1
13. Pedestal grinder (3 speed) 1 1 1 1 1 1 1 1 1
14. Angle grinder (Disc type) 2 2 2 2 2 2 2 2 2
15. Centre punch set 6 6 5 5 4 4 3 2 2
16. Ball pein hammer (10kg) 6 6 5 5 4 4 3 2 2
19. Imperial open end spanners (set) 1 1 1 1 1 1 1 1 1
20. Metric open end spanners (set) 1 1 1 1 1 1 1 1 1
21. Electric Power Saw 1 1 1 1 1 1 1 1 1
22. Pipe Die Machine 1 1 1 1 1 1 1 1 1
23. Bench Grinder with Grinding Wheels 115V 50HZ

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Tools & Equipment Requirements for Pipefitting Training Programme

(Cont’d.)
PIPEFITTING (CONT’D.)

24 22 20 18 16 14 12 10 8
24. Lifting Gear (Shop Crane) 1 1 1 1 1 1 1 1 1
25. Air Compressor (90 CFM) 1 1 1 1 1 1 1 1 1
26. Hand Drill 2 2 2 2 2 2 2 2 2
27. Steel Rules 6 6 6 5 5 5 3 3 3
28. Mallets 3 3 3 3 3 2 2 2 2
29. Metal Files Set 6 6 6 5 5 5 3 3 3
30. Drill Bit Set 6 6 6 5 5 5 3 3 3
31. Chisel Set 6 6 6 5 5 5 3 3 3
32. Hand Files Set 6 6 6 5 5 5 3 3 3
33. Combination Squares 3 3 3 3 3 2 2 2 2
34. Pry Bar set 1 1 1 1 1 1 1 1 1
35. Drill Press 2 2 2 1 1 1 1 1 1
36. Electric Saw 1 1 1 1 1 1 1 1 1
37. Straight Pipe Welding Vise 2 2 2 2 2 2 1 1 1
38. Angle Pipe Welding Vise 2 2 2 2 2 2 1 1 1
39. Elbow Pipe Welding Vise 2 2 2 2 2 2 1 1 1
40. Lineup Dogs 2 2 2 2 2 2 2 2
41. Hickey Bars 2 2 2 2 2 2 2 2 2
42. Mathey Dearman Sturdi Jack II 4 4 4 4 4 4 2 2 2
43. Hold‐down Clamps 4 4 4 4 4 4 2 2 2

publishers
Tools & Equipment Requirements for the Pipefitting Training Programme

(Cont’d.)
PIPEFITTING (WELDING COMPONENT)

24 22 20 18 16 14 12 10 8
1 AC ‐ DC Welding machines 2 2 2 2 2 1 1 1 1
Gas tungsten – Arc welding station (complete)
2 1 1 1 1 1 1 1 1 1
TIG
3 Inert gas cylinders (spares) 1 1 1 1 1 1 1 1 1
Gas metal – Arc Welding station (complete)
4 1 1 1 1 1 1 1 1 1
GMAW
5 Plasma – Arc gutter 1 1 1 1 1 1 1 1 1
6 MIG welding machine 2 2 2 2 2 1 1 1 1
7 Adjustable head shield (Lens) 3 3 3 3 3 2 2 2 2
8 Safety helmets 12 11 10 9 8 7 6 5 4
9 Arc welding head shields 3 3 3 3 3 2 2 2 2
10 Arc welding hand shields 3 3 3 3 3 2 2 2 2
11 Safety clear goggles 24 22 20 18 16 14 12 10 8
12 Safety welding boots 24 22 20 18 16 14 12 10 8
13 Welding spats 24 22 20 18 16 14 12 10 8
14 Welding sleeves 3 3 3 3 3 2 2 2 2
15 Welding leggings or gaiter 6 6 5 5 4 4 3 3 2
16 Welding aprons 6 6 5 5 4 4 3 3 2
17 Combination wire brush 6 6 5 5 4 4 3 3 2
18 Chipping hammer 6 6 5 5 4 4 3 3 2
19 Electrode holders 6 6 5 5 4 4 3 3 2
20 Ground clamps 6 6 5 5 4 4 3 3 2
21 Oxygen and Acetylene bottles 3 3 2 2 2 2 1 1 1

publishers
Tools & Equipment Requirements for Pipefitting Training Programme

(Cont’d.)
PIPEFITTING (WELDING COMPONENT)–CONT’D.


24 22 20 18 16 14 12 10 8
22 Bottle wrench 3 3 2 2 1 1 1 1 1
23 Portable bottle trolley with safety chain 2 2 2 2 1 1 1 1 1
24 Oxygen regulators 3 3 2 2 2 2 1 1 1
25 Acetylene regulators 3 3 2 2 2 2 1 1 1
26 Oxygen and Acetylene hose (25ft) 3 3 2 2 2 2 1 1 1
27 Welding torch complete with mixing chamber 6 6 5 5 4 4 3 3 2
28 Spark lighter 6 6 5 5 4 4 3 3 2
29 Packs lighter flint refills 1 1 1 1 1 1 1 1 1
30 No. 1 welding tips 6 6 5 5 4 4 3 2 2
31 No. 2 welding tips 6 6 5 5 4 4 3 2 2
32 No. 3 welding tips 6 6 5 5 4 4 3 2 2
33 No. 4 welding tips 6 6 5 5 4 4 3 2 2
34 No. 5 welding tips 6 6 5 5 4 4 3 2 2
35 Tip cleaner sets 6 6 5 5 4 4 3 2 2
36 Cutting torch (complete) 6 6 5 5 4 4 3 2 2
37 No. 1 cutting tips 6 6 5 5 4 4 3 3 2
38 No. 2 cutting tips 6 6 5 5 4 4 3 3 2
39 No. 3 cutting tips 6 6 5 5 4 4 3 3 2
40 No. 4 cutting tips 6 6 5 5 4 4 3 3 2
41 No. 5 cutting tips 6 6 5 5 4 4 3 3 2
42 Electrode drying oven (110V) 1 1 1 1 1 1 1 1 1
43 Oxy‐Acetylene welding goggles 6 6 5 5 4 4 3 3 2

publishers
Tools & Equipment Requirements for the Metal Work Engineering Training
Programme (Cont’d.)
PIPEFITTING (WELDING COMPONENT) –CONT’D.

24 22 20 18 16 14 12 10 8
44 Profile cutting machine with attachments 1 1 1 1 1 1 1 1 1
45 Nibbler heavy‐duty metal cutting machine 1 1 1 1 1 1 1 1 1
46 Metal drill bits (set) 2 2 2 1 1 1 1 1 1
47 Inert gas regulators 2 2 2 1 1 1 1 1 1
48 Metal scribers 6 6 5 5 4 4 3 3 2
49 Metal gauge 2 2 2 2 1 1 1 1 1
50 Welding cable (set) 6 6 5 5 4 4 3 3 2
51 Holding tongs 6 6 5 5 4 3 3 2 1
52 Clamping pliers 6 6 5 5 4 3 3 2 1
53 Chaining type clamp pliers 6 6 5 5 4 3 3 2 1
54 Coupon Cutter 2 2 2 2 2 2 1 1 1
55 Pipefitter’s square 2 2 2 2 2 2 1 1 1
56 Protractors 2 2 2 2 2 2 1 1 1
57 Spacing Wedges 2 2 2 2 2 2 1 1 1
58 Pipe Wrap (Wrap Around) 4 4 4 4 4 4 2 2 2
59 Centering Head 2 2 2 2 2 2 1 1 1
60 Mechanical Flange Spreader 2 2 2 2 2 2 1 1 1

publishers
Floor Plan of Oval Conference Layout Training Space for 20 trainees
https://law.duke.edu/images/actech/classrooms/4044.gif

publishers
Facility suitable for modification and adoption as Pipefitting Workshop
http://www.fao.org/docrep/003/v9468e/v9468e08.gif
Video of a Pipefitting workshop in operation

Retrieved March 10, 2016 from website: https://youtu.be/OAIu66BluNo

publishers
Pictorial Layout of Oval Conference Arrangement
https://law.duke.edu/sites/default/files/migrated/content_image_-images-actech-classrooms-4044small_1.jpg

publishers
U Shape Training Space for 20 trainees

publishers
U Shape Picture of Training Space

for 20 trainee
Sturdi Jack XL Pipe Stand

http://www.mathey.com/Site/themed-
images/sturdijack-xl-pipe-stand-360x270.jpg
http://www.embl.de/training/eicat/atc/rooms/03_cou
rtyard_A/cy_large3.jpg
Pipefitting Tools/Accessories
Industrial worker using a mechanical drill

machine, in an industrial environment
http://thumbs.dreamstime.com/x/industrial-
Sturdi Jack II Pipe Stand worker-using-mechanical-drill-machine-
http://www.mathey.com/Site/themed- 28798975.jpg
images/sturdijack-ii-pipe-stand-360x270.jpg
SAU-FSMEM 1.0/ Facilities Standards for Metal Work Engineering

Standards and Assessment Development Unit, NCTVET February. 2016 Page 27 of 32
publishers

Metal Work Tools
Large Industrial Pipefitting Workshop https://encrypted-
https://encrypted- tbn2.gstatic.com/images?q=tbn:ANd9GcRsTafL5f
tbn2.gstatic.com/images?q=tbn:ANd9GcQkEnxA fabfF0YdIAcpNoT6XdZPIZTzDIa74O96NE-
qLEHImGtqiv5YkaMMvigdwj1EgG- vxm3WDfng
b1QrvYzMtKkpoH1W
Worker using Disc Grinder Worker using the Hold Down Clamp in the
pipefitting workshop
https://encrypted-
tbn0.gstatic.com/images?q=tbn:ANd9GcStnY8krk http://www.mathey.com/Site/themed-
i3cWYds431VlSWQq6- images/holddown-clamp-360x270.jpg
KnFXPdAp28vmWEB9lIZegPRpqA


publishers
Internal Flange Alignment Tool Flange Alignment Pins

http://www.mathey.com/Site/themed- http://www.mathey.com/Site/themed-
images/flange-alignment-tool-360x270.jpg images/flange-line-up-pins-360x270.jpg
Worker demonstrating the use of a disc Mechanical Flange Spreader

grinder http://www.mathey.com/Site/themed-
https://encrypted- images/flange-spreader-mechanical-360x270.jpg
tbn0.gstatic.com/images?q=tbn:ANd9GcRwNFkn
BLnovJmHoRmX1p2Si1EFLefP1fgNXE6uKd8M
fqN3zodI

publishers

Protractors
Coupon Cutter http://www.mathey.com/Site/themed-
http://www.mathey.com/Site/themed- images/protractors-all-360x270.jpg
images/coupon-cutter-360x270.jpg

Pipefitter’s Square
Framing Squares http://www.mathey.com/Site/themed-
http://www.mathey.com/Site/themed- images/pipefitters-square-360x270.jpg
images/framing-square-360x270.jpg


publishers

Spacing Wedges Centering Head
http://www.mathey.com/Site/themed- http://www.mathey.com/Site/themed-
images/wedge-user-360x270.jpg images/centering-head-front-360x270.jpg

Using the Pipe Wrap (Wrap Around)
http://www.mathey.com/Site/themed-images/pipe-
wrap-user-360x270.jpg


publishers
Facilities Standards for Metal Work Engineering
References
1. Duke Law, Jeffrey P.Hughes Seminar Room. Retrieved February 29, 2016 from the
World Wide Web : https://law.duke.edu/sites/default/files/migrated/content_image_-
images-actech-classrooms-4044small_1.gif
2. European Molecular Biology Laboratory Advance Training Centre Meeting

Rooms.(2009). Retrieved February 29, 2016, from World Wide Web :
http://www.embl.de/training/eicat/atc/rooms/03_courtyard_A/
3. Harold Hall, The Metalworkers Workshop, Retrieved February 20, 2016 from website:
http://www.homews.co.uk/page3.html
4. MATHEY DEARMAN, Pipefitting Tools, Retrieved March 1, 2016 from website

http://www.mathey.com/tools-all-products.htm
5. HEART-NTA, MEM20415 Pipefitting Level 11.doc
6. HEART-NTA, MEM30415 Pipefitting Level !!!.doc
7. HEART-NTA, Plumbing F.S.doc

publishers

Facilities Standards - Pipefitting

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NATIONAL COUNCIL ON TECHNICAL AND VOCATIONAL

EDUCATION AND TRAINING

FACILITIES STANDARDS FOR

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

The work functions and tasks were obtained from:

It is therefore the responsibility of programme sponsors and facilitators to ensure that:

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

Facilities Standards Objectives

Assumptions Regarding Size of Training Group

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

Assumptions Regarding Size of Training Group (Cont’d.)

Basic Design Concept

 the planning and ordering of tools and materials from stores

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

Programme Limitations (Cont’d.)

Non-Traditional Training Programme

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

Levels Training Group Size

I. adequate walking area

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

Workshop Layout (Cont’d.)

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

The main factors which determine the lighting requirements are:

i. how much natural light is to be utilized

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

General Safety and First Aid

i. taking action to avoid, minimize or eliminate known hazards

General Safety and First Aid (Cont’d.)

Housekeeping is an important component in the workshop to ensure risks of injury from

Outdoor Training Site

Facilities, Activities, Equipment, Tools and Resource Requirements Checklist

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

Facilities, Activities, Equipment, Tools and Resource Requirements Checklist

Specific Requirements Recommended Features

1. Plant Space Specifications

Floor Space per Trainee - 9.3sq. metre per trainee

Classroom Space - Separate location or locate stool/chair

Office Space - Located in position that provides

Standards for Doors

- Power circuits - Four wire, three-phase (4w 3Ø)

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

Facilities, Activities, Equipment, Tools and Resource Requirements Checklist

Specific Requirements Recommended Features

- Installation of lighting circuits - Installed in cable conduits

3. Storage and Special Areas

- Location of waste area - Wooden container in activity area size

- Learners’ changing room - Approximately 20 sq. metres with wall mirror,

- Window area in shop - Approximately 25%

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

Facilities, Activities, Equipment, Tools and Resource Requirements Checklist

Specific Requirements Recommended Features

4. Visual Comfort (Cont’d.)

Light-Reflection Value Minimum Maximum

- Ceiling - 50% - 90%

Illumination Level for the Following Equipment

- Workbench - 538 lumens/m2

- Ceiling - It should reduce the impact of direct sunlight on the

- Heat extraction - Install extractor fan system

- Drinking water - Water cooler per 25 students to be located outside

- Sanitary facilities - Separate for male and female learners

SAU-FSMEM 1.0/ Facilities Standards for Pipefitting

Facilities, Activities, Equipment, Tools and Resource Requirements Checklist

6. Plumbing Facilities (Cont’d.)