Using hand methods to bend and form marine pipe

This standard identifies the competences you need to bend and form pipe for marine applications, using hand methods, in accordance with approved procedures. The type of pipe to be bent and formed will include ferrous, non-ferrous and non-metallic pipe. In producing pipe bends and forms, you will be expected to use a range of hand tools, forming equipment and techniques, appropriate to the type of material and operations being performed.

Activities will include cutting the pipes to the required lengths using hand sawing, band sawing or pipe/cutting machines, bending pipes using hand bending machines, springs, fillers or heating techniques, and the use of templates or set wires to check the bend profiles. The pipework produced will have features that include angular bends, offsets, bridge sets and expansion loops.

Your responsibilities will require you to comply with organisational policy and procedures for the marine pipe bending and forming activities undertaken, and to report any problems with the equipment, materials or pipe bending activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with either a high level of supervision or as a member of a team.  You will be expected to work to instructions, either alone or in conjunction with others, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will provide an informed approach to applying hand bending and forming procedures for marine pipe. You will have an understanding of the pipe bending and forming activities used, and their application, and will know about the pipe bending and forming equipment and techniques, in adequate depth to provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when carrying out the marine pipe bending activities, and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. follow the correct component drawing and any other related specifications for the component to be produced
3. determine what has to be done and how this will be achieved

4. use the appropriate tools and equipment for the pressure shaping operations and check that they are in a safe and usable condition

5. cut and prepare the pipes to the required specification using appropriate methods and techniques

6. bend and form the pipes to the required specification using appropriate methods and techniques

7. check that all the required pressure shaping operations have been completed to the required standard
8. deal promptly and effectively with problems within your control and report those that cannot be solved

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1. the specific safety precautions to be taken when working with marine pipe bending and cutting equipment
2. the specific personal protective equipment (PPE) to be worn when carrying out the marine pipe bending activities
3. the hazards associated with the marine pipe bending activities (such as handling long pipe lengths, using bending equipment, using heating equipment) and how they can be minimised
4. how to obtain and interpret information from job instructions, drawings and specifications, in relation to the work undertaken
5. principles and methods of marking out pipework and the type of equipment used (such as direct marking, use of templates, use of set wires)
6. how to prepare the pipes in readiness for the marking out activities (such as visually checking for defects, cleaning the materials, removing burrs and sharp edges)
7. methods of holding and supporting pipework during the marking out activities, and equipment that can be used
8. the allowances to be made in the marking out, for bending or the assembly of the various fittings that will be used
9. the characteristics of the various materials that are to be used with regard to the bending operations, and why some materials may require the addition of heat/hot air to aid the bending process
10. the methods used to hand bend and form the pipe (including the use of bending springs, hand bending machines, fillers, heating methods)
11. how to produce the various bends required (such as angled bends, dog-leg sets, bridge sets and expansion loops)
12. the tools and equipment used in the bending and forming process
13. recognition of contaminants and the problems they can create and the effects and likely symptoms of contamination in the pipe system
14. why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
15. the procedure for the safe disposal of waste materials
16. the recording documentation to be completed for the marine pipe bending and forming activities undertaken and where appropriate, the importance of marking and identifying specific pieces of work in relation to the documentation
17. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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1. Carry out all of the following during the marine pipe hand forming and bending activities:

   1. use the correct issue of drawings, specifications and quality documentation
   2. check that bending and forming equipment is in a safe and usable condition
   3. apply safe working practices at all times
   4. return all tools and equipment to the correct location on completion of the activities
   5. leave the work area in a safe condition

2. Mark out the pipework using two of the following methods:

   1. direct marking using tapes and markers      
   2. producing set wires
   3. set-outs of pipework using templates   
   4. set-outs of pipework onto the floor

3. Bend and form one of the following types of pipe:

   1. alloy (such as nickel-aluminium, silicon-brass, cupro-nickel, carbon steel, stainless steel)
   2. ferrous
   3. copper                            
   4. aluminium
   5. plastic

4. Cut and prepare pipework using three of the following:

   1. hacksaws                             
   2. de-burring reamers
   3. power saw                       
   4. abrasive discs
   5. pipe/tube cutter

5. Create bends and forms in pipe using two of the following:

   1. bending springs      
   2. pipe expander  
   3. swaging kit
   4. pipe bender            
   5. heating methods     
   6. fillers
   7. crimped fittings
   8. pushed fittings

6. Produce pipework forms that include three of the following:

   1. angular bends                   
   2. radii
   3. offsets flat
   4. offsets rolled                              
   5. external swaged ends
   6. bridge sets                       
   7. internal swaged ends
   8. expansion loops

7. Produce pipe bends and forms, in accordance with one of the following standards:

   1. BS, EN or ISO standards and procedures
   2. customer (contractual) standards and requirements
   3. company standards and procedures
   4. specific system requirements
   5. recognised compliance agency/body's standards
   6. other accepted international standards

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You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:

• strong work ethic
• positive attitude
• team player
• dependability
• responsibility
• honesty
• integrity
• motivation
• commitment

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2

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2021

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Current

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Original

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Semta

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SEMME2011

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Engineering, Engineering and Manufacturing Technologies

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5235

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Engineering; marine; manual; bending; forming; pipe; cutting; formers; saw

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