Assembling pipework components to mechanical equipment
Overview
This standard identifies the competences you need to assemble and fit pipework components to mechanical equipment, in accordance with approved procedures. You will be required to check that specified components are available and fit for purpose, to obtain all relevant and current documentation, to obtain the tools and equipment required for the assembly operations and to check that they are in a safe and usable condition. In carrying out the assembly operations, you will be required to follow company procedures and specified assembly techniques, in order to assemble the pipework and components and to fit them to the mechanical equipment.
The assembly activities will also include making all necessary checks and adjustments to ensure that the pipework and components are correctly orientated, positioned and aligned and that all fasteners are tightened to the correct torque and the assembled parts are checked for completeness.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the assembly activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with a minimum of supervision, 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 good understanding of your work, and will provide an informed approach to applying pipework fitting and assembly techniques and procedures. You will have an understanding of the mechanical product being assembled, and its application, and will know about the equipment, relevant components and joining 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 assembly activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
- use the appropriate methods and techniques to assemble the components in their correct positions
- secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
- complete the required production documentation
- deal promptly and effectively with problems within your control and report those that cannot be solved
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken while carrying out the fitting of pipe work systems to mechanical assemblies (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area in which you are carrying out the assembly activities, and the responsibility these requirements place on you
- COSHH regulations with regard to the substances used in the assembly process
- he hazards associated with assembling pipe work and pipe components to mechanical equipment, and how to minimise them and reduce any risks
- he personal protective equipment and clothing (PPE) to be worn during the assembly activities
- how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken
- the general principles of producing pipe work assemblies, and the purpose and function of the components and materials used, including identification systems (such as colour codes)
- the application of different pipe work assembly methods and techniques
- preparations to be undertaken on the pipe work prior to fitting them to the assembly
- the pipe work assembly/joining methods and procedures to be used, and the importance of adhering to these
- the importance of using the specified pipe work and fittings for the assembly, and why you must not use substitutes
- the quality control procedures to be followed during the assembly operations
- how to conduct any necessary checks to ensure the safety, accuracy, position, security, function and completeness of the pipe work assembly
- how to identify pipe work assembly defects (such as ineffective joining techniques, component damage), and what to do to rectify them
- how to check that the tools and equipment to be used are in a safe and serviceable condition
- the importance of ensuring that all tools are used correctly and within their permitted operating range
- the problems that can occur with the pipe work assembly activities, and what to do if these occur
- the extent of your own authority and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the assembly activities:
- obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation)
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- check that tools and measuring instruments to be used are fit for service
- ensure that components and pipes used are free from damage, foreign objects, dirt or other contamination
- use appropriate and approved fitting and assembly techniques at all times
- use lifting and slinging equipment (where appropriate) in accordance with health and safety guidelines and procedures
- leave the work area in a safe and appropriate condition on completion of the activities
Use appropriate techniques to assemble two of the following types of pipework to the mechanical equipment:
- steel pipe
- copper pipe
- plastic pipe
- flexible hoses
Connect and secure pipework using two of the following methods:
- compression
- screwing
- push fit
- cementing/bonding
- bolting
- brazing
- soldering
Fit and secure five of the following pipework components:
- straight connectors
- tee pieces
- curved/profiled sections
- reduction pieces
- flanges
- couplings
- straight sections
- elbows
- angular sections
plus one more from the following:
10. control components (such as valves, taps, regulators)
11. storage devices (such as tanks, reservoirs)
12. monitoring components (such as sensors, meters, gauges)
13. fluid distribution components (such as motors, pumps)
Carry out all of the following quality checks using appropriate equipment, to include:
- alignment
- correct direction and flow
- completeness
- component security
- positional accuracy
- component quality (such as free from ripple, creases, foreign objects)
Produce pipework assemblies which comply with one of the following quality and accuracy standards:
- BS, ISO or BSEN standards and procedures
- customer standards and requirements
- company standards and procedures
- specific system requirements