Set Up Process For Tube And Pipe Production Training

Objectives:
• Understand the scope and outcomes of the unit standard
• Identify different types of tubes and pipes used in industry
• Describe the basic production process flow
• Recognise safety and quality requirements

Topics:
• Overview of unit standard 119053
• Types of tubes and pipes: materials, sizes, applications
• Production process stages: cutting, bending, joining, finishing
• Safety protocols in tube and pipe production
• Quality standards and specifications

Objectives:
• Distinguish between common tube and pipe materials
• Explain material properties affecting production
• Select appropriate material for given applications
• Interpret material specifications and certifications

Topics:
• Steel, stainless steel, copper, aluminium, plastic pipes
• Mechanical properties: strength, ductility, hardness
• Corrosion resistance and thermal properties
• Material standards (e.g., ASTM, SANS)
• Material handling and storage

Objectives:
• Identify and use basic measurement instruments
• Perform dimensional inspections on tubes and pipes
• Record measurements accurately
• Interpret inspection results against specifications

Topics:
• Vernier callipers, micrometres, tape measures
• Go/no-go gauges, wall thickness gauges
• Measuring diameter, wall thickness, ovality
• Inspection procedures and documentation
• Tolerance interpretation

Objectives:
• Describe manual and mechanical cutting methods
• Set up and operate cutting equipment safely
• Achieve square and burr-free cuts
• Inspect cut quality

Topics:
• Hacksaws, tube cutters, abrasive saws
• Band saws, chop saws, cold saws
• Blade selection and speed settings
• Cutting parameters for different materials
• Deburring techniques

Objectives:
• Explain bending principles: springback, neutral axis
• Use hand benders for small diameter pipes
• Calculate bend allowance
• Inspect bend quality

Topics:
• Bending theory: tension, compression, neutral axis
• Hand benders: lever type, ratchet type
• Bend allowance calculations
• Springback and overbending
• Common defects and remedies

Objectives:
• Set up and operate a manual pipe bender
• Perform mandrel bending for thin-wall tubes
• Adjust bend radius and angle
• Troubleshoot bending issues

Topics:
• Manual rotary draw benders
• Mandrel bending: when and how
• Setting bend angle and radius stops
• Lubrication and cooling
• Troubleshooting wrinkles, flattening, cracks

Objectives:
• Programme a simple CNC bender
• Perform multi-bend sequences
• Understand springback compensation
• Apply advanced bending methods

Topics:
• CNC bender controls and programming
• Multi-bend sequences and collision avoidance
• Springback compensation techniques
• Heat bending for large diameters
• Induction bending overview

Objectives:
• Identify threaded and mechanical joining methods
• Set up threading dies and machines
• Cut threads on pipe ends
• Assemble mechanical joints

Topics:
• Thread types: BSP, NPT, metric
• Manual and machine threading
• Thread cutting dies and chasers
• Mechanical fittings: compression, flared, push-fit
• Sealants and jointing compounds

Objectives:
• Prepare pipe ends for welding
• Set up welding equipment (MIG/TIG)
• Execute basic tack welds
• Inspect weld preparation quality

Topics:
• Weld joint designs: butt, socket, fillet
• Beveling techniques for thick walls
• MIG and TIG welding principles
• Setting welding parameters
• Tack welding procedures

Objectives:
• Perform full penetration welds on pipe
• Braze copper and brass fittings
• Apply post-weld heat treatment if needed
• Inspect welded joints for defects

Topics:
• Full welding procedures for steel and stainless
• Brazing: filler metals, fluxes, heating
• Post-weld heat treatment basics
• Non-destructive testing (visual, dye penetrant)
• Weld defect identification

Objectives:
• Describe flanging and grooving methods
• Set up roll grooving machine
• Assemble flanged joints
• Perform leak tests

Topics:
• Flange types: slip-on, weld neck, blind
• Roll grooving for grooved couplings
• Flange bolting and gasket selection
• Torque tightening sequences
• Hydrostatic testing

Objectives:
• Plan pipe routing and support placement
• Assemble pipe spools and fittings
• Install hangers and supports
• Align and connect pipe sections

Topics:
• Pipe routing principles
• Spool piece fabrication
• Hanger types: clevis, roller, spring
• Support spacing and load calculations
• Alignment techniques: laser, straight edge

Objectives:
• Set up pressure test equipment
• Conduct hydrostatic and pneumatic tests
• Identify and repair leaks
• Document test results

Topics:
• Hydrostatic test procedure and safety
• Pneumatic test precautions
• Leak detection methods: soap solution, ultrasonic
• Repair techniques: sealants, re-welding
• Test records and certification

Objectives:
• Clean and prepare pipe surfaces
• Apply protective coatings
• Inspect coating quality
• Understand coating standards

Topics:
• Cleaning methods: abrasive blasting, chemical
• Primer and paint application
• Wrapping tapes and heat shrink sleeves
• Coating thickness measurement
• Standards: SSPC, NACE

Objectives:
• Implement quality checks throughout production
• Use inspection checklists
• Complete traceability documentation
• Identify non-conformances and corrective actions

Topics:
• QC plan for tube and pipe production
• Inspection checkpoints: raw material, in-process, final
• Traceability: heat numbers, batch records
• Non-conformance reports
• Corrective and preventive actions

Objectives:
• Apply HSE regulations in tube and pipe production
• Use personal protective equipment correctly
• Identify and mitigate hazards
• Respond to emergencies

Topics:
• OHS Act and relevant regulations
• Hazard identification: pinch points, hot work, pressure
• PPE: gloves, goggles, welding screens
• Fire safety and extinguisher use
• Emergency response procedures

Objectives:
• Read and interpret production drawings
• Develop a production sequence
• Create work instructions
• Estimate material and time requirements

Topics:
• Isometric drawings and P&IDs
• Bill of materials and cut lists
• Sequence of operations
• Time estimation and production rates
• Work instruction templates

Objectives:
• Describe automation options for tube production
• Understand CNC and robotic integration
• Use digital tools for quality tracking
• Discuss benefits and challenges of automation

Topics:
• Automated cutting and bending cells
• Robotic welding for pipe joints
• Digital measurement and data logging
• Industry 4.0: IoT, cloud-based QC
• Cost-benefit analysis of automation

Objectives:
• Diagnose common production defects
• Apply root cause analysis techniques
• Implement corrective actions
• Evaluate effectiveness of solutions

Topics:
• Common defects: ovality, wrinkling, weld porosity
• Root cause analysis: fishbone diagram, 5 Whys
• Corrective action plans
• Process adjustment techniques
• Continuous improvement principles

Objectives:
• Demonstrate end-to-end production process
• Complete a practical project from cutting to testing
• Apply quality and safety standards
• Present final product and documentation

Topics:
• Practical project: fabricate a pipe assembly
• Cutting, bending, joining, testing
• Quality inspection and documentation
• Final assessment and feedback
• Course review and certification