Skills for Employment

Investment Program (SEIP)

COMPETENCY-BASED LEARNING
MATERIAL
(STUDENT GUIDE)
FOR

PLUMBING
(CONSTRUCTION SECTOR)

Finance Division, Ministry of Finance

Government of the People’s Republic of Bangladesh
 Table of Contents

Copyright 4
How to Use this Competency-based Learning Material 5
List of Icons 6
Modules 7
Module 1: Perform pipe threading operation 7
Learning Outcome 1.1 - Gather and check tools, equipment and materials 8
Learning Outcome 1.2 - Carry out steel pipe cutting operation 16
Learning Outcome 1.3 - Carry out thread cutting operation 22
Learning Outcome 1.4 - Assemble pipe run 26
Learning Outcome 1.5 - Clean/maintain the work area 29
Answer Key 33
Module 2: Perform access cutting and encroachment works 35
Learning Outcome 2.1 - Interpret drawings and plumbing plans 36
Learning Outcome 2.2 - Inspect encroachment work area 39
Learning Outcome 2.3 - Gather tools, equipment and materials 41
Learning Outcome 2.4 - Cut and make access through walls and floors 45
Learning Outcome 2.5 - Clean/maintain the work area 47
Answer Key 48
Module 3: Carry out water supply line installation using G.I, PPR/HDP pipes 49
Learning Outcome 3.1 - Gather and inspect tools, equipment and materials 50
Learning Outcome 3.2 - Perform pipe cutting operation 56
Learning Outcome 3.3 - Perform pipe threading operation 62
Learning Outcome 3.4 - Assemble pipe runs 65
Learning Outcome 3.5 - Clean/maintain the work area 68
Answer Key 69
Module 4: Carry out water supply line installation using PVC/UPVC pipes 70
Learning Outcome 4.1 - Gather and inspect tools, equipment and materials 71
Learning Outcome 4.2 - Perform PVC/UPVC pipe run operation 75
Learning Outcome 4.3 - Perform PVC/UPVC pipe run assembly 81
Learning Outcome 4.4 - Clean/maintain the work area 85
Answer Key 86
Module 5: Carry out sewer pipe line installation 87
Learning Outcome 5.1 - Plan out foe sewer pipe line installation 88
Learning Outcome 5.2 - Gather tools, equipment and materials 90
Learning Outcome 5.3 - Carry out trenching and bedding works 95
Learning Outcome 5.4 - Lay sewer pipe and finish final pipe run 98
Learning Outcome 5.5 - Finish final pipe run 101

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Learning Outcome 5.6 - Clean/maintain the work area 104
Answer Key 105
Module 6: Carry out plumbing fixtures installation 106
Learning Outcome 6.1 - Prepare for plumbing fixture installation 107
Learning Outcome 6.2 - Gather tools, equipment and materials 111
Learning Outcome 6.3 - Install a new toilet bowl (commode) 112
Learning Outcome 6.4 - Install other plumbing fixtures 118
Learning Outcome 6.5 - Clean/maintain the work area 127
Answer Key 128
Module 7: Perform pressure testing of piping system 129
Learning Outcome 7.1 - Prepare for pressure testing 130
Learning Outcome 7.2 - Gather tools, equipment and materials 133
Learning Outcome 7.3 - Carry out pressure testing 136
Learning Outcome 7.4 - Clean/maintain the work area 139
Answer Key 140

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Copyright

The Competency-based Learning Material (Student Guide) for Plumbing is a document, aligned to its
applicable competency standard, for providing training consistent with the requirements of industry in order
for individuals who graduated through the established standard via competency-based assessment to be
suitably qualified for a relevant job.

This document is owned by the Finance Division of the Ministry of Finance of the People’s Republic of
Bangladesh, developed under the Skills for Employment Investment Program (SEIP).

Public and private institutions may use the information contained in this competency-based learning
material for activities benefitting Bangladesh.

Other interested parties must obtain permission from the owner of this document for reproduction of
information in any manner, in whole or in part, of this Competency-based Learning Material, in English or
other language.

This document is available from:

Skills for Employment Investment Program (SEIP) Project

Finance Division
Ministry of Finance
Probashi Kallyan Bhaban (Level – 16)
71-72 Old Elephant Road
Eskaton Garden, Dhaka 1000
Telephone: +8802 551 38598-9 (PABX), +8802 551 38753-5
Facsimile: +8802 551 38752
Website: www.seip-fd.gov.bd

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Skills for Employment Investment Programme (SEIP)
How to Use this Competency-based Learning Material

Welcome to the competency-based learning material for Plumbing for use in construction works. These
modules contain training materials and learning activities for you to complete in order to become competent
and qualified as a skilled worker.
There are seven (7) modules that make up this course which comprises the skills, knowledge and attitudes
required to become a skilled worker including:
1. Perform pipe threading operation
2. Perform access cutting and encroachment works
3. Carry out water supply line installation using G.I, PPR/HDP pipes
4. Carry out water supply line installation using PVC/UPVC pipes
5. Carry out sewer pipe line installation
6. Carry out plumbing fixtures installation
7. Perform pressure testing of piping system
As a learner, you will be required to complete a series of activities in order to achieve each learning
outcome of the module. These activities may be completed as part of structured classroom activities or
simulated workplace demonstrations.
These activities will also require you to complete associated learning and practice activities in order to gain
the skills and knowledge needed to achieve the learning outcomes. You should refer to Learning Activity
pages of each module to know the sequence of learning tasks and the appropriate resources to use for
each task.
This page will serve as the road map towards the achievement of competence. If you read the Information
Sheets, these will give you an understanding of the work, and why things are done the way they are. Once
you have finished reading the Information Sheets, you will then be required to complete the Self-Check
Quizzes.
The self-check quizzes follow the Information Sheets in this learning guide. Completing the self-check
quizzes will help you know how you are progressing. To check your knowledge after completion of the
Self-Check Quizzes, you can review the Answer Key at the end of each module.
You are required to complete all activities as directed in the Learning Activity and Information Sheet.
This is where you will apply your newly acquired knowledge while developing new skills. When working,
high emphasis should be laid on safety requirements. You will be encouraged to raise relevant queries or
ask the facilitator for assistance as required.
When you have completed all the tasks required in this learning guide, formal assessment will be scheduled
to officially evaluate if you have achieved competency of the specified learning outcomes and are ready for
the next task.

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List of Icons

Icon Name Icon

Module content

Learning outcomes

Performance criteria

Contents

Assessment criteria

Resources required

Information sheet

Self-check Quiz

Answer key

Activity

Video reference

Learner job sheet

Assessment plan

Review of competency

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Module 1: Perform pipe threading operation

MODULE CONTENT

Module Descriptor: This module covers the skills, knowledge and attitudes to perform pipe threading
operation for plumbing works in construction which includes gathering and
checking tools, equipment and materials, carrying out steel pipe cutting
operation, carrying out thread cutting operation, assembling pipe run, and
cleaning and maintaining the work area. It also includes information sheets,
activity sheets, job sheets, self-check quizzes and answer keys.

Nominal Duration: 40 hours

Learning Outcomes:

Upon completion of the module, the student/trainee will be able to:

1.1 Gather and check tools, equipment and materials

1.2 Carry out steel pipe cutting operation
1.3 Carry out thread cutting operation
1.4 Assemble pipe run
1.5 Clean/maintain the work area

Performance Criteria:

1. Required pipe size and dimensions are identified in accordance to plumbing plan/design
2. Pipes are selected and gathered in accordance to specification
3. Personal protective equipment (PPE) is selected and used
4. Tools, equipment and materials are selected, gathered and checked for usability
5. Pipes are measured and marked in accordance to plumbing plan/drawing specification
6. Steel pipes are clamped and fixed using appropriate clamping device
7. Pipe run length is measured and cut using appropriate cutting tool
8. Pipes are cut in accordance with plumbing plan/drawing and the type of attachment fittings
9. Pipe run length is measured within the specified tolerance
10. Newly cut pipe is de burred/removed of burr using appropriate de burring tool
11. Diestocks are adjusted and initiated into the pipe end squarely
12. Thread cutting is carried out on pipes in accordance to workplace procedure
13. Coolant is used during thread cutting operation
14. Pipes are laid down in accordance with the planned/designed pipe run
15. Pipes and pipe fittings are assembled and fixed in accordance with planned/designed pipe run
16. Pipes, fittings and pipe runs are checked for damage/quality of work
17. Plumbing tools/equipment are cleaned and checked for operability
18. Work area is cleaned, and waste materials are disposed of in accordance with workplace
requirements

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 Learning Outcome 1.1 - Gather and Check Tools, Equipment and Materials

Contents:

▪ Names of personal protective equipment (PPE) and their uses: safety helmet, safety shoes, hand
gloves, safety glasses, safety belt, apron, dust mask and ear plug
▪ List of main tools, equipment and materials uses

Assessment criteria:

1. Required pipe size and dimensions are identified in accordance to plumbing plan/design.
2. Pipes are selected and gathered in accordance to specification.
3. Appropriate personal protective equipment (PPE) is selected and used.
4. Necessary tools and equipment are selected, gathered and checked for usability.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), welding rod, masking tape and plumbing plan/drawing

Learning Activity 1.1.1

Learning Activity Resources/Special Instructions/References

Gather and check tools, equipment and ▪ Information Sheet: 1.1.1

materials ▪ Self-Check Quiz: 1.1.1
▪ Answer Key: 1.1.1
▪ https://www.youtube.com/watch?v=hZbp-s3LJYo

Information Sheet 1.1.1

Learning Objective: to identify and uses of the personal protective equipment in the workplace.

 Personal Protective Equipment:

When undertaking plumbing works, the following personal protective equipment (PPE) should be worn:

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 Safety Helmets:
A hard hat is a type of helmet used in workplace
environments to protect the head from injury due
to falling objects.

Eye Protector/Goggles/Safety Glasses:

Goggles are forms of protective eyewear that
usually enclose or protect the eye area.

Ear plugs/ear muffs:

An earplug is used to protect the user's ears from
loud noises or the intrusion of water, foreign
bodies, dust or excessive wind.

Dust Mask:
Dust mask is necessary for dust protection in
workplace.

Safety cloth (overalls)/apron:

Apron has been designed to protect the body
from injury in the workplace.

Safety vest:
This is reflective safety equipment used to
increase visibility of a worker.

Safety belt:
This is used for fall protection of construction
worker and also used for additional tools holding
effective for high-rise building.

Safety harness:
A belt/body harness is designed to catch and
secure a person in case of falling while working
at height level.

Hand gloves:
These are used to protect the hands while
working and safeguarding of hands.

Safety shoes/Footwear/Boots:
Safety shoes are used to protect the legs/feet
from any harms or injuries.

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 Self-Check Quiz 1.1.1

Check your understanding by answering the following questions:

Fill in the blanks with the correct answer:

1. ______________ is used to protect eyes from flying particles which may cause injury to the worker.
2. ______________ is reflective and visible used by construction workers.
3. ______________ is used to protect the hands when working.
4. ______________ used to protect one’s feet from sharp object to fall.
5. ______________ protects workers to fall and also holds additional tools.

Learning Activity 1.1.2

Learning Activity Resources/Special Instructions/References

Gather and check tools, equipment and ▪ Information Sheet: 1.1.2, 1.1.3, 1.1.4
materials ▪ Self-Check Quiz: 1.1.2, 1.1.3, 1.1.4
▪ Answer Key: 1.1.2, 1.1.3, 1.1.4
▪ https://www.globalindustrial.com/c/plumbing/plumbing-
tools
▪ https://www.plumbingsupply.com/tools.html

Information Sheet 1.1.2

Learning Objective: to identify, gather and check usability of tools and equipment used for distempering
works.

 Tools and equipment:

To perform plumbing works, it requires use of the following tools and equipment:

Measuring tape:
This is used to measure items.

Steel rule:
Steel rules are the most widely used measuring
tools.
Marking Pencil/Pen/Chalk:
These are used to marking out on the material for a required measurement

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 Pencil Pen Chalk
Callipers:
A Vernier/slide callipers/callipers is a handy instrument used to measure diameter of a pipe and can
also be measure the thickness of pipe.

Vernier/slide callipers Inside calliper Outside calliper

Adjustable wrench:
An adjustable wrench allows you to work with
many different sizes without having to change
tools.

Pipe wrench:
The pipe wrench is an adjustable wrench used
for turning metal pipes and fittings with a rounded
surface.

Monkey wrench:
Used to loosen and tighten the pipes and bolts

Combination pliers:
Combination pliers or pliers are used to cut wire
etc.

Die stocks:
This Die Stock is designed for threading using
separate "drop heads" for each size required.

Pipe cutter:
Pipe cutter is a manual or hand tool mainly used
for cutting the metal pipes of different diameter.

Scissors type pipe cutter:

A scissors type pipe cutter is mainly used to cut
PPR. Occasionally it is used to cut PVC pipes
too.
Hacksaw:
The tool is mainly used in cutting metals like
plates, pipes, rods, bars, angles with minimal
thickness, width and length. Sometimes this tool
is used for cutting plastic pipes and other
materials that suit to its purpose.
Pipe vice:
A pipe vice is a plumbing tool used to hold pipe or
tube securely so that it can be cut or threaded.

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 Screw drivers:
These are used to loosen and tighten the screws. The type depends on the shape of slot head of the
screws.

Flared Phillips Ratchet

Spirit level:
It is used to check for level of horizontal, vertical
and 45 degree angular surfaces.

Pipe reamer:
A reamer is used to remove internal burrs from
the ends of the cut pipe. The reamer is available
as either as a simple hand held tool or to be fitted
into a brace.
Files (flat, half round, round):
Files are cutting tools used to remove/smooth rough and sharp edges from cut metal. They are also
used to file metal to shape or size.

Flat file Half-round file Round file

Hammer:
A hammer is a tool or device that delivers a blow to an object. Most hammers are hand tools used to
drive nails, fit parts, forge metal, and break apart objects. Hammers vary in shape, size, and structure,
depending on their purposes.

Ball peen hammer Claw hammer Mallet Sledge hammer

Cold chisel:
A cold chisel is used mainly for chipping away at
old mortar, concrete, cement, and plaster.
Steel wire brush:
A wire brush is a tool consisting of a brush whose
bristles are made of wire, most often steel wire.

Oil can:
An oil can is usually holding motor oil
for lubricating machines. It also be used to fill oil-
based lanterns.

Individual Activity:
▪ Identify the tools and equipment used in plumbing works
▪ Check the usability/function ability of the tools and equipment

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 Self-Check Quiz 1.1.2

Check your understanding by answering the following questions:

No. Write the name of the tools given Name

below
1

Information Sheet 1.1.3

Learning Objective: to identify, uses and check of tools, equipment and materials in plumbing works.

 Tools and equipment:

No. Picture Name and Used for

1 Drill Machine
Drilling holes in masonry, steel and timber surfaces

2 Angle Grinder
Cutting brickwork and steel grinding steel surfaces

3 PPR Welding Device

Fusion welding of PPR pipes and fittings

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 4 Heat Gun
Heat up area to be worked on

5 Breaker Machine
Demolish masonry, concrete areas required

6 Scanner
Scan the surface for any cables or conduit

7 PPR pipe cutter

Used to cut PPR pipes to the required length

Self-Check Quiz 1.1.3

Check your understanding by answering the following questions:

No. Picture Used for

1

Information Sheet 1.1.4

Learning Objective: to identify, uses and check of tools, equipment and materials in plumbing works.

 Materials:
1 Teflon tape is used to seal the thread of pipes

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 2 Hemp is a fibre that it is the traditional method of aiding the
sealing of heavier gauge pipe work. It must be used in
conjunction with a suitable paste sealant
3 Solvent cement and primer is used to glue cpvc/pvc/ uPVC
joints

Self-Check Quiz 1.1.4

Check your understanding by answering the following questions:

1. Why Teflon tape is used in plumbing works?

2. What is Hemp?

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 Learning Outcome 1.2 - Carryout Steel Pipe Cutting Operation

Contents:

▪ Pipes and their uses: galvanized iron (GI) pipe, PVC pipe, stainless steel (SS) pipe, Boehringer
Ingelheim (BI) pipe and cast iron (CI) pipe
▪ Fittings and their uses: elbow 90°, Elbow 45°, tee, coupling, nipple, plug, cap, socket etc.
▪ Steel pipe cutting procedures

Assessment criteria:

1. Pipes are measured and marked in accordance to plumbing plan/drawing specification.

2. Steel pipe is clamped using appropriate clamping device.
3. Pipe run length is measured and cut using appropriate cutting tool.
4. Pipe length is measured and cut in accordance with plumbing plan/drawing and the type of attachment
fittings.
5. Pipe run length is measured within the specified tolerance.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), welding rod, masking tape and plumbing plan/drawing
▪ Pipes: GI pipe, PVC pipe, stainless steel pipe, BI pipe and cast iron pipe
▪ Fittings: elbow 90° & 45°, tee, coupling, nipple, plug, cap and socket etc.

Learning Activity 1.2.1

Learning Activity Resources/Special Instructions/References

Carryout steel pipe cutting operation ▪ Information Sheet: 1.2.1, 1.2.2

▪ Job Sheet 1
▪ Self-Check Quiz: 1.2.1, 1.2.2
▪ Answer Key: 1.2.1, 1.2.2
▪ https://en.wikipedia.org/wiki/Pipe_Cutting

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 Information Sheet 1.2.1

Learning Objective: to identify and uses of different types of pipes in a workplace.

 Pipes:

GI (Galvanised Iron) pipes: These pipes are much stronger

and economical, used to transfers water in various
plumbing applications.

Poly Propylene Random (PPR) Pipe: These are the best

pipes used to transfer hot and cold water.

PVC (polyvinyl chloride) pipe: These are common, strong

but lightweight plastic pipe used in construction, only for
cold water.

uPVC (Un-plasticized polyvinyl chloride) pipe: If no

plasticizers are added, it is known as uPVC (un-plasticized
polyvinyl chloride), rigid PVC.

MS (Mild Steel) pipes: These are heavy duty and costly

pipes used to transfers gas / water in various plumbing
applications.

SS (Stainless Steel) pipes: These are also heavy duty and

costly pipes used to transfers gas / water in various
plumbing applications.

CI (Cast Iron) pipes: These are most suitable and used for
rain water disposal and waste water disposal etc.

Copper pipes: These pipes are used for industrial

purposes for heavy flows.

Concrete pipes: For heavy drainage water disposal,

concrete pipes of large diameters are used. Smaller
diameter pipes are used for small flows.

Asbestos Cement Pipes: These pipes are used as vent

pipes, soil pipes and rain water pipes. They are very cheap
compared to all but they can break easily.

High Density Polyethylene (HDP) pipes: This pipe is used

for water supply, waste water disposal and as electrical
conduit.
1

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 Self-Check Quiz 1.2.1

Check your understanding by answering the following questions:

No. Different types of Pipe Name of the pipe

1

Information Sheet 1.2.2

Learning Objective: to identify and uses of different types of plumbing fittings in the workplace.

Elbow:
Elbow is used to join two lengths of pipe (equal or un-
equal diameter).

Bend:
Bend is used to join two lengths of pipe (equal or un-
equal diameter).

Tee (T):
Tee is used to connect three lengths of pipe (equal or
un-equal diameter) comes in a number of sizes.

Union:
Union is used to connect two pipe lengths together
comes in a number of sizes. It is used where a pipe line
is opened to replace a damaged section or to cut into an
existing line.

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 Reducer:
Reducer is used to join two different size pipes in a
straight way.

Socket:
Socket is used to connect two pipe lengths together
comes in a number of sizes.

Nipple:
A nipple is used between two fittings.

Bush:
A bush is used to connect the male end of a pipe to a
fitting of larger or smaller diameter pipe.

Adapter (male/female):
An adapter is used to connect the threaded end of a pipe
to a fitting.

Plug:
Plug is used to seal off a GI fitting.

Cap:
Cap is used to seal off pipe end.

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 JOB SHEET 1
Qualification: Plumbing

Learning unit: Perform pipe cutting operation:

Cut G I/PVC/uPVC/PPR/CI pipes
Learner name:

Personal protective Hand gloves, visibility vest, safety goggles, safety boots, hard hat and dust
equipment (PPE): mask
Materials: G I/PVC/uPVC/PPR/CI pipes, lubricant

Tools and equipment: Measuring tape, foot rule, hack saw, hack saw, marker pen, pipe cutter, pipe
vice, 3-wheel type pipe cutter, C I chain cutter
Performance criteria: For G. I/PVC/uPVC/PPR pipes: For C.I pipes:
1. Cut the GI / PVC/uPVC/PPR pipe 1. Cut Cast Iron pipe using a single
with a hacksaw / pipe cutter stroke chain cutter
2. Measurement error must be within 2. Measurement error must be within
approximately 2mm approximately 2mm
3. Pipes must be cut uniformly one 3. Pipes must be cut uniformly one
end to another end end to another end
Measurement: Cut GI pipe as per drawing using Cut a C I soil pipe 500mm long from
hacksaw and 3-wheel type cutters. the flanged fitting using a single
Cut PVC/uPVC/PPR pipe as per stroke Chain cutter
drawing using hacksaw.

Procedure: 1. Identify the type pipe required 1. Identify the fittings and pipe
2. Measure, cut using a hacksaw as required
per measurement on drawing 2 x 2. Measure, cut a 1 X 500 mm length
450 mm lengths of 20mm ɸ GI of 100 mm ɸ C I pipe.
pipe. 3. Pipes must be cut uniformly one
3. Measure, cut using a 3-wheel type end to another end.
pipe cutter 1 x 250mm length 4. Measurement error must be
20mm ɸ PVC pipe. within approx. 2mm
4. 1 x 450 mm lengths of 20mm ɸ
PVC pipe.
5. All pipes must be cut uniformly
one end to another end.
6. Measurement error must be within
approx. 2mm

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 Learner signature: Date:

Assessor signature: Date:

Quality Assurer
Date:
signature:

Assessor remarks:

Individual Activity:
▪ Watch the video on ‘How to cut water supply pipes’ and summarise the key points (if facilities
available)
▪ Cut the pipes following the Job Sheet 1 (see above)

Self-Check Quiz 1.2.2

Check your understanding by answering the following questions:

Read the following statements and mark whether true or false accordingly:

No. Description True False

1. Elbow is used to join three lengths of pipe (equal or un-equal diameter)
2. Tee is used to connect two lengths of pipe (equal or un-equal diameter)
comes in a number of sizes
3. Union is used, where a pipe line is opened to replace a damaged section or
to cut into an existing line
4. Reducer is used to join two different size pipes in a straight way
5. Socket is used to connect three pipe lengths together comes in a number of
sizes
6. A nipple is used between two fittings
7. A bush is used to connect the male end of a pipe to a fitting of larger or
smaller diameter pipe
8. An adapter is used to connect the threaded end of a pipe to a fitting
9. Cap is used to seal off a GI fitting
10. Plug is used to seal off pipe end

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 Learning Outcome 1.3 – Carry Out Thread Cutting Operation

Contents:

▪ De-burring tool uses: flat file, round file, half round file. pipe reamer and sandpaper
▪ Coolant: water, oil, air, synthetic, nitrogen
▪ Thread cutting procedure

Assessment criteria:

1. Steel/metal pipes are clamped and fixed using pipe vice.

2. Newly cut pipe is de burred/removed of burr using appropriate de burring tool.
3. Diestocks are adjusted and initiated into the pipe end squarely.
4. Thread cutting is carried out on pipes in accordance to workplace procedure.
5. Coolant is used during thread cutting operation.
6. Threads are checked to conform with the specified form and measured in accordance with
plan/drawing.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), welding rod, masking tape and plumbing plan/drawing
▪ Pipes: GI pipe, PVC pipe, stainless steel pipe, BI pipe and cast-iron pipe
▪ Fittings: elbow 90° & 45°, tee, coupling, nipple, plug, cap and socket etc.

Learning Activity 1.3.1

Learning Activity Resources/Special Instructions/References

Carryout thread cutting operation ▪ Information Sheet: 1.3.1

▪ Specification Sheet 1
▪ Job Sheet 2
▪ Self-Check Quiz: 1.3.1
▪ Answer Key: 1.3.1
▪ https://en.wikipedia.org/wiki/Threading_(manufacturing)
▪ https://www.instructables.com/id/Thread-Cutting-Internal-and-
External-on-a-

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 Information Sheet 1.3.1

Learning Objective: to identify and uses of pipe vice, de burring tool, diestocks and coolant in the
workplace.

Pipe vice:
A pipe vice is a plumbing tool used to hold pipe or tube
securely so that it can be cut or threaded.

De burring tools:
Files (flat, half round, round): Files are cutting tools used to remove/smooth rough and sharp edges
from cut metal. They are also used to file metal to shape or size.

Flat file Half-round file Round file

Pipe reamer:
A reamer is used to remove internal burrs from the ends
of the cut pipe. The reamer is available as either as a
simple hand held tool or to be fitted into a brace.
Sand paper:
Sand paper is used as a de burring tool. It is available
with various grades.

Die stocks:
This Die Stock is designed for threading using separate
"drop heads" for each size required.

Coolant:
In plumbing system coolant plays important role. Water, oil, air, synthetic and nitrogen etc. used as
coolants.

SPECIFICATION SHEET 1
 Thread Length Data:

Nominal Pipe Threads Approximate Approximate Approximate Total Thread

Size (in inches) Per Inch Length of Thread Numbers of Makeup Engagement (In
(In Inches) Threads to be Cut Inches)
½ 14 ¾ 10 7/16

3/4 14 ¾ 10 ½
1 11 ½ ⅞ 10 9/16

1½ 11 ½ 1 11 9/16

2 11 ½ 1 11 5/8

2½ 8 1½ 12 ⅞
3 8 1½ 12 1
4 8 15/8 13 11/16

6 8 1¾ 14 13/16

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 JOB SHEET 2
Qualification: Plumbing

Learning unit: Perform pipe threading operation:

Cut an external thread of 14 TPI on a ¾ inch G I pipe
Learner name:

Personal protective Hand gloves, visibility vest, safety goggles, safety boots, hard hat and dust
equipment (PPE): mask
Materials: G I pipe, lubricant

Tools and equipment: Die Stock and pipe vice, round and flat files

Measurement:

Notes: • Cut an external thread of 14 TPI on a ¾ inch GI pipe.

• The thread must be uniform
• No threads are to be broken
• Thread when be cut to be visible 1 to 2 threads of the die stock
• Lubricant to be applied during threading operation
Procedure: 1. Collect tools, materials and equipment.
2. Place pipe vice on the ground
3. Fix the GI pipe into the vice
4. Adjust die stock as per diameter of the pipe
5. Insert die stock into the pipe
6. Rotate the die stock in clockwise direction.
7. Apply lubricant on the pipe.
8. Rotate the die stock anticlockwise after 4 to 5 times clockwise
9. Cut thread until one or two threads out of die is visible.
10. Remove the die set from the pipe.
11. Clean thread and workplace
12. Restore all tools and materials
Learner signature: Date:

Assessor signature: Date:

Quality Assurer
Date:
signature:

Assessor remarks:

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 Individual Activity:
▪ Watch the video on ‘How to cut external thread on a GI pipe’ and summarise the key points (if
facilities available)
▪ Cut the pipes following the Job Sheet 2 (see above)

 Field Visit:
• Visit a construction site working with plumbing works in the neighbourhood
• Observe some activities there like:
- What tasks are being performed?
- Which tools are being used and for what purpose?
- Are the workers worn adequate PPE? List out the names
- Anything more observed you may mention
• Fill-up the ‘Field Visit Format’ given and submit to your trainer
• Present the experience group wise as per instruction of your trainer

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 Learning Outcome 1.4 - Assemble Pipe Run

Contents:

▪ Plan and design of pipe run

▪ Assembling procedure
▪ Checking for damage/quality check of pipes, fittings and pipe run

Assessment criteria:

1. Pipes are laid down in accordance with the planned/designed pipe run.
2. Pipes and pipe fittings are assembled and fixed in accordance with planned/designed pipe run.
3. Pipes, fittings and pipe runs are checked for damage/quality of work.
4. Assembled pipe runs are measured/checked within tolerable dimensions/length in accordance with
design/specification.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), welding rod, masking tape and plumbing plan/drawing
▪ Pipes: GI pipe, PVC pipe, stainless steel pipe, BI pipe and cast iron pipe
▪ Fittings: elbow 90° & 45°, tee, coupling, nipple, plug, cap and socket etc.

Learning Activity 1.4.1

Learning Activity Resources/Special Instructions/References

Assemble pipe run ▪ Information Sheet: 1.4.1

▪ Self-Check Quiz: 1.4.1
▪ Answer Key: 1.4.1
▪ https://www.todayshomeowner.com/video/how-to-align-pvc-pipe-fitting-
during-
▪ https://www.youtube.com/watch?v=fWiXTr-6N4I
▪ https://www.youtube.com/watch?v=eMQRX2yXIsE

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 Information Sheet 1.4.1

Learning Objective: list the tools, equipment and materials required for making pipe joints, explain the
necessity of assembling pipe run, and describe the procedure of assembling pipe run.
On completion of this task you will be able to complete the following steps:

1. Collect tools, equipment and materials.

2. Cut the pipe as per required measurement with pipe cutter or hack saw.
3. Lay down the pipes in accordance with the planned/designed pipe run.
4. Assembled and fixed the pipes and pipe fittings in accordance with planned/designed pipe run.
5. Temporarily join pipes and fittings and make sure that the pipe in the run is facing the right direction.
6. Use a felt-tip pen to make alignment marks on all the joints where the fitting must face correctly.
7. Disassemble, keeping careful track of the order of installation.
8. Apply primer to each pipe end and each fitting.
9. Apply solvent/cement and join each pipe in order.
10. Checked the pipes, fittings and pipe runs for damage/quality of work.
11. Assembled pipe runs are measured/checked within tolerable dimensions/length in accordance with
design/specification.
12. Conduct leakage test using water.
13. Clean the workplace.
14. Restore the tools equipment and materials.

PVC Drainage Pipe Joints

PVC Pipe Joints

PPR Pipe Joints GI Pipe Joints

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 Individual Activity:
▪ Watch the videos on ‘How to bend PVC’ and summarise key points (if facilities available)
▪ Watch the videos on ‘How to PPR’ and summarise key points
▪ Complete the assigned jobs as per drawing/instructions

 Assignment:
The trainee will identify the following pictures and submit to the trainer. Pictures can be collected from the
market, net or other sources. They should be neatly put in a file with names and uses.

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 Learning Outcome 1.5 - Clean and Maintain the Work Area

Contents:

▪ Importance and necessity of cleaning tools and equipment and workplace

▪ Methods of cleaning, tools and equipment required for cleaning
• Lubricants
• Advantages of proper storing of tools and equipment; types of storage

Assessment criteria:

1. Plumbing tools and equipment are cleaned and maintained.

2. Work area is cleaned.
3. Waste materials are disposed of in accordance with workplace requirements.

Resources required:

Students/trainees must be provided with the following resources:

• Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Cleaning tools and equipment: dusters, dust pans, mops, polishing clothes, brooms, brushes,
buckets, dust bins and cotton rags
▪ Materials: water, detergents, abrasives, bleaches and lubricants (oil, grease and powder)

Learning Activity 1.5.1

Learning Activity Resources/Special Instructions/References

Clean and maintain the work area ▪ Information Sheet: 1.5.1
▪ Self-Check Quiz: 1.5.1
▪ Answer Key: 1.5.1
▪ https://www.wikihow.life/Clean-a-House
▪ https://www.goodhousekeeping.com/home/cleaning/g2550/best-
cleaning-

Information Sheet 1.5.1

Learning Objective: to clean and lubricate necessary tools and equipment and store the same as per
standard procedures and clean workplace.
General information:
After plumbing works cleaning is very important and essential for both tools and equipment used and the
workplace where plumbing work has done. To keep the tools and equipment clean, extra attention and

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experience required considering how to remove dirt, including dust, stains, bad smells, and clutter on
surfaces. For this, we can use some cleaning agents as follows:
▪ Water (the best cleaning agent)
▪ Soap or detergent
▪ Calcium hypochlorite (powdered bleach)
▪ Sodium hypochlorite (liquid bleach)
▪ Acetic acid (vinegar)
Methods of cleaning: cleaning can be done with following methods:
▪ Dusting
▪ Shaking and beating
▪ Sweeping
▪ Mopping
▪ Washing
▪ Polishing

Rough Cleaning:
▪ First remove all debris either by hand or use of brushes, brooms, scrapers, squeegees etc.
▪ Collect and dispose of all debris appropriately.
▪ A warm rinse is recommended to complete the rough cleaning.
Removal of Excess Water:
▪ Any areas where water has extensively pooled may serve as a medium for bacteria growth and should
be dried.
▪ Equipment that has the potential to rust should also be dried.

Tools and equipment for cleaning:

Broom:
A broom is a cleaning tool consisting of usually stiff fibres, also known
as coconut broom.

Dusters/Dust protector:
A duster/dust protector is a light, loose-fitting long coat.

Dust pan:
A dustpan is used in combination with a broom. It is used to collect
dust/waste/small debris.

Cleaning brushes:
Cleaning brushes are tool with bristles, wire or other filaments, used
for cleaning, painting, and surface finishing, and for many other
purposes.

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 Mop:
A mop is a bundle of coarse strings or a piece of cloth, sponge, or other
absorbent material, attached to a stick. It is used to soak up liquid,
for cleaning floors and other surfaces, to mop up dust, or for other
cleaning purposes.

Waste container:
A waste container is a container for temporarily storing waste and is
usually made out of metal or plastic. Some common terms
are dustbin, garbage can, trash can and dumpster.

Cotton rags:
A rag is a piece of old cloth which can be used to clean or wipe things.

Lubricant:
• A lubricant is used to reduce friction between surfaces.
• Adequate lubrication allows smooth operation of equipment, reduces the rate of wear and prevents
excessive stresses.
Advantages of proper storage of tools and equipment:
▪ Ensures that tools and equipment remain in good condition and last for a long time.
▪ Easy to find when needed and are less likely to be lost.
▪ Productivity is increased because time is not lost looking for tools and equipment.
Common types of storage:

Bin Tool box

Cabinets

Bucket bag Tote bag Storage bag

Tool racks Work bench Shelving

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 Self-Check Quiz 1.5.1

Check your understanding by answering the following questions:

1. What are the methods of cleaning?

2. What is a broom?
3. Write the uses of mops.
4. What is the common type of storage for plumbing tools and equipment?
5. What are the advantages of properly storing plumbing tools and equipment?

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 ANSWER KEYS

Answer Key 1.1.1

1. Eye protector/goggles/safety glasses

2. Safety vest
3. Hand gloves
4. Safety shoes/footwear/boots
5. Safety belt

Answer Key 1.1.2

1. Pipe wrench
2. Die stocks
3. Pipe cutter
4. Scissors type pipe cutter
5. Pipe reamer

Answer Key 1.1.3

1. Drilling holes in masonry, steel and timber surfaces.

2. Cutting brickwork and steel grinding steel surfaces.
3. Fusion welding of PPR pipes and fittings.
4. Heat up area to be worked on.
5. Cut PPR pipes to the required length by cutter.

Answer Key 1.1.4

1. Teflon tape is used to seal the thread of pipes.

2. Hemp is a fibre type material that is used for sealing of heavier gauge pipe work.

Answer Key 1.2.1

1. GI (Galvanised Iron)
2. Poly Propylene Random (PPR)
3. PVC (Polyvinyl Chloride)
4. Concrete
5. Copper

Answer Key 1.2.2

1. False
2. False
3. True
4. True
5. False
6. True
7. True
8. True
9. False
10. False

Answer Key 1.5.1

1. Methods of cleaning are: dusting, shaking and beating, sweeping, mopping, washing, polishing.
2. A broom is a cleaning tool consisting of usually stiff fibres, also known as coconut broom.

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3. Mops are used to soak up liquid, for cleaning floors and other surfaces, to mop up dust, or for other
cleaning purposes.
4. Tool rack is a common type of storage of painting tools and equipment.
5. The advantages of properly storing plumbing tools and equipment are: ensure good condition, last
for a long time, easily find, less likely to be lost and increase productivity.

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Module 2: Perform access cutting and encroachment works

MODULE CONTENT

Module Descriptor: This module covers the skills, knowledge and attitudes to perform access
cutting and encroachment works which includes interpreting drawings and
plumbing plans, inspecting encroachment work area, gathering tools,
equipment and materials, cutting and making access through walls and floors,
and cleaning and maintaining the work area. It also includes information
sheets, activity sheets, job sheets, self-check quizzes and answer keys.

Nominal Duration: 32 hours

Learning Outcomes:

Upon completion of the module, the student/trainee will be able to:

2.1 Interpret drawings and plumbing plans

2.2 Inspect encroachment work area
2.3 Gather tools, equipment and materials
2.4 Cut and make access through walls and floors
2.5 Clean/maintain the work area

Performance Criteria:

1. Building drawing/plumbing plan is collected and correctly interpreted.

2. Work area/line of encroachment and the possible obstructions/limitations along the line of
encroachment work are identified.
3. Obstructions/limitations are planned out.
4. Tools, equipment and materials are selected, gathered and checked for usability.
5. Appropriate personal protective equipment (PPE) is selected, checked and used.
6. Lay out for access/encroachment work is properly made.
7. Wall and floor are cut to create pipe access/encroachment as per workplace requirements.
8. Cutting walls and floors are made without causing damage to the wall or floor and adjacent
installations.
9. Used tools and equipment are cleaned and maintained.
10. Work area is cleaned and waste materials are disposed in accordance with workplace
requirements.

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 Learning Outcome 2.1 - Interpret Drawings and Plumbing Plans

Contents:

▪ Building drawing: detail plumbing plan, elevation and section

▪ Encroachment of floor, wall, ceiling, slab, beam and column

Assessment criteria:

1. Building drawing/plumbing plan is collected.

2. Building drawing/plumbing plans are interpreted.
3. Work area/line of encroachment is identified.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, hacksaw, cold chisel, hammer
▪ Equipment: power hacksaw, electric drill machine
• Materials: soft stone (marker), marking pen, pencil, masking tape and plumbing plan/drawing

Learning Activity 2.1.1

Learning Activity Resources/Special Instructions/References

Interpret drawings and plumbing plans ▪ Information Sheet: 2.1.1

▪ Self-Check Quiz: 2.1.1
▪ Answer Key: 2.1.1
▪ https://en.wikipedia.org/wiki/Plumbing_drawing

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 Information Sheet 2.1.1

Learning Objective: to identify encroachments and interpret the building drawing/plumbing plans used in
the workplace.

 Building drawing:

Building drawing is an essential part for

plumbing works. It requires calculating the
quantity of water to be supplied for the
dwellers to ensure at different locations. So, it
needs to study the drawing/plumbing plans or
sections, identify the source of water and line
of encroachment for a successful installation
of different kinds of plumbing fixtures.

Typical Plumbing System of a 3-Storeyed Building

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 Line of encroachment: in a plumbing system, the line of encroachment may include floors, walls,
ceilings, slabs, beams, columns etc.

Self-Check Quiz 2.1.1

Check your understanding by answering the following questions:

1. Write the line of encroachment in plumbing works.

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 Learning Outcome 2.2 - Inspect Encroachment Work Area

Contents:

▪ Obstructions/limitations along the line of encroachment: built in appliance, cabinet, concrete column
and beam, doors, widows and existing pipe run
▪ Possible solutions/remedies to overcome

Assessment criteria:

1. Possible obstructions/limitations along the line of encroachment work are identified.

2. Possible solutions/remedies needed for identified.
3. Obstructions/limitations are planned out.
4. Tools, equipment and materials required to carry out encroachment work are identified.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, cold chisel, claw hammer, mallet adjustable wrench, box set
wrench, pipe wrench, pliers, hacksaw, spirit level
▪ Equipment: jack hammer, drill press, angle grinder, portable drill, oxy-acetylene cutting outfit and
welding machine
▪ Materials: soft stone (marker), marking pen, pencil, welding rod, cement, sand, putty

Learning Activity 2.2.1

Learning Activity Resources/Special Instructions/References

Inspect encroachment work area ▪ Information Sheet: 2.2.1

▪ http://www.donleyservice.com/media/articles/2018/03/how-
plumbers-fix-tre

Information Sheet 2.2.1

Learning Objective: to inspect encroachment work area for plumbing fixtures installation.
 Obstructions/limitations:
In plumbing system along the line of encroachment we commonly met the following possible
obstructions/limitations:

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 ▪ Built in appliance
▪ Cabinet
▪ Concrete column
▪ Concrete beam
▪ Doors
▪ Widows
▪ Existing pipe run etc.

 How to overcome obstructions/limitations:

In plumbing system to overcome obstructions/limitations the following actions should be done:
▪ Collect and study the building plan and plumbing design/drawing
▪ Identify the line of encroachment
▪ Identify and planned out the obstructions/limitations
▪ Report and discuss with the immediate superior
▪ Determine the possible solutions/remedies to overcome obstructions/limitations
▪ Make a list of tools, equipment and materials to carry out the encroachment works

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 Learning Outcome 2.3 – Gather Tools, Equipment and Materials

Contents:

▪ List of main tools, equipment and materials uses

▪ Name of personal protective equipment (PPE) and their uses: safety helmet, safety shoes, hand gloves,
safety glasses, safety belt, apron, dust mask, ear plug

Assessment criteria:

1. Necessary tools, equipment and materials are selected, gathered and checked for usability.
2. Appropriate personal protective equipment (PPE) is checked and used.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, cold chisel, claw hammer, mallet adjustable wrench, box set
wrench, pipe wrench, pliers, hacksaw, spirit level
▪ Equipment: jack hammer, drill press, angle grinder, portable drill, oxy-acetylene cutting outfit and
welding machine
▪ Materials: soft stone (marker), marking pen, pencil, welding rod, cement, sand, putty, scaffold and
plumbing plan/drawing

Learning Activity 2.3.1

Learning Activity Resources/Special Instructions/References

Collecting and checking tools, equipment ▪ Information Sheet: 2.3.1, 2.3.2, 2.3.3, 2.3.4
and materials ▪ Self-Check Quiz: 2.3.1
▪ Answer Key: 2.3.1

Information Sheet 2.3.1

Learning Objective: to identify and uses of personal protective equipment in the workplace.

 Personal Protective Equipment (PPE):

Same as Information Sheet 1.1.1 – Gather and check tools, equipment and materials (page 8-9)

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 Information Sheet 2.3.2

Learning Objective: to identify, uses and check of tools, equipment and materials in plumbing works.

 Tools and equipment:

Same as Information Sheet 1.1.2 – Gather and check tools, equipment and materials operation (page
10 - 12)

Information Sheet 2.3.3

Learning Objective: to identify, uses and check of tools, equipment and materials in plumbing works.

 Tools and equipment:

Same as Information Sheet 1.1.3 – Gather and check tools, equipment and materials (page 13 - 14)

Information Sheet 2.3.4

Learning Objective: to identify, uses and check of tools, equipment and materials in plumbing works.

 Materials and pipes:

1 Teflon tape is used to seal the thread of pipes

2 Hemp is a fibre that it is the traditional method of aiding the

sealing of heavier gauge pipe work. It must be used in
conjunction with a suitable paste sealant

3 PVC Solvent Cement and Primer is used to glue cpvc/pvc

joints

4 Poly Propylene Random (PPR) Pipe used for transfer hot

and cold water

5 PVC (polyvinyl chloride) is a common, strong but

lightweight plastic used in construction

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 6 uPVC pipe: If no plasticizers are added, it is known as
uPVC (un-plasticized polyvinyl chloride), rigid PVC.

7 GI (Galvanised Iron) pipes: Transfers water in various

plumbing applications

8 MS (Mild Steel) pipes: Transfers gas / water in various

plumbing applications

9 SS (Stainless Steel) pipes: These are also heavy duty

and costly pipes used to transfers gas / water in various
plumbing applications.

10 CI (Cast Iron) pipes: These are most suitable and used

for rain water disposal and waste water disposal etc.

11 Copper pipes: These pipes are used for industrial

purposes for heavy flows.

12 Concrete pipes: For heavy drainage water disposal,

concrete pipes of large diameters are used. Smaller
diameter pipes are used for small flows.

13 Asbestos Cement Pipes: These pipes are used as vent

pipes, soil pipes and rain water pipes. They are very
cheap compared to all but they can break easily.

14 High Density Polyethylene (HDP) pipes: This pipe is

used for water supply, waste water disposal and as
electrical conduit.

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 Self-Check Quiz 2.3.1

Check your understanding by answering the following questions:

1. Why Teflon tape is used in plumbing works?

2. What is Hemp?
3. Write the full name of PPR pipe.
4. Write the full name of PVC pipe.
5. Write the full name of GI pipe.
6. Write the full name of CI pipe.

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 Learning Outcome 2.4 - Cut and Make Access Through Walls and Floors

Contents:

▪ Lay out for access/encroachment work

▪ Techniques of cutting walls and floors

Assessment criteria:

1. Lay out for access/encroachment work is made.

2. Concrete wall and floor are cut to create pipe access/encroachment in accordance to plumbing
plan/specification.
3. Cutting walls and floors are made without causing damage to the wall or floor and adjacent installations.
4. Appropriate tools and equipment are used.

Resources required:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, hacksaw, cold chisel, hammer
▪ Equipment: power hacksaw, electric drill machine
▪ Materials: soft stone (marker), marking pen, pencil, masking tape and plumbing plan/drawing

Learning Activity 2.4.1

Learning Activity Resources/Special Instructions/References

Cut and make access through ▪ Information Sheet: 2.4.1

walls and floors ▪ https://www.bhg.com/home-improvement/plumbing/how-to-run-
pipes-throug

Information Sheet 2.4.1

Learning Objective: to cut and make access through walls and floors for plumbing fixtures installation.

 Lay out: In plumbing system lay out helps in many ways to cut and make access through walls and
floors for plumbing fixtures installation in a desired location.

 How to cut and make access through walls and floors?

▪ Collect and study the building drawing and plumbing design/drawing
▪ Prepare a layout for access/encroachment work
▪ Make a list of tools, equipment and materials to carry out the works
▪ Collect the appropriate tools, equipment and materials

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 ▪ Use appropriate tools and equipment to cut the walls and floors
▪ Take special care during cutting the walls and floors to avoid damage to the wall or floor and
adjacent installations
▪ Cut the walls and floors to create pipe access/encroachment in accordance to plumbing
plan/specification
▪ Repair the cutting spots after completion of piping works
▪ Clean the tools and equipment
▪ Dispose excess and waste materials.

Do you know?
▪ Right layout for access or encroachment works can help to avoid damage of other installations?
▪ Use of inappropriate tools and equipment may cause serious accident in the workplace.

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 Learning Outcome 2.5 - Clean and Maintain the Work Area

Same as Learning Outcome 1.5 – Clean and maintain the Work Area (page 29 - 32)

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 ANSWER KEYS

Answer Key 2.1.1

1. Line of encroachment in plumbing works are floors, walls, ceilings, slabs, beams, columns etc.

Answer Key 2.3.1

1. Eye protector/goggles/safety glasses

2. Safety vest
3. Hand gloves
4. Safety shoes/footwear/boots
5. Safety belt

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Module 3: Carry out water supply line installation using G.I, PPR and HDP pipes

MODULE CONTENT

Module Descriptor: This module covers the skills, knowledge and attitudes to carry out water
supply line installation using G.I pipe, PPR and HDP pipes which includes
gathering and inspecting tools, equipment and materials, performing pipe
cutting operation, pipe threading operation, assembling pipe runs, and
cleaning/maintaining the work area. It also includes information sheets, activity
sheets, job sheets, self-check quizzes and answer keys.

Nominal Duration: 50 hours

Learning Outcomes:

Upon completion of the module, the student/trainee will be able to:

3.1 Gather and inspect tools, equipment and materials
3.2 Perform pipe cutting operation
3.3 Perform pipe threading operation
3.4 Assemble pipe runs
3.5 Clean/maintain the work area

Performance Criteria:

1. Personal protective equipment (PPE) is selected and used.

2. Tools, equipment and materials are gathered and checked for usability.
3. Pipes are identified and gathered in accordance with plumbing plan and specifications.
4. Pipes are measured and marked as per plan/drawing specification.
5. Pipes are clamped and fixed using appropriate clamping device.
6. Pipes are cut using appropriate cutting tool.
7. Pipes are cut within the specified dimension and considering specified tolerance.
8. Diestocks are adjusted and initiated into the pipe end squarely.
9. Thread cutting is carried out on pipes in accordance to workplace procedure.
10. Coolant is used during thread cutting operation.
11. Threads are checked to conform with the specified form and measurement in accordance with
plan/drawing
12. Pipe runs is positioned on the corresponding areas as per plumbing plan.
13. Piping joints and fittings are tightened using appropriate tools and sealant.
14. Pipe clamps and fixtures along pipe runs are installed in accordance with plumbing plan.
15. Leaks and non-conformance to plumbing design/plans are checked and corrected.
16. Holes and openings are filled with cement plasters and finishing.
17. Plumbing tools/equipment is cleaned and maintained.
18. Work area is cleaned and waste materials are disposed of in accordance with workplace
requirements.

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 Learning Outcome 3.1 - Gather and Inspect Tools, Equipment and Materials

Contents:

▪ Name of personal protective equipment (PPE) and their uses: safety helmet, safety shoes, hand gloves,
safety glasses, safety belt, apron, dust mask, ear plug
▪ List of main tools, equipment and materials uses
▪ Different kinds of pipes with uses: galvanized iron (GI), polypropylene (PPR) and high-density
polyethylene (HDP) pipe

Assessment criteria:

1. Personal protective equipment (PPE) is selected and used.

2. Tools, equipment and materials are gathered and checked for usability.
3. Pipes are identified and gathered in accordance with plumbing plan and specifications.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, sealant (plastic, rubber,
synthetic) thread tape (Teflon), welding rod, masking tape
▪ Pipe: GI, PPR and HDP pipes (different diameter)
▪ Fittings: gate valve, check valve, globe valve and foot valve

Learning Activity 3.1.1

Learning Activity Resources/Special Instructions/References

Gather and check tools, equipment ▪ Information Sheets: 3.1.1, 3.1.2, 3.1.3, 3.1.4, 3.1.5, 3.1.6
and materials ▪ Self-Check Quiz: 3.1.1, 3.1.2
▪ Answer Key: 3.1.1, 3.1.2

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 Information Sheet 3.1.1

Learning Objective: to identify and uses of the personal protective equipment in the workplace.
 Personal Protective Equipment (PPE):

Same as Information Sheet 1.1.1 – Gather and check tools, equipment and materials (page 8 - 9)

Information Sheet 3.1.2

Learning Objective: to identify, uses and check tools, equipment and materials in plumbing works.

 Tools and equipment:

Same as Information Sheet 1.1.2 – Gather and check tools, equipment and materials (page 10 - 12)

Information Sheet 3.1.3

Learning Objective: to identify, uses and check tools, equipment and materials in plumbing works.

 Tools and equipment:

Same as Information Sheet 1.1.3 – Gather and check tools, equipment and materials (page 13 - 14)

Information Sheet 3.1.4

Learning Objective: to identify, uses and check tools, equipment and materials in plumbing works.

 Materials:

Same as Information Sheet 1.1.4 – Gather and check tools, equipment and materials (page 14 - 15)

Information Sheet 3.1.5

Learning Objective: to identify and uses of different types of plumbing fittings in the workplace.

 Fittings: are used in pipe systems to connect straight pipe or tubing sections, adapt to different sizes
or shapes and for other purposes.

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 Elbow:
Elbow is used to join two lengths of pipe (equal or un-
equal diameter).

Bend:
Bend is used to join two lengths of pipe (equal or un-
equal diameter).

Tee (T):
Tee is used to connect three lengths of pipe (equal or
un-equal diameter) comes in a number of sizes, it also
used to connect a reduced branch line.

Union:
Union is used to connect two pipe lengths together
comes in a number of sizes. It is used where a pipe line
is opened to replace a damaged section or to cut into an
existing line.
Reducer:
Reducer is used to join two different size pipes in a
straight way.

Socket:
Socket is used to connect two pipe lengths together
comes in a number of sizes.

Nipple:
A nipple is used between two fittings.

Bush:
A bush is used to connect the male end of a pipe to a
fitting of larger or smaller diameter pipe.

Adapter (male/female):
An adapter is used to connect the threaded end of a pipe
to a fitting.

Plug:
Plug is used to seal off a GI fitting.

Cap:
Cap is used to seal off pipe end.

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 Self-Check Quiz 3.1.1

Read the following statements and write/mark true or false accordingly:

No. Description True False

1. Elbow is used to join three lengths of pipe (equal or un-equal diameter)
2. Tee is used to connect two lengths of pipe (equal or un-equal diameter)
comes in a number of sizes
3. Union is used, where a pipe line is opened to replace a damaged section or
to cut into an existing line
4. Reducer is used to join two different size pipes in a straight way
5. Socket is used to connect three pipe lengths together comes in a number of
sizes
6. A nipple is used between two fittings
7. A bush is used to connect the male end of a pipe to a fitting of larger or
smaller diameter pipe
8. An adapter is used to connect the threaded end of a pipe to a fitting
9. Cap is used to seal off a GI fitting
10. Plug is used to seal off pipe end

Information Sheet 3.1.6

Learning Objective: to identify and uses of different types of valves in the workplace.

 Valves: in a plumbing system valves are used to start or stop liquid, steam or gas flow.

Stopcock:
Stopcock is used to shut off the flow of water in
a pipe

Gate valve:
Gate valve is used to start or stop liquid, steam
or gas flow.

Butterfly valve:
A butterfly valve is a valve that isolates or
regulates the flow of a fluid.

Ball valve:
This is a valve with a spherical disc, the part of
the valve which controls the flow through it.

Check valve:
This type of valve allows to flow only in one
direction.

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 Globe valve:
Globe valves are mainly supply to stop or
connect the medium in the pipelines.

Non-return valve:
Non-return valves are used to allow the flow
only in one direction.

Float valve:
A float valve is used inside the flashing tank to
fill and control water in tank.

Foot valve:
Foot valves are always fitted with filters or
strainers.

Pressure reducing valve:

It is installed to maintain a pre-set (desired)
constant pressure in the downstream of the
valve.

Pressure relief valve:

In a water supply system pressure relief valve
is used to prevent or to relieve excessive high
pressure in piping or in any appliances.

Safety Valve:
This is a safety device which automatically
controls the pressure and discharges certain
amount of fluid by itself without any electric
power support.

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 Self-Check Quiz 3.1.2

Check your understanding by answering the following questions:

No. Identify the valves given below Name of the valve

1

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 Learning Outcome 3.2 - Perform Pipe Cutting Operation

Contents:

▪ GI, PPR and HDP pipes and their uses

▪ Clamping device (pipe stand, bench vice (w/v blocks), vice grip, pipe chuck, threading machine chucks)
▪ Cutting tools
▪ Tolerance

Assessment criteria:

1. G.I/PPR/HDP pipes are measured and marked as per plan/drawing specification.

2. G.I/PPR/HDP pipes are clamped using appropriate clamping device.
3. G.I/PPR/HDP pipes are cut using appropriate cutting tool.
4. G.I/PPR/HDP pipes are cut within the specified dimension and considering specified tolerance.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, sealant (plastic, rubber,
synthetic) thread tape (Teflon), welding rod, masking tape
▪ Pipe: GI, PPR and HDP pipes (different diameter)

Learning Activity 3.2.1

Learning Activity Resources/Special Instructions/References

Perform pipe cutting operation ▪ Information Sheets: 3.2.1, 3.2.2

▪ Self-Check Quiz: 3.2.1
▪ Answer Key: 3.2.1
▪ https://www.youtube.com/watch?v=RMvw5m1nNx4

Information Sheet 3.2.1

Learning Objective: to identify and uses of different types of pipes in a workplace.

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 Pipes:

Same as Information Sheet 2.3.4 – Gather Tools, Equipment and Materials (page 42 - 43)

Information Sheet 3.2.2

Learning Objective: to identify and uses of measuring tools, marking tools, clamping device and cutting
tools in a workplace.

 Measuring, Marking, Clamping and Cutting tools/devices:

Measuring Tape:
Used to measure different lengths of pipes

Steel rule:
Used to measure pipe diameter etc.

Marker pen:
Marking out on the material a required
measurement
Pipe vice:
A pipe vice is a plumbing tool used to hold pipe or
tube securely so that it can be cut or threaded.

Tripod Chain Pipe Vice

Portable Vice to clamp pipe when threading or
cutting

Single Stroke Chain Pipe Cutter:

To cut steel and cast-iron water and soil pipes

Ratchet Type Chain Pipe Cutter:

To cut steel and cast-iron water and soil pipes

Hacksaw:
Cutting GI pipe and metal material

Three Wheel Type Pipe Cutter:

The three-wheel type pipe cutter has two high
speed steel wheels positioned in the body of the
cutter and one high speed wheel position in the
adjustable slide
Roller Pattern Pipe Cutter:
The roller pattern cutter has one high speed
wheel positioned in the body and two rollers
positioned in the adjustable slide.

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 PPR pipe cutter:
The PPR pipe cutter is used to cut PPR pipe.

 Tolerance:
In Engineering, tolerance is the permissible limit
or limits of variation in a physical dimension.

 To cut pipes the following activities need to be done:

1. Select tools, materials and drawing
2. Use appropriate personal protective equipment (PPE)
3. Place pipe vice on the ground
4. Mark the cutting point of the pipe as per measurement using marker pen
5. Fix the pipe firmly with the grip of pipe vice
6. Cut the pipe using pipe cutter or hack saw or hand saw depending on the types of pipe
7. Remove pipe from the pipe vice
8. Clean the work place
9. Restore all tools and materials

Self-Check Quiz 3.2.1

Check your understanding by answering the following questions:

Match the pictures shown in column A to the names in column B:

No Column A No Column B

1 i Steel rule

ii Measuring Tape
2

3 iii PPR pipe cutter

4 iv Tripod Chain Pipe Vice

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 5 v Pipe vice

6 vi Ratchet Type Chain Pipe Cutter

vii Single Stroke Chain Pipe Cutter

7

viii Roller Pattern Pipe Cutter

8

ix Three Wheel Type Pipe Cutter

9

x Marker pen
10

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 JOB SHEET 3
Qualification: Plumbing

Learning unit: Perform pipe cutting operation:

Cut G I/PPR/HDP pipes
Learner name:

Personal protective Hand gloves, visibility vest, safety goggles, safety boots, hard hat and dust
equipment (PPE): mask
Materials: G I / PPR / HDP pipes, lubricant

Tools and equipment: Measuring tape, foot rule, hack saw, back saw, marker pen, pipe cutter, pipe
vice, 3-wheel type pipe cutter
Performance Criteria 1. Cut the GI / PPR/HDP pipe with a hacksaw / pipe cutter
2. Measurement error must be within approximately 2mm
3. Pipes must be cut uniformly one end to another end.
Measurement: ▪ Cut GI pipe as per drawing using hacksaw and 3-wheel type cutters.
▪ Cut PPR pipe as per drawing using hacksaw.
▪ Cut HDP pipe as per drawing using hacksaw.

Procedure: 1. Identify the type pipe required.

2. Measure, cut using a hacksaw as per measurement on drawing 2 x 450
mm lengths of 20mm ɸ GI pipe.
3. Measure, cut using a 3-wheel type pipe cutter 1 x 250mm length 20mm ɸ
PPR pipe.
4. 1 x 450 mm lengths of 20mm ɸ PPR pipe.
5. Measure, cut using a hacksaw 1 x 250mm length 20mm ɸ HDP pipe.
6. 1 x 450 mm lengths of 20mm ɸ HDP pipe. All pipes must be cut uniformly
one end to another end.
7. Measurement error must be within approx. 2mm
Learner signature: Date:

Assessor signature: Date:

Quality Assurer
Date:
signature:

Assessor remarks:

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 Individual Activity:
▪ Watch the video on ‘How to cut water supply pipes’ and summarise the key points (if facilities
available)
▪ Cut the pipes following the Job Sheet 3 (see above)

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 Learning Outcome 3.3 - Perform Pipe Threading Operation

Contents:

▪ GI, PPR and HDP pipes clamping procedure.

▪ Diestocks adjustment technique
▪ Thread cutting procedure
▪ Coolant: water, oil, air, synthetic, nitrogen
▪ Threads checking

Assessment criteria:

1. GI, PPR and HDP pipes are clamped and fixed using appropriate clamping device.
2. Diestocks are adjusted and initiated into the pipe end squarely.
3. Thread cutting is carried out on pipes in accordance to workplace procedure.
4. Coolant is used during thread cutting operation.
5. Threads are checked to conform with the specified form and measurement in accordance with
plan/drawing.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, sealant (plastic, rubber,
synthetic) thread tape (Teflon), welding rod, masking tape
▪ Pipe: GI, PPR and HDP pipes (different diameter)

Learning Activity 3.3.1

Learning Activity Resources/Special Instructions/References

Perform pipe threading ▪ Information Sheet: 3.3.1

operation ▪ https://www.wikihow.com/Thread-Pipe

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 Information Sheet 3.3.1

Learning Objective: to identify and uses of pipe vice, de burring tool, diestocks and coolant in the
workplace.

 Pipe threading activities (pictorial representation):

A. PREPARE PIPE FOR THREADING

1. Place pipe to be treaded into the pipe vice
and tighten

2. In order for the pipe die stock to get a grip it

is important to taper the pipe edge. This can
be achieved by either filing the bevel to the
edge or by using a grindstone.

B. REMOVE BURRS
3. Remove all burrs on the interior of pipe using
a round file to file off any burrs.

4. Push the reamer into the pipe, turn the

reamer clockwise in short even strokes until
the inside burrs are removed

5. Remove the outside burrs with a file if a

three-wheel cutter is used

C. CUT EXTERNAL THREAD

6. Prior to cutting the thread place some
lubricant to proposed cut area

7. Place the correct size pipe guide and die

into the diestock.
• Thread per inch (TPI) must be 14 for ½” and
¾” diameter pipes and 11 for 1-inch
diameter pipes.
8. Apply uniform pressure and turn the die
stock clockwise, proceed for about four to
five turns

9. After five turns clockwise start to rotate the

die stock in an anticlockwise direction

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 10. During the treading clear out the cuttings
from the die or blow them out with
compressed air.

11. Proceed to cut the thread until one or two

threads are visible

12. Remove the die set from the pipe checking

the cut area for any broken threads

SPECIFICATION SHEET 1

 Thread Length Data:

Same as Information Sheet 1.3.1 – Gather and check tools, equipment and materials (page 13 - 14)

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 Learning Outcome 3.4 - Assemble Pipe Run

Contents:

▪ Piping joints and fittings tightening: techniques and safety precautions

▪ Sealants: thread tape (Teflon), cement, seals (plastic, rubber, synthetic & silicone)
▪ Pipe clamps and fixtures: steel pipe hanger, plastic pipe hanger, pipe clamps (plastic, steel and rubber)
and tapes
▪ Leak and non-conformance: leak, length (dimension), pipe size, pipe offset angles, obstacles and
aesthetics/appearance
▪ Finishing: caulk, cement, paint, tiles/marble and grommet

Assessment criteria:

1. G.I/PPR/HDP pipe run is positioned on the corresponding areas as per plumbing plan.
2. Piping joints and fittings are tightened using appropriate tools and sealant.
3. Pipe clamps and fixtures along pipe run is installed in accordance with plumbing plan.
4. Leaks and non-conformance to plumbing design/plans are checked and corrected.
5. Holes and openings are filled with cement plasters and finishing.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), welding rod, masking tape, cement, sand and plumbing plan/drawing
▪ Pipe: GI, PPR and HDP pipes (different diameter)

Learning Activity 3.4.1

Learning Activity Resources/Special Instructions/References

Assemble pipe run ▪ Information Sheet: 3.4.1

▪ https://knowledge.autodesk.com/support/inventor-
products/learn-explore/

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 Information Sheet 3.4.1

Learning Objective:

▪ List out the tools, equipment and materials required for making pipe joints
▪ Explain the necessity of assemble pipe run
▪ Describe the procedure of assemble pipe run

On completion of this task you will be able to complete the following steps:

1. Collect tools, equipment and materials.

2. Cut the pipe as per required measurement with pipe cutter or hacksaw.
3. Lay down the pipes in accordance with the planned/designed pipe run.
4. Assembled and fixed the pipes and pipe fittings in accordance with planned/designed pipe run.
5. Temporarily join pipes and fittings and make sure that the pipe in the run is facing the right direction.
6. Use a felt-tip pen to make alignment marks on all the joints where the fitting must face correctly.
7. Disassemble, keeping careful track of the order of installation.
8. Apply primer to each pipe end and each fitting.
9. Apply solvent/cement and join each pipe in order.
10. Checked the pipes, fittings and pipe runs for damage/quality of work.
11. Assembled pipe runs are measured/checked within tolerable dimensions/length in accordance with
design/specification
12. Conduct leakage test using water
13. Clean the workplace
14. Restore the tools equipment and materials.

GI Pipe Joints PPR Pipe Joints

 Sealant: is a substance used to block the passage of fluids through the surface or joints or openings
in materials. It may be weak or strong, flexible or rigid, permanent or temporary. These are
not adhesives but some have adhesive qualities and are called adhesive-sealants or structural
sealants. The followings may include as sealant in plumbing works:
▪ Thread tape (Teflon)
▪ Cement
▪ Plastic based seals
▪ Rubber based seals
▪ Synthetic seals
▪ Silicon seals

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 Different types of Pipe clamps and fixtures:

In plumbing system steel, rubber and plastic made pipe clamps, fixtures and hangers are used.

Pipe strap Pipe clip Split ring hanger

Cushion clamp Split ring hanger Single hole wrap strap

Channel nut Swivel loop hanger J-hook hanger

Rowel plug Screw Concrete drilling

 Non-conformance:
▪ Leak
▪ Length (dimension)
▪ Pipe size
▪ Pipe offset angles
▪ Obstacles
▪ Aesthetics/appearance.

 Finishing materials:
▪ Caulk
▪ Cement
▪ Enamel Paint
▪ Tiles/marble
▪ Grommet

 Pipe Insulation: is thermal or acoustic insulation used on pipework. Some methods of application for
pipe insulation are as follows:
▪ Condensation control:
▪ Pipe freezing:
▪ Energy saving:
▪ Protection against extreme temperatures:
▪ Control of noise:

Individual Activity:
▪ Watch the videos on ‘How to bend PVC’ and summarise key points
▪ Watch the videos on ‘How to PPR’ and summarise key points (if facilities available)

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 Learning Outcome 3.5 - Clean and Maintain the Work Area

Same as Learning Outcome 1.5 – Clean and maintain the Work Area (page 29 - 32)

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 ANSWER KEYS

Answer Key 3.1.1

1. False
2. False
3. True
4. True
5. False
6. True
7. True
8. True
9. False
10. False

Answer Key 3.1.2

1. Stop cock
2. Gate valve
3. Butterfly valve
4. Ball valve
5. Check valve
6. Globe valve
7. Float valve
8. Foot valve

Answer Key 3.2.1

No. Name the Tools

1 ii
2 i
3 x
4 v
5 iv
6 vii
7 vi
8 ix
9 viii
10 iii

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Module 4: Carry out water supply line installation using PVC/UPVC pipes

MODULE CONTENT

Module Descriptor: This module covers the skills, knowledge and attitudes to carry out water
supply line installation using PVC/UPVC pipes which includes gathering and
inspecting of tools, equipment and materials, performing PVC/UPVC pipe
cutting operation, performing PVC/UPVC pipe run assembly, and
cleaning/maintaining the work area. It also includes information sheets, activity
sheets, job sheets, self-check quizzes and answer keys.

Nominal Duration: 44 hours

Learning Outcomes:

Upon completion of the module, the student/trainee will be able to:

4.1 Gather and inspect tools, equipment and materials

4.2 Perform PVC/UPVC pipe cutting operation
4.3 Perform PVC/UPVC pipe run assembly
4.4 Clean/maintain the work area

Performance Criteria:

1. Personal protective equipment (PPE) is selected and used.

2. Tools, equipment and materials are gathered and checked for usability.
3. PVC/UPVC pipes sizes and schedules are identified and gathered.
4. PVC/UPVC pipes are measured and marked as per plan/drawing specification.
5. PVC/UPVC pipes are clamped using appropriate clamping device.
6. PVC/UPVC pipes are cut using appropriate cutting tool.
7. PVC/UPVC pipes are cut within the specified dimension and considering specified tolerance.
8. PVC/UPVC pipe runs is positioned on the corresponding location as per plumbing plan.
9. PVC/UPVC piping joints and fittings are assembled using appropriate tools and sealant.
10. Pipe clamps and fixtures along pipe runs are installed in accordance with plumbing plan.
11. Leaks and non-conformance to plumbing design/plans are checked and corrected.
12. Holes and openings are filled with cement plasters and finishing.
13. Plumbing tools/equipment is cleaned and maintained.
14. Work area is cleaned and waste materials are disposed of in accordance with workplace
requirements.

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 Learning Outcome 4.1 - Gather and Inspect Tools, Equipment and Materials

Contents:

▪ Names of personal protective equipment (PPE) and their uses: safety helmet, safety shoes, hand
gloves, safety glasses, safety belt, apron, dust mask, ear plug
▪ List of main tools, equipment and materials uses
▪ Different sizes of PVC/UPVC pipes with uses

Assessment criteria:

1. Personal protective equipment (PPE) is selected and used.

2. Tools, equipment and materials are gathered and checked for usability.
3. PVC/UPVC pipes sizes and schedules are identified and gathered.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, sealant (plastic, rubber,
synthetic) thread tape (Teflon), welding rod, masking tape
▪ Pipe: PVC/UPVC pipes (different diameter)

Learning Activity 4.1.1

Learning Activity Resources/Special Instructions/References

Gather and check tools, ▪ Information Sheets: 4.1.1, 4.1.2, 4.1.3, 4.1.4, 4.1.5, 4.1.6
equipment and materials ▪ Self-Check Quiz: 4.1.1
▪ Answer Key: 4.1.1
▪ https://www.plumbingsupply.com/tools.html
▪ https://www.homedepot.com/b/Plumbing-Plumbing-Tools/N-
5yc1vZbqlq

Information Sheet 4.1.1

Learning Objective: to identify and uses of the personal protective equipment in the workplace.

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 Personal Protective Equipment (PPE):

Same as Learning Outcome 1.1.1 – Gather and check tools, equipment and materials (page 8 - 9)

Information Sheet 4.1.2

Learning Objective: to identify, uses and check tools, equipment and materials in plumbing works.

 Tools and equipment:

Same as Information Sheet 1.1.2 – Gather and check tools, equipment and materials (page 10 - 12)

Information Sheet 4.1.3

Learning Objective: to identify, uses and check tools, equipment and materials in plumbing works.

 Tools and equipment:

Same as Information Sheet 1.1.3 – Gather and check tools, equipment and materials (page 13- 14)

Information Sheet 4.1.4

Learning Objective: to identify, uses and check tools, equipment and materials in plumbing works.

 Tools and equipment:

Same as Information Sheet 1.1.4 – Gather and check tools, equipment and materials (page 14 - 15)

Same as Information sheet: 1.1.4 of module-1: Performing pipe threading operation

Information Sheet 4.1.5

Learning Objective: to identify and uses of different types of plumbing fittings in the workplace.

 Fittings: are used in pipe systems to connect straight pipes, adapt to different sizes or shapes and
for other purposes.

Elbow:
Elbow is used to join two lengths of pipe (equal or
un-equal diameter).

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 Bend:
Bend is used to join two lengths of pipe (equal or
un-equal diameter).

Tee (T):
Tee is used to connect three lengths of pipe
(equal or un-equal diameter) comes in a number
of sizes, it also used to connect a reduced branch
line.
Union:
Union is used to connect two pipe lengths
together comes in a number of sizes. It is used
where a pipe line is opened to replace a damaged
section or to cut into an existing line.
Reducer:
Reducer is used to join two different size pipes in
a straight way.

Socket:
Socket is used to connect two pipe lengths
together comes in a number of sizes.

Nipple:
A nipple is used between two fittings.

Bush:
A bush is used to connect the male end of a pipe
to a fitting of larger or smaller diameter pipe.

Adapter (male/female):
An adapter is used to connect the threaded end
of a pipe to a fitting.

Plug:
Plug is used to seal off a pipe fitting.

Cap:
Cap is used to seal off pipe end.

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 Self-Check Quiz 4.1.1

Check your understanding by answering the following questions:

Read the following statements and write/mark true or false accordingly:

No. Description True False

1. Elbow is used to join three lengths of pipe (equal or un-equal diameter)
2. Tee is used to connect two lengths of pipe (equal or un-equal diameter)
comes in a number of sizes
3. Union is used, where a pipe line is opened to replace a damaged section or
to cut into an existing line
4. Reducer is used to join two different size pipes in a straight way
5. Socket is used to connect three pipe lengths together comes in a number of
sizes
6. A nipple is used between two fittings
7. A bush is used to connect the male end of a pipe to a fitting of larger or
smaller diameter pipe
8. An adapter is used to connect the threaded end of a pipe to a fitting
9. Cap is used to seal off a pipe fitting
10. Plug is used to seal off pipe end

Information Sheet 4.1.6

Learning Objective: to identify and uses of different types of valves in a workplace.

 Valves:

Same as Information Sheet 3.1.6 – Gather and Inspect Tools, Equipment and Materials (page 54 - 55)

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 Learning Outcome 4.2 - Perform PVC/UPVC Pipe Cutting Operation

Contents:

▪ PVC/UPVC pipes and uses

▪ Clamping device
▪ Cutting tools
▪ Tolerance

Assessment criteria:

1. PVC/UPVC pipes are measured and marked as per plan/drawing specification.

2. PVC/UPVC pipes are clamped using appropriate clamping device.
3. PVC/UPVC pipes are cut using appropriate cutting tool.
4. PVC/UPVC pipes are cut within the specified dimension and considering specified tolerance.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), masking tape and plumbing plan/drawing
▪ Pipe: PVC/UPVC pipes (different diameter)

Learning Activity 4.2.1

Learning Activity Resources/Special Instructions/References

Perform PVC/UPVC pipe cutting operation ▪ Information Sheets: 4.2.1, 4.2.2

▪ Job Sheet 4
▪ Self-Check Quiz: 4.2.1
▪ Answer Key: 4.2.1
▪ https://www.youtube.com/watch?v=_D8wtNYeX40
▪ https://www.instructables.com/id/Tips-on-Cutting-
PVC-Pipe/

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 Information Sheet 4.2.1

Learning Objective: to identify and uses of different types of pipes in the workplace.
 Pipes:

Same as Information Sheet 2.3.4 – Gather Tools, Equipment and Materials (page 42 - 43)

Information Sheet 4.2.2

Learning Objective: to identify and uses of measuring tools, marking tools, clamping device and cutting
tools in the workplace.

 Measuring, Marking, Clamping and Cutting tools/devices:

Same as Information Sheet 3.2.2 – Perform Pipe Cutting Operation (page 58 - 59)

 Tolerance:

Same as Information Sheet 3.2.2 – Perform Pipe Cutting Operation (page 58 - 59)

 To cut pipes the following activities to be done:

1. Collect tools, materials and drawing.

2. Use appropriate personal protective equipment (PPE).
3. Place pipe vice on the ground.
4. Mark the cutting point of the pipe as per measurement using marker pen.
5. Fix the pipe firmly with the grip of pipe vice.
6. Cut the pipe using pipe cutter or hack saw or hand saw depending on the types of pipe.
7. Remove pipe from the pipe vice.
8. Clean the work place.
9. Restore all tools and materials.

 Pipe cutting activities (pictorial representation):

To measure the cutting length of the PVC / uPVC pipes

take the length that you will require to cut, minus the
length of the fitting and add the length that the pipe will
thread or join into the fitting.

This will give you the correct cut length. Mark this on the
different pipes to be cut.

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 Transfer the mark around the circumferance of the
different pipes

Start cut by carefully placing the hacksaw blade on the

mark and drawing back. Pressure should be applied on
the forward stroke and released on the backward stroke
and strokes should be slow and even

Cut with a backsaw. When top of backsaw

touches the "top" of the pipe, turn it over to finish cutting.

Using the scissor type pipe cutter squeeze the handles

together to cut the pipe.

To cut PVC pipe place the pipe cutter and secure in

position of the marked measurement turn and tighten
every couple of turns until the pipe is eventually cut
through.

Self-Check Quiz 4.2.1

Check your understanding by answering the following questions:

No. Description Name of the tool

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 5

10

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 JOB SHEET 4
Qualification: Plumbing

Learning unit: Perform PVC/UPVC pipe cutting operation

Learner name:

Personal protective Hand gloves, visibility vest, safety goggles, safety boots, hard hat and dust
equipment (PPE): mask
Materials: PVC / UPVC pipes

Tools and equipment: Measuring tape, foot rule, hack saw, back saw, marker pen, pipe cutter, tube
vice
Performance Criteria 1. Cut the PVC / UPVC pipe with a hacksaw / pipe cutter
2. Measurement error must be within approximately 2mm
3. Pipes must be cut uniformly one end to another end.
Measurement: Cut PVC / UPVC pipe as per drawing using hacksaw or pipe cutter.

Procedure: 1. Identify the type pipe required.

2. Measure, cut using a 3-wheel type pipe cutter 1 x 250mm length 20mm ɸ
PVC/UPVC pipe.
3. 1 x 450 mm lengths of 20mm ɸ PVC/UPVC pipe.
4. Measure, cut using a hacksaw 1 x 250mm length 20mm ɸ PVC/UPVC
pipe.
5. 1 x 450 mm lengths of 20mm ɸ PVC/UPVC pipe. All pipes must be cut
uniformly one end to another end.
6. Measurement error must be within approx. 2mm

Learner signature: Date:

Assessor signature: Date:

Quality Assurer
Date:
signature:

Assessor remarks:

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 Individual Activity:
▪ Watch the video on ‘How to cut water supply pipes’ and summarise the key points (if facilities
available).
▪ Cut the pipes following the standard method and Job Sheet 4 (see above)

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 Learning Outcome 4.3 - Perform PVC/UPVC Pipe Run Assembly

Contents:

▪ Piping joints and fittings tightening: techniques and safety precautions

▪ Sealants: thread tape (Teflon), cement, seals (plastic, rubber, synthetic & silicone)
▪ Pipe clamps and fixtures: steel pipe hanger, plastic pipe hanger, pipe clamps (plastic, steel and rubber)
and tapes
▪ Leak and non-conformance: leak, length (dimension), pipe size, pipe offset angles, obstacles and
aesthetics/appearance
▪ Finishing: caulk, cement, paint, tiles/marble and grommet

Assessment criteria:

1. PVC/UPVC pipe runs is positioned on the corresponding location as per plumbing plan.
2. PVC/UPVC piping joints and fittings are assembled using appropriate tools and sealant.
3. Appropriate curing time for sealant is done to create strong bond.
4. Pipe clamps and fixtures along pipe runs are installed in accordance with plumbing plan.
5. Leaks and non-conformance to plumbing design/plans are checked and corrected.
6. Holes and openings are filled with cement plasters and finishing.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), masking tape and plumbing plan/drawing
▪ Pipe: PVC/UPVC pipes (different diameter)

Learning Activity 4.3.1

Learning Activity Resources/Special Instructions/References

Perform PVC/UPVC pipe run ▪ Information Sheet: 4.3.1
assembly ▪ http://www.iitk.ac.in/ce/test/IS-codes/is.13593.1992.pdf

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 Information Sheet 4.3.1

Learning Objective: list the tools, equipment and materials required for making pipe joints, explain the
necessity of assemble pipe run, and describe the procedure of assemble pipe run.

 PVC/UPVC Pipe Joints activities (pictorial representation)

A. Bell Joint in PVC/UPVC Pipes using the Traditional Method:

1. To form a bell in a UPVC pipe the traditional method is being

used in Bangladesh that is to heat the pipe on an open fire.

2. The pipe is held over the heat on the outside to start the
softening the area to form the bell in the pipe

3. The pipe is held over the heat at angle so as to enable the

heat to be transferred to the inside of the pipe, to start the
softening the area to form the bell in the pipe

4. Once the pipe has become softened in the area required for
the bell bring the other pipe closer ready to form the bell
before the heat is lost.

5. Taking the other pipe insert the pipe’s end into the softened
section of the heated pipe, thereby expanding the pipe to bell
out to the required depth.

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 6. Remove the pipe and allow the heated pipe to harden and
retain the bell shape required.

B. Bell Joint in PVC/UPVC Pipes using the Heat Gun:

1. Take the heat gun and after setting the temperature on high
position the gun transfers the heat over the mouth of the pipe

2. Transfer the heat gun to inside area of the pipe and allow the
pipe to soften in the area of the proposed bell joint.

3. Remove the heat gun from the inside to concentrate on the

surrounding exterior of the proposed area of the bell joint

4. Insert the Joining pipe into the softened area of the pipe end
and push until the required depth of the bell is achieved.

5. Remove the pipe to allow the bell joint area to harden and
set, ready for assembly.

6. To join the pipe and fitting a coat of primer is applied to the

outside of the pipe and the inside of the fitting

7. Solvent cement is applied to the outside of the pipe and

inside the fitting

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 8. The pipe and fitting are pushed together and given a quarter
turn and held for 15 seconds to set

On completion of this task you will be able to complete the following steps:

1. Collect tools, equipment and materials.

2. Cut the pipe as per required measurement with pipe cutter or hack saw.
3. Lay down the pipes in accordance with the planned/designed pipe run.
4. Assembled and fixed the pipes and pipe fittings in accordance with planned/designed pipe run.
5. Temporarily join pipes and fittings and make sure that the pipe in the run is facing the right direction.
6. Use a felt-tip pen to make alignment marks on all the joints where the fitting must face correctly.
7. Disassemble, keeping careful track of the order of installation.
8. Apply primer to each pipe end and each fitting.
9. Apply solvent/cement and join each pipe in order.
10. Checked the pipes, fittings and pipe runs for damage/quality of work.
11. Assembled pipe runs are measured/checked within tolerable dimensions/length in accordance with
design/specification.
12. Conduct leakage test using water.
13. Clean the workplace.
14. Restore the tools equipment and materials.

PVC/UPVC Pipe Joints

 Sealant:

Same as Information Sheet 3.4.1 – Assemble Pipe Run (page 66 - 67)

 Different types of Pipe clamps and fixtures:

Same as Information Sheet 3.4.1 – Assemble Pipe Run (page 66 - 67)

 Non-conformance:

Same as Information Sheet 3.4.1 – Assemble Pipe Run (page 66 - 67)

 Finishing:

Same as Information Sheet 3.4.1 – Assemble Pipe Run (page 66 - 67)

 Pipe Insulation:

Same as Information Sheet 3.4.1 – Assemble Pipe Run (page 66 - 67)

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 Learning Outcome 4.4 - Clean and Maintain the Work Area

Same as Learning Outcome 1.5 – Clean and maintain the Work Area (page 29 - 32)

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 ANSWER KEYS

Answer Key 4.1.1

1. Drilling holes in masonry, steel and timber surfaces.

2. Cutting brickwork and steel grinding steel surfaces.
3. Fusion welding of PPR pipes and fittings.
4. Heat up area to be worked on.
5. Cut PPR pipes to the required length by cutter.

Answer Key 4.2.1

1. Measuring Tape
2. Steel rule
3. Marker pen
4. Pipe vice
5. Tripod Chain Pipe Vice
6. Single Stroke Chain Pipe Cutter
7. Ratchet Type Chain Pipe Cutter
8. Three Wheel Type Pipe Cutter
9. Roller Pattern Pipe Cutter
10. PPR pipe cutter

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Module 5: Carry out sewer pipeline installation

MODULE CONTENT

Module Descriptor: This module covers the skills, knowledge and attitudes to carry out sewer pipe
line installation which includes planning out for sewer pipe line installation,
gathering tools, equipment and materials, carrying out trenching and bedding
works, laying sewer pipe, finishing final pipe run, and cleaning and maintaining
the work area. It also includes information sheets, activity sheets, job sheets,
self-check quizzes and answer keys.

Nominal Duration: 28 hours

Learning Outcomes:

Upon completion of the module, the student/trainee will be able to:

5.1 Plan out for sewer pipe line installation

5.2 Gather tools, equipment and materials
5.3 Carry out trenching and bedding works
5.4 Lay sewer pipe
5.5 Finish final pipe run
5.6 Clean/maintain the work area

Performance Criteria:

1. Work activities are confirmed by making site visit/inspection.

2. Pipe run and elevation are identified in accordance with plumbing plans/specification.
3. Personal protective equipment (PPE) is selected and used.
4. Tools, equipment and materials are gathered and checked for usability.
5. Size of trench/excavation is made in accordance with workplace and plumbing plan requirement.
6. Grade/slope/pitch of trench is applied in accordance with workplace and plumbing plan
requirement.
7. Bedding materials are laid in accordance to workplace and plumbing plan requirement.
8. Sewer pipes are laid on the trench in accordance with workplace and plumbing plan requirements.
9. Bell ended sewer pipes are laid by placing the bell end at the uphill side of the pipe run.
10. PVC sewer pipes are installed by using appropriate sealing/gluing materials.
11. Fittings are installed to complete the final run of the sewer pipe installation.
12. Final pipe run is checked for leaks and non-conformance to workplace and plumbing line
requirements.
13. Covering materials are laid on top of the sewer pipe run in accordance with workplace and
plumbing plan requirement.
14. Plumbing tools/equipment is cleaned and maintained.
15. Work area is cleaned and waste materials are disposed in accordance with workplace
requirements.

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 Learning Outcome 5.1 - Plan Out for Sewer Pipeline Installation

Contents:

▪ Work activities: area cleaning, traffic re-routing, trench/excavation, tools and equipment gathering,
materials gathering and stacking, concreting works
▪ Pipe line slope/pitch

Assessment criteria:

1. Work activities are confirmed by making site visit/inspection.

2. Pipe run and elevation are identified in accordance with plumbing plans/specification.
3. Pipe line slope/pitch is determined in accordance with plumbing plans/specification and result of site
visit.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine.
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), welding rod, masking tape, cement, sand and plumbing plan/drawing.
▪ Pipe: sewer pipes (different diameter)

Learning Activity 5.1.1

Learning Activity Resources/Special Instructions/References

Plan out for sewer pipe line ▪ Information Sheet: 5.1.1

installation ▪ Self-Check Quiz: 5.1.1
▪ Answer Key: 5.1.1
▪ https://www.piercecountywa.org/DocumentCenter/View/886/P02-
Building

Information Sheet 5.1.1

Learning Objective: to confirm the work activities related to plan out for sewer pipe line installation done in
the workplace.

 Work activities: needed to be confirmed by making site visit/inspection when plan out for sewer pipe
line installation in the workplace are:

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 ▪ Area clearing: The entire area of the sewer pipe line installation must be cleared to avoid obstacles
and free to work as per standard practice.
▪ Traffic re-routing: Signs and signals to be displayed and alternate routes to be showed so that
traffic can move safely.
▪ Trenching/excavation: Follow the standard procedure of lay outing for trenching and excavation
works in accordance with workplace and plumbing plan requirement.
▪ Tools and equipment gathering: Collect and gather required quantity of tools and equipment and
checked for usability.
▪ Materials gathering and stacking: Gather quality materials and stack suitable places for uses.
▪ Concreting works: Prepare concrete as per standard procedure and place/apply in accordance with
workplace and plumbing plan requirement.

 Plumbing plans:

▪ Plumbing and piping plans clearly display where the fixtures, pipes and valves are.
▪ The job of the drain-waste part of the system is to carry waste water and sewage from sinks,
bathtubs, showers, toilets and water-using appliances such as dishwashers and washing machines
and deliver those wastes to the septic tank or public sewer.

 Sewer pipe runs and elevation:

▪ To start, you must determine how far the pipe needs to go and determine the elevation at which
the pipe will be connected to the specific fixture or if it will be connected to another pipe.
 Sewer pipe line slope/pitch:
▪ Be careful, a drop greater than ¼” per foot is not adequate as water will flow faster than solids.
▪ The recommended pitch for 4" pipe is 1/8" to 1/4" per foot.

Self-Check Quiz 5.1.1

Write the correct answer for the following:

1. What is the recommended pitch per foot for 4" pipe?

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 Learning Outcome 5.2 - Gather Tools, Equipment and Materials

Contents:

▪ Names of personal protective equipment (PPE) and their uses: safety helmet, safety shoes, hand
gloves, safety glasses, safety belt, apron, dust mask, ear plugs
▪ List of main tools, equipment and materials uses
▪ Sewer pipe sizes and uses

Assessment criteria:

1. Required tools, equipment and materials are identified in accordance with plumbing plan and result of
site visit/inspection.
2. Sewer pipe sizes/schedules are identified and gathered.
3. Personal protective equipment (PPE) is selected and used.
4. Tools, equipment and materials are gathered and checked for usability.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), welding rod, masking tape and plumbing plan/drawing
▪ Pipe: Sewer pipes (different diameter)

Learning Activity 5.2.1

Learning Activity Resources/Special Instructions/References

Gather tools, equipment and materials ▪ Information Sheets: 5.2.1, 5.2.2, 5.2.3, 5.2.4, 5.2.5
▪ Self-Check Quiz: 5.2.1
▪ Answer Key: 5.2.1

Information Sheet 5.2.1

Learning Objective: to identify and uses of the personal protective equipment in the workplace.

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 Personal Protective Equipment (PPE):
Same as Information Sheet 1.1.1 – Gather and Check Tools, Equipment and Materials (page 8 - 9)

Information Sheet 5.2.2

Learning Objective: to identify, uses and check tools, equipment and materials in plumbing works.

 Tools and equipment:

Same as Information Sheet 1.1.2 – Carry out steel pipe cutting operations (page 10 - 12)

Information Sheet 5.2.3

Learning Objective: to identify, uses and check tools, equipment and materials in plumbing works.

 Tools and equipment:

Same as Information Sheet 1.1.3 – Carry out thread cutting operation (page 13 - 14)

Information Sheet 5.2.4

Learning Objective: to identify, uses and check tools, equipment and materials in plumbing works.

Materials:
 Sewer: A sanitary sewer or foul sewer is an underground carriage system specifically for
transporting sewage from houses and commercial buildings through pipes to treatment or disposal.
Sanitary sewers are part of an overall system called sewerage or sewage system.
 Types of sewers according to material:
1. PVC sewer
2. UPVC sewer
3. Cast Iron (CI) sewer
4. Plain concrete and reinforced cement concrete sewers
5. Asbestos Cement (AC) sewer

1 PVC (polyvinyl chloride) is a common, strong but

lightweight plastic used in construction

2 uPVC pipe: If no plasticizers are added, it is known as

uPVC (un-plasticized polyvinyl chloride), rigid PVC.

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 3 CI (Cast Iron) pipes: Used as a pressure pipe for
transmission of water, gas and sewage and as a water
drainage pipe

4 Concrete pipes: For heavy drainage water disposal,

concrete pipes of large diameters are used. Smaller
diameter pipes are used for small flows.

5 Asbestos Cement (AC) pipes: This kind of pipes are made

from a mixture of Portland cement and asbestos fibre and
used as vent pipes, soil pipes and rain water pipes. They
are very cheap compared to all but they can break easily.

Self-Check Quiz 5.2.1

Write the correct answer for the following:

1. Write the full name of PVC pipe.
2. Write the full name of UPVC pipe.
3. Write the full name of CI pipe.

Information Sheet 5.2.5

Learning Objective: to identify and uses of different types of plumbing fittings in the workplace.

 Fittings: are used in pipe systems to connect straight pipes, adapt to different sizes or shapes and for
other purposes.

PVC/UPVC pipe fittings:

Avaiable in different types and sizes, which are
used for PVC/UPVC pipe connections

Galvanized pipe (GI) fittings:

2 Avaiable in different types and sizes, which are
used for GI pipe connections

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 Cast iron pipe fittings:
Avaiable in different types and sizes, which are
used for CI pipe connections

Concrete pipe fittings:

Avaiable in different types and sizes, which are
used for concrete pipe connections

Elbow/Bend:
This is most common types of pipe fitting used in plumbing works.

90 degrees 45 degrees
Tee (T) joint:
This is also common types of pipe fitting used in
plumbing works. It is available in equal or
unequal sizes.

Wye (Y)- joint:

This is a common type of pipe fitting used in sewer line and available in equal or unequal sizes.

Croos(X) joint:
This is also common type of pipe fitting used in
plumbing works and also available in equal or
unequal sizes.

Offset joint:
This is used in plumbing works with overcoming
offsets in the alignment.

Grating:
Gratings over drains and air vents are used
as filters, to block movement of large particles
and to allow movement of small particles.

Cowel:
This is used on top of the soil/waste/vent pipe
which cover the pipe and controls the way
gas/smoke flows out only.

Coupler:
It is used in pipe systems to connect
straight pipe, adapt to different sizes or shapes
and for other purposes, such as regulating
fluid flow.

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 Socket:
It is also used in pipe systems to connect
straight pipe, adapt to different sizes or shapes
and for other purposes, such as regulating
fluid flow.
Multi-Croos(X) joint:
This is used in plumbing works and also available
in equal or unequal sizes.

Traps:
In plumbing, a trap is a device which has a shape that uses a bending path to capture water to
prevent sewer gases from entering buildings. In domestic applications, traps are typically U, S, or P-
shaped pipe located below or within a plumbing fixture. The most common of these traps in houses is
referred to as a P-trap.

S-shaped P-shaped U-shaped

Do you know?
1. All fittings to be used as per instruction of the manufacturer.
2. Combination of different fittings (materials) should be avoided.

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 Learning Outcome 5.3 - Carry Out Trenching and Bedding Works

Contents:

▪ Trench/excavation layout procedure

▪ Grade/slope of trench: methods of determining and applying
▪ Bedding materials: sand, gravel, concrete and bricks

Assessment criteria:

1. Trench/excavation area/line is laid out in accordance with plumbing plan and result of site visit.
2. Size of trench/excavation is made in accordance with workplace and plumbing plan requirement.
3. Grade/slope of trench is applied in accordance with workplace and plumbing plan requirement.
4. Bedding material is laid in accordance to workplace and plumbing plan requirement.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: Measuring tape (5m), steel rule, spirit level, shovel, spade, cold chisel, hammer, string lines,
▪ Equipment: trenching/digging equipment
▪ Materials: marking pen, pencil, marking powder, masking tape, bedding materials and plumbing
plan/drawing

Learning Activity 5.3.1

Learning Activity Resources/Special Instructions/References

Carry out trenching and bedding works ▪ Information Sheet: 5.3.1

▪ Self-Check Quiz: 5.3.1
▪ Answer Key: 5.3.1
▪ http://www.mbwaterservicesboard.ca/pubs/specs/022180-
pipe-excavatio

Information Sheet 5.3.1

Learning Objective: to carry out trenching and bedding works for sewer pipe line installation in the
workplace.

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 Important activities:
To carry out trenching and bedding works the following activities need to perform as per plumbing plans
and requirements:
1. Collect and study the plumbing plans/specification and visit the site.
2. Calculate the pipe runs according to planned route.
3. Lay out for trenching and excavation works.
4. Size of the trench/excavation in accordance to job requirement.
5. Protect the sides of trench to avoid sliding or erosion (if happen).
6. Apply grade/slope of trench as per specification and job requirement.
7. Spread bedding materials for safety of sewer pipe.
 Trench and Bedding:
▪ Start by opening the trench. Be careful once the trench is open and follow all safety measures to
protect workers inside and outside the trench.
▪ Remove all loose dirt at the trench bottom and grade the trench bottom so the pipe could be
installed over a smooth surface.
▪ Sometimes it needs to place a bedding material to provide additional support to the sewer pipe, to
reduce the possibility of ‘sag’ after the trench has been backfilled.
▪ Sand is the best material to use for bedding, but brick chips or gravel can also be used for bedding.
▪ Be careful on not to use sharp stone or other materials that sometimes can punctuate the sewer
pipe.

 Grade/Slope:
▪ Proper slope of gravity drainage and sewer pipes is important so that liquids flow smoothly, which
helps transport solids away without clogging.
▪ A pipe that is too flat will prevent waste from flowing away. It is also commonly thought that pipes
that are too steep will allow liquids to flow so quickly that solids will not be carried away.
 Standard horizontal drainage pipe slope:
▪ According to the International Plumbing Code, drainage pipes should be run with a uniform slope
at the following minimum pitches:

Pipe diameter Minimum slope

2 ½" or smaller 1/4" per foot

3" to 6" 1/8" per foot

8" or larger 1/16" per foot

 Large diameter sewer pipe slopes:

▪ Large sewer lines require calculations to determine the proper pitch. In general, sewer mains
should be designed to have a flow rate of 2 feet-per-second during peak dry-weather conditions.
▪ Flow rates are usually kept below 10 feet per second. For floor rates greater than 10 feet-per-
second, the pipes should be designed with anchors or other means of preventing the pipe from
shifting.

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 Bedding and support materials:
▪ It is important in determining and ordering the correct quantities of bedding material for the sanitary
drainage systems in a workplace.
▪ If the correct procedures are not adhered to drainage materials can be damaged and leaking may
result in structural damage to buildings.
▪ Drainage systems must be installed in stable ground that is free from rocks and sharp objects.
▪ When laying pipes in loam, rock, shale, gravel or clay ground the pipe must be laid on a suitable
bedding material such as:
- Sand
- Broken brick/crushed stone
- Cement mortar
- Cement concrete
• The same material used for bedding can be used for side support and for overlay zones.

Concrete bedding

Self-Check Quiz 5.3.1

Read the following statements and write/mark true or false accordingly:

No. Description True False

1. Drainage systems must be installed in stable ground that is free from rocks
and sharp objects.
2. According to the International Plumbing Code, drainage pipes should be run
with a uniform slope/pitch for 2½ inches diameter is 1/4" per foot.
3. According to the International Plumbing Code, drainage pipes should be run
with a uniform slope/pitch for 3 to 6 inches diameter is 1/2" per foot.
4. According to the International Plumbing Code, drainage pipes should be run
with a uniform slope/pitch for 8 inches or larger diameter is 1" per foot.
5. The best material to use for bedding material is sand.

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 Learning Outcome 5.4 - Lay Sewer Pipe

Contents:

▪ Sewer pipe laying procedure

▪ Bell ended sewer pipes
▪ PVC sewer pipes
▪ Alignment and pipe elevation
▪ Sealing/gluing materials: solvents, cement, sealant (plastic, rubber, synthetic silicone, PVC primer

Assessment criteria:

1. Sewer pipes are laid on the trench in accordance with workplace and plumbing plan requirements.
2. Bell ended sewer pipes are laid by placing the bell end at the uphill side of the pipe run.
3. PVC sewer pipes are installed by using appropriate sealing/gluing materials.
4. Alignment and pipe elevation are checked in accordance to workplace and plumbing plan requirements.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, spirit level, shovel, spade, cold chisel, hammer, string lines,
▪ Equipment: trenching/digging equipment
▪ Materials: marking pen, pencil, marking powder, masking tape and plumbing plan/drawing

Learning Activity 5.4.1

Learning Activity Resources/Special Instructions/References

Lay sewer pipe ▪ Information Sheet: 5.4.1, 5.4.2

▪ Self-Check Quiz: 5.4.1
▪ Answer Key: 5.4.1
▪ https://www.ehow.com/how_5063577_lay-sewer-pipe.html

Information Sheet 5.4.1

Learning Objective: to lay sewer pipe on the trench in the workplace.

 Tips for installation of new sewer lines

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 ▪ Map sewer line route: Check where the underground hazards are located and then map out the
route of the sewer lines. This will help to not only see where it will go, but also plan for materials
will need.
▪ Lay out pipes: Lay out the pipes according to plan before make any permanent connections. Once
everything fits in place, then can cement the pipes together.
▪ Keep proper grade: When the grade of the ground is sloping downward do not need to have any
type of extra help for the sewage to flow to the tank. If the land is level, then dig trench for the sewer
lines at a gradual slope so the waste will naturally travel in the direction towards the tank and not
sit still in the pipes.
▪ Install plenty of traps: Set sufficient numbers of traps at various places along the sewer line so
that a plumber can access the pipes to flush them out.
▪ Insulate pipes: The sewer pipe will remain safe and avoid any damage if insulate the pipes with
sand or brick/stone chips, instead of placing the sewer lines on the bare ground.
 How to Install a Sewer Pipe?
▪ A sewer pipe needs to be installed carefully with adequate slope.
▪ The installation methods and processes are almost identical for all types of pipe or culvert materials.
▪ Depending on the sewer pipe material, things could be easier or more complicated because the
installation process might be more challenging, more equipment and labour might be needed.
 Lay the sewer pipe:
▪ Once the select portion of trench has been prepared, lay the sewer pipe in the trench.
▪ It is recommended to start at the lower end of the pipe run, up to the higher elevation.
▪ If the sewer pipe has a bell end; the bell end must be placed on the uphill side of the pipe run,
reducing the possibility of leakage.
▪ Insert the male end of the pipe into the female end and twist a little bit.
▪ Install a string along the pipe run to ensure the alignment and pitch are being followed correctly.
▪ The string must be installed with the same slope as the pipe will be, but just one foot over the
finished level.

Self-Check Quiz 5.4.1

Read the following statements and write/mark true or false accordingly:

No. Description True False

1. The sewer lines are an integral part of the waste water system.
2. Traps in a sewage line are not important to being able to make repairs or
remove clogs.
3. To safe the sewer pipe and avoid any damage, insulate the pipes with sand
or brick/stone chips plays important role, instead of placing the sewer lines
on the bare ground.
4. When the grade of the ground is sloping downward, you do not need to have
any type of extra help for the sewage to flow to the tank.
5. To reduce the possibility of leakage, the bell end of pipe must be placed on
the downhill side of the pipe run.

Information Sheet 5.4.2

Learning Objective: to install PVC sewer pipes in the workplace.

 How to install PVC sewer pipe (pictorial representation):

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 Same as Learning Outcome 4.3 – Perform PVC/UPVC Pipe Run Assembly (page 81 - 84)

 Bell Joint in PVC pipes using the Traditional Method:

Same as Information Sheet 4.3.1 – Perform PVC/UPVC Pipe Run Assembly (page 81 - 84)

 Bell Joint in PVC pipes using the Heat Gun:

Same as Information Sheet 4.3.1 – Perform PVC/UPVC Pipe Run Assembly (page 81 - 84)

 Sealing/gluing materials:
Sealant is a substance used to block the passage of fluids through the surface or joints or openings in
materials. It may be weak or strong, flexible or rigid, permanent or temporary. These are
not adhesives but some have adhesive qualities and are called adhesive-sealants or structural
sealants. The followings may include as sealing/gluing materials to carry out sewer pipe line installation:
▪ Solvents
▪ Cement
▪ Plastic based sealants
▪ Rubber based sealants
▪ Synthetic sealants
▪ PVC primer
▪ Silicon sealants

Remember:
• Once the pipe has become softened in the area required for the bell bring
the other pipe closer ready to form the bell before the heat is lost.
• Apply primer to each pipe end and each fitting.

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 Learning Outcome 5.5 - Finish Final Pipe Run

Contents:

▪ Leaks and non-conformance: leaks, pipe size, fitting size, pipe run slope/grade, pipe damage
▪ Covering materials: sand, gravel and concrete

Assessment criteria:

1. Fittings are installed to complete the final run of the sewer pipe installation.
2. Final pipe run is checked for leaks and non-conformance to workplace and plumbing line requirements.
3. Re-works or revision is made where necessary.
4. Covering materials are laid on top of the sewer pipe run in accordance with workplace and plumbing
plan requirement.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, spirit level, shovel, spade, cold chisel, hammer, string lines,
▪ Equipment: trenching/digging equipment
▪ Materials: marking pen, pencil, marking powder, masking tape, covering materials and plumbing
plan/drawing

Learning Activity 5.5.1

Learning Activity Resources/Special Instructions/References

Finish final pipe run ▪ Information Sheet: 5.5.1

▪ Self-Check Quiz: 5.5.1
▪ Answer Key: 5.5.1

Information Sheet 5.5.1

Learning Objective: to finish final pipe run in the workplace.

 Leaks and Non-conformance:

The following points are important to consider as non-conformance:
▪ Leaks
▪ Pipe size (diameter)
▪ Pipe fitting size

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 ▪ Pipe run slope/grade
▪ Pipe damage

 Covering materials:
The following materials may be used as covering materials:
▪ Excavated soil
▪ Sand
▪ Brick chips/Stone chips
▪ Cement mortar
▪ Cement concrete
▪ Warning tape

 Final pipe run:

▪ It is probable that the last portion of the run will need just a fraction of a pipe.
▪ Be aware that it will also need additional fittings to complete the installation.
▪ Once the pipe has been installed completely, check for any pipe that could be disconnected, broken
or not installed properly.
▪ Place the sand and/or gravel over the pipe, enough to cover at least 10” over the sewer pipe.
▪ Start to compact the material with a rammer or any other compaction equipment suitable for the
type of pipe being installed.
▪ On long pipe runs, this process could be started once the pipe has been installed and while working
on the next pipe segment.
▪ It is important to install a warning tape over the first layer of compacted soil, so others will be aware
when excavating that a pipe is located under the detectable warning tape.

 Backfilling of excavations:
• Backfilling is the replacement of excavated earth into a trench around the embedment area or
against a trench.
• To backfill of a trench can be done by using the same material that was originally excavated,
provided it is free from any rocks, builders' waste or other materials that may damage the pipe.

 Calculating material quantities:

▪ To calculate volume, it needs to know the width, length and depth (at the deep end and the shallow
end) of the trenches.
▪ Volume to be excavated, V = Length x Width x Depth (average)

Do you know?
• The backfill of a trench can be done by using the same material that was originally excavated,
but must be free from any rocks, builders' waste or other materials that may damage the pipe.
• For house sewer inspection pit must be provided after 20 feet (6.0 m) apart in straight line
and in every turning point.

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 Self-Check Quiz 5.5.1

Write the correct answer of the following:

1. Why warning tape is used in sewer pipe line installation?

2. What kind of materials should not use for backfilling?
3. How you can calculate the volume of material in excavating from the trench?
4. What is the maximum distance in between house sewer inspection pits that must be provided in a
straight line?

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 Learning Outcome 5.6 - Clean and Maintain the Work Area

Same as Learning Outcome 1.5 – Clean and maintain the Work Area (page 29 - 32)

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 ANSWER KEYS

Answer Key 5.1.1

1. The recommended pitch for 4" pipe is 1/8" to 1/4" per foot.

Answer Key 5.2.1

1. Polyvinyl chloride pipe

2. Un-plasticized polyvinyl chloride pipe
3. Cast Iron pipe

Answer Key 5.3.1

1. True
2. True
3. False
4. False
5. True

Answer Key 5.4.1

1. True
2. False
3. True
4. True
5. False

Answer Key 5.5.1

1. It is important to install a warning tape over the first layer of compacted soil, so others will be aware
when excavating that a pipe is located under the detectable warning tape.
2. Any type of sharp pointed materials, builders' waste or other materials that may damage the pipe
should not be used for backfilling.
3. To calculate the volume for excavation, V = Length x Width x Depth (average).
4. For house sewer inspection pit must be provided after 20 feet (6.0 m) apart in straight line and every
turning point.

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Module 6: Carry out plumbing fixtures installation

MODULE CONTENT

Module Descriptor: This module covers the skills, knowledge and attitudes to carry out plumbing
fixtures installation which includes preparing for plumbing fixture installation,
gathering tools, equipment and materials, installing new toilet bowl (commode),
installing other plumbing fixtures, and cleaning and maintaining the work area. It
also includes information sheets, activity sheets, job sheets, self-check quizzes,
and answer keys.

Nominal Duration: 60 hours

Learning Outcomes:

Upon completion of the module, the student/trainee will be able to:

6.1 Prepare for plumbing fixture installation

6.2 Gather tools, equipment and materials
6.3 Install a new toilet bowl (commode)
6.4 Install other plumbing fixtures
6.5 Clean/maintain the work area

Performance Criteria:

1. Work activities are confirmed by making site visit/inspection to install plumbing fixtures as per plan
and workplace requirements.
2. Personal protective equipment (PPE) is selected and used.
3. Tools, equipment and materials are gathered and checked for usability.
4. The new toilet bowl is placed on the flange aligning the bolt holes with the bolts of the flange and
wax ring in its proper place.
5. Nuts with washers are tightened squarely without over tightening.
6. Additional sealing material is applied around the base of the bowl in accordance to workplace
requirements.
7. The water tank is installed on the bowl in accordance with manufacturer’s instruction.
8. Plumbing fixtures are installed in accordance with plumbing plan and following manufacturer’s
instruction/specification.
9. Check newly installed plumbing fixtures for leaks and non-conformance with workplace
requirements.
10. Plumbing tools/equipment is cleaned and maintained.
11. Work area is cleaned and waste materials are disposed of in accordance with workplace
requirements.

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 Learning Outcome 6.1 - Prepare for Plumbing Fixture Installation

Contents:

▪ Work activities for installation/repair of toilet bowl (commode), shower, bath tub, wash basin, kitchen
sink, urinals, water closet, bidets, drinking fountains, terminal valves/faucets
▪ Plumbing fixture: toilet bowl (commode), shower, bath tub, wash basin, kitchen sink, urinals, water
closet, bidets, drinking fountains, terminal valves/faucets

Assessment criteria:

1. Work activities are confirmed in accordance with plumbing plan and workplace requirements.
2. Work site is visited and prepared prior to installation works.
3. Plumbing fixture is determined, collected and checked for workability and quality.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, hacksaw, screw driver (star, flat, positive), spirit level,
pipe reamer, files (flat, half round, round), cold chisel, hammer
▪ Equipment: pipe threading machine, power hacksaw, drill press, angle grinder, welding machine
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), welding rod, masking tape, cement, sand and plumbing plan/drawing
▪ Fixtures: toilet bowl (commode), shower, bath tub, wash basin, kitchen sink, urinals, water closet,
bidets, drinking fountains, terminal valves/faucets

Learning Activity 6.1.1

Learning Activity Resources/Special Instructions/References

Prepare for plumbing fixture installation ▪ Information Sheets: 6.1.1, 6.1.2

▪ Self-Check Quiz: 6.1.1
▪ Answer Key: 6.1.1
▪ https://ptpnaples.com/plumbing-fixture-installation-
repair/
▪ https://homeguides.sfgate.com/install-plumbing-new-
home-56399.html

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 Information Sheet 6.1.1

Learning Objective: to confirm the work activities related to prepare for plumbing fixture installation in the
workplace.

 Work activities:
The following work activities are needed to be confirmed by making site visit/inspection when
installation of plumbing fixtures in a workplace:
▪ Tools and equipment gathering: Collect and gather required quantity of tools and equipment and
checked for usability.
▪ Materials gathering and stacking Gather quality pipes and other materials and stack suitable places
for uses.
▪ Plumbing fixtures and fittings: Collect and gather good quality plumbing fixtures and fittings as per
workplace requirements.

 Plumbing plans:
Plumbing and piping plans clearly display where the fixtures, pipes and valves are. Plumbing and piping
plans are of great importance to design a house or building plan.

 Installation of plumbing fixtures:

▪ Toilet bowl (Commode)
▪ Water closet (Pan)
▪ Wash hand basin (WHB)
▪ Kitchen sink
▪ Shower
▪ Bath tub
▪ Urinals

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 ▪ Drinking fountains
▪ Terminal valve/faucet
▪ Bidet

Information Sheet 6.1.2

Learning Objective: to determine, collect and check plumbing fixtures for workability and quality.

 Plumbing Fixtures:
A plumbing fixture is an exchangeable device which can be connected to a plumbing system to collect
or receive and deliver or drain water and human waste.

Water closet (Commode):

This is used to collect and remove human waste.

Long Pan:
This is also used to collect and remove human
waste.

Wash Basin: is used to collect water for wash hands and face. These maybe of different types.

Pedestal type Rectangular shape Round shape

Glass bowl shape
Kitchen sink:
This is a bowl-shaped plumbing fixture used for
dishwashing and other purposes.

Shower:
This is used for spray warm or hot water to wash
or bathe oneself.

Bath tub: is a large or small container used for

holding water in which a person or a person’s pet
may bathe.

Urinals: is a sanitary plumbing fixture for urination only and predominantly used by males.

Bowl type
Squatting type Sensor-operated urinals
Drinking fountains:
This is used for drinking purposes.

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 Terminal valve/faucet:
Terminal valve/faucet is used for dishwashers,
ice makers, humidifiers or other purposes.

Bidet:
Bidet is installed in a bathroom for washing the
genitalia, perineum, inner buttocks and anus of
the human body.

Hand dryer:
It is fixed in wall and used as automatic hand
dryer.

Sensor basin faucet:

It is fixed with wash basin and used as automatic
hand wash with water.

Self-Check Quiz 6.1.1

Check your understanding by identifying the following plumbing fixtures:

No. Picture Name of the fixture

1

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 Learning Outcome 6.2 - Gather Tools, Equipment and Materials

Same as Learning Outcome 1.1 – Gather and Check Tools, Equipment and Materials (page 8 -
15)

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 Learning Outcome 6.3 - Install A New Toilet Bowl (Commode)

Contents:

▪ Toilet bowl (commode) installation

▪ Accessories: wax ring, nuts & bolts, washers etc.
▪ Water tank installation with necessary accessories
▪ Sealing materials: cement concrete, grommet (rubber & plastic), sealants (rubber, silicone, plastic and
synthetic), wax seal

Assessment criteria:

1. Toilet bowl flange is installed securely making sure the bolts are in place.
2. A new wax ring is placed at the bottom of the toilet bowl accurately.
3. The new toilet bowl is placed on the flange aligning the bolt holes with the bolts of the flange and wax
ring in its proper place.
4. Nuts with washers are tightened squarely without over tightening.
5. Apply additional sealing material around the base of the bowl in accordance to workplace requirements.
6. The water tank is installed on the bowl in accordance with manufacturer’s instruction.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, hacksaw, screw driver (star, flat, positive), spirit level,
pipe reamer, files (flat, half round, round), cold chisel, hammer
▪ Equipment: pipe threading machine, power hacksaw, drill press
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), welding rod, masking tape, cement, sand and plumbing plan/drawing
▪ Plumbing fixture: toilet bowl (commode), water tank and manufacturer’s instruction / specification /
manual

LEARNING ACTIVITY 6.3.1

Learning Activity Resources/Special Instructions/References

Install a new toilet bowl (commode) ▪ Information Sheet: 6.3.1

▪ Job Sheet 5
▪ https://www.youtube.com/watch?v=wM-6bgV7G5s
▪ https://www.wikihow.com/Install-a-Toilet

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 Information Sheet 6.3.1

Learning Objective: to install a new toilet bowl (commode) in the workplace.

 Install a new toilet bowl (commode):

1. Collect commode set, necessary tools, equipment, materials and drawing.
2. Mark the floor and wall area as per layout.
3. Cut the floor/wall as per measurement and drawing.
4. Place the commode on the floor to mark the drill point on the floor.
5. Drill the marking points using drill machine.
6. Put the rowel plug into the hole.
7. Place the commode on the floor.
8. Put the commode screw in the drilling point and tighten properly.
9. Fix the seat and seat cover with commode.
10. Level the installation area of commode using white cement mixture
11. Connect soil pipe with commode as per layout.
12. Connect angle valve with cistern and commode using connection pipe.
13. Mark the area to set the push shower
14. Drill the drilling point using drill machine to fix the push shower.
15. Fix push shower stand with screw.
16. Connect the push shower with two-in-one bibcock.
17. Switch ON/OFF the commode low down and push shower; check the performance.
18. Clean the workplace and restore the tools, equipment and extra materials.

 A new toilet bowl (commode) installation activities (pictorial representation):

Place the commode’s pan on the floor in the exact

position it is to be installed.
Hold the pan firmly in position and using a pencil
mark the shape of the pan's pedestal on the floor.
Remove the pan and place in a safe position.

Use an angle grinder to cut the area where the hole

must be made in the concrete floor

Use hammer and chisel to open up hole in the floor

and fit the closet bend

Drill holes in concrete for rowel bolts to be inserted

Place the floor flange over the closet bend until the
flange rests on the finished floor.

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 Using uPVC make a joint to form the soil pipe

Put two rowel bolts with their threaded ends up into

the flange slots.

Turn the bowl upside down on protective waste

newspaper or wooden strips to avoid scratching.
Set the wax gasket over the horn

Turn the bowl right side up and set it on the flange

Setting the bowl on the flange with the bolts through

the holes of the bowl

Place a washer and nut on each bolt tightening

each alternately until the bowl is set and the nut
caps are fitted.

Ensure that the bowl is in a level position

Mark out the route of the cold-water supply to the

commode and push shower for the installation of
the angle stopcocks

Use an angle grinder to cut the chase in the walls

Remove the chased area using a hammer and cold

chisel.

Assemble the cistern/flashing tank

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 Fix the washers of the bolts that secure the cistern
to the bowl

Pull the anchoring bolts from the inside of the

cistern

Tighten the lock nuts in position

Secure the cistern in position on the bowl

Prepare to install the seat and seat cover

Fasten the seat and seat cover in position

Install angle stopcocks and connect to the cold-

water supply

Connect cold water supply from the angle stopcock

to the cistern/flashing tank

Install and connect the push shower with the angle

stopcock

Join the commode’s outlet to the uPVC trap and

soil pipe with primer and solvent cement

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 JOB SHEET 5
Qualification: Plumbing

Learning unit: Install a new toilet bowl (commode)

Learner name:

Personal protective Hand gloves, visibility vest, safety goggles, safety boots, hard hat and dust
equipment (PPE): mask
Materials: Thread tape (Teflon), cement, sand, brick/stone chips, commode set, push
shower, angle stopcocks and connection pipes.
Tools and equipment: Measuring tape, marking pen/pencil, grinding machine, pipe range, hack saw,
pipe cutter, chisel, hammer, flat file, die-stock, oil-can, steel wire brush, elbow,
bend, socket, tee (T), union.
Performance Criteria 1. Install commode set as per drawing without any error.
2. Correct hand and power tools are used safely.
3. Wax seal is installed correctly.
4. Cistern is installed securely in correct position.
5. Commode must be level and operate without leakages.
6. Push shower must operate without leakages.
7. Connection to soil pipe should be without leakages.
Note: ▪ Install a commode as per the drawing
▪ Connect the commode with angle stopcock
▪ Install a push shower as per drawing
▪ Connect push shower to an angle stopcock
Procedure:
1. Collect and gather tools, equipment and materials to needed
2. Place the floor flange over closet bend until the flange rests on the finished
floor
3. Make a joint with uPVC
4. Put two rowel bolts with their threaded ends up into the flange slots
5. Turn the commode upside down set the wax gasket over the horn
6. Turn the bowl upright and set it on the flange with the bolts through
7. Place nut on bolts tighten
8. Ensure that the bowl is level
9. Fix the cistern in position with seat and seat cover
10. Connect both commode and push shower with angle stopcocks
Learner signature: Date:

Assessor signature: Date:

Quality Assurer
Date:
signature:

Assessor remarks:

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 Sealing material:
▪ Solvents
▪ White cement
▪ Cement/concrete
▪ Plastic grommet
▪ Plastic based sealants
▪ Rubber grommet
▪ Rubber based sealants
▪ Synthetic sealants
▪ Wax seal
▪ PVC primer
▪ Silicon sealants

Individual Activity:
▪ Watch the video on ‘How to install a new toilet bowl (commode)’ and summarise the key points (if
facilities available)
▪ Install the commode following the activity sheet and Job Sheet 5 (see above)

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 Learning Outcome 6.4 - Install Other Plumbing Fixtures

Contents:

▪ Wash hand basin

▪ Shower
▪ Bath tub
▪ Kitchen sink
▪ Urinals
▪ Water closet
▪ Bidets
▪ Drinking fountains
▪ Terminal valves/faucets
▪ Leaks and non-conformance: leaks, damaged fixtures, broken/damaged fittings, wrong pipe size,
wrong fitting size, damage flooring/walls

Assessment criteria:

1. Plumbing fixtures are installed in accordance with plumbing plan and following manufacturer’s
instruction/specification.
2. Check newly installed plumbing fixtures for leaks and non-conformance with workplace requirements.
3. Reworks/adjustment is carried out in accordance with workplace requirements.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, hacksaw, screw driver (star, flat, positive), spirit level,
pipe reamer, files (flat, half round, round), cold chisel, hammer
▪ Equipment: pipe threading machine, power hacksaw, drill press
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), welding rod, masking tape, cement, sand and plumbing plan/drawing
▪ Plumbing fixture: shower, bath tub, wash basin, kitchen sink, urinals, water closet, bidets, drinking
fountains, terminal valves/faucets

Learning Activity 6.4.1

Learning Activity Resources/Special Instructions/References

Install other plumbing fixtures ▪ Information Sheet: 6.4.1

▪ Job Sheet 6
▪ Self-Check Quiz: 6.4.1
▪ Answer Key: 6.4.1
▪ https://www.youtube.com/watch?v=a_8-zz8tc7U

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 Information Sheet 6.4.1

Learning Objective: to install other plumbing fixtures in the workplace.

 Install a wash hand basin:

1. Collect basin with all necessary accessories, tools, equipment, materials and drawing.
2. Mark the area of basin, looking glass, shelf, soap case, trowel rail and liquid dispenser as per
drawing and layout.
3. Drill the marking points using drill machine.
4. Put the rowel plug into the hole
5. Fix the basin screw/nut into the hole.
6. Fix basin waste and pillar cock with basin.
7. Place washbasin with basin screw as per layout.
8. Connect bottle trap with basin and waste line.
9. Connect the angle stop cock with pillar cock.
10. Level the installation area of wash basin using white cement.
11. Place looking glass shelf over the basin using screw.
12. Set mirror over the glass-shelf using screw.
13. Fix soap case/liquid dispenser in the wall using screw
14. Hang the towel rail in the wall using screw.
15. Conduct leakage test of wash basin and check the clear drainage.
16. Clean the workplace and restore the tools, equipment and extra materials.

 Wash hand basin, Fitting and Accessories:

Wash hand Basin (wall hanged/cantilever)

Used to collect water to wash hands and face

Pillarcock
This faucet controls the water into the wash basin

Angle Stopcock
Used to control the hot and cold water supply

Basin waste
This fitting is used to enable a plug to be inserted
to keep the water inside the basin

Bottle trap
This is a trap that distributes waste water from the
basin

Glass shelf
To store toiletries on the shelf

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 Towel rail
This is used to hang towels on it

Mirror
This is used to reflect an image

Liquid soap case

It is used to dispense liquid soap to wash hands

Soap case
This is used to hold soap in the case

 A new wash hand basin installation activity (pictorial representation):

Use the appropriate sealing material to seal the

area for the basin waste to be installed.

Insert the waste into sealing material

Apply the appropriat sealing material on the back

washer

Fit the back washer in place

Tighten the lock nut for basin waste

Unscrew the back nut and washer from the new

pillar cock

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 Place the washer in position ready to install

Place the pillar cock in the hole of the basin

Place the back nut onto the threaded section

under the basin

Tighten the back nut of the pillar cock with the help
of a box spanner

Securely fit the pillar cock

Connect flexi connector to the cold water supply to

the pillar cock and fix to the angle stopcock in
position

Mark out the position of the wash hand basin, the

centre lines of the cold water supply and the holes
through the wall for the cold water supply by using
a pencil and tape

Mark the position of the centre line of the waste

pipe

Drill the hole through the wall for the cold water
pipe

Cut the chase area as marked on the wall and floor

by using hammer and cold chisel

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 Mark the position of the centre line of the waste
pipe

Fit two numbers semi concealed brackets in the

wall

Place the basin level against the finished wall

surface at the correct height.

Insert the rowel plugs into the holes

The basin is fitted in postion to the wall onto the

two semi concealed brackets

Fix bottle trap to the waste

Scan wall for any electrical or water pipes to locate

safe drilling area

Mark out the position for mirror fixing

Mark out the position of the shelf’s brackets

Drill the holes and insert plugs into hole

Place glass shelf into position

Fix towel rail to wall

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 Apply adhesive to back of the mirror

After levelling place the temporary supports in

position

Place mirror onto the temporary supports

Press firmly the mirror into position and leave for

adhesive to set

Completed mirror in position

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 JOB SHEET 6
Qualification: Plumbing

Learning unit: Install a wash hand basin

Learner name:

Personal protective Hand gloves, visibility vest, safety goggles, safety boots, hard hat and dust
equipment (PPE): mask
Materials: Thread tape (Teflon), cement, sand, basin, basin waste, pillar cock, angle stop
cock, glass shelf, mirror, liquid soap dispenser, soap case
Tools and equipment: Measuring tape, hack saw, pencil, pipe vice, tripod pipe vice, angle grinder,
hammer action drill and masonry bits, hammer, cold chisel, and screw drivers,
combination pliers, pipe wrench, adjustable wrench basin spanner and box
spanner

Performance Criteria 1. Basin is Installed as per drawings

2. Shelf, Mirror and Towel rail are installed as per drawing
3. Waste line and water supply are installed in correct position
4. All fittings and fixtures are correctly installed and sealed with sealing
compound.
5. No leaks are present in system.
6. All fittings and fixtures are secured correctly.
7. Basin is connected to floor drain correctly.

Measurement: ▪ The measurement must be 750 mm to the top of the basin from the floor.

Note:
▪ Fix pillar cock to basin.
▪ Fix basin’s waste outlet using the appropriate sealing compound and
fixings.
▪ Install wall hung single semi-concealed basin brackets fixed with rawl
plugs.
▪ Install a bottle trap.
▪ PVC waste pipe must be cased into the wall/ floor and be connected to
the floor drain.
▪ Install an angle stopcock at the basin.
▪ Connect the ½“ cold water to the pillar cock with flexible connectors.

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 Procedure:
1. Collect tools, material and drawing.
2. Mark the area of basin, looking glass, shelf, soap case, trowel rail and
liquid dispenser as per drawing and layout.
3. Drill the marking points using drill machine.
4. Put the rowel plug into the hole
5. Fix the basin screw/nut into the hole.
6. Fix basin waste and pillar cock with basin.
7. Place washbasin with basin screw as per layout.
8. Connect bottle trap with basin and waste line.
9. Connect the angle stop cock with pillar cock.
10. Level the installation area of wash basin using white cement.
11. Place looking glass shelf over the basin using screw.
12. Set mirror over the glass-shelf using screw.
13. Fix soap case/liquid dispenser in the wall using screw.
14. Hang the towel rail in the wall using screw.
15. Conduct leakage test of wash basin and check the clear drainage.
16. Clean the workplace and restore the tools, equipment.

Learner signature: Date:

Assessor signature: Date:

Quality Assurer
Date:
signature:

Assessor remarks:

 Leaks and Non-conformance:

▪ Leaks
▪ Damage fixtures
▪ Broken/damaged fittings
▪ Wrong pipe size
▪ Wrong fitting size
▪ Damage flooring/walls

Individual Activity:
▪ Watch the video on ‘How to install a wash hand basin’ and summarise the key points (if facilities
available).
▪ Install the commode following the activity sheet and Job Sheet 6 (see above)

SELF-CHECK QUIZ 6.4.1

Identify the following picture and write their names and what they are used for:

No. Picture Names and Used for

1.

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 2.

3.

4.

5.

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 Learning Outcome 6.5 - Clean and Maintain the Work Area

Same as Learning Outcome 1.5 – Clean and maintain the Work Area (page 29 - 32)

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 ANSWER KEYS

Answer Key 6.1.1

1. Toilet bowl (Commode)

2. Water closet (Pan)
3. Wash hand basin (WHB)
4. Kitchen sink
5. Bath tub

Answer Key 6.4.1

1. Wash hand Basin: used to collect water to wash hands and face.
2. Pillarcock: used to control the water into the wash basin.
3. Angle Stopcock: used to control the hot and cold water supply.
4. Basin waste: used to enable a plug to keep the water inside the basin.
5. Soap case: used to hold soap in the case.

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Module 7: Perform pressure testing of piping system

MODULE CONTENT

Module Descriptor: This module covers the skills, knowledge and attitudes to perform pressure
testing of piping system which includes preparing for pressure testing, gathering
tools, equipment and materials, carrying out pressure testing, and cleaning and
maintaining the work area. It also includes information sheets, activity sheets,
job sheets, self-check quizzes and answer keys.

Nominal Duration: 24 hours

Learning Outcomes:

Upon completion of the module, the student/trainee will be able to:

7.1 Prepare for pressure testing

7.2 Gather tools, equipment and materials
7.3 Carry out pressure testing
7.4 Clean/maintain the work area

Performance Criteria:

1. Work activities are identified in accordance with plumbing plan and workplace requirements.
2. Maximum test pressure is determined in accordance with plumbing plan/design specification.
3. Pressure testing method is identified in accordance with plumbing plan/workplace requirements.
4. Piping system connections are reviewed and checked for tightness/integrity.
5. Devices, fixture or components in the piping systems that needs to be isolated is shut off to avoid
damage.
6. Required tools, equipment and materials are identified in accordance with plumbing plan and
workplace procedure on pressure testing.
7. Pressure testing tools, equipment and materials are collected and checked for usability/accuracy.
8. Personal protective equipment (PPE) is gathered and strictly used.
9. Preliminary, intermediate and final test pressures are applied progressively into the system in
accordance with workplace pressure testing plan/procedure.
10. Appropriate Leak testing method is applied for each applied pressure to determine presence of
leaks.
11. Leak testing result is reported to the concern person.
12. Test results are recorded in accordance with workplace requirements.
13. Safety precaution is observed when performing pressure testing.
14. Plumbing tools/equipment is cleaned and maintained.
15. Work area is cleaned and waste materials are disposed of in accordance with workplace
requirements.

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 Learning Outcome 7.1 - Prepare for Pressure Testing

Contents:

▪ Work activities for pressure testing: checking tightness of valves/fittings, measuring pipe runs,
identifying of pipe run for pressure testing, identifying of fittings to be isolated and isolating system
components
▪ Pressure testing method: pneumatic testing and hydrostatic testing

Assessment criteria:

1. Work activities are identified in accordance with plumbing plan and workplace requirements.
2. Maximum test pressure is determined in accordance with plumbing plan/design specification.
3. Pressure testing method is identified in accordance with plumbing plan/workplace requirements.
4. Piping system connections are reviewed and checked for tightness/integrity.
5. Devices, fixture or components in the piping systems that needs to be isolated is shut off to avoid
damage.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, hacksaw, screw driver (star, flat, positive), spirit level, pipe
reamer, files (flat, half round, round), cold chisel, hammer
▪ Equipment: air compressor, water pump, nitrogen pump/tank, pressure gauge and quick connect
couplers/adapters
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape (Teflon)
and masking tape

Learning Activity 7.1.1

Learning Activity Resources/Special Instructions/References

Prepare for pressure testing ▪ Information Sheet: 7.1.1

▪ Self-Check Quiz: 7.1.1
▪ Answer Key: 7.1.1
▪ https://www.youtube.com/watch?v=9lqF9sRt_FM
▪ https://www.hunker.com/12218547/how-to-pressure-
test-plumbing

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 Information Sheet 7.1.1

Learning Objective: to confirm the work activities related to prepare for prepare for pressure testing in a
workplace.

 Work activities:
The following work activities must consider preparing for pressure testing in a workplace:
▪ Checking tightness of valves/fittings
▪ Measuring pipe runs
▪ Identifying piping run which are subject for pressure testing
▪ Identifying fittings to be isolated
▪ Isolating system components.

 In other ways, the followings are need to be confirmed for preparation of pressure testing:
▪ Site visit/inspection: The requirement of site visit/inspection of a plumbing system to perform
pressure testing is important.
▪ Plumbing drawing/plan: Collect and study the plumbing drawing/plan to know about the whole
plumbing system.
▪ Tools and equipment gathering: Collect and gather required quantity of tools and equipment and
checked for usability.
▪ Materials gathering: Gather quality materials for problem solving.
▪ Plan out for pressure testing: Divide the plumbing system into sections and select spot for pressure
testing.
▪ Perform pressure testing: Piping system connections to be reviewed and checked for
tightness/integrity.
▪ Devices, fixture or components in the piping systems that needs to be isolated is shut off to avoid
damage.
▪ Determine maximum test pressure using proper tools and equipment and following the standard
method/procedure.

 Plumbing drawing/plan:

Same as Information Sheet 2.1.1 – Interpret Drawings and Plumbing Plans (page 37 - 38)

 Pressure testing method:

▪ Pressure tests are performed to ensure the safety, reliability, and leak tightness of pressure
systems.
▪ A pressure test is required for a new pressure system before use or an existing pressure system
after repair or alteration.
▪ Methods for pressure tests:
▪ Hydrostatic
▪ Pneumatic
▪ Hydrostatic testing is the most common method employed for testing pipes and pressure vessels.
It is performed by using water as the test medium and pneumatic test uses air, nitrogen or any non-
flammable and non- toxic gas.
▪ Hydrostatic testing is a process where components, such as piping or pressure vessels are tested
for strength and leaks by filling the equipment with pressurized liquid.
▪ For pipelines, hydro tests are conducted while the pipeline is out of service.
▪ All oil and/or natural gas are typically vented off, and the line is mechanically cleaned prior to
testing.
▪ Hydrostatic testing works by completely filling the component with liquid (usually, but not always,
water), until a specific pressure is reached.
▪ The hydro test pressure often exceeds the designed working pressure of the equipment,
sometimes by over 150%, depending on the exact regulations and code requirements, as
applicable.
▪ The pressure is then held for a specific amount of time to inspect visually for leaks.
▪ The visual inspection can be enhanced by applying either tracer or fluorescent dyes to the liquid
as suitable.

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 ▪ Hydrostatic testing is often required as a final proof test after repairs are completed and equipment
is returned to service.

Self-Check Quiz 7.1.1

Write the correct answer for the following:

1. What are the methods of pressure testing?
2. What is the medium used for hydrostatic test?
3. What is the medium used for pneumatic test?

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 Learning Outcome 7.2- Gather Tools, Equipment and Materials

Contents:

▪ Names of personal protective equipment (PPE) and their uses: safety helmet, safety shoes, hand
gloves, safety glasses, safety belt, apron, dust mask, ear plugs
▪ List of main tools, equipment and materials uses
▪ Pressure testing tools, equipment and materials

Assessment criteria:

1. Required tools, equipment and materials are identified in accordance with plumbing plan and workplace
procedure on pressure testing.
2. Pressure testing tools, equipment and materials are collected and checked for usability/accuracy.
3. Personal protective equipment (PPE) is gathered and strictly used.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), adjustable wrench, box wrench set, pipe wrench, mechanical pliers, screw
driver (star, flat, positive)
▪ Equipment: pressure gauge, quick connects couplers/adapters, air compressor, water pump and
nitrogen pump/tank
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape
(Teflon), masking tape

Learning Activity 7.2.1

Learning Activity Resources/Special Instructions/References

Gather tools, equipment and materials ▪ Information Sheets: 7.2.1, 7.2.2, 7.2.3, 7.2.4
▪ Self-Check Quiz: 7.2.1
▪ Answer Key: 7.2.1

Information Sheet 7.2.1

Learning Objective: to identify and uses of the personal protective equipment in the workplace.

 Personal Protective Equipment (PPE):

Same as Information Sheet 1.1.1 – Gather and Check Tools, Equipment and Materials (page 8 - 9)

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 Information Sheet 7.2.2

Learning Objective: to identify and uses of tools, equipment and materials in plumbing works.

 Tools and equipment:

Same as Information Sheet 1.1.2 – Carry out steel pipe cutting operation (page 10 - 12)

Information Sheet 7.2.3

Learning Objective: to identify and uses of tools, equipment and materials in plumbing works.

 Tools and equipment:

No. Picture Name and Used for

1 Pressure Gauge:
A pressure gauge is a mechanical instrument
designed to measure the internal pressure and/or
vacuum of a vessel or piping system.

2 Quick connect couplers/adapters:

Used to connect and disconnect lines fully pressurized
lines.

3 Air compressor:
An air compressor is a device that converts power into
potential energy stored in pressurized air.

4 Water pump:
A water pump uses a rotating impeller to move water
into the pump and pressurize the discharge flow.

5 Nitrogen pump/tank:
A high-pressure pump or compressor unit capable of
delivering high-purity nitrogen gas for use in oil or gas
wells.

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 Self-Check Quiz 7.2.1

Identify the following picture and write their names and what they are used for:

No. Picture Used for

1

Information Sheet 7.2.4

Learning Objective: to identify, uses and check tools, equipment and materials in plumbing works.

 Materials and pipes:

Same as Information Sheet 2.3.4 – Collect and Check Tools, Equipment and Materials (page 42 -
43)

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 Learning Outcome 7.3 - Carryout Pressure Testing

Contents:

▪ Pressure testing method/procedure

▪ Leak testing method: soap solution, leak testing instrument
▪ Safety precaution

Assessment criteria:

1. Preliminary, intermediate and final test pressures are applied progressively into the system in
accordance with workplace pressure testing plan/procedure.
2. Appropriate Leak testing method is applied for each applied pressure to determine presence of leaks.
3. Leak testing result is reported to the concern person.
4. Test results are recorded in accordance with workplace requirements.
5. Safety precaution is observed when performing pressure testing.

Resources required:

Students/trainees must be provided with the following resources:

▪ Personal protective equipment (PPE): safety helmet, safety shoes, hand gloves, safety glasses,
safety belt, apron, dust mask, ear plug/guard
▪ Tools: measuring tape (5m), steel rule, callipers, adjustable wrench, box wrench set, pipe wrench,
combination pliers, die stock, pipe cutter, pipe vice, hacksaw, screw driver (star, flat, positive), spirit
level, pipe reamer, files (flat, half round, round)
▪ Equipment: pressure testing tools, equipment and materials
▪ Materials: coolant (water based), soft stone (marker), marking pen, pencil, solvent, thread tape (Teflon)
and masking tape

Learning Activity 7.3.1

Learning Activity Resources/Special Instructions/References

Carry out pressure ▪ Information Sheet: 7.3.1

testing ▪ Self-Check Quiz: 7.3.1
▪ Answer Key: 7.3.1
▪ https://copperplumbing.org.uk/sites/default/files/content_attachments/pre

Information Sheet 7.3.1

Learning Objective: to carry out pressure testing in a workplace.

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 Hydrostatic pressure testing:
▪ Hydrostatic Pressure Testing is a non-destructive testing (NDT) method of finding leaks or verifying
performance and durability in pressure vessels such as pipe, tubing, and coils.
▪ This is considered a non-destructive test and failures are rare, they can occur when the test piece
does not meet performance or durability specifications and may render the piece unusable.
▪ Pressure shall be raised gradually.
▪ An initial examination may be made at low pressure (say 10% of the specified test pressure).
▪ Pressure shall be gradually increased to a value 50% of the specified test pressure.
▪ Thereafter the pressure will be increased in stages of approximately 10% of the specified test
pressure until the test pressure is reached.
▪ Generally, 1.5 times of working pressure apply for testing.
▪ After the strength test pressure is reached, the pipework shall be isolated from the pressure source
and held for a minimum of 5 minutes.
▪ There shall be no appreciable drop in pressure during this time.

 Leak: is a flow of liquid or gas through the wall of a vessel or pipe. Leaks require a pressure difference
to generate the flow; they always flow from higher pressure to lower pressure.

 Leak testing:
▪ There are a variety of leak testing techniques in use today.
▪ When considering an item requiring leak testing it is important to ascertain first whether detection
of the leak or measurement of the leakage rate is more important.
▪ The methods for leak testing are:
- Hydrostatic: by pressurizing liquid (water and dye)
- Air pressure: by pressurizing air or gas into the system (soap solution-visual and sound)

▪ Leak detection:
The common feature of methods used to detect leaks is that they are almost always operator-
dependent, require strict supervision and are often very messy.

▪ Observation: Components are filled with pressurized gas and immersed in a liquid. Typically, they
are filled with air and immersed in water, but nitrogen under acetone is also used. The most
common observation technique is to look for a bubble stream.

▪ Leak location: Sometimes it critical to find out the location of the leak in the system.

▪ Leak measurement: It is important to measure the size of the leak and/or quantity of leakage in
the system.

 Safety Checklist
• In order to prevent accident from hydrostatic test operation, it demands to make good preparation
prior to do the test, during the pressurization process and depressurizing operation.
• The job should be made in the form standard operating procedure.

 Hydrostatic test preparation:

1. All test equipment and tools shall be inspected for wear and damage.
2. Pressure measurement tools are calibrated and their statuses of calibration are still valid.
3. Pressure gauges used in the test have enough capacity. The gauges are recommended to have
150% of the maximum allowable working pressure.
4. Pressure gauges must be installed at a proper location so that it can be easily read and do not
create additional hazards to the hydrostatic test.
5. Vents are available and installed the high points to vent air. Check the vent line before testing and
make sure it is not blocked.
6. Choose drain valve at the lowest point in order to completely empty the vessel and pipe.
7. The hydrostatic-pressurizing pump is completed with safety relief valve.
8. Wear proper personal protective equipment.

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 Pressurization process:
1. Remove all air from the vessel and pipe line by water through vent line.
2. Pressurization is conducted gradually/slowly.
3. Mark all leak points and repair them before preceding the test.
4. Do not monitor during pressurization step directly from the front of sight glass or level glass.

 De-pressurization process:
1. Start de-pressurization by opening gradually the vent valve. Do it slowly.
2. Do not open the drain valve if the vent valve if still closed.
3. Open the lowest drain point to completely remove water from the vessel and pipeline.
4. Ensure that no remaining pressure trapped inside the pipe line or vessel.

Just checking:
1. What is leak?
2. Why a safety check list is required before starting testing operation?

Self-Check Quiz 7.3.1

Read the statement carefully and justify whether it is ‘True’ or ‘False’.

No. Description True False

1. Hydrostatic Pressure Testing is a non-destructive testing (NDT) method of
finding leaks or verifying performance and durability in plumbing system.
2. A leak is a flow of liquid or gas through the wall of a vessel or pipe.
3. For the hydrostatic test, the gauges are recommended to have 100% of the
maximum allowable working pressure.
4. Pressurization is conducted gradually/slowly.
5. For the hydrostatic test, generally oil and dye used as pressurizing liquid.

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 Learning Outcome 7.4 - Clean and Maintain the Work Area

Same as Learning Outcome 1.5 – Clean and maintain the Work Area (page 29 - 32)

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 ANSWER KEYS

Answer Key 7.1.1

1. There are two methods for pressure tests: hydrostatic and pneumatic.
2. Water is use as medium of hydrostatic test.
3. Air, nitrogen or any non-flammable and non- toxic gas are use as medium of pneumatic test.

Answer Key 7.2.1

1. Pressure gauge: used to measure the internal pressure and/or vacuum of a vessel or piping system.
2. Quick connect couplers/adapters: used to connect and disconnect lines fully pressurised lines.
3. Water pump: used to move water into the pump and pressurize the discharge flow.

Answer Key 7.3.1

1. True
2. True
3. False
4. True
5. False

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