MODULE 63103-02 - PIPELINE MECHANIC HAND AND POWER TOOLSTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperCopies of Quick QuizModule ExaminationPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentA variety of wrenches, including:

Straight pipe wrenchesOffset pipe wrenchesStrap wrenchesChain wrenches

A variety of spanner wrenches, including:Pin spannersFlat hook spannersAdjustable hook eyesFace spannersAdjustable face types

A variety of tin snips, including:Right offsetLeft offsetRight cut aviationLeft cut aviationStraight cut aviationCombination bladeStraight blade

Pieces of sheet or plate metal, several scribers, and layout dyePacking pullers and stuffing boxesInspections mirrors and flashlightsRetaining ring pliers, shafts, rods, and spindlesTaper gauge and section of pipeWoodruff key seaters, including one smaller than 2 inches and one 2-inch cutter

1

PIPELINE MECHANICALMaterials and Equipment

National Center for Construction Education & ResearchP. O. Box 141104, Gainesville, FL 32614-1104

Tel: (352) 334-0920 Fax: (352) 334-0931 E-mail: info@nccer.org

Level One

MODULE 63104-02 - PIPING AND MECHANICAL BLUEPRINT READINGTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule ExaminationsPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of your companys policy and procedures manualCopies of 49 CFR Part 195 (Liquid) and/or 49 CFR Part 192 (Gas)Copies of sample P&IDsCopies of sample machine drawingsCalculatorsEnlarged copies of Figure 6

MODULE 63105-02 - TUBING,THREADED PIPE, AND HOSESTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule ExaminationsPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of your companys policy and procedures manualCopies of 49 CFR Part 195 (Liquid) and/or 49 CFR Part 192 (Gas)Several sections of tubing and a rule, outside caliper, or caliper ruleSeveral sections of copper, steel, stainless steel, aluminum, Monel, Inconel, Hastelloy, and poly tubingSection of tubing and a sharp pencil, colored felt tip pen, or silver marking pencilSections of tubing with OD and ID burrs and a tube deburring toolSeveral sections of tubing and a variety of tubing cutters, including a hacksaw, a bandsaw, and snipsSpring tube bender and a section of soft metal tubingCompression-type hand bender, table- or bench-mounted tubing bender, and several sections of tubing of different size and thicknessPipe threader and die headAssorted couplings, unions, bushings, and reducersSeveral lengths of pipe and a variety of fittingsPipe joint compounds, including Teflon tape, liquid Teflon, and pipe dopeA variety of nonmetallic hosesMale, female, and splicer push-on fittings

2

MODULE 63106-02 - FASTENERSTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperCopies of Quick QuizModule ExaminationPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of your companys policy and procedures manualCopies of 49 CFR Part 195 (Liquid) and/or 49 CFR Part 192 (Gas)A variety of threaded fastenersA variety of retainer rings and several pairs of pliersA variety of cotter pins, including a standard pin, humped pin, clinch pin, and hitch, and a section of a shaft with holes drilled crosswiseA variety of pin fasteners and the necessary tools to install themSeveral sections of insulation and a variety of insulation fastenersA variety of threaded, nonthreaded, expandable, and nonexpandable fasteners; the appropriate tools to installthese fasteners; and sections of drywall, concrete blocks, and insulation materials

MODULE 63107-02 - IDENTIFY, INSTALL, AND MAINTAIN VALVES (CTS 19.119.4)TransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperCopies of the Performance Verification for Covered Task 19Copies of the Quick QuizModule ExaminationsPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of your companys policy and procedures manualCopies of 49 CFR Part 195 (Liquid) and/or 49 CFR Part 192 (Gas)Appropriate tools for assembling and disassembling various types of valvesSeveral valve stems, including:

Rising stemsNonrising stemsOutside screw-and-yoke stems

Gate, ball, plug, and expanding gate valvesGlobe, angle, Y-type, butterfly, and diaphragm valvesCopies of a valve maintenance logValve packing-removal tools and a valve packing assembly

3

MODULE 63108-02 - IDENTIFY TYPES OF VALVE ACTUATORS/OPERATORSTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperCopies of Quick QuizModule ExaminationPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of your companys policy and procedures manualCopies of 49 CFR Part 195 (Liquid) and/or 49 CFR Part 192 (Gas)Sample equipment warranties for valve actuatorsSeveral copies of manufacturers instructions for a variety of valve actuators

MODULE 63109-02 - INSTALLING SEALS AND GASKETSTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperCopies of Quick QuizModule ExaminationPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of your companys policy and procedures manualCopies of 49 CFR Part 195 (Liquid) and/or 49 CFR Part 192 (Gas)Sample seal materials, including:

Buna-NLeatherSiliconeNeoprene

Plastic and elastomer compoundsRoom temperature vulcanizing sealsA variety of O-rings and lip and oil sealsAppropriate tools to install O-rings and lip and oil sealsMounting thimble, shaft, and sealMeasuring tapes, gasket cutters, hole punches, and a variety of gasket materials, including:

Natural rubberEthylene propylene dieneterpolymerNeopreneNitrileSiliconeVitonGylon

4

MODULE 63201-02 - INTRODUCTION TO PNEUMATIC SYSTEMSTransparenciesBlank acetate sheetsTransparency pensOverhead projector and screenFelt-tip markers/chalkPencils and scratch paperModule ExaminationsCopies of the Quick QuizPerformance Profile SheetsWhiteboard/chalkboardAppropriate personal protective equipmentSliding-vane compressorAir compressor and filtersSeveral grades of in-line mesh filtersValve actuatorCopies of your companys policy and procedures manual

MODULE 63202-02 - INTRODUCTION TO HYDRAULIC SYSTEMSTransparenciesFelt-tip markers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule ExaminationsCopies of the Quick QuizPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentSamples of various types of hydraulic fluidsDifferent schedules of steel pipe, including Schedule 40 and Schedule 60Piping, tubing, and fittingsCheck valvesHydraulic pumpsLubricants with different pour pointsGlass jarsSeveral frozen ice packsCoolerDifferent types and sizes of strainers and filtersHydraulic fluidCommon cylinder

5

Level Two

MODULE 63203-02 - SPECIALTY AND PRECISION TOOLSTransparenciesFelt-tip markers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule ExaminationsCopies of Quick QuizPerformance Profile SheetsOverhead projector and screenWhiteboard/ChalkboardAppropriate personal protective equipmentTorque wrenchTorque multiplierHex turn flange spreaderT-handle flange spreaderRatchet action flange spreaderHydraulic flange spreaderMechanics levelMaster levelShimsScrap woodOptical levelMetal tapeBevel protractorUniversal bevel protractorsPlasti-gaugeJo blocksDrill shanks of various sizesInside and outside calipersMicrometersTelescoping gaugesDial indicatorsStroboscopic tachometer

6

MODULE63204-02 - INSPECT AND REPAIR VALVES (CT 20, 21.2, 21.3)TransparenciesBlank acetate sheetsTransparency pensOverhead projector and screenFelt-tip markers/chalkPencils and scratch paperModule Examinations*Performance Profile Sheets*Copies of the Quick Quiz**Copies of the Performance Verifications for Covered Tasks 20, 21.1, and 21.3 Copies of 49 CFR Part 195 (Liquid) and/or 49 CFR Part 192 (Gas)Copies of your companys policy and procedures manualWhiteboard/chalkboardSlab-type gate valveExpanding plug valveVarieties of rigging hardwareValve assembly

MODULE 63205-02 - MAINTAIN AND REPAIR PRESSURE LIMITING DEVICES AND RELIEF VALVES (CT 22, 23.1, 23.2, 24)

TransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule Examinations*Performance Profile Sheets*Overhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualSeveral relief valves and PLDs, including:Spring-type pressure relief valveBoot-type relief valveSafety valveRupture disc deviceControl valveElectro-hydraulic relief valveA copy of your companys procedures for inspecting tank pressure/vacuum breakersCopies of the Performance Verifications for Covered Tasks 22, 23.1, 23.2, and 24

7

MODULE 63206-02 - INTRODUCTION TO METERING DEVICES AND PROVERSTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule ExaminationsPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualCopies of API Chapter 4Mass flow metersA variety of orifice platesSeveral types of meters or photographs of several types of meters, including:Turbine metersPositive displacement metersUltrasonic metersMass flow metersCoriolis-type mass flow metersVortex metersSample meter factor logsGraph paper

8

MODULE 63207-02 - INTRODUCTION TO PUMPSTransparenciesBlank acetate sheetsTransparency pensMarkers/chalkOverhead projector and screenPencils and scratch paperModule ExaminationsPerformance Profile SheetsWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your companys policy and procedures manualGears, including:HelicalSpurHerringboneSamples or photographs of each type of pump, including:Centrifugal pumpsRotary pumpsReciprocating pumpsMetering pumpsCopies of Figures 2 and 20

MODULE 63208-02 - INTRODUCTION TO GAS COMPRESSORSTransparenciesBlank acetate sheetsTransparency pensMarkers/chalkOverhead projector and screenPencils and scratch paperModule Examinations*Performance Profile Sheets*Copies of Quick Quiz**Whiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualCopies of Figure 1 with the callouts covered

9

MODULE 63209-02 - INSTALL AND MAINTAIN BEARINGSTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule ExaminationsPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of your companys policy and procedures manualAssorted plain bearingsAssorted ball bearingsRoller bearingsPlain, roller, and ball flanged bearingsOne- and two-piece pillow block bearings and takeup bearingsBearings with various identification codesUsed bearings, lintless rags, clean oil, 3-volt ohmmeter, Permatex or Teflon tape, fine-tooth filePlain bearings and appropriate tools for disassembling and reassembling themEquipment required for installing standard sleeve bearingsA bearing that failed due to fatigue and a bearing that failed due to overloadBearings that have failed for various reasonsEquipment and materials required for packing a bearingEquipment required for removing a bearing using a manual bearing pullerEquipment required for removing a bearing using a pressEquipment required for removing a bearing using the hydraulic methodEquipment required for removing a bearing using the temperature methodEquipment required for installing tapered roller bearings using the temperature mounting methodEquipment required for installing a thrust bearing using the press mounting methodEquipment required for installing spherical roller bearings using a hydraulic nut or locknutSplit-housing pillow block bearings and equipment needed to assemble/disassemble themEquipment and materials for troubleshooting, removing, and repairing or replacing bearings

10

MODULE 63210-02 - INSTALL MECHANICAL SEALSTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule ExaminationsPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of the Quick Quiz**Copies of your companys policy and procedures manualSeveral types of mechanical sealsExamples of failed mechanical sealsEquipment required for removing and inspecting mechanical seals from a pumpEquipment required for installing mechanical seals on a pump

MODULE 63211-02 - MAINTAIN AND REPAIR DRIVERSTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule ExaminationsPerformance Profile SheetsOverhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of your companys policy and procedure manualSample engine power ratingsExamples or photos of electric, diesel, gas, and turbine driversNew bearingsExamples of various types of failed bearingsAccess to bearings requiring replacementEquipment required to remove and install bearingsAccess to pipeline driversEquipment required for driver maintenanceAccess to a driver requiring replacementEquipment required to replace drivers

11

MODULE 63301-02 - INSTALLING ROTATING EQUIPMENTTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperCalculatorsModule Examinations*Performance Profile Sheets*Overhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualA variety of base platesInstallation drawingsSample pumps and/or motors with physical damageSample base plates that are warped, damaged, or crackedEquipment to perform the bearing heating methodTools and equipment necessary to level base plates, including:Jack boltsAnchor boltsShimsWrenchesWedgesHammersLevelsShim packsStraightedgesFeeler gaugesTools and materials necessary to perform clearance and interference installation, including:Brass hammersKey and setscrew couplingsCleaning solventsShop clothesTapered shaftsLocking nutsMicrometersNonshrink and epoxy groutForms to practice groutingTools to work the grout

12

Level Three

MODULE 63302-02 - UNIT ALIGNMENTTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule Examinations*Performance Profile Sheets*Copies of Quick Quiz**Overhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualCalculatorsCopies of Figures 1, 2, 3, 4 , 23, 24, and 25 with the titles coveredCopies of Figure 33 with the callouts coveredAlignment simulatorsDial calipersStraightedgesScalesRulesFeeler gaugesChain indicator jigsDial indicatorsGraphical alignment chartsGraph paperReverse indicator plotting guidesSample alignment records

13

MODULE 63303-02 - VIBRATION ANALYSISTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule Examinations*Performance Profile Sheets*Overhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualA variety of transducers, including:Velocity transducersAccelerometersDisplacement transducersA variety of vibration test equipment, including:MetersOscilloscopesSpectrum analyzersElectronic filtersStroboscopesA variety of vibration recording instruments, including strip chart recorders and data collectorsSample vibration monitoring forms

MODULE 63304-02 - MAINTAIN,TROUBLESHOOT, AND REPAIR PUMPSTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule Examinations*Performance Profile Sheets*Overhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualCompleted inspection reportsSample manufacturers manuals, including procedures, schematics, and line drawingsCopies of Figure 13 with the callouts covered

14

MODULE 63305-02 - MAINTAIN,TROUBLESHOOT, AND REPAIR GAS COMPRESSORSTransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule Examinations*Performance Profile Sheets*Overhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualCopies of Figures 1, 2, and 3 with the callouts coveredCopies of manufacturers specifications for gas compressorsCopies of manufacturers maintenance manuals, including recommended startup checklistsGas compressors on which to practice maintenance and repair techniquesTools and materials to repair common rotary compressor components, including:Mechanical sealsO-ringsThread caulkingSilicone caulkingOil pumpsCouplingsLubricantFastenersOilStraightedgesTools and materials to repair commonreciprocating compressor components, including:CrossheadsDrive chainsScrewsNutsDust plugsSprocketsDrift punchesWashersValve capsBoltsO-ringsMachinists rulesLube oil pump chain sprocketsSprocket setscrewsWoodruff keysGasketsMetal files

15

MODULE 63305-02 - MAINTAIN,TROUBLESHOOT, AND REPAIR GAS COMPRESSORS (Continued)

LubricatorPry barsScrewdriversValve toolsAnti-seize lubricantValve retainerLubricantSample documentation for startup and operational checks

MODULE 63306-02 - MAINTAIN,TROUBLESHOOT, AND REPAIR PNEUMATIC VALVE ACTUATORS/OPERATORS AND SYSTEMS (CT 19.6 AND 21.1)

TransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule Examinations*Performance Profile Sheets*Copies of Quick Quiz**Copies of Performance Verifications for Covered Tasks 19.6 and 21.1Overhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualSample manufacturers warrantiesSample preventive maintenance records and schedulesSample equipment recordsPneumatic schematic diagramsSample actuators/operators and the necessary tools for disassembly and reassemblyManufacturers instruction manuals for the sample actuators/operatorsA variety of new and damaged gaugesSample valve maintenance logs

16

MODULE 63307-02 - MAINTAIN,TROUBLESHOOT, AND REPAIR HYDRAULIC VALVE ACTUATORS/OPERATORS AND SYSTEMS (CT 19.7 AND 21.4)

TransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule Examinations*Performance Profile Sheets*Copies of Performance Verifications for Covered Tasks 19.7 and 21.4**Overhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualSample preventive maintenance schedulesSample maintenance records and equipment logsPyrometerClamp-on ammeterSample hydraulic pump with the necessary tools for disassembly and assemblyManufacturers instruction manuals for the sample hydraulic pumpsHydraulic system control valves and the necessary tools for disassembly and assemblyA variety of replacement parts for a hydraulic actuator/operator and the corresponding manufacturersspecificationsA variety of hydraulic hoses and the necessary tools to cut themHydraulic schematic drawingsCopies of manufacturers instruction manuals for a variety of hydraulic system components

17

MODULE 63308-02 - MAINTAIN,TROUBLESHOOT, AND REPAIR ELECTRIC VALVE ACTUATORS/OPERATORS AND SYSTEMS (CT 19.5 AND 21.5)

TransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule Examinations*Performance Profile Sheets*Copies of Performance Verifications for Covered Tasks 19.5 and 21.5**Overhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualSample valve maintenance logsComputer-generated work ordersGrease gunsValve stemsCopies of Figure 10 with the legend coveredTools and materials to

Apply external and internal lubricantsDisassemble bolt-on and machine-fitted spur-gear attachmentsRemove worm gear assemblies

Tools and materials to disassemble and assembleSingle reduction worm gearsActuator/operator bearing assembliesBevel gear actuator/operators

LubricantsBrushesCleaning solventsShop clothsSample P&IDsInspection checklistsBolt-on and machine-fitted spur gear attachmentsManufacturers instruction manuals for limit switchesTorque switchStem nut assembly

18

MODULE 63309-02 - MAINTAIN,TROUBLESHOOT, AND REPAIR METERING DEVICES AND PROVERS

TransparenciesMarkers/chalkBlank acetate sheetsTransparency pensPencils and scratch paperModule Examinations*Performance Profile Sheets*Overhead projector and screenWhiteboard/chalkboardAppropriate personal protective equipmentCopies of 49 CFR Part 192 (Gas) and/or 49 CFR Part 195 (Liquid)Copies of your company policy and procedures manualAPI Manual of Petroleum Measurement StandardsTypical strainer assemblyTools and materials to clean a typical strainer assembly and to disassemble a turbine meterMeter clearance recordsPractice metersAppropriate measuring gaugesComponents of a disassembled positive displacement meterMaterials to clean positive displacement meter componentsProving spheresCalipersSizing ringsSteel tape

19

20