Mechanical Skills Flashcards by Kay H

Designed to make a job easier and enable you to work more efficiently

Tools

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The misuse of hand tools causes about ___ of all mishap injuries each year

7 to 8%

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Used to apply a striking force

Hammers, mallets, and sledges

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Hammers are designed according to ___

Weight, style, and shape

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Drives and draws nails

Carpenter’s hammer

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Have a variable-shaped peen, rather than a claw, at the opposite end of the face

Machinist’s hammer (ball peen hammer)

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Short-handled tool used to drive wooden-handle chisels, gouges or wooden pins, it is also used to shape sheet metal. The heads are made from soft materials

Mallet

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Steel-headed, heavy duty driving tool

Sledge

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Used to drive bolts, drift pins, and large nails, and to strike cold chisels

Short handled sledge

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Used to break rock and concrete, drive spikes, bolts, or stakes, and strike rock drills and chisels

Long handled sledge

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The head of a sledge is normally made of ___ and may weigh ___

High carbon steel

6 to 12 lbs

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Basic tool that is used to exert a twisting force on bolt heads, nuts, studs, and pipes

Wrench

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The best wrenches are made of __

Chrome vanadium steel

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Solid, non adjustable wrenches with openings in one or both ends

Open-end wrench

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Safer than open end wrenches, they completely surround or box a nut or bolt head

Box wrench

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Wrench designed to have one end open and the other end a box

Combination wrench

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Wrench consists of a handle and a socket

Socket wrench

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Four types of handles used with sockets

Ratchet
Hinged
Sliding T-bar handle
Speed handle

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Gives greatest possible leverage to remove bolts and nuts

Hinged handle

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This wrench has a curved arm with a lug or hook on the end

Spanner wrench

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Pipe wrench sizes vary from __

8 to 48 inches

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Wrench used to open 55 gallon barrels

Bung wrench

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Bung wrench is made from

Non-ferrous, non-sparking material

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Used for cutting sheet metal and steel of various thicknesses and shapes

Snips and shears

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Shears cut ___ materials, while snips cut ___

Heavier and thicker | Thinner

Giant shears with very short blades and long handles

Bolt cutters

Bolt cutters sizes range from ___

18 - 36 inches

Large bolt cutters will cut rods up to ___

1/2 inch

Used to cut metal that is too heavy for snips or bolt cutters

Hacksaws

Hacksaws can hold blades in sizes from ___

8 to 16 inches

Two types of hacksaw blades

All hard | Flexible

Four different kinds of hacksaw blades

Alternate Double alternate Raker Wave

The teeth are staggered, one to the left and one to the right

Alternate

The teeth are to two adjoining teeth staggered to the right, two to the left, and so on

Double alternate

Every third tooth remains straight and the other two are set alternately

Raker

Short sections of teeth or bent in opposite directions

Wave

Tools used for chipping or cutting metal

Chisels

Used in cutting rivets, split nuts, chip castings, and cutting thin metal sheets

Cold chisel

Used for special jobs like cutting keyways, narrow grooves and square corners

Cape chisel

Makes circular grooves and chips inside corners with a fillet

Round nose chisel

Used for cutting v-grooves and sharp corners

Diamond point chisel

Files are graded according to ____

the degree of fineness and whether they have single or double cut teeth

Have rows of teeth cut parallel to each other, used for sharpening tools, finish filing, and draw filing

Single-cut files

Have rows crisscrossed which form the teeth in a diamond shape and are used for fast cutting

Double-cut files

File teeth are set at a ___ angle

65 degree with the centerline

Coarsest file

Bastard cut

Used to file acute angles and to clear out square corners

Triangle file

Tapered in both width and thickness. One edge has no teeth, used for smoothing lathe work, draw filing, and other fine, precision work. Always single cut

Mill files

General purpose files and may be either single or double cut

Flat files

Tapered on all four sides and used to enlarge rectangular-shaped holes and slots

Square files

Tapered and used on round openings

Round files

Means the file is being moved across the surface of the work in a crosswise direction

Cross filing

Produces a finer surface finish and usually a flatter surface than cross filing

Draw filing

The teeth of the file clog up with metal filings and scratch the work

Pinning

Used to determine the size of a drill

Drill gauge

Soft low carbon steel bits are used only for __

Cutting wood

High carbon steel bits can be used on ___

Wood or metal

Inexpensive black coating that provides heat and corrosion resistance

Black oxide

Very hard ceramic material that can extend the cutting life by three or more times

Titanium Nitride (TiN)

Coating frequently used, considered superior to TiN and can extend tool life five or more times

Titanium Aluminium Nitride (TiAN)

Used as an abrasive, most often for cutting tile, stone, and other very hard materials

Diamond powder

Tool that is held in the hand and struck on one end with a hammer

Hand punch

Used for marking the center of a hole to be drilled

Center punch

Used when the intersection of two layout lines needs to be exact

Prick punch

Sometimes called starting punches, have long tapers from the tip to the body. Made to withstand heavy blows, may be used to knock out rivets after the head is removed or for freeing pins that are frozen in their holes

Drift punch

Used when the drift punch may be too large to finish the job and thus damage the object

Pin punch

Used for assembling units of machine or flanges. It is usually about a foot long and has a long gradual taper. Its main purpose is to line up holes in mating parts

Alignment punch

Used for cutting holes in gasket material

Gasket punch

Used to cut threads in metal, plastics, or hard rubber

Taps and dies

Used for cutting internal threads

Taps

Used for cutting external threads

Dies

Most common types of taps

Taper, plug, bottoming, and pipe

Hand tap has a chamfer length of 8 to 10 threads. These taps are used when starting a tapping operation when tapping holes

Taper (starting)

Hand tap has a chamfer length of 3 to 5 threads and are designed to use after a starting tap

Plug

Hand tap used for threading the bottom of a blind hole and are used after the other two taps

Bottoming

Tap used for pipefitting

Pipe

Two styles of threads

National Course | National Fine

Two types of tap wrenches

Straight handle | T-Handle

Dies are of ___ or ___ design

Solid | Adjustable

Used to remove broken screws without damaging the surrounding material or the threaded hole

Screw extractor

Used to remove broken taps

Tap extractor

Straight screw extractor remove broken screws having ___ to ___ outside diametres

1/4 to 1/2 inch

Spiral tapered screw extractors are sized to remove screws and bolts from ___ to ___ outside diametres

3/16 to 2 1/8 inches

Designed to drive and remove screws

Screwdrivers

Three parts to a standard screwdriver

Grip Shank Blade

Screwdrivers are classified by size according to the ___

Combined length of shank and blade

A Phillips screwdriver has a ___ degree fluke angle and a ___

30 | Blunt end

Reed and Prince screwdriver has a ___ degree fluke angle and a ___

45 | Sharper pointed end

At least ___ of the slot should be filled by the blade or tip of the screwdriver

75%

Can be used for cutting purposes as well as holding and gripping small articles in situations where it may be inconvenient or impossible to use hands

Pliers

Most common pliers

Slip-joint

The jaws are straight and serrated. The screw or pivot which fastens the jaws together may be moved to either of two positions

Slip-joint pliers

Can be used for holding objects regardless of their shape. A screw adjustment in one of the handles makes them suitable for several different sizes

Wrench pliers

Also called vice-grips

Wrench pliers

Originally designed for tightening or removing water pump packing nuts

Water pump pliers

Have a jaw adjustable to seven different positions. Have slip-joints and jaw teeth that can be coarse or smooth

Water pump pliers

Another version of the water pump pliers and are easily identified by the extra long handles which make them a very powerful gripping tool

Groove joint pliers

Common name of this tool is channel-lock pliers

Groove joint pliers

Have grooves in one jaw and lands on the other

Groove joint pliers

Used for cutting small, light material such as wire and cotter pins in areas which are inaccessible to the larger cutting tools

Diagonal cutting pliers

Known as side-cutters or lineman pliers

Electrician pliers

Principally used for holding, bending, and cutting thin materials or small gauge wire. They are also used extensively for stripping insulation from wire and for twisting wire when making a splice. The jaws are hollowed out on one side just forward of the pivot point, the opposite side is used for cutting

Electrician pliers

Electrician pliers are designated by ___

Overall length

Used in confined areas where fingers cannot be used

Needle-nose pliers

Have a tapered jaw to a joint, which makes them well adapted to installing and removing small cotter pins. They have serrations at the nose end and a side cutter near the throat

Needle-nose pliers

May be used to hold small items steady, to cut and bend safety wire, or to do numerous other small jobs which are too intricate or too difficult to be done by hand

Needle-nose pliers

Three-way pliers which hold, twist, and cut

Aircraft lockwire pliers

Designed to reduce the time used in twisting safety wire on nuts and bolts

Aircraft lockwire pliers

Useful when removing or installing snap rings

Snap ring pliers

Designed to strip small wiring and use with solderless terminals

Wire stripper, crimper

Store pliers with the jaw ___

Closed

Used to mechanically join individual parts of machinery, piping, and equipment

Fasteners

Type of fastener characterized by a helical ridge, known as an external thread or just thread, wrapped around a cylinder

Bolt

Three parts of a bolt

Head, shank, thread

Three lengths used to identify a bolt

Nominal length, grip length, thread length

Five unified screw thread series

``` UNC (Unified Coarse Thread) UNF (Unified Fine Thread) UN (Constant Pitch Thread) UNJ series NC (National Coarse Thread) ```

Thread pitch of a bolt or nut can be determined by using a special hand tool called ___

A thread gauge

Looks like a collection of several small saw blades pinned together on one end and each with a different number of teeth

Thread gauge

To measure the length and diametre of bolts and screws, use ___

Machinist rule or rigid measuring device such as a slide caliper

Used to dress damaged threads on bolts

Thread files

Two types of black oxide coatings

Thermal | Chemical

Identify fastener material characteristics, identification markings, and suggested use

NSTM, Chapter 075

Type of hardware fastener with a threaded hole

Nut

Almost always always used opposite a mating bolt to fasten parts together

Nut

Also known a a nyloc, polymer insert lock nut, or elastic stop nut

Nylon insert lock nut

Kind of nut that includes a nylon collar insert

Nylon insert lock nut

Nyloc nuts retain their locking ability up to ___

250 degrees F

Also called a castle nut or slotted nut

Castellated nut

Nut with slots cut into one end

Castellated nut

Used in low torque applications, such as holding a wheel bearing in place

Castellated nut

Thin plate, most often disk-shaped, with a hole usually in the middle that is normally used to distribute the load of a threaded fastener

Washer

Type of fastener characterised by a helical ridge, known as external thread or just thread, wrapped around a cylinder. Designed to cut a helical groove in a softer material as it is inserted

Screw

Has an unthreaded shank below the head. It is designed to attach two pieces of wood together

Wood screw

Similar to a wood screw except that it is generally much larger, running up to 15 inches in length with diametres from 1/4 to 1/2 inch and a hexagonal head

Lag screw/bolt

Designed for fastening heavy timbers to one another or fastening wood to masonry or concrete

Lag screw/bolt

Has sharp threads that cut into materials such as sheet metal, plastic, or wood. They are sometimes notched in the tip to aid in chip removal during thread cutting

Sheet metal screw

The shank is usually threaded to the head, and make excellent fasteners for attaching metal hardware to wood

Sheet metal screw

Similar to the sheet metal screw but it has a drill-shaped point to cut through the substrate to eliminate the need for drilling a pilot hole

Self-drilling screws

Designed for use in soft steel or other metals. The points are numbered from 1 - 5; the larger the number, the thicker the metal it can go through without a pilot hole

Self-drilling screws

A small fastener (less than 1/4 diametre) threaded the entire length of its shank that usually has a recessed drive type, may also be made with socket heads

Machine screws

Headless screw but can be any screw used to fix a rotating part to a shaft

Set screw

Permanent mechanical fastener consisting of a smooth cylindrical shaft with a head on one end. The end opposite the head is called the buck-tail

Rivet

The tail of the rivet is upset how much?

About 1.5 times the original shaft diametre

Rivet body is normally manufactured using one of three methods

Wire Tube Sheet

Two types of pressure gauges

Bourbon tube gauges | Manometres

Used for measuring pressures and vacuums

Bourbon tube gauges

Used for measuring low pressures or vacuums

Manometre

Pressure gauges have three primary purposes

Indicate machinery condition Help spot system problems early Supply readings for machinery logs

0 indicates a perfect vacuum

psia

1 psi = __ Hg, and ___ inches of water

2. 036 | 27. 6778

C-shaped, curved, or twisted tube that is open at one end and sealed at the other. The open end fixed in position, and the sealed end is free to move. The tube is oval in cross-section

Bourbon tube gauge

The bourbon tube attempts to ___ when there is an increase in the volume or the internal pressure of the contained fluid

Straighten

Bourbon tube gauges can be used to measure __

Both pressure and vacuum

Bourbon tubes are made of

``` Brass Phosphor bronze Stainless steel Beryllium copper Other metal that does not react with the system ```

Types of bourbon tube gauges

``` Simplex Duplex Vacuum Compound Differential pressure gauges ```

Has one bourbon tube, measures pressures above atmospheric pressure, calibrated in psi or psig

Simplex bourbon tube gauge

Has two bourbon tubes and two separate gear mechanisms, used to measure pressures above atmospheric pressure. Measures two separate pressures at the same time, such as a differential drop. Calibrated in psi or psig

Duplex bourbon tube gauges

Has one bourbon tube, measures pressures below atmospheric pressures. Commonly used in vacuum sewage systems and A/C and refrigeration systems. Calibrated in psia or Hg

Vacuum bourbon tube gauge

Any pressure less than atmospheric pressure

Vacuum

Has one bourbon tube, read both pressure and vacuum, calibrated in both psig and Hg

Compound pressure gauge

Has two bourbon tubes but only one pointer. Used to measure the pressure differential across strainers and filters, calibrated in psig or psi

Differential pressure gauges

Protects the needle and internal components from excessive vibration from outside sources. Also acts as a pressure snubber and prevents damage to the gauge from excessive pulsations from the system

Liquid filled gauge

Hydraulic shock

Pressure fluctuations

Glass tube of uniform diametre filled with liquid

Manometres

Three basic types of manometres

U-tube Well Inclined tube

Manometres are most commonly filled with __

Water | Special oils

Interaction of an indicating liquid with the tube walls due to surface tension

Meniscus

Shipboard gauges are generally accurate to within __

+/- 3% for sizes below 3 1/2 inches | +/- 1% for sizes 3 1/2 inches and above

A pressure gauge needs to have a range in which the anticipated maximum normal working pressure is about ___ of the maximum scale reading

66%

A pressure gauge need the system normal working pressure to be ___

The middle third of the scale (33-66%)

Safety gauge safety information is found in ___

NSTM, Chapter 504

The rate of increasing pressure for pressure gauges should be kept below ___

200 psig/sec

Operate on the principle that the expansion of solids, liquids, and gasses has a known relationship to temperature change

Expansion thermometres

Three types of expansion type thermometres

Liquid-in-glass Bimetallic expansion Filled-system

Oldest, simplest, and most widely used devices for measuring temperatures

Liquid-in-glass thermometres

Has a bulb and a very fine bore capillary tube. The tube contains alcohol or some other liquid that uniformly expands or contracts as the temperature rises or falls

Liquid-in-glass thermometres

The operating range of a liquid-in-glass thermometre

-102 to 760 degrees F

Make use of different metals having different coefficients of linear expansion

Bimetallic thermometre

One end of a straight bimetallic strip is fixed in place. As the strip is heated, the other end tends to curve away from the side that has ___

The greater coefficient of linear expansion

Operating range of a bimetallic thermometre

-40 to 750 degrees F

Bimetallic thermometre accuracy is ___

1% of of full span

Measurement accuracy of liquid-in-glass thermometre is generally ___

One-half of the smallest scale division

Used in locations where the indicating part of the instrument must be placed some distance away from the point where the temperature is to be measured

Filled-system thermometres

Often called distant reading thermometres

Filled-system thermometres

Distant reading thermometres may have capillaries as long as __

125 ft

Operating range for a filled-system thermometre

-40 to 1200 degrees F

Measurement accuracy of filled system thermometre

One percent of full span

Simplest, least known accessories used in industrial temperature measurement applications. Closed-end tube design to accommodate a temperature sensor in piping installations

Thermowells

Two basic kinds of thermowells

Low pressure | High pressure

Used to provide isolation between a temperature sensor and the environment, liquid, gas, or slurry

Thermowell

Allows the temperature sensor to be removed and replaced without compromising either the ambient region or the process

Thermowell

Thermowells installed in systems with operating temperatures above ___ should be positioned vertically to prevent gradual sagging of the protective tube

400 degrees F

The comparison of a measurement system or device of unverified accuracy with a measurement system of known and greater accuracy to detect and correct any deviation from required performance specifications of the unverified measurement system or device

Gauge calibration

Maximum length of time established between calibration services during which equipment is expected to remain within acceptable performance levels under normal conditions of handling and use

Calibration interval

All instrumentation must be calibrated using an __

Instrument Calibration Procedure (ICP)

ICP

Instrument Calibration Procedure

Current ICPs will be issued to the ___ by ___

MATs | MLCLANT

CG calibration intervals are ___ for most pressure gauges and pressure transducers, ___ for metres, and ___ for temperature gauges

24 months 24 months 36 months

Pressure gauges located in weapons spaces shall be calibrated at ___ intervals

12 months

Calibration sticker has four pieces of information

Date calibrated Next due date FCA lab code Technician performing the calibration

Indicate that a gauge was calibrated and accurately indicated the pressure on the day of calibration and when it is due to be calibrated again

Calibrated stickers

Indicates that the gauge failed when tested

Rejected sticker

Colour or rejection sticker

Red

Used on systems and gauges that do not measure critical pressures or temperatures

Calibration NOT required sticker

A gauge is deemed to be critical if when it inaccurately reflects an equipment parametre, the result is ___

Serious equipment damage Personal injury Jeopardised cutter mission Potential violation of environmental regulations

Any device used to control fluids in a closed system

Valve

The discs and seats of alloy steel valves are usually surfaced with __

Chromium cobalt alloy known as Stellite

Brass and bronze valves are never used in systems where the temperatures exceed ___

550 degrees F

___ valves are used for all services above 500 degrees F, and in lower temperature systems, where internal or external conditions of high pressure, vibration, or shock would be too severe

Steel

__ valves are used almost exclusively in systems that carry salt water

Bronze

Two general groups of valves

Stop valves | Check valves

Used to control the flow of fluid or air in a system, may also be referred to as flow control valves

Stop valves

Three types of valve stem configurations on a stop valve

Non-rising Rising Outside screw and yoke

The stem is threaded and the gate or disc travels up and down on the stem

Non-rising

The stem is threaded with the bonnet assembly. The stem travels up and down through the packing

Rising

The stem is threaded with the yoke and handwheel assembly. The stem travels up through the packing, yoke, and handwheel

Outside yoke and screw

Five groups of stop valves

``` Globe Gate Butterfly Ball Plug ```

Most common type of stop valve in the CG

Globe valve

Globular shaped body, three types of functions: Straight-flow, angle-flow, and cross-flow. Throttling valve, position of disk regulates flow, can be installed in either direction. Normally installed so flow is to the bottom of the disk

Globe valve

Used when a straight-flow of fluid and minimum flow restriction are needed. The valve portion that controls the flow acts like a gate. Allow maximum flow when opened fully

Gate valve

Two types of gate valves

Rising stem | Non-rising stem

Gate valves are not used for ___

Throttling

Small, lightweight, and quick-acting valve, provides positive shutoff, and can also be used for throttling

Butterfly valve

Stop valves that use a ball to stop or start the flow of fluid

Ball valves

Rotary valve similar to a ball valve. It controls flow by means of a cylindrical or tapered plug with a hole in the center that lines up with the flow path of the valve to permit flow

Plug valve

Plug valve in smaller form used to provide a quick, rapid source to drain overpressure or dregs from tanks or storage bins

Petcock

Simple type of DCV. Allow the fluid or gas to flow in one direction only

Check valves

Three types of check valves

Swing pivot Vertical lift Spring-loaded

This check valve uses gravity to keep it closed

Swing pivot check valve

Operates in the same manner as the swing pivot check valve, except the element moves in an up and down motion

Vertical lift check valve

This check valve uses a spring to hold the valve shut

Spring-loaded check valve

Three types of spring-loaded check valves

Ball Poppet Sleeve

Two basic types of check valves

Simple | Compound

Used in a fluid system or air system to maintain fluid lines at or near a preset pressure

Regulating valves

Operates in a similar manner to a globe valve. Designed with a long-tapered needle and seat. The needle acts as the disk. Very fine threads allow flow rates to be controlled very accurately

Needle valve

Based on temperature, an element inside of the valve expands or contracts, which in turn regulates the flow of liquid

Thermostatic expansion valve

Two types of thermostatic expansion valves

Single-acting | Three-way

Electromechanical device which controls the flow of a gas or liquid

Solenoid

Best way to extend the life of a valve

Preventive maintenance

If it is necessary to remove a valve from the system, ensure the valve is marked for ___

Direction of flow Valve position Flange alignment Relief valve discharge direction

The method used to visually determine whether the seat and the disk of a valve make good contact with each other is called ___

Spotting-in

When spotting-in, rotate the disk ___

1/4 turn

Use ___ when spotting in

Prussian Blue (Blue Dykem)

The manual process used to remove small irregularities by grinding together the contact surfaces of the seat and disk

Grinding-in

Process used to remove irregularities that are larger than can be removed by grinding in

Lapping

Exactly the same size and shape as the valve disk used to true the valve seat surface

Lap

Two methods of cutting packing

Butt or square joint | Bevel or skive

Packing cut only used on preformed types

Step cut or step joint

All vital valves should be operated ___ from fully opened to fully closed

Monthly

White valve

Steam

Dark blue valve

Potable water

Light gray valve

Nitrogen

Dark grey valve

HP air

Tan valve

LP air

Light green valve

Oxygen

Dark green valve

Salt water

Purple valve

JP-5

Yellow valve

Fuel oil/gasoline

Stripped yellow/black valve

Lube oil

Red valve

Fire plug

Stripped red/green valve

Foam discharge

Light blue valve

Feed water

Orange valve

Hydraulic

Chartreuse valve

Hydrogen

Buff valve

Helium

Striped buff/green valve

Helium/oxygen

Gold valve

Sewage

Improper selection and/or installation of piping and tubing components could result in ___

Serious power loss Ruptured hose assembly Harmful liquid contamination

Assembly of pipe and/or tubing, valves, fittings, and other related components

Piping

Form a whole system or part of a system, used to transfer liquids and gases through a cutter, small boat, or station

Piping

Pipe and pipe fittings are classified by ___

Nominal size and wall thickness

Any metal having a high content of carbon containing iron

Ferrous metal

Mixture of copper and nickel

Copper alloy

Common percentages of copper and nickel within a copper alloy are ___

90-10 and 70-30

The nickel in a copper alloy gives it ___

Strength

Plastic materials should only be used on ____ piping systems

Nonvital

PVC is used for ___

Cold water due to its incompatibility with heat

ABS is used for ___

Drain lines

Colour of PVC

White

Colour of ABS

Black

The pipe's actual inside measurement will vary depending on wall thickness. This measurement is also known as the pipe's ___

Nominal pipe size (NPS)

A pipe that measures 1/8" to 12" in diametre is sized by its ___

Nominal ID (approximate internal measurement)

A pipe that measures over 12" in diametre is sized by __

Its actual OD (outside diametre)

When wall thickness increases or decreases, the outside diametre will ___

Remain the same

Three common grades of piping

Standard Extra strong Double extra strong

Identifies what material is flowing through the pipe

Painting the pipe

Piping on weather decks shall be painted ___

The same colour as the surrounding structure

Piping shall be marked to ___

Show the functional name of the system that the piping is going to Show direction of flow

Piping passing through unmanned spaces shall be labeled __

Once per space

Piping passing through machinery spaces shall be labeled ___

Twice, once when it enters the space, and once near the exit

Pipe markings shall be made with __

Stencils and black paint

Stencil size is determined by ___

Outside diametre of the pipe or covering which is being marked

When pipes are too small for stenciling ___

Use of wire labels is acceptable

Permit piping to be taken down for repair and alteration

Unions

Four parts to a union

Two tail pieces, one union ring, gasket or seat

Connects two pieces of the same diametre pipe together. Has female threads on both ends

Coupling

Also known as a bell reducer

Reducer coupling

Used to join two sections of pipe of different size. One opening is larger than the other, and both openings have female threads

Reducer coupling

Used to connect pipe of one size to a fitting of a larger size. One end of the bushing has female threads and the other end has male threads

Reducer bushing

Used to provide branches in a piping system. Four openings at 90 degree angles from one another. All openings are female threads

Cross fitting

Used to provide branches in a piping system. Three openings in the shape of a T. All openings have female threads

T-fitting

Used to change direction of piping, female ends

Elbows

Common angles of elbows

45, 60, 90

Used to cap off the ends of pipes, has female threads

Pipe cap

Used to plug the ends of fittings, has male threads

Pipe plugs

Pre-manufactured short lengths of pipe with male threads

Pipe nipples

Pipe nipples come in three lengths

Close, short, long

Any fitting with one of the openings smaller than the others

Reducing fittings

Pipe may be cut with ___

Pipe cutter Hacksaw Chop saw with aluminium oxide blade Horizontal band saw

Designed specifically for cutting pipe. Equipped with an adjustable jaw with a sharp cutting wheel and two rollers

Pipe cutters

Pipe cutter should be turned in the direction of __

The opening of the cutter

Two sizes of pipe cutters

No. 2 pipe cutter | No. 4 pipe cutter

No. 2 pipe cutter

Cutting capacity of 1/8" to 2"

No. 4 pipe cutter

Cutting capacity of 2" to 4"

A __ is used to cut nonferrous pipe that is to be brazed or soldered

Saw

Pointed or conical device with blades that remove burrs. The ratcheting handle is used to rotate the ream while light pressure is used to force the ream into the pipe end

Pipe ream

Once a plastic pipe has been cut, the outside edges should be __

Beveled approximately 1/16" at a 10 to 15 degree angle with a coarse file

Two types of threads on pipes

Parallel | Taper

Taper threads are denoted by ___

The letter R

Parallel threads are denoted by ___

The letter G

A pipe die is rotated in a ___ direction

Clockwise

Pipe over __ is best threaded on a machine

2 inches

Used to manually thread pipe

Die sets

Five types of die sets

``` Drop head One-piece Screw adjust pipe die Two-piece rectangular pipe die Two-piece collet pipe die ```

Machines that can cut and thread pipe

Pipe threading machines

The tightness of a threaded connection is a result of __

The clearance between the threads

A pipe die that is adjusted inward will cause the clearance between the threads to ___

Increase

Three products to prevent threads from seizing together

Teflon anti-seize tape Anti-seize compound Pipe dope

White and comes in small rolls, keeps fittings from seizing, also acts as a seal. It does not have adhesive, and is very thin, conforms to shape of the threads

Teflon tape

Do not use teflon tape on __

Petroleum systems, natural gas systems

Wrap teflon tape in the __

Opposite direction of the thread rotation

Do not use anti-seize compound on __

Potable water systems

Always use anti-seize compound on __

Stainless steel

Thick pasty substance used to seal threads

Pipe sealing compound

Sealing compound used on petroleum systems

Pipe sealing compound

Most common way to join plastic pipe

Solvent welding

Solvents in plastic pipe joining work by ___

Breaks down the pipe and fitting, and then the two pieces harden together

Store plastic pipe and fittings to be joined in an area of the same temperature for ___ prior to joining

1 hour

Do not solvent weld plastic pipe if the temperature is above ___ or below ___

90 degrees F | 40 degrees F

Allow a minimum of __ drying time before testing plastic pipes which have been solvent welded

48 hours

When solvent welding, twist the two pieces __

1/4 turn

When solvent welding, hold the joint together for ___

10 to 15 seconds

When solvent welding, do not move the pipe for ___

2 minutes

Serves the same function as piping, it can be either rigid or flexible

Tubing

The essential difference between pipe and tubing is __

Wall thickness

Tubing has __ walls

Thinner

Tubing can never be ___

Threaded

Sizes of tubing are listed by ___

Actual OD and wall thickness

Copper tubing is primarily used in ___

Low pressure applications where vibration is limited

Copper tubing has a tendency to ___

Harden and break due to stress and vibration

Three types of copper tubing

K L M

Primarily used for general purpose plumbing and underground service

Type K copper tubing

Solely used in a general plumbing environment

Type L copper tubing

Used with soldered fittings only. It is hard drawn and it will come in straight lengths

Type M copper tubing

Types K & L may be either __

Hard tempered or annealed

Used in flow lines for fluids and gases in pneumatic, hydraulic, or process applications, or for specialised uses such as medical or food processing

Stainless steel tubing

Two most commonly used steel grades for tubing are ___

304 and 316

304 stainless steel tubing comes in three different finishes

White pickled (No. 1 unpolished) Bright annealed Polished OD and ID

316 stainless steel tubing comes in two different finishes

Bright annealed | Polished finish that has been pickled

Similar to PVC but it is better for handling corrosive water at temperatures 40 to 60 degrees F above the limits for other vinyl plastics

CPVC

CPVC functions at ___ in pressure systems

180 degrees F

Six ways to join metal pipe

``` Welded joint Silver brazed joint Threaded joint Soldered joint Expansion joint Flanged joint ```

Tubing can be cut with __

Hacksaw | Tubing cutter

If using a hacksaw to cut tubing, it should have a pitch of ___

32 teeth per inch

Preferred method for cutting tubing

Tubing cutter

After each complete turn of the tubing cutter, turn the adjusting handle __

1/8th of a turn

Flexible copper pipes can be joined using

Soldering | Compression fittings or flared fittings

The objective of tube bending

Obtain a smooth bend without flattening the tube

Has a radius block that is marked in degrees, and it consists of a handle, a bend ranging from 0 to 180 degrees, a radius block, a clip, and a slide bar

Hand tube bender

Mechanical tube bender bends tubes from ___

1/4 to 3/4 inch in diametre

Used as a means of making a tubing connection when periodic disconnection is required. Have a compression ring known as a ferrule which fits over the tube. Then a compression nut fits over the ferrule and into the fitting which, when tightened down compresses the ferrules onto the tubing

Compression fittings

Method of making a tubing connection when it is necessary to periodically disassemble the connection. A threaded female connecting nut is placed onto the tubing, and then the end of the tubing is flared. The flared end fits onto a cone-shaped male connector, and the two connectors are joined and tightened

Flared fittings

Used to make single or double flares in the ends of soft copper, brass, or aluminium tubing

Flaring tools

Forming process in which a metal tube end is expanded to a desired size or shape by forcing it into a rotating or stationary swaging tool into the end of the tube or pipe

Swaging

Fuel gas made up of carbon and hydrogen (C2 and H2)

Acetylene

Acetylene flame can reach temperatures of ___

5700 and 6300 degrees F

Colour or Acetylene

Colourless

Acetylene is unstable at pressures above ___

15 psi

Acetylene is extremely hazardous at pressures greater than __

25 psi

Acetylene/air mixtures can be ignited when they contain anywhere from ___ Acetylene

2.5 to 80 percent

Oxygen is stored in __

Green cylinders

Green cylinder with one white stripe at the top

Technical grade or medical grade oxygen

Green cylinder with two white stripes at the top

Aviation grade oxygen, with low moisture content

Aviation oxygen is used for all purposes on board a ship except

Medical usage

Oxygen cylinders must be labeled ___

Twice in locations opposite each other

When an oxygen cylinder is a shatterproof cylinder, it will be labeled ___

NON SHAT

OIL FREE label on gas cylinder means that ___

The cylinder was filled using a procedure that had no oil

Acetylene can be compressed into cylinders up to __

250 psi

Oxygen can be compressed into cylinders up to __

2000 psi

Size of compressed gas cylinder is determined by __

The amount of cubic ft it will hold

Acetylene cylinders must be standing up on end for __ prior to use

2 hours

Leave cylinders with at least __ in them

25 psi

Mark empty cylinders __

Store oxygen and acetylene a minimum of __ apart

20 feet

Do not store cylinders in temperatures above __

130 degrees F

Only the __ can give permission to store cylinders below decks

Only open the acetylene valve ___

1/2 turn

Two common safety devices in gas cylinders

Fusible plug | Unbacked safety cap

Hex shaped plug that is threaded into the cylinder or cylinder valve. Melts at a specified temperature

Fusible plug

Consists of a frangible disc that covers a port in the valve body, referred to as the rupture disc. When the pressure exceeds 3360 psi the disc will break

Unbacked safety cap

Reduces the pressure in the cylinder to a workable pressure

Regulator

Regulators have two gauges

Delivery (working) pressure | Cylinder pressure

Two types of regulators

Single stage | Double stage

This regulator requires no adjustment as the cylinder pressure decreases

Double stage

Acetylene threads are __

Left handed

Colour of acetylene hose

Red

Malfunction that allows the flame to travel into and beyond the mixing chamber

Flashback

Stops the flame from traveling backward through the system

Flashback arrestor

Momentary burning of flame into the tip

Backfire

Have internal mixing chamber that mixes the gas to produce a single flame, tubular in shape and bent to 65 degrees, also comes in 90 degrees. Tip is tapered slightly. The tip size determines the temperature

Welding/brazing attachments

Used for general purpose heating and is commonly known as a rose bud

Heating attachment

Commonly used to preheat and postheat weldments, it may be used to braze very large fittings. It is shaped like a welding/brazing attachment with an oversize, multiple orifice tip

Heating attachment

Used to remove carbon and slag buildup from the tips of the attachments

Tip cleaner

Shaded lens to use for light brazing or small fittings

Shaded lens to use for light gas cutting, brazing, and plasma cutting

Shaded lens to use for medium gas cutting and welding

6-7

Shaded lens to use for heavy gas cutting and welding

8-9

Only use a ___ to light the torch

Striker

Three types of flames that can be generated

Carburizing (reducing), neutral, oxidising

Pure acetylene flame is __

Long and bushy with a yellowish colour

Burning an excess of acetylene produces this flame, achieved by opening the oxygen valve slowly until you have an inner bluish while cone with a greenish feather at the end surrounded by a bluish flame.

Carburizing (reducing) flame

Carburizing flame is how hot?

5700 degree F

In the carburizing flame, the greenish feather should be ___

About twice the length of the inner cone

Three distinct colours of the carburizing flame

Bluish-white inner cone Greenish feather Light-blue outer flame

Produced by burning equal parts of oxygen and acetylene. Obtained by opening the oxygen valve further until the greenish feather disappears and clearly defined inner cones are visible

Neutral flame

The neutral flame is how hot?

5900 degrees F

This flame is used for welding, brazing, and cutting operations

Neutral flame

The oxidising flame is how hot?

6300 degrees F

Produced by burning an excess of oxygen. Achieved by opening the oxygen valve further until you see a short outer flame and small blue inner cone

Oxidising flame

This flame makes a hissing sound

Oxidising flame

The oxidising flame makes the steel __

Bubble and spark

The inner cone is somewhat pointed and purplish at the tip

Oxidising flame

Method of making a permanent connection between metals which uses a lower temperature than brazing

Soldering

Soldering us used with temperatures below __

800 degrees F

Unlike glue with forms a solely physical adhesive bond, solder __

Chemically reacts with the other metals to form a different alloy

Four basic elements of soldering

Base metals Flux Solder Heat

Metals that readily react with solder to form strong chemical and physical bonds. They include copper, bronze, silver, brass, and some steels

Base metals

Metals that are difficult or impossible to solder include __

Aluminium, high alloy steels, and cast iron

The more oxidation present, the __ the solder bond

Weaker

Primary material used to overcome problems caused by oxidation

Flux

Two general classes of flux

Acid-based | Non-acid based

Flux both cleans and prevents oxidation, it is corrosive

Acid-based

Flux prevents oxidation but does not clean

Non-acid based

Often applied to the surface of the base metals prior to soldering

Flux

Its primary purpose is to stop the base metals from oxidising while they are being heated to the soldering temperature

Flux

Solder for P/W systems is made from __

95% tin and 5% antimony

P/W system solder is referred to as __

95-5 solder

It is the custom of the solder industry to state the __ content first

Tin

Largest portion of all solders in use

Tin-lead

The higher the tin content, the __ the melting temperature

Lower

Tin increasing the __ ability and lowers the __ of the solder

Wetting | Cracking potential

Antimony increases the ___ of the solder

Strength and mechanical properties

How much antimony can be in solder?

Up to 6%

Solder used for joining aluminium alloys

Tin-zinc

91/9 and 60/40 tin-zinc solders are for __

Higher temperature ranges (over 300 degrees F)

80/20 and 70/30 tin-zinc alloys are normally used as ___

Pre-coating solders

Solder used for refrigeration work or for joining copper to cast-iron joints. The most common is 95/5

Tin-antimony

Solder useful where strength at moderately high temperatures is required

Lead-silver

Used where there is a need to have cadmium and lead-free solder

Tin-silver

Can be used as a replacement for tin-antimony solder (95/5)

Tin-silver

This process uses nonferrous filler metal that melts below 840 degrees F in which the base metal is not melted. The filler metal is distributed in the joint by capillary action

Soldering

This process uses nonferrous filler metal that melts above 840 degrees F in which the base metal is not melted. The filler metal is distributed in the joint by capillary action

Brazing

Refrigerants produce __ when heated

Phosgene gas

Ability of a liquid to move into a small, tightly fitted space

Capillary action

To have successfully brazed a joint __ must have occurred

Capillary action

When a very thin continuous film of filler metal coats the base metal

Tinning

Tinning is produced by ___

Capillary action

Process by which heat flows from molecules in metal

Conduction

In the molten state, filler metal flows from the __ to the ___ areas

Colder | Hotter

Refers to the fit between two members to be brazed

Fit-up

Best way to clean surfaces to be brazed

Sand them with an emery cloth

All brazing operations require the use of a __

Flux

Flux used for high temperatures (up to 1800 degrees F) and is good for steel brazing

Black flux

Flux used for lower temperature (1100 to 1500 degrees F) applications

White flux

Brazing filler metals are ___

Nonferrous metals or alloys

Filler metals containing __ produce the strongest joints

Silver

Grades 0, I, and II are suitable for joining ___ (filler metal)

Ferrous metals

Grade III is intended only for brazing ___

Copper and copper-base alloys

Grade IV is used for joining ___ except those having melting points __ than the filler metal

Ferrous and nonferrous metals | Lower

Grade V is used when the ___ but ___

Characteristics of Grade IV are required | Where close tolerances cannot be maintained or when the addition of a filler is desired

This grade should be used to braze carbide tool tips to steel shanks

Grade V

The size of the brazing tip is determined by ___

The size of the joint to be brazed

Two methods used in brazing joints

Feed-in method | Insert method

Sticks or wire filler metal is manually fed into the joint once it is heated to the proper temperature. This is the most common method

Feed-in method

A ring of filler metal is inserted into the joint before it is heated. When heated, the filler metal melts and is distributed through the joint

Insert method

When brazing, the tip is held how far from the joint?

2 to 4 inches

When loosening flange bolts, loosen the bolts in a __ pattern

Criss-cross

Sealing materials fall into one of two categories

Static seal | Dynamic seal

Seal used in joints where there is no relative motion between the seal and any parts in contact with the seal. Frequently referred to as a gasket

Static seal

Sealing device used between parts that have relative motion such as piston or shaft seals. Frequently referred to as packing

Dynamic seal

Five sealing device materials

``` Synthetic rubber Cork Metal Fabric material Asbestos ```

This sealing material is very popular in piping applications because it will not deteriorate when it comes in contact with petroleum products

Synthetic rubber

Temperature range of synthetic rubber

-65 to 700 degrees F

Very popular sealing material, but has a limited use in hydraulics. Good compressibility, can be cut to almost any shape, temperature range up to 270 degrees F

Cork

Widely used material for sealing device, holds its shape well

Metal

Temperature range of copper metal sealing devices

Up to 450 degrees F

Most common metal for metal sealing devices

Copper

Temperature range of fabric material sealing device

Up to about 200 degrees F

This sealing material is derived from a natural formation of magnesia and silica

Asbestos

This sealing material has the highest temperature range and can be used up to 1000 degrees F

Asbestos

Two methods of cutting a gasket

Gasket cutting kit | Ball-peen hammer

One of the first sealing systems considered when a fluid closure is designed

O-ring

Solid-ribber, doughnut-shaped seals. Can form both static or dynamic seals

O-rings

Groove or cavity that O-ring is mounted in

Gland

When installed, the ___ of the O-ring cross section enables it to seal low fluid pressures

Compression

Fabricate an O-ring with __

O-ring splicing kit

Six common O-ring failures

``` Abrasions Compression set Chemical degradation Explosive decompression Installation damage Overcompression ```

O-ring exhibits a flat surface parallel to the direction of motion. Loose particles and scrapes may be found on surface

Abrasion

Contributing factors to O-ring abrasion

Rough sealing surfaces. Excessive temperature. Process environment containing abrasive particles