WORK SHEET
Task: Install a urinal.

TOOLS/EQUIPMENT: Monkey wrench, plumber’s wrench, slit socket spanner, Star screw

                 driver, open wrench 11, T.Z 15 N special wrench.

MATERIALS: Sealing tape, water and waste cloth.
step one 

1. Prepare for fitting.
   
2. Attach the flange
   
3. Attach a seal gasket/rubber packing outlet of the urinal and attach the urinal. Tighten the screws.
4. Install the spud
5. Insert the spud through the wash bowl inlet
6. Put on the skirt parking
7. Pull the body forward, insert the spring washer and tighten the nut.
8. 
   
   
9. 
   
   
10. 
    Install the flush valve.
11. • Wind sealing tape on the screw end
    • Tighten the valve in by hand and securely by wrench.
     Note: Wind waste cloth around the valve to prevent it from getting scratches when tightening by wrench.
12. 
    
    
13. 
    
    
14. 
15. Install the flush pipe.
16. Insert the items below as in the  order:
    • Asbestos/steel packing
    • Two nuts in opposite direction, one to fix to the flush pipe to the flush valve and the other to the spud.
    • Spring washer
    • Rubber washer
    • 
      
    
      
17. Tighten the nuts by hand and finally using wrench. Remember not to over tighten as this action will crash the urinal.
18. 
    
    
19. 
    
    
20.                                                                                                                                                                                        wow! that is the project. well done proceed and open the water supply and test for leakagesif no leakage is found then you earned it you become a proffessional. good luck          enjoy plumbing.prepared by Gilbert Niwamanya- instructor Uganda.

General safety for plumbers 
Read and understand all instructions. Failure to follow all instructions listed below may result in electric shock, fire, and/or serious personal injury.
Work Area Safety
1. Keep your work area clean and well lit.
Cluttered benches and dark areas invite accidents.
2. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes.
3. Keep bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control.
4. Do not let visitors contact the tool or extension cord. Such preventative measures reduce the risk of injury.
Electrical Safety
1. Grounded tools must be plugged into an outlet, properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adapter plugs. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. If the tools should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user.
2. Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electrical shock if your body is grounded.
3. Don’t expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electrical shock.
4. Does not abuse cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electrical shock.
5. When operating a power tool outside, use outdoor extensions cord marked “W-A” or “W”. These cords are rated for outdoor use and reduce the risk of electrical shock.
6. Connect the tool to an AC power supply that matches the name plate specification. Incorrect voltage supply can cause electrical shock or burns.
7. Use only three-wire extension cords which have three-prong grounding plugs and three pole receptacles which accept the machines plug. Use of other extension cords will not ground the tool and increase the risk of electrical shock.
Personal Safety
1. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol, or medications. A moment of inattention while operating power tools may result in serious personal injury.
2. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.
3. Avoid accidental starting. Be sure switch is OFF before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch ON invites accidents.
4. Remove adjusting keys or switches before turning the tool ON. A wrench or a key that is left attached to a rotating part of the tool may result in personal injury.
5. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations.
6. Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.
Tool Use and Care
1. Use clamp or other practical way to secure and support the work piece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control.
2. Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed.
3. Do not use tool if switch does not turn it ON or OFF. Any tool that cannot be controlled with the switch is dangerous and must be repaired.
4. Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool. Such preventive safety measures reduce the risk of starting the tool accidentally.
5. Store idle tools out of the reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.
6. Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools with sharp cutting edges are less likely to bind and are easier to control.
7. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool's operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools.
8. Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool may become hazardous when used on another tool.
9. Inspect tool and extension cords periodically and replace if damaged. Damaged cords increase the risk of electrical shock.
10. Keep handles dry and clean; free from oil and grease. Allows for better control of the tool.
11. Store tools in dry place. Such measures reduce the risk of electrical shock.
Service
1. Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified repair personnel could result in injury.
2. When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance Section of this manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electrical shock or injury.
3. Follow instructions for lubricating and changing accessories. Accidents are caused by poorly maintained tools.
Specific Safety Information
The Operator’s Manual contains specific safety information and instructions for your protection against serious injuries including:
1. Loss of fingers, hands, arms or other body parts if clothing or gloves get caught in moving parts;
2. Electrical shock or burns from contact with wires, motor or other power drive parts;
3. Impact injuries, including broken bones if machine tips over or work piece falls;
4. Eye injuries, including being blinded by the work piece or work piece chips.
5. Read and follow safety labels on machine! Know the location and functions of all controls before using this tool.
Foot Switch Safety
The foot switch is for your safety. It lets you SHUT OFF the motor by removing your foot. If clothing should become caught in the machine, it will continue to wind up, pulling you into the machine. Because the machine has high torque, the clothing itself can bind around your arm or other body parts with enough force to crush or break bones.
Threading Machine Safety
1. Machine is made to thread and cut pipe or bolt. Follow instructions in Operator’s Manual on machine uses. Other uses may increase the risk of injury.
2. Secure machine to bench or stand. Will keep the machine from tipping over.
3. Keep covers in place. Do not operate the machine with covers removed. Exposure to moving parts may result in entanglement and serious injury.
4. Support long heavy pipe with pipe supports. Will prevent tipping of the machine.
5. Do not wear gloves or loose clothing. Keep sleeves and jackets buttoned. Do not reach across the machine or pipe. Clothing can be caught by the pipe resulting in entanglement and serious injury.
6. Clothing/gloves can be caught in moving parts. Fingers, hands, arms or other body parts can be crushed or broken.
7. Do not use machine if foot switch is broken. Foot switch is a safety device to prevent serious injury.
8. Lock foot switch when not in use. Avoids accidental starting.
9. Use foot switch.
10. Operate machine from switch side only.
11. Do not block or disconnect foot switch.
12. Keep foot switch in working order.
13. Make sure switch is in the OFF position before plugging power cord or when using nipple chuck wrench.
14. Make sure you can quickly remove your foot from the foot switch.
15. Keep hands away from rotating pipe and fittings.
16. Stop machine when screwing fittings on pipe or wiping thread.

REMEMBER THAT IT IS SO MUCH IMPORTANT FOR YOU TO UNDERSTAND THE SAFETY PROCEDURES AT ANY TIME IN A WORKPLACE TO AVOID LOSS OF LIFE .
LATER WE WILL SHARE HOW TO REPORT AN ACCIDENT THAT HAS OCCURRED IN THE WORKSHOP/ AT THE WORK PLACE.

PREPARED BY 
GILBERT NIWAMANYA 
INSTRUCTOR 
NAKAWA VOCATIONAL TRAINING INSTITUTE 
UGANDA.

Hydraulics
Flow
An open channel is a duct which a liquid flows with a free surface. At all points along its length the pressure on this surface will be the same, usually atmospheric pressure. A channel may be covered, provided that it is not running full; a partly filled pipe is treated as an open channel. Since the pressure at the surface of the liquid is constant, flow is not due to the pressure differences along the channel but is caused by the differences in the potential energy head due to the slope of the channel.
Open channel flow, a branch of hydraulics, is a type of liquid flow with in a conduit with a free surface, known as a channel. The other type of flow with in a conduit is pipe flow. These two types of flow are similar in many ways but differ in one important respect, the open channel has a free surface whereas pipe flow does not.
Steady flow- the depth of flow does not change over time or if it can be assumed to be constant during the time interval under consideration.
Un steady flow-the depth of flow does change with time.
Uniform flow: the depth of flow is the same at every section of the channel. Uniform flow can be steady or unsteady, depending on whether or not the depth changes with time (although the unsteady uniform flow is rare).
Varied flow – the depth of flow changes along the length of the channel.
Rapidly varied flow- the depth changes abruptly over comparative short distance. examples include the hydraulic jump and the hydraulic drop.
NB: a hydraulic jump is a phenomenon in the science of hydraulics which is frequently observed in open channel flow such as rivers or spillways. When a liquid at high velocity discharges into a zone of lower velocity a rather abrupt rise occurs in the liquid surface. The rapid flowing liquid is abruptly slowed and increases in height converting some of the flow’s initial kinetic energy into an increase in potential energy.
Properties of channels.
Artificial channels are made by man; they include irrigation canals, navigation canals, and spillways. Sewers, culverts and drainage ditches. They are constructed in a regular crossectional shape throughout. They are made from concrete, steel, or earth and they have the surface roughness reasonably well defined.
Natural channels are not regular and their surface roughness will often change with time distance and even elevation.
The wetted perimeter.
The length of the wetted surface measured normal to the direction of flow.
Area – the crossectional area of flow normal to the direction of flow.
In open channels the wetted perimeter can be defined as the surface of the channel bottom and sides in direct contact with the aqueous body. Friction losses typically increase with an increasing wetted perimeter.
For a rectangular channel of width B in which the depth of liquid is D.
Then Perimeter P= B+2D
Hydraulic gradient: the slope of the energy grade line of slope of the line representing the sum of the kinetic and potential energy along the channel length. It is equal to the slope of water surface in steady uniform flow.
Hydraulic radius (hydraulic mean depth): a measure of water depth in a channel defined as crossectional area of flowing water divided by the length of wetted perimeter.

The Chezy formula.

In fluid dynamics the Chezy formula describes the mean velocity of steady, or turbulent open channel flow. This was named after Antoine de Chezy the French hydraulics engineer in 1775.

This formula can be used to calculate mean flow velocity in pipes and channels and

worked example

worked example

prepared by Gilbert Niwamanya.

happy blogging 

thank you for your comment in advance.

Work Sheet PPR pipe work
Task : Assemble PPR pipe work

1.      Prepare materials, tools and equipment to be used.

The tools and equipment needed are:

-          Poly fusion welding machine

-          Polyvinyl Cutter / wheel cutter / Hacksaw

-          Allen key

-          Tape measure

-          Gloves 

1.      The Materials required are:

-         polypropylene Random  (PPR) pipes

-          Fittings (unions, elbows, tees, straight sockets etc

note that the Hack saw and blade is only needed when you have to change pipe type say PPR to GI other wise Vinyl cutter is the only recommended tool for cutting this type of pipe.

2.   Fix a 19 mm diameter heating models using  allen key 

3. connect the machine to power socket;

4.    Switch on the Poly fusion welding machine to make sure that the green light is on. The red light follows the green one showing that the machine has gone into automatic control.

5.   Cut the pipe on square using a vinyl cutter.

6. Heat the pipe and fitting as per    the depth given in the table.

7.Do not rotate pipe and fitting during heating, removing and cutting.

8.     For a 19 mm diameter pipe, the heating time is 5 seconds minimum and the working time  4 s whereas the cooling time is 2 s. The depth of weld is 14 mm.

9.    Fit a tee and an elbow all in the same direction. length of pipe to be cut is

300-28=272 mm

10. Fit a pipe 372 mm in the elbow and fit another 

11. Follow the same procedure as in 10 and 11

12. Repeat the procedure as in 9 to 11

13. Fit an equal tee in the middle and weld as in above. 

14. Unions are a key in easy dismantling of pipe work and should be fitted. 

15. Tighten the union and begin on the second model.

wow!! the project looks like this.

Try understanding the procedure. you will learn how to join PPR pipes and fittings using the poly fusion welding machine.

happy blogging!! 

prepared by.

Gilbert Niwamanya

Instructor Nakawa Vocational Training Institute

Uganda.

work sheet:

Task: assemble GI and PVC pipe work using screwed fittings.

Tools required

1. hack saw

2. tape measure

3. hand stock die

4. file

5. pipe cutter

6. pipe wrenches

7. Wire brush.

8. reamer

(a)   cut the pipe,

(b)  Thread

(c) wrap the threads with PTFE thread tape, onto the threads

(d)  Fix the fitting.

(e)  To fix the next fitting take the calculation

Length of pipe to be cut =L-2 (B-A) where L is the whole length given. B is the length from center of the fitting to the end of it and A is the length of the threads.

Revise the working drawing so as to come with the right work model.

The pipe work should be clean and the tee in the middle should face up and elbows in the right direction.

(f) To measure the pipe remaining, first insert the nipple and union.

(g)  measure the balance length to the tee.

(h) To tighten the union, pull up one side of pipe work to enable you tighten the piece .

(i)  Close the union lastly and make sure that the GI tees are at right angles.

(j) Confirm the entire dimensions of the base as you prepare to begin the PVC pipes.

(k) Thread cut the PVC pipes to size

(l) Fix them as shown one can first fix the elbows onto the pipes before fixing them onto the base.

(m) The final product!!!!!!!

(n) Clean the product, confirm the dimensions

(o)  Proceed for water test.

Remarks:

1. Measure twice and cut one as improper measurement will waste material

2. Only pipe/plumbers vices to be used for pipe assembly

3. Wear gloves to protect your hands from GI burrs and swarfs.

4. Prepare packing for the union to prevent leakage.

The above work sheet enables the plumber to exhibit masterly of skills like measuring, cutting, interpreting working drawings,threading  and safety precautions. such practice should be under taken after the trainees have been introduced to measuring and marking, straight cutting (hack saw and blade or pipe cutter) and threading as we saw in the previous threading worksheet.

the trainees will find joy when they test for leakages and the assembly is found test free.

some time we will explain how to operate a hydraulic test pump.

try it out in your workshop and share with us how unions behave as you will try the assembly.

In case you would like to test, loosen the back nut of the union on the PVC loop and start pumping, this will allow escape of air from the pipework , after you see the first drop at this union, tighten the back nut and proceed pumping, check on your gauge.

waiting to share your experience and feed back

thank you so much.

prepared by 

Gilbert Niwamanya 

Instructor- Nakawa Vocational Training Institute 

Uganda.

PLUMBING TOOLS
There is a saying known the world over by all craft men and women, particularly plumber: ‘ a good workman never blames his tools.’ All too often, however, tools are blamed for jobs that go wrong or for mistakes that are made. This is usually because the wrong tool has been used for a job or because the tools have not been maintained properly. “This information will show you all the common tools used by a plumber, what they are used for and tips on how to get the best out of them. Most plumbing activities involve the following:-
1. Measuring and setting tools

2. Cutting tools

The installation of sanitary fixtures/appliances involves the cutting or drilling of timber, sheet metal, metal pipes, earthen ware pipes and fittings, steel plates, plastic pipes and fittings and asbestos cement pipes. Some of the tools used with these materials are hacksaws, wood saws, power saws, scrappers, cold chisels, wood chisels, drill bits, files, pipe cutters, brace and bits, washer cutters.

N:B: Washer cutters have special, adjustable diameter bits. They may be used to cut washers of various sizes from sheet metal, lead, zinc, copper, leather or rubber.

Typical range of cutting tools are shown below.

3. Forming tools

The sanitary plumber will require special tools to flare copper pipes, to form sheet metal and zinc sheet plus zincalume, aluminium, stainless steel and to bend pipes and tubes. These tools may consist of a tube flaring tool (block and pin or an easy-flare tool), bossing mallets, mandrels, rubber mallets, pipe and tube threading dies (ratchet dies 12 mm-mm and 25 mm -50 mm) and machines and pipe and tube bending machines. Also, copper and copper alloy fabrication tools for forming junctions and branches in waste, soil and vent pipe installations. These are available for square (90 deg,  etc.) and oblique (45 deg) branches in the combinations shown in the drilling chart further on.

Jointing tools

For jointing materials such as galvanized sheet steel, zincalume sheet, copper aluminium, stainless steel sheet, mild steel pipe, plate and angle, UPVC pipe, brass and copper tube and others.

5. Percussive and Driving tools

These tools are primarily used to drive nails and screws, form materials and to secure fixtures and fittings.

The following tools are required: Screwdrivers, hammers of all descriptions, mallets, lead dressers, metal working stakes, anvils and jimmy bar (pinch bar).

6. Gripping tools

Various gripping tools are necessary for the installation of pipes, taps and fittings associated with sanitary plumbing fixtures. The following are essential;

Engineer’s vice, stillsons (both straight and offset), chain tongs, multi grips, foot prints, adjustable spanners of various designs and sizes, pliers of various shapes and sizes, tube spanners and pipe vices.

7. Digging and laying tools

The sanitary plumber or the drainer will be involved in laying sewers and storm water drains. A basic kit of digging tools and tools for working mortar, concrete, epoxy jointing materials and plaster are necessary. The essentials are: a shovel (various shapes), a spade, a crowbar, a pick, various types of trowels, concrete floats, spatulas and plaster small tools, underground boring machine, ditch-witch or trenching machine for special applications and larger jobs.

the above items are just some of the tools and or equipment that can enable the plumber to perform different tasks.

happy blogging.

Prepared by 

Gilbert Niwamanya