Instrument tubing workbook — Process Academy

Record

Learner details

Name Employee / ID no. Site / area Date started

Part A

Pre-job hold points

Before you cut any tube, confirm each control. Tick an item only when you could show the evidence.

Work pack, drawing or hook-up detail identifies tube OD, wall, material and routing. Fittings are the correct size, material and manufacturer, with no mixing of metric and imperial. Permit, isolation and depressurisation are confirmed for any connection to a live system. Tube cutter, deburring tool, bender (correct size), gap gauge and backup wrench are available and serviceable. Tube stock is free of scratches, dents and ovality, and ends are capped to keep it clean. The routing slopes as required, avoids hot surfaces and walkways, and has support points identified. Leak-test method, medium, pressure and acceptance criteria are defined in the approved procedure. PPE is correct for the task, including eye protection for cutting and pressure testing.

Part B

Tube identification drill

Each tube was measured with a calibrated vernier. Choose the nominal size it matches. A small error here leads to a blow-out later.

Part C

Put the make-up sequence in order

Use the arrows to arrange the steps from first to last, then check your sequence.

Part D

Bend calculations

Work out each answer to the nearest 0.1 mm. Answers within ±0.5 mm are accepted. Formulas: setback = R·tan(θ/2), arc = π·R·θ/180, gain = 2·setback − arc, developed length = A + B − gain.

Part E

Fitting make-up record

Record each fitting you make up in practice or under supervision. The status updates from the turns and gap-gauge result. The expected turns are typical two-ferrule values — use your manufacturer's figure if it's different.

Fitting ID	Size	Material	Manufacturer / series	Turns applied	Gap gauge	Status	Remove

Part F

Leak-test record

Enter the values from your pressure-decay test. The workbook converts to absolute pressure and corrects the end reading for temperature change before comparing it with the allowable drop. This is a simplified learning check — your procedure's acceptance method takes precedence.

System / line tag Test medium Lowest component rating (bar g) Test pressure (bar g) Hold time (min) Start pressure (bar g) End pressure (bar g) Allowable drop (bar) Start temperature (°C) End temperature (°C) Leak-detection fluid applied to every joint? Tested by

Measured drop: —
Temperature-corrected drop: —
Result: Enter test values

Part G

Final assessment

Eight questions. The pass mark is 7 out of 8. You can retake it — explanations appear after you submit.

Part H

Reflection & sign-off

Reflect on your practical work, then ask your supervisor to review the workbook and sign off.

What went well in your practical make-up and bending? What would you do differently next time, and why? Supervisor name Sign-off date Supervisor observed at least one fitting made up, gap-gauged and leak-tested by the learner. Supervisor comments

Training boundary: This workbook is a learning record, not a certificate of competency. Completion in the workbook does not authorise tubing, pressure-testing or live-plant work. Follow manufacturer instructions, project specifications and approved procedures, and get formal assessment where your site requires it.