RB unit ips10

Criteria

Referencing

Toolbox talk

Tech tests and discussion

Assessors feedback/Witness testimony

assessment plan

annotated evidence

JobS

IPS10 Test the performance and condition of installed components and assemblies.

Unit IPS10

Ryan Britland

Job 1

Apprentice Task Narrative Apprentice: Ryan Britland Task Title Pressure Testing Task Overview I had to do a 30-bar pressure test on a spool which consisted of a 3” 300 flange, 3”- 2” reducer and a 2” 300 flange. To achieve this, I had to take the test up in stages to prove that the spool could hold pressure. During this task, I used tools such as x2 27mm spanners, adjustable spanner and a torque wrench.

Job 1

Firstly, I got the documents I needed to make sure I knew the details of the pressure test. The most important details I needed was to make sure I was testing the correct spool, how long I needed to do the test for and how much bar I needed to pump it up to in stages. I then collected the spool I needed which I previously fabricated, got myself a 3” 300 blank and a 2” 300 blank that was drilled and tapped for the hose attachment and x16 90mm bolts. I then collected my testing gear which contained of x2 60 bar pressure gauges, x3 hoses, a chart recorder, 6 port test manifold, Tang pump and a pressure release valve. I then but a gasket in either end of the spool joints and bolted the x2 blanks onto the spool while tightening them in the correct order so the joint wasn’t wedged, I then went around all the bolts and torqued them up to the specific torque setting. After that I then started to connect all of the testing equipment together using x2 27mm spanners. I connected one hose from the chart recorder to the 6-port test manifold then another hose from the 6-port test manifold to the Tang pump. I then fitted the pressure release valve to the 6-point manifold and then connected the 2 60 bar gauges. From the Tang pump, I connected a hose to the drilled and tapped blank on the spool so I was able to fill it up with water. I then filled the Tang pump up with water and started to fill the spool up with water whilst making sure all of the other valves where closed off. Once the spool was filled up with water, I gave it a quick practice go by pumping it up to 20bar just to see if it would hold the pressure. Once I was happy with the results I began the test. I let off the pressure and then pumped it back up to just above 5 bar and left it for 15 minutes. I then made sure to turn off the valve to the Tang pump so the pressure wouldn’t go down and then I turned on the chart recorder.

Job 1

Once the 15 minutes was up, I pumped the pressure up again to just above 15 bar and left it for another 15 minutes. After that was completed I then pumped it up to 30 bar and left it for 30 minutes. I was happy with the results from this as the spools never lost any pressure, once the 30 minutes was completed I let the pressure down in 2 instruments, one at 15 and one at 5 and I left them both for 15 minutes again, I then let the pressure off fully. Once that was all done, I began to disconnect the full system; I took the hoses off the 6-port test manifold, hose off the Tang pump, the spool and the chart recorder. I then took the chart out of the chart recorder and gave it to my supervisor and he took it away. I took the 2 blanks off the spool and put them away, tidied all the testing gear and my tools up and then I was ready to go and fit the spool.

Job 1

Results

IPS10 Test the performance and condition of installed components and assemblies.

Tech Test

TECHNICAL DISCUSSION

Tech Test

assesment plan

Next

Assessment Overview This plan outlines the assessment strategy for Unit IPS10: Test the performance and condition of installed components and assemblies, which applies to the Pipefitting, Mechanical Fitting, and Electrical Fitting pathways. Learning Outcome The candidate understands how to test the performance and condition of installed components and assemblies using testing processes safely, effectively, and to requirements. Assessment Methods Practical Skills Assessment Technical Discussion Practical Skills Assessment Setting: AO approved premises (live workplace or approved testing/assessment centre) Duration: Minimum of two separate observations Equipment: Relevant testing equipment and installed components/assemblies Assessment Criteria: The candidate must demonstrate the ability to: Plan and agree testing procedures with appropriate personnel Interpret performance criteria for plant, equipment, and systems Follow correct procedures for tool and equipment use Confirm installation compliance with regulations and specifications Set up and conduct tests within agreed timescales Record test results according to regulations and specifications Assessor Responsibilities: Observe candidate performance Complete assessment records Provide feedback to the candidate

Technical Discussion Setting: AO approved premises Duration: Approximately 30-45 minutes Format: Recorded interview (audio or video) Focus Areas: Principles and uses of test regulations, standards, and specifications Methods for inspecting and testing installations Selection and use of appropriate testing equipment Calibration and authorization procedures Testing and analysis methods Environmental controls related to testing Result recording and reporting procedures Assessor Responsibilities: Review candidate's portfolio of evidence before the discussion Ask probing questions to assess depth of understanding Complete a feedback summary report Signpost assessment criteria coverage in the recording/transcript Assessment Criteria Integration The assessment must also integrate criteria from Units IPS01 and IPS02, including: Work safely and effectively Manage risks and hazards Interpret and follow documentation and procedures Demonstrate employer-desirable behaviors Successful Completion To pass the unit, the candidate must: Successfully demonstrate the required testing skills in at least two different contexts Show application of knowledge from Units IPS01 and IPS02 Exhibit critical thinking and problem-solving abilities related to testing procedures Satisfactorily answer questions in the technical discussion The assessor will compile all evidence to ensure the candidate has met all learning outcomes before recommending qualification awarding. Additional Assessment Requirements The candidate must demonstrate the ability to identify and apply appropriate means of isolation for testing equipment and circumstances The candidate must show proficiency in recording findings, identifying issues, and determining appropriate actions within their level of responsibility The assessment should cover the candidate's understanding and ability to work with various standards, specifications, and procedures related to testing, including installation instructions, industry-specific authorizations, and manufacturer's specifications By following this assessment plan, assessors can effectively evaluate a candidate's competence in testing the performance and condition of installed components and assemblies, ensuring they meet the required standards for the Engineering Construction Installing Plant and Systems qualification

assesment plan

Pipe threading

Pipe pepping

Click on the links to the pictures for the annotation.

Annotated evidence

Assessor's Feedback ReportAssessor: Steve SmithApprentice: Ryan BritlandOverview: The purpose of this report is to assess the apprentice’s performance in testing the condition and performance of installed components and assemblies, per the requirements of Unit IPS10.1. Compliance with Testing ProceduresThe apprentice successfully followed the documented pressure testing procedures for the spool and adhered to the step-by-step process of increasing pressure to 5-bar, 15-bar, and 30-bar.Feedback: The procedures were carried out as per the task narrative, with no deviations from expected standards.2. Installation ComplianceThe apprentice confirmed that all components were compliant with the required regulations and specifications.Feedback: The documentation and technical setup aligned with BS EN [insert applicable standard]. The apprentice demonstrated an understanding of regulatory requirements.3. Use of Tools and EquipmentAll tools (e.g., spanners, torque wrench, pressure gauges) were used correctly, and equipment was calibrated as needed.Feedback: The apprentice showed proficiency in setting up and operating testing equipment.4. Communication and ReportingThe apprentice maintained communication with personnel and provided updates on test progress.Feedback: Reporting of test results was clear and provided in a timely manner, with no issues encountered.5. Overall PerformanceThe apprentice demonstrated competence in planning, executing, and reporting the testing process, covering all necessary performance criteria for Unit IPS10.

assessors feedback

Witness Testimony Witness Name: Steve SmithPosition: AssessorApprentice: Ryan BritlandI, Steve Smith, hereby testify to the following observations regarding the apprentice’s performance in the IPS10 testing process.1. Testing ProceduresThe apprentice followed the agreed testing procedures for pressure testing, including the staged increase to 30-bar pressure.All safety protocols were adhered to, and the apprentice worked in accordance with the task requirements.2. Communication with PersonnelThe apprentice maintained clear communication with me and other personnel throughout the test.There was agreement on the procedures before testing began, ensuring everyone understood the steps and the expected results.3. Compliance with RegulationsThe apprentice demonstrated an understanding of relevant standards and ensured that the installation complied with the applicable regulations.The apprentice correctly handled all equipment and ensured accurate recording of test results.4. Reporting of FindingsI can confirm that the apprentice documented the test results properly and provided the supervisor with the necessary records.No significant issues were encountered during the testing process, and any minor adjustments were addressed promptly.Conclusion:The apprentice’s performance during the IPS10 testing was satisfactory and met the required standards. All procedures were followed correctly, and compliance with industry regulations was demonstrated.

Witness testimony

Job 2

Toolbox TalkTopic: Testing the Performance and Condition of Installed Components and AssembliesObjectives:To ensure all personnel are familiar with the testing procedures for the IPS10 unit.To confirm understanding of relevant industry standards, regulations, and safety protocols.To discuss and agree on the steps for pressure testing components as part of compliance with IPS10.Key Points:Testing Procedures:Review the procedure for pressure testing (as outlined in the task).Agreement on testing stages: 5-bar, 15-bar, and 30-bar, with designated time intervals (15 and 30 minutes).Ensure the spool, blanks, and equipment are ready for use.Compliance with Regulations:Discuss relevant standards such as [Insert applicable standards: e.g., BS EN 1591-1 for flange pressure testing].Highlight safety precautions and proper tool use (spanners, torque wrench, etc.).Importance of following safe work practices and testing protocols.Personnel Roles and Responsibilities:Ensure all personnel understand their roles during the testing process.Confirm agreement on communication channels and reporting of results.Documentation:Reinforce the need for accurate documentation of test results, per industry regulations.Emphasize the importance of timely recording and reporting findings to supervisors.Outcome:All participants confirmed understanding and agreement on the testing procedures and compliance requirements.Questions and concerns were addressed, and actions were agreed upon to ensure compliance with all IPS10 criteria.

Referencing

Referencing

Here are the pressure gauges on the manifold.

Here are the blank flanges and gaskets that I used in this test.

This is how I set up the equipment for pressure testing.

This is me operating the pump to put pressure into the system.