plumbing

PROMOSI KOMPETENSI SISWA(PKS)

SEKOLAH MENENGAH KEJURUAN

TINGKAT NASIONAL KE XII - 2004

BIDANG LOMBA

PLUMBING

DEPARTEMEN PENDIDIKAN NASIONAL

DIREKTORAT JENDERAL PENDIDIKAN DASAR DAN MENENGAH

DIREKTORAT PENDIDIKAN MENENGAH KEJURUAN

2004

The Technical Committee in accordance with the Competition Rules, has adopted the following minimum requirement for trade :

0. Competitor

0.1 Words implying masculine gender only shall include the feminine gender.

0.2 Competitor of each province are to be nominated by a Regional Selection Committee

0.3 Each participating province shall nominate one (1) Competition for each trade competed; and

0.4 Competitor age shall not exceed twenty (20) years at the year of the competition and must still as a student by Senior Technical High school.

1. Name and description of trade

The name of trade is Plumbing

Plumbing covers the construction of sanitary fixture, and their

maintenance and repair; the installation of water and effluent

pipes using commercial materials and the appropriate accessories and

appliances.

Scope of Work

The test project consists only of practical work, the project will comprise a 20 hours test to asses pipe work skill

The theoretical knowledge is limited to that necessary to carry out the

practical work.

Knowledge of rules and regulations is not examined.

Practical Work

The competitor has to carry out, independently, the following tasks:

Processing commercial materials into a simple installation according to drawings, making use of the necessary technical skill.

Building up part of water or effluent pipe

Constructing a sub-assembly of an installation

Complying with the standard dimensions drawn up

The appropriate technical skill are:

Measuring and making of appliances and pipe work

Bending of pipes by pipe bender and by hand with sand

Soft Soldering, Silver Soldering, jointing with cement/ adhesives

Connecting by threading ( loose and tight fit ) clamping, compression joints

Assembly of pipes, appliances and accessories, on a mounting board fixed by means of saddle clamps, flanges of clips, keeping dimensions and alignment as indicated

Pressure test

Pipe Bending Schedule

Hand Bend

Machine Bend

Fittings

Copper

Copper

Copper

16

X

X

X

22

X

X

X

Radius of hand bends in copper not to exceed four times the outside diameter of the pipe.

Theoretical Knowledge

Interpretation and execution of drawings, sketches and diagrams

according to ISO-standards.

Drawing of the test project in scale 1 : 10, or by calculations the section,

f.i.to Z or X measurements.

Knowledge of plumbing materials and how to process them.

Materials

Appliances: WC assembly, was basin, shower, mirror and water heater

( electric, gas ) with their accessories and safety devices.

Galvanized, copper pipe, plastic pipe (PVC) for drinking

water and waste, fitting, sealing and fixing materials.

Workshop Installations

A vertical fixing surface on which the competitor will assemble the project

to comply with the drawing.

General lay out.
Working area.

The following machine and equipment will be made available to each

competitor.

Q’ty

Work bench with engineers vice and pipe vice of standards size

1

Oxy-acetylene gas welding unit for silver soldering

1

Soft soldering equipment, with torch and propane gas

1

Electrical connections (type to be specified before the competition)

1

Lay out block wood

1

Mounting board approx 1000 x 1200 m

1

Working booth 600 x 2400 x 1800

1

Plastic container for material storage

1

Water pot (bracket or drum)

1

Wash stand

1

Olie Can

1

The following equipment will be made available to 1 for 4

competitor

Pressure test pump
Anvil

The following list of tools which the competitors could bring is provide

for guidance

Q’ty

" Chinese" threading machine for ½" and ¾"

1

Pipe cutter for PVC pipe

1

Pipe bender for Cu ( copper) 22

1

Pipe bender for Cu (copper) 16

1

Screw drivers – and +

1

Pipe cutter for GIP ( Galvanized Iron Pipe)

1

Hand drill, 12 V, battery rechargeable, portable

1

Steel ruler 500 mm

1

Tape ruler 5000 mm

1

Torch pliers

1

Level (spirit) 500 mm

1

Engineer square

2

Adjustable spanner

2

Engineer try square

2

Screw wrench

1

45 Y try square

1

Pipe wrench

2

Pipe cutter for copper pipe

1

Marking AWL

1

Deburrer for copper pipe

1

Piercer

1

Gas lighter

1

Flat chisel

1

250 g hammer

1

Steel wire brush

1

Dust cloth

1

Several files

Plate shears

1

Half round scraper

1

Metal cutting saw

1

Test Project Marking

The expert will decide together on the test project, the marking criteria

and the dimensional tolerances on forms 5, 5A and 6, they will prepare

the material list.

All dimension are C-C ( center to center of pipe ); shoulder to center of

pipe.

Mark:

Perfect = 10 points
Very good = 9 points
Good = 8 points
Rather good = 7 points
Sufficient = 6 points
Medium = 5 points
Weak = 4 points
Insufficient = 3 points
Very bad = 2 points
Zero = 1 points

Rating:

Item Max. Points

Primary 28
Secondary 14
Bend angles 10
Bend radii 10
Pipe inclines 12
Material 8
Pressure test 8
Finish and joint 10

Deduction will be made from the total mark obtained as follows

For each additional meter of pipe 1.0

For each additional connection 0.5

Dimensional tolerances will be

Full dimension mark ± 2 mm

Full dimension mark ± 4 mm

For all linier dimensions and bend radius.

Pressure test

Hot and cold water pipe work will be tested to 3 bar for 3 minutes. Pressure test scoring will be no leaks full mark for pressure test factor.

1 leak 60 % mark for pressure test factor

2 leak 20% mark for pressure test factor

Competitor’s work will not be marked if

not finish

change the type of joints

change from HB to MB or vice versa

use templates

Conversion to the 400-600 scale will be done by computer.

Effective Date

The chairman of the Technical Committee

Picture: See Appendix

Appendix

MATERIAL LIST

( per competitor )

Waste Pipe

PVC F 4" x 4" x 4" ( T Junction ) - 1 no

PVC F 4" x 4" x 2" ( Y Junction ) - 1 no

PVC F 4" 45⁰Bend - 2 nos

PVC F 4" pipe - 2000 mm

PVC F 1 1/2" pipe - 4000 mm

PVC F 1 ½" 90 ⁰Bend - 1 no

PVC F 1 ½" x 1 ½" X1 ½" ( T-Junction ) - 1 no

PVC F 1 ½" x 1 ½" X1 ½" ( Y-Junction) - 1 no

PVC F 2" x 1 ½" Socket Reducer - 1 no

PVC F 2" pipe - 250 mm

PVC F 1 ½" 45 ⁰ Bend - 1 no

Cold Water Pipe

GS F 3/4" Elbow - 3 nos

GS F 1/2" Elbow - 5 nos

GS Tee F 3/4" x 3/4" x 3/4" - 1 no

GS F 3/4" pipe - 4000 mm

GS F 1/2" pipe - 2000 mm

1" quarter turn brass valve ¾" - 1 no

GS F 3/4" Cap - 1 no

Plug F 1/2" - 3 nos

GS F 3/4" Nipple - 5 nos

GS F 1/2" Nipple - 5 nos

GS F 3/4" 45⁰ Bend - 4 nos

GS F 1/2" 45⁰ Bend - 6 nos

GS F 1/2" Tee - 1 no

GS Tee reducer F 3/4" x 3/4" x 1/2" - 1 no

GS Socket reducer F 3/4" x 1/2" - 1 no

Hot Water Pipe

CU 22 F pipe - 1600 mm

CU 27 adaptor male reducer 22 - 3 nos

CU Socket Reducer 22 x 16 - 1 no

CU 16 F pipe - 2200 mm

CU elbow 16 - 2 nos

Plug 16 - 2 nos

CU 22 Elbow - 2 nos

CU Tee reducer 22 x 22 x 16 - 1 no

1 Quarter turn brass valve ¾" - 1 no

Form No : 5

No :

Calculation Sheet

12^th National Skills Competition

For subjective markings

Trade No:

Computer No:

Name:

Member:

Subdivision:

Piece Position

Marking Aspect

Nominal Size

Score

Actual Value

Calculation

P001

Top of GS ½" / CU 16

R 1000

2.8

P002

CU 22 (hot)

L 400

2.8

P003

CU 22 (hot)

B 1050

2.8

P004

GS ¾"

B 800

2.8

P005

Bet. hot/cold basin

400

2.8

P006

PVC 1 ½"

B 100

2.8

P007

GS ½" (cold) shower

B 475

2.8

P008

GS ½" closed

R 400

2.8

P009

CU 16 (Hot)/GS ½" Basin

R 600

2.8

P010

PVC 4"

R 1700

2.8

28.0

No.

Expert

Institution / Industries

Signature

Remarks

P.M. = Primary Measurement

Signature Chief Expert:

.

Semarang: .

Form No : 5

No :

Calculation Sheet

For subjective markings

Trade No:

Computer No:

Name:

Member:

Subdivision:

Piece Position

Marking Aspect

Nominal Size

Score

Actual Value

Calculation

SM01

CU 22 (hot)

L 1100

1.4

SM02

GS ¾"

B 1160

1.4

SM03

GS ¾"

L 100

1.4

SM04

GS ½"

B 200

1.4

SM05

CU 16 (hot) basin

B 600

1.4

SM06

PVC 1 ½"

B 400

1.4

SM07

CU 16 (hot) shower

B 325

1.4

SM08

Bet. Shower

150

1.4

SM09

GS ½"

R 250

1.4

SM10

PVC 2" / 1 ½"

R 1350

1.4

14.0

No.

Expert

Institution / Industries

Signature

Remarks

S.M. = Secondary Measurement

Signature Chief Expert:

.

Semarang: .

Form No : 5

No :

Calculation Sheet

For subjective markings

Trade No:

Computer No:

Name:

Member:

Subdivision:

Piece Position

Marking Aspect

Nominal Size

Score

Actual Value

Calculation

B001

CU 22 (left) detail 1

45⁰

1.0

B002

CU 16 (left) detail 2

45⁰

1.0

B003

GS ¾" detail 5

45⁰

1.0

B004

GS ½" detail 7

45⁰

1.0

B005

CU 16 (right) detail 4

45⁰

1.0

B006

GS ½" detail 3

45⁰

1.0

B007

CU 16 (hot) basin

90⁰

1.0

B008

CU 16 (hot) shower

90⁰

1.0

B009

PVC 1 ½"

88 ½ ⁰

1.0

B010

PVC 1 1/2"

90⁰

1.0

10.0

No.

Expert

Institution / Industries

Signature

Signature Chief Expert:

.

Semarang: .

Form No : 5

No :

Calculation Sheet

For subjective markings

Trade No:

Computer No:

Name:

Member:

Subdivision:

Piece Position

Marking Aspect

Nominal Size

Score

Actual Value

Calculation

R001

CU 16 (hot) basin

R60

2.0

R002

Cu 22 (left) detail 1

R70

2.0

R003

CU 22 (right) detail 1

R70

2.0

R004

CU 16 (right) detail 2

R60

2.0

R005

CU 16 (left) detail 2

R60

2.0

10.0

No.

Expert

Institution / Industries

Signature

Signature Chief Expert:

.

Semarang: .

Form No : 5

No :

Calculation Sheet

For subjective markings

Trade No:

Computer No:

Name:

Member:

Subdivision:

Piece Position

Marking Aspect

Nominal Size

Score

Actual Value

Calculation

L001

GS ¾"

1.2

L002

GS ¾"

1.2

L003

GS ½"

1.2

L004

GS ½"

1.2

L005

CU 22 (hot)

1.2

L006

CU 16 (hot)

1.2

L007

PVC 1 ½" (waste)

1.2

L008

PVC 1 ½" (vent)

1.2

L009

PVC 4"

1.2

L010

CU 16 (hot)

1.2

12.0

No.

Expert

Institution / Industries

Signature

Signature Chief Expert:

.

Semarang: .

Form No : 5

No :

Calculation Sheet

For subjective markings

Trade No:

Computer No:

Name:

Member:

Subdivision:

Piece Position

Marking Aspect

Nominal Size

Score

Actual Value

Calculation

No additional pipe and additional connection

8.0

1) Additional pipe

2) Additional connection

No.

Expert

Institution / Industries

Signature

Signature Chief Expert:

.

Semarang: .

Form No : 5

No :

Calculation Sheet

For subjective markings

Trade No:

Computer No:

Name:

Member:

Subdivision:

Piece Position

Marking Aspect

Nominal Size

Score

Actual Value

Calculation

No Leak

8.0

1 leak

4.8

2 leaks

1.6

3 and more leaks

0.0

No.

Expert

Institution / Industries

Signature

Signature Chief Expert:

.

Semarang: .

Form No : 5 A

No :

Calculation Sheet

For subjective markings

Trade No:

Computer No:

Name:

Member:

Subdivision:

Piece Position

Weighting Factor (WF)

Marking Aspect

Expert Score

0 – 10

Calculation

2.0

Soft soldering

3.0

Silver soldering

3.0

Thread

1.0

Fixing

1.0

Cleaning

No.

Expert

Institution / Industries

Signature

Score 0 – 10

Formula

Signature Chief Expert:

Semarang: .

Perfect = 10 points

Very good = 9 points

Good = 8 points

Rather good = 7 points

Sufficient = 6 points

Medium = 5 points

Weak = 4 points

Insufficient = 3 points

Bad = 2 points

Very bad = 1 points

Zero = 0 points

∑ Score x WF

CP= -----------------

5 x Experts

Form No : 6

No :

Calculation Sheet

For subjective markings

Trade No:

Computer No:

Name:

Member:

Assessment Criteria

Weighting

Day 1

Day 2

Day 3

Marks

Primary

Secondary

Bend angles

Bend radii

Pipe inclines

Material

Pressure test

Finish and joints

100

No.

Expert

Institution / Industries

Signature

Signature Jury-President:

.

Signature Chief Expert:

.

Semarang: .

APPLAINCES FOR EACH COMPETITOR

1 Set - wash basin complete with bracket and taps
1 Set - WC seating type complete with system

WOOD SPACER (mm)

Type of Pipe	L (mm)	W (mm)	T (mm)	Number Wood
CU 16	90	25	32	7
CU 22	100	25	29	4
GS ¾"	110	25	22	11
GS ½"	100	25	29	6
PVC 4"	200	25	18	5
PVC 1 ½"	120	25	16	9

LIST OF EQUIPMENT, TOOLS AND MATERIALS PLUMBING (TRADE 05)
NO.	NAME	DESCRIPTION	Q’TY	REMARKS
	Working booth	600 x 2400 x 1800 mm	20
	Work bench	1800 x 800 x 800 mm with wood work surface	20
	Bucket	Steel/plastic plate	20
	Plastic container	Small, plastic for waste material	40
	Electric outlet	220 V / 15 A, 1 phase	20
	Oxy-acetylene gas welding	Mobile oxy-acetyline (including nozzle, hoses, carts, cylinder holder, regulator, flame damper ignition spark lighter, welder goggles and gloves)	20
	Soldering equipment	2,5 kg, complete with torch	20
	Pressure test pump	0 – 60 bar, 20 L manual	5
	Working vice	150 mm, with protective jaws mounted on work bench	20
	Pipe vice	15 mm mounted on work bench	20
	Anvil	80 kg on base	5
	Screw 1" – 2"	½" -2"	20 box
	Metal plate	For copper pipe radius	20
	Olie can	Small ± 200 ml	20

12^th NATIONAL SKILLS COMPETITION

Semarang – Indonesia, 20 ^th – 23 ^th June 2004

Sekretariat : Kantor Dinas Pendidikan dan Kebudayaan Propinsi Jawa Tengah, Jl. Pemuda No. 134 Semarang 50132 Telp. (024) 3515301 Fax. (024) 3520071

No.	Name	Description	Q’ty	Supplier	Reference

Others
	Adhesive	Quick-dried, for PVC, 500 g	20
	Brazing material	Soft solder	20
	Compound/flux	Cream type, 250 g	20
	Metal	Galvanized, 900 x 900, for template, t : 0.3	20
	Paper	A1	60
	Sand paper	# 320	40
	Silver rod	¥Ö2.0 / € 3 x 1.2	40
	Hanef	fine	1
	Sand	Dia. 0,5 mm	1
	Olie	Mesran 1 liter	5
	Pipe clamp	For CU 16	100
	Pipe clamp	For GS ½"	100
	Pipe clamp	For CU 22	80
	Pipe clamp	For GS ¾"	120

12^th NATIONAL SKILLS COMPETITION

Semarang – Indonesia, 20 ^th – 23 ^th June 2004

Sekretariat : Kantor Dinas Pendidikan dan Kebudayaan Propinsi Jawa Tengah, Jl. Pemuda No. 134 Semarang 50132 Telp. (024) 3515301 Fax. (024) 3520071

The following equipment will be made available for expert

No.	Name	Description	Q’ty	Supplier	Reference

	Engineer rule 1000 mm		1
	Tape rule 5000 mm		1
	Engineer square 200x300 mm		1
	Engineer try square		1
	Spirit level 1800 mm		1
	Bevel protector		1
	Vernier clipper		1
	Shear/straight curve		1
	Scriber		1
	Geometry set		1

No.	Name	Description	Q’ty	Supplier	Reference

Site requirement
	Paper		1
	Marker		1
	Clock (wall watch)		1
	Table		1
	Chair		1
	Locker		1
	White board		1

12^th NATIONAL SKILLS COMPETITION

Semarang – Indonesia, 20 ^th – 23 ^th June 2004

Sekretariat : Kantor Dinas Pendidikan dan Kebudayaan Propinsi Jawa Tengah, Jl. Pemuda No. 134 Semarang 50132 Telp. (024) 3515301 Fax. (024) 3520071

TRADE 05

PLUMBING

COMPETITIONS-SCHEDULE

DAY 1

DATE TIME	ACTIVITIES	WHERE
07.00	Briefing by the Chief Expert
08.00	Study Period for the competitors
08.45	Break
09.00	Competition COMMENCES
12.00	LUNCHEON
13.00	Competition
17.00	END OF DAY 1

DAY 2

DATE TIME	ACTIVITIES	WHERE
07.00	Briefing by the Chief Expert
07.15	Study Period for the competitors
07.30	Competition COMMENCES
12.00	LUNCHEON
13.00	Competition
17.00	END OF DAY 2

DAY 3

DATE TIME	ACTIVITIES	WHERE
07.00	Briefing by the Chief Expert
07.15	Study Period for the competitors
07.30	Competition COMMENCES
17.00	END OF COMPETITION

APPLAINCES FOR EACH COMPETITOR

1 Set - wash basin complete with bracket and taps
1 Set - WC seating type complete with system

WOOD SPACER (mm)

Type of Pipe	L (mm)	W (mm)	T (mm)	Number Wood
CU 16	90	25	32	7
CU 22	100	25	29	4
GS ¾"	110	25	22	11
GS ½"	100	25	29	6
PVC 4"	200	25	18	5
PVC 1 ½"	120	25	16	9

LIST OF EQUIPMENT, TOOLS AND MATERIALS PLUMBING (TRADE 05)
NO.	NAME	DESCRIPTION	Q’TY	REMARKS
	Working booth	600 x 2400 x 1800 mm	20
	Work bench	1800 x 800 x 800 mm with wood work surface	20
	Bucket	Steel/plastic plate	20
	Plastic container	Small, plastic for waste material	40
	Electric outlet	220 V / 15 A, 1 phase	20
	Oxy-acetylene gas welding	Mobile oxy-acetyline (including nozzle, hoses, carts, cylinder holder, regulator, flame damper ignition spark lighter, welder goggles and gloves)	20
	Soldering equipment	2,5 kg, complete with torch	20
	Pressure test pump	0 – 60 bar, 20 L manual	5
	Working vice	150 mm, with protective jaws mounted on work bench	20
	Pipe vice	15 mm mounted on work bench	20
	Anvil	80 kg on base	5
	Screw 1" – 2"	½" -2"	20 box
	Metal plate	For copper pipe radius	20
	Olie can	Small ± 200 ml	20

No.	Name	Description	Q’ty	Supplier	Reference

Others
	Adhesive	Quick-dried, for PVC, 500 g	20
	Brazing material	Soft solder	20
	Compound/flux	Cream type, 250 g	20
	Metal	Galvanized, 900 x 900, for template, t : 0.3	20
	Paper	A1	60
	Sand paper	# 320	40
	Silver rod	¥Ö2.0 / € 3 x 1.2	40
	Hanef	fine	1
	Sand	Dia. 0,5 mm	1
	Olie	Mesran 1 liter	5
	Pipe clamp	For CU 16	100
	Pipe clamp	For GS ½"	100
	Pipe clamp	For CU 22	80
	Pipe clamp	For GS ¾"	120

The following equipment will be made available for expert

No.	Name	Description	Q’ty	Supplier	Reference

	Engineer rule 1000 mm		1
	Tape rule 5000 mm		1
	Engineer square 200x300 mm		1
	Engineer try square		1
	Spirit level 1800 mm		1
	Bevel protector		1
	Vernier clipper		1
	Shear/straight curve		1
	Scriber		1
	Geometry set		1


Site requirement
	Paper		1
	Marker		1
	Clock (wall watch)		1
	Table		1
	Chair		1
	Locker		1
	White board		1

The following list of tools which the competitors could bring is provide

for guidance

	Q’ty
" Chinese" threading machine for ½" and ¾"	1
Pipe cutter for PVC pipe	1
Pipe bender for Cu ( copper) 22	1
Pipe bender for Cu (copper) 16	1
Screw drivers – and +	1
Pipe cutter for GIP ( Galvanized Iron Pipe)	1
Hand drill, 12 V, battery rechargeable, portable	1
Steel ruler 500 mm	1
Tape ruler 5000 mm	1
Torch pliers	1
Level (spirit) 500 mm	1
Engineer square	2
Adjustable spanner	2
Engineer try square	2
Screw wrench	1
45 Y try square	1
Pipe wrench	2
Pipe cutter for copper pipe	1
Marking AWL	1
Deburrer for copper pipe	1
Piercer	1
Gas lighter	1
Flat chisel	1
250 g hammer	1
Steel wire brush	1
Dust cloth	1
Several files
Plate shears	1
Half round scraper	1
Metal cutting saw	1

Figure :

MATERIAL LIST

( per competitor )

Waste Pipe

PVC F 4" x 4" x 4" ( T Junction ) - 1 no

PVC F 4" x 4" x 2" ( Y Junction ) - 1 no

PVC F 4" 45⁰Bend - 2 nos

PVC F 4" pipe - 2000 mm

PVC F 1 1/2" pipe - 4000 mm

PVC F 1 ½" 90 ⁰Bend - 1 no

PVC F 1 ½" x 1 ½" X1 ½" ( T-Junction ) - 1 no

PVC F 1 ½" x 1 ½" X1 ½" ( Y-Junction) - 1 no

PVC F 2" x 1 ½" Socket Reducer - 1 no

PVC F 2" pipe - 250 mm

PVC F 1 ½" 45 ⁰ Bend - 1 no

Cold Water Pipe

GS F 3/4" Elbow - 3 nos

GS F 1/2" Elbow - 5 nos

GS Tee F 3/4" x 3/4" x 3/4" - 1 no

GS F 3/4" pipe - 4000 mm

GS F 1/2" pipe - 2000 mm

1" quarter turn brass valve ¾" - 1 no

GS F 3/4" Cap - 1 no

Plug F 1/2" - 3 nos

GS F 3/4" Nipple - 5 nos

GS F 1/2" Nipple - 5 nos

GS F 3/4" 45⁰ Bend - 4 nos

GS F 1/2" 45⁰ Bend - 6 nos

GS F 1/2" Tee - 1 no

GS Tee reducer F 3/4" x 3/4" x 1/2" - 1 no

GS Socket reducer F 3/4" x 1/2" - 1 no

Hot Water Pipe

CU 22 F pipe - 1600 mm

CU 27 adaptor male reducer 22 - 3 nos

CU Socket Reducer 22 x 16 - 1 no

CU 16 F pipe - 2200 mm

CU elbow 16 - 2 nos

Plug 16 - 2 nos

CU 22 Elbow - 2 nos

CU Tee reducer 22 x 22 x 16 - 1 no

1 Quarter turn brass valve ¾" - 1 no

KEMBALI

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	Q’ty
Work bench with engineers vice and pipe vice of standards size	1
Oxy-acetylene gas welding unit for silver soldering	1
Soft soldering equipment, with torch and propane gas	1
Electrical connections (type to be specified before the competition)	1
Lay out block wood	1
Mounting board approx 1000 x 1200 m	1
Working booth 600 x 2400 x 1800	1
Plastic container for material storage	1
Water pot (bracket or drum)	1
Wash stand	1
Olie Can	1