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Process Technology Equipment
Chapter 3 Tools
Page 1
CHAPTER 3 Tools
Table of Contents
Contents
Page
Chapter Overview
2
Class Preparation Checklist
2
Chapter Objectives
2
Agenda
3
Lesson Plan
4
3.1 Tools
6
3.2 Lifting Equipment
10
3.3 Basic Hand and Power Tool Safety
3.4 Process Technician’s Role in Tool Care and
Maintenance
13
17
Summary and Wrap-Up
17
Suggested Student Activities
17
End of Chapter Review Questions
18
Clicker Questions
Appendix
25
28
Process Technology Equipment
Chapter 3 Tools
Page 2
CHAPTER 3 Tools
Chapter Overview
Knowledge of hand and power tools is an integral part of the process technician’s daily
responsibilities. Knowing how to use tools safely and correctly is vital. This chapter
provides an overview of the types of tools most commonly used by process technicians,
their applications, associated safety issues, and proper tool care and maintenance.
There are many different types of tools process technicians might use to perform daily
tasks. Two categories of tools presented in today's lesson include essential hand tools
and power tools. Regardless of the type of tool, each has a specific purpose as well as
established guidelines for proper use.
Expectations of the process technician include understanding and applying the safety
guidelines for the tools and devices used at work. Another expectation is for the process
technician to maintain all tools in proper and safe working order. Following inspection
and maintenance procedures could prevent a personal injury or keep a technician from
damaging equipment.
Class Preparation Checklist
1.
Familiarize yourself with the chapter content.
2.
Bring cutaways or other hands-on teaching aids if available.
3.
Copy and distribute any fill-in-the-blank handouts for today's content.
4.
Safety Minute prepared or assigned
5.
Review the PowerPoint slides associated with this chapter (if used) and
make sure that your computer is correctly set up to navigate the slide deck
smoothly.
6.
Request the appropriate A/V equipment (if needed) and make sure that
your computer is correctly synched with the projector to avoid any delays in
the classroom.
Chapter Objectives
3.1 List the types of tools used by technicians in the process industries (NAPTA Tools
and Equipment).
3.2 Describe lifting equipment used in process industries (NAPTA Tools and
Equipment).
3.3 Describe basic safety guidelines for tools and devices described in this chapter
(NAPTA Tools and Equipment).
3.4 Describe the process technician’s role in tool care and maintenance (NAPTA Tools
and Equipment).
Process Technology Equipment
Chapter 3 Tools
Page 3
Class Agenda
Activity
Minutes
PPTs
Handouts
(title, if
any)
1. Welcome to Class
1
1
2. Introduction and Agenda
2
2
3. Safety Minute
2
3
4. Objectives
2
4
5. Terms
3
5
6. Terms (cont.)
2
6
7. Tools Used in Process Industries
1
7
8. Hand Tools
1
8
9. Hammers
1
9
10. Pliers
3
10
11. Screwdrivers
1
11
12. Tubing Cutter and Flaring Tools
2
12
13. Wrenches
3
13
14. Power Tools
1
14
15. Lifting Equipment Used in Process Industries
1
15
16. Hoists
2
16
17. Cranes
3
17
18. Forklifts
2
18
19. Personnel Lifts
1
19
20. Dollies
1
20
21. Basic Hand and Power Tool Safety
1
21
22. Safety Tips for Tool Use
1
22
23. General Hazards
1
23
24. Hand Tools
2
24
25. Power Tools
5
25
26. Process Technician’s Role in Tool Care and
Maintenance
1
26
27. Summary and Wrap-Up
4
27
Process Technology Equipment
Chapter 3 Tools
Page 4
Chapter 3 Lesson Plan
Welcome Everyone to Class
Time: 1 minute
Resources: Slide 1
Introduction and Agenda
Time: 2 minutes
Resources: Slide 2
Sample Instructor Script:
Safety Minute
Time: 2 minutes
Resources: Slide 3
(Note to Instructor: Follow this procedure for the Safety Minute.)
• Announce who has responsibility for today’s Safety Minute.
• Have the student present the Safety Minute.
• Announce who is presenting the Safety Minute next class.
Objectives
Time: 2 minutes
Resources: Slide 4
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Chapter 3 Tools
Page 5
Terms
Time: 3 minutes
Resources: Slide 5
Sample Instructor Script:
Turn to the terms page in today’s chapter in the textbook. I’ll call on some of you to take
turns reading the term and definition aloud and then using that term in a sentence. We’ll
begin with the following terms:
• Adjustable pliers
• Hammer
• Hand tool
• Hoist
• Hydraulic tool
• Impact wrench
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• Pneumatic tool
Terms (cont.)
Time: 2 minutes
Resources: Slide 6
Other terms process technicians should be familiar with include the following:
3.1 Tools Used in Process Industries
Time: 1 minute
Resources: Slide 7
3.1.1 Hand Tools
Time: 1 minute
Resources: Slide 8
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Chapter 3 Tools
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3.1.2 Hammers
Time: 1 minute
3.1.3 Pliers
Time: 3 minutes
Resources: Slide 10
Sample Instructor Script:
Locking pliers (sometimes referred to as Vise-Grips®) are pliers that can be locked
into place when the handgrips are squeezed together. Locking pliers contain an
adjustment screw that allows the distance between the jaws to be adjusted. Because of
their locking mechanism, locking pliers provide a firm grip and prevent slippage.
Needle nose pliers are small pliers that have long, thin jaws for fine work; for example,
holding small items in place, removing cotter pins, or bending wire.
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3.1.4 Screwdrivers
Time: 1 minute
Resources: Slide 11
Sample Instructor Script:
3.1.5 Tubing Cutter and Flaring Tools
Time: 2 minutes
Resources: Slide 12
3.1.6 Wrenches
Time: 3 minutes
Resources: Slide 13
Sample Instructor Script:
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Adjustable wrenches are also referred to as Crescent® wrenches. They are open-
ended wrenches with an adjustable jaw that contains no teeth or ridges (the jaw is
smooth).
Socket wrenches are wrenches that contain interchangeable socket heads of varying
sizes that can be attached to a ratcheting wrench handle or other driver. Most socket
wrenches contain a ratcheting mechanism that allows a nut or bolt to be tightened or
loosened in a continuous motion, as opposed to the socket or handle being removed
and refitted after each turn.
Like socket wrenches, impact wrenches can accommodate removable sockets of many
different shapes and sizes. Because they use repetitive blows instead of a single stroke
of brute force, impact wrenches are often more effective than traditional wrenches at
removing bolts that are extremely tight.
Torque wrenches are manual wrenches that use a gauge to indicate the amount of
torque (rotational force) being applied to the nut or bolt. Torque wrenches are used
when a specific amount of torque is needed for operational or safety reasons.
3.1.7 Power Tools
Time: 1 minute
Resources: Slide 14
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Chapter 3 Tools
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Sample Instructor Script:
Power tools are tools driven by electricity, pneumatic power, hydraulic pressure, or
powder charges (small charges filled with explosive materials such as gunpowder).
When using power tools, make sure to wear all required personal protective equipment
and follow all company safety rules regarding their use. Examples of power tools
include the following items.
3.2 Lifting Equipment Used in Process Industries
Time: 1 minute
Resources: Slide 15
3.2.1 Hoists
Time: 2 minutes
Resources: Slide 16
Sample Instructor Script:
A hoist is a device composed of a pulley or gear system with a cable or chain used to
lift and move heavy objects.
Basic safety requirements for using hoists include:
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3.2.2 Cranes
Time: 3 minutes
Resources: Slide 17
Sample Instructor Script:
A crane is a mechanical lifting device that can be used to lift and lower materials or
Jib cranes consist of a pivoting head and boom assembly that carries a hoist and
trolley unit. The pivoting head is supported either by a floor-mounted mast providing
360-degree boom rotation or by an existing building column that provides 180 degrees
of boom rotation.
Monorail cranes are cranes that travel on a single runway beam. These types of
• Chains should be inspected for bent or broken links and signs of corrosion.
• Ropes should be inspected for fraying and broken threads, and steel ropes
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should be inspected for corrosion.
3.2.3 Forklifts
Time: 2 minutes
Resources: Slide 18
Sample Instructor Script:
A forklift is a vehicle with elongated prongs (or forks) used for lifting and transporting
3.2.4 Personnel Lifts
Time: 1 minute
Resources: Slide 19
Sample Instructor Script:
Personnel lifts (also referred to as manlifts, cherry pickers, Condors®, or JLGs®)
contain a pneumatic, hydraulic, or electric arm with a personnel bucket attached at the
end. Many personnel lifts can be operated from the ground or the personnel bucket.
Basic safety requirements for personnel lifts include:
Process Technology Equipment
Chapter 3 Tools
Refer to the textbook for a more complete list of safety requirements related to
personnel lift use.
3.2.5 Dollies
Time: 1 minute
Resources: Slide 20
Sample Instructor Script:
A dolly is a wheeled cart or hand truck that is used to transport heavy items such as
barrels, drums, and boxes.
Basic safety requirements for the operation of dollies include:
3.3 Basic Hand and Power Tool Safety
Time: 1 minute
Resources: Slide 21
Sample Instructor Script:
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3.3.1 Safety Tips for Tool Use
Time: 1 minute
Resources: Slide 22
Sample Instructor Script:
3.3.2 General Hazards
Time: 1 minute
Resources: Slide 23
Sample Instructor Script:
Some general hazards presented by tools include:
Refer to the textbook for a more complete list of general hazards related to tool use.
3.3.3 Hand Tools
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Time: 2 minutes
Resources: Slide 24
Sample Instructor Script:
Hand tools are tools that are operated manually instead of being powered by electricity,
pneumatics, hydraulics, or other forms of power. The greatest hazards associated with
the use of hand tools are caused by misuse and improper maintenance.
Some general tips for proper use and safety when using hand tools include:
Some general safety suggestions that apply specifically to wrenches include:
• Valve wheel wrenches should fit over the valve wheel rim completely.
• A pipe extension or cheater bar should never be used to apply excessive
leverage to a wrench.
• Wrenches should not be struck with hammers or other objects.
Refer to the textbook for a more complete list of safety suggestions for hand tools and
wrenches.
3.3.4 Power Tools
Time: 5 minutes
Resources: Slide 25
Sample Instructor Script:
The main types of power tools are electric, pneumatic, fuel-operated, hydraulic, or
powder-actuated. While each of these tools can enhance performance, they also can
pose a variety of hazards including:
Some general safety practices for power tools include:
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Chapter 3 Tools
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• Understand the capabilities, limitations, and hazards of the tool being used.
• Check that all safety features work properly.
• Use only intrinsically safe or explosion-proof tools in flammable environments.
• Make sure cords or hoses are not lying across a walkway, thus presenting a trip
hazard.
• Keep your finger off the switch when carrying the tool or before it is in position to
avoid accidental start-up.
Electric tools are tools operated by electrical means (either AC or DC). The following
are some safety practices related to electric tools:
Refer to the textbook for a more complete list of hazards related to power tools.
Pneumatic tools are tools powered by pneumatic (air or gas) pressure. The following
are safety practices related to pneumatic tools:
Hydraulic tools are tools powered by hydraulic (liquid) pressure. Many of the safety
precautions for hydraulic tools are the same as those for pneumatic tools. However, one
added hazard is exposure to hot and/or harmful hydraulic fluids.
Fuel-operated tools are tools powered by the combustion of a fuel (for example,
gasoline). Process technicians should always use caution when operating these tools
and ensure that proper grounding practices are used when refuelling. Both filling and
tool operation produce static electricity, which can result in a fire or explosion.
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3.4 Process Technician’s Role in Tool Care and Maintenance
Time: 1 minute
Resources: Slide 26
Summary and Wrap-Up
Time: 4 minutes
Resources: Slide 27
Sample Instructor Script:
Let’s summarize today’s lesson and consider what we will be doing in the next class.
(Note to Instructor: To wrap up the lesson, complete the following activities.)
• Summarize today’s lesson.
• Answer questions.
• Announce the next reading assignment and homework.
• Remind the next person who will be doing a Safety Minute.
Suggested Student Activities
