Outline of Piping Construction Diploma

Piping Construction Diploma (PCD) is a chain of knowledge that covers all

steps of construction piping activities (fabrication, erection, piping components,
piping supports, valves, special piping components, test packs, Punch cycles,
testing, reinstatement, mechanical completion, and pre-commissioning)
PCD is a complete cycle that starts from what is the meaning of the project up to
mechanical completion (MC) and startup of projects).
In addition, PCD covers around 12 ASME Codes and technical sites
+ 14 years (of instructor Experience).
Our Piping diploma divided into two levels
Level One
Overview of Oil and Gas project, Piping application, Engineering Sycle, Material Sycle,
Fabrication Stage, Pipe data, Flanges, Orifice Flange, Line Blanks, Bolting, Gasket, Piping
Fitting, Pipe Branches, Piping Inspection, How to Read Piping Isometric Drawings and How
to Read PID). We will cover around 12 ASME Codes also We will transfer 14 years of
experience in Oil and Gas Projects through our diploma. (instructor Experience).
. # Level 01: from chapter 01 to chapter 15.
Level Two
Site work (Erection, Pipe support, Valves, special piping components, Test Pack, Punch,
Testing, Reinstatement, Mechanical Completion, and overview of the Pre-commissioning
team) + 14 years’ (instructor Experience). # Level: 02 from chapter 16 to chapter 29.
Chapters No Content
Overview and Introduction
▪ The idea of piping chain diploma.
▪ Objectives of piping chain diploma (PCC).
Chapter-01 ▪ Piping application.
▪ Project Stage and Piping careers.
▪ Piping chain diploma divided into (Three Parts)
▪ Types of Projects Contract (Overview).
Engineering (Project Documentation)
▪ BFD (Block flow diagram).
▪ PFD (Process flow diagram).
Chapter-02
▪ PID (Piping & Instrumentation Diagram.
▪ Legend.
▪ Piping drawings.
 ▪ Piping supports drawing.
▪ Concept of piping design.
▪ LDT (Line Designations table).
▪ Plot plan and General arrangement GA.
Procurement. (General Information)
▪ PO (Purchasing Order) and Ordering time.
▪ VAL (Vendors approval list).
Chapter-03 ▪ Materials receiving and MRR
▪ MTC (Mil test certificate)
▪ Material Storage, Preservation and Segregation
▪ Consequences of lack of preservation.
Pipe Data.
▪ Pipe manufacturing.
▪ Pipe schedule.
▪ Pipe diameter (NPS vs OD)
▪ Pipe dimension codes.
▪ Pipe weight vs schedule.
Chapter-04
▪ Pipe size.
Workshop
▪ Pipe end finishes.
(Fabrication)
▪ Pipe Length.
▪ Pipe Tolerance (diameter and Thickness).
▪ Pipe marking.
▪ ASTM vs ASME
▪ Pipes color coding.
▪ Types of materials.
▪ Tube vs. Pipe.
Flanges and Orifice Flanges
▪ Flange Codes
▪ Flange Classification.
▪ Types of flanges.
▪ Application of each type
Chapter-05
▪ Site Technicality for (Socket and slip-on)
▪ Special flanges.
▪ Flange Marking
▪ Flange Selection
▪ Flange Preservation
Orifice Flanges (ASME B16.36)
▪ Function of Orifice Flanges
Chapter-06
▪ Types of Orifice Flanges
▪ Requirement of fit-up of Orifice Flanges
 ▪ How to inspect Orifice Flanges
▪ Case Study
▪ Orifice plate vs Restriction plate
Line Blanks
▪ Function of Line Blanks.
Chapter-07 ▪ Types of Line Blanks.
▪ ASME Codes B 16.48.
▪ How to identify installed blink with PID.
Types of Bolting
▪ Stud Bolts vs Machine Bolts
▪ Bolts Selection
Chapter-08 ▪ Bolting Marking and Identification.
▪ Material of Bolting
▪ Use of Shorter Bolt Lengths
Types of Gaskets
▪ Non-Metal Gaskets
▪ Metal Gaskets
▪ Gaskets Code and Standard
▪ Marking of spiral metal gasket
Chapter-09 ▪ Ring Identification and Marking
▪ Insulation Gasket kits
▪ Function of Insulation Gasket kits
▪ Types of Insulation Gasket kits
▪ Requirement of Insulation Gasket kits.
Piping Fitting ASME B16.9 $ ASME B16.11
▪ Types of elbows.
▪ Pipe take-off
▪ Types of tees.
▪ Types of reducers
▪ Application of Eccentric Reducer
Chapter-10 ▪ Tolerances of Piping Fitting.
▪ Case Study
▪ Socket Fittings ASME B16.11
▪ Threaded Fitting ASME B16.11
▪ Types of fitting by class and NPS
▪ Relationship between Class and Schedule
▪ Swage vs Nipple.
 ▪ Piping Components Codes and Standard
Pipe Branches.
▪ Types of Branches
▪ Special Branches
▪ Types of Reinforcement
Chapter-11 ▪ Function and concept of use Reinforcement
▪ What is the function of the vent hole?
▪ General requirements
▪ Branch Selection
▪ Site technicality.
General Requirements of Workshop
▪ Concept of Weld Map
▪ Spools Identification.
Chapter-12 ▪ General Notes
▪ Consequence of wrong weld map.
▪ Consequence of Lack of Preservation
▪ Pickling
Piping Fabrication
▪ Pipe cutting and Traceability.
▪ Trimming and Permitted of Misalignment
Chapter-13
▪ Assemble, Fit-up
▪ Types of Tack weld
▪ Requirements and consequences.
Piping Inspection
▪ How to inspect Pipe to Pipe
▪ How to inspect Pipe to Elbow
▪ How to inspect Tee to Elbow
▪ How to inspect Angle Line 90 &45
▪ How to inspect Pipe to Flange
Chapter-14 ▪ Gap consideration
▪ Establishing Centerlines on Pipe with Square and Level
▪ Cutting Angle of Elbow
▪ Alignment of Seam Weld.
▪ Traceability for Piping Spools.
▪ Fabrication and Erection of Small Bore
How to Read Piping Isometric Drawings
Chapter-15
▪ How to read piping drawings without offset
▪ How to read piping drawings with offset
 ▪ Welding Types (Overview)
▪ How to a voided Welding Distortion
▪ Apply NDT and PWHT (Not covered).
▪ Release for painting and Release for shipment. End of Level -01
Erection Activities (Site Work)
▪ Material receiving at the site.
▪ Consequences of lack of Preservation.
Underground Piping (U/G).
▪ Types of Non-ferrous Material
▪ HDPE-GRP -GRE-PVC
▪ Wrapping and Holiday Test
Chapter-16 ▪ Piping Sleeve
▪ Puddle Flange
Level -02 Aboveground Piping (A/G).
Erection
▪ Sequence of Erection.
Activities (Site
▪ Materials Handling & Lifting activity.
Work)
▪ Clean Buildup System.
▪ Air Blowing before Erection.
▪ Lesson Learned.
▪ Pipe slope.
▪ Piping Fit-up.
▪ Piping Insulation.
▪ Field Weld & Piping Inspection.
▪ Welding, NDT, and PWHT (Not covered).
Supports
▪ Type of Supports.
▪ Piping Support Application.
Chapter-17
▪ Which one to be installed first pipe or support
▪ Jacketing Pipes.
▪ Steam Tracing.
Valves
▪ Type of Valves.
▪ Valve components.
▪ Valve operability and Valve Orientation
Chapter-18 ▪ Valve End Connection.
▪ Valves Preservation
On-Off Valves
▪ Ball valve.
▪ Gate valve.
 ▪ Plug valve.
▪ Butterfly valve.
Throating Valves
▪ Globe valve.
▪ Regulating Valve.
▪ Needle valve.
Safety Valves
▪ Pressure safety Valve PSV
▪ Pressure relief Valve PRV.
Non-Return Valves
▪ Check Valves.
▪ Ball check valve.
Control Valves
▪ Globe valves.
▪ Gate valves.
▪ Rupture Discs.
Piping Connecting to Equipment
▪ Piping Connecting to Fixed Equipment
Chapter-19 ▪ Piping Connecting to Skid Equipment
▪ Piping Connecting to Machinery equipment.
▪ Site Technicality
Special Piping Component
▪ Expansions Below (Types, how to install and Inspection)
▪ Strainer (Types, how to install, and Inspection).
▪ Ultrasonic flowmeters (Function and requirement of installation)
▪ Vortex Flowmeter (Function and requirement of installation)
▪ Earthing Lug (Function and requirement of installation)
▪ Funnel (Function and requirement of installation)
Chapter-20 ▪ Bird screen (Function and requirement of installation)
▪ Drip Pan (Function and requirement of installation)
▪ Sight glass (Function and requirement of installation)
▪ Level transmitters (Function and requirement of installation)
▪ Transition-Pieces (Function and requirement of installation)
▪ Injection Lance. (Function and requirement of installation)
▪ Insertion Nozzle (Function and requirement of installation)
▪ Sight glass (Function and requirement of installation)
Jacketed Pipe
▪ Function of Jacket Pipe
Chapter-21
▪ How the jacket system works.
▪ Partial Jacket Pipe
 ▪ Full Jacket Pipe
▪ Steam Manifold Function, requirement of installation and Inspection
▪ Components of Jacketed Pipe
▪ Steam Tracing (Function, requirement of installation, and Inspection)
Test Packs
▪ Project systems and Types of Plants
▪ Process, Utilities and Treatment Plants
▪ Concept of System Distribution
▪ Test packs Control Sheet (Register)
Chapter-22 ▪ Test Package Flow Diagram
▪ How to establish Limits of Test Packs)
▪ Relationship between material class and marked-up PID.
▪ Marked-up PID vs Material class.
▪ Content of Test Package.
▪ How to review test packs.
Cycle of Walk Down/ Walkthrough (line checking)
▪ ITP Inspection Test Plan
▪ Punch Categories.
▪ Punch – A.
Chapter-23 ▪ Punch – B.
▪ Punch – C.
▪ Examples for each type.
▪ Cold Spring
▪ As-built (Red mark) (types and approval)
Chapter-24 Quiz (more than 50 site conditions to check your knowledge)
Type of test packs.
▪ Inspection, Examination, and Testing
▪ Visual test pack
Chapter-25 ▪ Service test pack.
▪ Hydro-test pack
▪ Pneumatic test pack.
▪ Combination of Test Packs.
Testing
▪ What is the concept of testing selection?
Hydro-testing.
Chapter-26 ▪ Test Pressure.
▪ Test Preparation &Test Fluid
▪ Pressure gauge.
▪ PG Calibration and Location.
 ▪ Water analysis.
▪ Time of hydrostatic.
▪ Dial indicating vs Digital recorded vs Chart recorded.
▪ Test Procedures
▪ Flange tester.
Requirement of Testing of Underground Pipe (Fire water system).
Pneumatic Testing
▪ Test Pressure.
▪ Test Preparation &Test Fluid.
▪ Test Procedures.
▪ Risk of pneumatic testing.
General Requirements for Leak Test
▪ Pressure safety valve (PSV)
▪ Test Manifold
▪ Removal items from Hydro-test.
▪ Before Hydro testing
▪ During Hydro testing
▪ After Hydro testing
Special Case
▪ Water is not available in the hydro-test.
▪ Test pressure is greater than 1.5 design pressure.
▪ Preliminary Pneumatic Test.
▪ Hydrostatic Test of Piping with Vessels as a system.
▪ Where the owner considers hydro-test and Pneumatic Testing are not
applicable.
▪ Test Fluid Expansion.
▪ Test of Jacketed Piping.
Dewatering / Drainage and Drying
▪ Max time between testing and drainage
▪ Drainage Procedures.
Chapter-27 ▪ Why draining of water is more important of hydro testing?
▪ Criticality of draining of water
▪ Drying types and Procedures
▪ Dew point
Reinstatement.
▪ What is the meaning of reinstatement?
▪ Clear punch B.
Chapter-28
▪ Item not installed during Reinstatement (Punch B not cleared)
▪ Closure Welds (Golden joint).
▪ Flange management.
 ▪ Punch transferring.
▪ Reinstatement signed Off
Mechanical Completion (MC)
▪ System document review and dossier handover
▪ System Walk down.
▪ Mechanical Completion signed Off
Overview of Pre-commissioning commissioning.
Chapter-29
▪ Purpose of Pre-commissioning activity.
▪ Tightening test
▪ Cleaning methods of the piping system.
Codes vs Standards vs Specifications Regulations and Recommended
Practices
Course Course information and Evaluation.
Powred By ▪ Open book exam 30 Question.
ZAD ▪ Closed book exam 110 questions.
Engineering ▪ You must get 72 % to be successful.
 (‫ سنة باالضافة لمحتوى الدبلومة‬14 ‫ سنة يعنى )هتاخد خبرة‬14 ‫المحاضر خبرة‬
Our instructor has 14 Years of experience in piping construction of Water Treatment, Oil
and Gas, Refinery Petrochemical, Ship Building, Firefighting, and fertilizer plants.
Instructor Experience, Our Instructor worked with the below companies.
▪ Mechanical Instructor (Piping and Flange management) at ZAD Engineering Academy.
▪ Mechanical lead at ThyssenKrupp-Udhe
▪ Sr.Mechanical QA/QC engineer at Bechtel corporation.
▪ Sr.Mechanical inspection engineer at BP (British Petroleum)
▪ QA/QC engineer at GS Engineering & Construction company.
▪ Piping and welding engineer at ENPPI-TOYO (JV) company.
▪ Plant inspector at Methanex Corporation
▪ Petroject.
▪ Egyptian Navy Shipyard Ship
▪ Perfect Engineering Work
Our instructor Certified that:
▪ API 653 - Authorized Tank Inspector from American Petroleum Institute
▪ API 570 -Authorized Piping Inspector from American Petroleum Institute
▪ API 510 - Authorized Pressure Vessel Inspector from American Petroleum
▪ CWI - Certified Welding Inspector from American Welding Institute
▪ Lead Auditor according to ERCA ISO 9001:2015
▪ Valve inspection and installation.
▪ Complete Preparation of ASME Codes (B 31, B16, B36, V, II, VIII and IX
▪ Level II _ (NDT Methods)
For more details https://wa.me/+201285841101