Petrotech Academy, Mahabubnagar
Non-Metallic Process Piping QA/QC Inspector
Oil & Gas Industry – Complete Professional Training Program
Inspection and quality control of PVC, CPVC, PP, HDPE, FRP/GRP and PVDF piping from material receiving and jointing to hydrotest and handover, aligned to Saudi Aramco (SAES/SAEP), SABIC, ADNOC and PDO standards and requirements.
20Modules
4Client standard sets: Aramco, SABIC, ADNOC, PDO
Practical & field exercisesJointing, fusion and hydro test practice
Bonus materialsChecklists, videos, Q&A, e-books
Course overview
About this course
A complete professional training program for QA/QC inspectors working on non-metallic process piping in Oil & Gas facilities. It covers materials, jointing methods, inspection at every stage, testing, documentation and client-specific quality requirements.
Who should attend
- QA/QC Inspectors
- Piping Supervisors
- Site Engineers
- Construction Engineers
- Project Engineers
- Anyone involved in Non-Metallic Piping Works
Learning outcomes
After completing this course, you will be able to:
- Understand non-metallic piping systems in Oil & Gas
- Perform inspection at all stages
- Interpret codes, standards and specifications
- Identify defects and ensure quality workmanship
- Prepare inspection reports and documentation
- Ensure reliability, safety and compliance of piping systems
Course content
Twenty modules that follow a non-metallic piping system from material selection to final records: receiving, jointing, testing, defects and corrective action, with hands-on practice.
Foundations: Role, Materials, Behaviour and Standards
Introduction
- Role of QA/QC Inspector in Non-Metallic Piping
- Importance in Oil & Gas Projects and Facilities
- Scope, Duties, Responsibilities & Authority
- Interfaces with Construction, Engineering, Procurement
- Quality Policy, HSE & Ethics
- Project Life Cycle & Inspection Points
Non-Metallic Piping Overview
- What is Non-Metallic Piping
- Advantages, Limitations & Applications
- Typical Services: Water, Firewater, Cooling, Chemical, Desalination, Drain, Vent, Instrument Air
- Comparison with Metallic Piping
Non-Metallic Piping Materials
- PVC / UPVC / CPVC (ASTM D1785, D2466)
- PP – Polypropylene (ASTM F2389)
- HDPE – PE100 / PE4710 (ASTM D3035, D3350)
- FRP / GRP (ASTM D2996) / GRE
- PVDF (ASTM D3222)
- PFA / FEP / ETFE
- RTR – Reinforced Thermosetting Resin
- Phenolic
- Others: ABS, PPH, PE-Xa, etc.
Material Properties & Behavior
- Physical Properties
- Mechanical Properties
- Chemical Resistance
- Temperature & Pressure Ratings
- UV Resistance
- Fire Behavior
- Creep & Stress Relaxation
- Long Term Performance
Codes, Standards & Specifications
- ISO Standards (ISO 15493, ISO 4437, ISO 10931)
- ASTM Standards (D1785, D2467, D3035, D3262, F441, F442, F714, F1483, D2996)
- ASME B31.3 (Plastic Piping Systems)
- AWWA Standards
- NACE Recommendations
- Manufacturer Standards
- Client Standards: Saudi Aramco, SABIC, ADNOC, PDO
- Project Specifications & ITP Overview
Components, Quality System, Receiving and Installation
Piping System Components
- Pipes (Non-Metallic)
- Fittings (Elbows, Tees, Reducers, Couplings, Unions, End Caps)
- Flanges (Loose, Threaded, Bonded – Material Specific)
- Valves (Ball, Butterfly, Diaphragm)
- Gaskets & Seals (EPDM, FKM, PTFE)
- Solvent Cement & Adhesives
- Supports & Hangers (Non-Metallic Compatible)
- Expansion & Flexible Joints
- Instruments & Accessories
Quality Management System
- Quality Management Principles (ISO 9001)
- Document & Record Control
- Hold Points, Witness Points & Surveillance Points
- Inspection & Test Plan (ITP) Preparation
- Method Statements
- Material Traceability
- NCR, CAR & Close Out
- QA/QC Reporting & Documentation
Material Receiving & Storage Inspection
- Document Review (MTC, CoC, SDR, PN, Test Reports)
- Visual Inspection
- Dimensional Check (OD, Wall Thickness, Length)
- Identification & Marking
- Surface Condition
- Batch / Lot Traceability
- Storage Conditions (Sunlight, Temperature, Stacking)
- Handling & Transportation Inspection
- Rejection Criteria & Reporting
Pre-Installation Inspection
- Verification of Approved Drawings
- Line Marking & Route Verification
- Trench / Support Readiness
- Environmental Conditions
- Tools & Equipment Calibration
- Material Staging & Identification
- Fit-up Area Inspection
Installation & Erection Inspection
- Pipe Cutting Inspection (Square Cut / Bevel)
- Deburring & Chamfering
- Dry Fit Inspection
- Alignment & Support Installation
- Jointing: Solvent Cement, Fusion, Mechanical, Flanged
- Adhesive Preparation & Application
- Solvent Cementing (Surface Prep, Dry Fit, Cement Application, Assembly)
- Fusion Welding (Butt, Socket, Electrofusion)
- Joint Assembly Time Compliance
- Environmental Conditions (Temp, Humidity)
- Workmanship & Cleanliness
Jointing, Dimensional Checks, Testing, Coating and Special Tests
Jointing Methods & Inspection
| Jointing method | Inspection points |
|---|---|
| Solvent Cement Joint (PVC / CPVC) | Surface preparation, cement type, application, assembly, bead check, cure time, alignment |
| Fusion Welding (HDPE / PP) | Equipment, parameter settings (temperature, pressure, time), bead appearance, joint strength |
| Electrofusion (HDPE) | Fitting and pipe cleaning, barcode scan, parameter check, completion indicator |
| Mechanical Joint | Installation of O-ring, gland assembly, bolt tightening, leakage check |
| Flanged Joint | Gasket type, alignment, bolt torque, leakage test |
Maintain inspection records and photos for every joint.
Dimensional & Visual Inspection
- Pipe OD Verification
- Wall Thickness (Where Applicable)
- Socket Depth / Insertion Length
- Straightness & Alignment
- Support Spacing
- Expansion / Movement Allowance
- Visual Surface Defects (Cracks, Voids, Discoloration, Deformation)
Testing & Pre-Commissioning Inspection
- Hydrostatic Testing (Water Test)
- Pneumatic Testing (Air Test)
- Test Pressure Calculation
- Test Medium Quality
- Test Setup Inspection
- Pressure Holding & Monitoring
- Leakage Inspection
- Documentation & Release (ITP Hold Point)
Painting, Coating & Insulation Inspection
- Surface Preparation (Where Applicable)
- Coating / Wrapping for Buried Piping
- Insulation Material & Thickness
- Jacketing
- Weather Protection
- Cold Insulation (Chilled Water, Glycol)
- Inspection of Insulation Joints & Finish
Non-Destructive & Special Tests
- Holiday Test (for Coated Pipe / FRP / GRP)
- Air Pressure Test (Leak Test)
- Vacuum Test
- Spark Test (Coating)
- Adhesion Test (Coating)
- Pull Off Test
- Weld Strength Test (Destructive – for HDPE)
- Pressure Decay Test (Air)
Records, Defects, Corrective Action, Safety and Practice
Documentation & Records
- Material Inspection Report (MIR)
- Receiving Inspection Report (RIR)
- Fit-up / Jointing Inspection Report
- ITP / Checklists
- Test Reports (Hydro, Air, Others)
- Non-Conformance Report (NCR)
- Photo Records
- As-Built Documentation
- Punch List & Closure
Common Defects & Causes
- Improper Surface Preparation
- Incorrect Cement Application
- Insufficient Cure Time
- Misalignment
- Poor Support / Excessive Load
- Overheating During Fusion
- Contamination
- Gasket Damage / Improper Seating
- UV Degradation / Improper Storage
Corrective Actions & Prevention
- Rework Procedures
- Joint Repair Methods
- Root Cause Analysis (RCA)
- Preventive Measures
- Lessons Learned
- Continuous Improvement
Health, Safety & Environment
- PPE Requirements
- Safe Handling of Chemicals (Solvents / Adhesives)
- Confined Space Awareness
- Hot Work (Where Applicable)
- Waste Management
- Environmental Protection & Sustainability
Practical & Field Exercises
- Material Identification Drill
- Solvent Cement Joint Making
- Fusion Welding Practice (HDPE)
- Joint Inspection Checklist
- Hydro Test Setup
- Case Studies from Saudi Aramco, SABIC, ADNOC & PDO Projects
Client-specific quality requirements
Learn how the same inspection steps are applied under Saudi Aramco, SABIC, ADNOC and PDO requirements.
Saudi Aramco (SAES / SAEP)
- SAES-H-005 – HDPE Piping Systems
- SAES-M-006 – FRP/GRP Piping Systems
- SAES-H-001 – General Piping Systems
- SAES-Q-001 – Quality Requirements
- SAEP-331 – Project Quality Management System
- SAEP-333 – Nonconformance Management
- SAEP-344 – Inspection & Surveillance
- SAES-L-009 – Method Statement Requirements
SABIC Standards
- SABIC Engineering Standards (SES)
- SES-PP-001 – Piping Systems
- SES-PP-002 – Plastic Piping Requirements
- SES-QC-001 – Quality Control Requirements
- Compliance with SABIC Engineering Guidelines & Specifications
ADNOC Standards
- ADNOC-S-PP-001 – Piping Systems Spec.
- ADNOC-S-QC-001 – Quality Requirements
- ADNOC Technical Standards & Procedures
- ITP, MDR, TQR as per ADNOC Requirements
PDO Standards
- PDO Technical Standard (PTS) for Piping
- Quality Requirements (PTS-Q-001)
- Material & Inspection Requirements
- HSE & Environment Compliance
International and Indian standards you will work with
Non-metallic piping relies on ASTM, ISO and manufacturer procedures more than metallic piping does. The course shows how to use them together with Indian standards and statutory rules.
International standards
ASME, ASTM, ISO, AWWA, PPI, DVS- ASME B31.3 Chapter VIINonmetallic piping and piping lined with nonmetals
- ASTM D1785 / D2466 / D2467 / F441 / F442PVC and CPVC pipe and fittings
- ASTM D3035 / D3350 / F714Polyethylene pipe and material designation
- ASTM D2996 / D2992Filament-wound fibreglass (RTR) pipe and hydrostatic design basis
- ASTM D3222 / F2389PVDF and polypropylene piping materials and pressure pipe
- ASTM D2855 / F493Solvent cementing of PVC and CPVC, solvent cements
- ASTM D2657 / F2620Heat fusion joining of polyolefin pipe and fittings
- ISO 15493 / ISO 10931Plastics piping systems for industrial applications (ABS, PVC, PVDF)
- ISO 4437 / ISO 14692Polyethylene piping, glass-reinforced plastics piping in petroleum industries
- AWWA C950 / M45Fibreglass pressure pipe and design guidance
- PPI TR-33 / DVS 2207Butt fusion and thermoplastic welding procedures
- NACE recommendationsCorrosion and chemical resistance guidance
- ISO 9001Quality management systems
BIS: Indian Standards
Mainly water, sewerage and utility services- IS 4984High density polyethylene (HDPE) pipes for water supply
- IS 14333HDPE pipes for sewerage
- IS 4985Unplasticized PVC pipes for potable water supplies
- IS 7834Injection moulded PVC socket fittings with solvent cement joints
- IS 15778CPVC pipes for potable hot and cold water distribution
- IS 15801Polypropylene random copolymer pressure pipes for hot and cold water
- IS 12709GRP pipes, joints and fittings for potable water supply
- IS 5382Rubber sealing rings for gas mains, water mains and sewers
Indian statutory and industry
Regulations and safety bodies- OISD standardsOil Industry Safety Directorate guidelines for plant safety
- Factories Act, 1948Statutory safety provisions, including chemical handling
- Pollution Control Board normsRequirements for effluent and wastewater handling systems
- BIS certification (ISI mark)Verification of certified products at material receiving
- Client and project specificationsAlways override and extend the general standards
The standard and edition that apply depend on the contract, client specification and manufacturer instructions. Inspectors are trained to confirm the governing document before inspection.
Deliverables
- Comprehensive Training Notes (PDF)
- ITP Samples & Checklists
- Inspection Report Formats
- Test Package Samples
- Photo Guide of Defects
- Case Studies & Best Practices
Bonus
- Inspection Checklists
- Jointing Method Videos
- Standard Drawings
- Interview Q&A
- E-Books & Reference Materials
Course content at a glance
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Build your career as a non-metallic piping QA/QC inspector
Ensure the reliability, safety and compliance of non-metallic piping systems in Oil & Gas projects.
Quality Today – Safety Tomorrow – Reliability Forever