Petrotech Academy, Mahabubnagar
Metallic Process Piping QA/QC Inspector
Oil & Gas – EPC Projects
A complete, inspection-first programme covering materials, drawings, fabrication, welding, NDT, testing and handover, built around ASME, API, ASTM, ISO and NACE standards, BIS Indian Standards, and client specifications from Saudi Aramco, SABIC, ADNOC and PDO.
25Modules
120+Hours
400+Practical examples
250+Inspection checklists
100+QA/QC formats
RealEPC project case studies
Course content
Twenty-five modules, taught in the order an inspector meets the work on a real project: from reading the documents, to receiving material, to witnessing the hydrotest and closing out the dossier.
Foundations: Role, Materials, Codes and Documents
Introduction
- Role of QA/QC Inspector
- Quality in Oil & Gas Projects
- Project Life Cycle Overview
- QA vs QC
- ITP, QCP, Procedures
- Hold / Witness / Surveillance Points
Piping Materials
- Carbon Steel (A106, A53, A333)
- Stainless Steel (304, 304L, 316, 316L, 321)
- Alloy Steel (P11, P22, P5, P9)
- Duplex & Super Duplex (2205, 2507)
- Nickel Alloys: Inconel, Monel, Hastelloy
- Material Identification (PMI)
- Material Traceability
Codes & Standards
- ASME B31.3 – Process Piping
- ASME B16.5 / B16.9 / B16.11 / B16.34
- API 570, API 574, API 598, API 6D, API 1104
- ASTM Material Standards
- MSS SP Standards
- NACE MR0175 / ISO 15156
- ISO / EN International Standards
- BIS (IS) Indian Standards, IBR and OISD
- Client & Project Specifications
Documents & Quality System
- Project Quality Plan (QAP)
- Inspection & Test Plan (ITP)
- Procedures & Method Statements
- Material Test Certificates (MTC)
- Data Sheets & Drawings
- Non-Conformance Report (NCR)
- Corrective & Preventive Action (CAPA)
- Document Control
Drawing & P&ID Review
- P&ID Reading for Inspectors
- Line List & Spec Review
- Isometric Drawing Review
- GA / Layout Drawings
- MTO & Bill of Materials
- Revision & Mark-up
Receiving, Fabrication and Welding Control
Material Receiving Inspection
- Visual Inspection
- Dimensional Check
- Coating & Marking
- Material Test Certificates
- PMI Verification
- Storage & Preservation
Fittings, Flanges & Valves Inspection
- Fittings Inspection (B16.9 / B16.11)
- Flanges Inspection (B16.5)
- Gasket & Stud Bolt Inspection
- Valve Inspection (API 6D / 598)
- Valve Seat & Closure Test
- Name Plate Verification
Fabrication Inspection
- Cutting Inspection
- Beveling Inspection
- Fit-up Inspection
- Alignment & Gap Check
- Tacking Inspection
- Dimensional Verification
Welding & Weld Process
- Welding Processes (SMAW, GTAW, GMAW, SAW, FCAW)
- WPS, PQR, WPQR Review
- Welder Qualification
- Welding Consumables
- Welding Parameters
- Pre-heat & Interpass Temperature
Weld Inspection (Visual)
- Pre-Weld Inspection
- In-Process Inspection
- Post-Weld Inspection
- Weld Profile
- Undercut / Overlap / Porosity
- Repairs & Rejection Criteria
Testing, Heat Treatment, Dimensions, Coating and Supports
Non-Destructive Testing (NDT)
- Radiographic Testing (RT)
- Ultrasonic Testing (UT)
- Magnetic Particle Testing (MT)
- Dye Penetrant Testing (PT)
- Phased Array UT (PAUT)
- Acceptance Standards (ASME B31.3 / SAES / ADNOC)
Heat Treatment & PWHT
- PWHT Requirement (B31.3)
- Temperature Monitoring
- Soak Time & Cooling Rate
- Thermocouple Placement
- Temperature Chart Review
- PWHT Documentation
Dimensional Inspection
- Pipe Spool Dimensions
- Overall Length & Run
- Flange Facing
- Parallelism & Perpendicularity
- Bolt Hole Alignment
- Inspection Tools & Calibration
Coating & Painting Inspection
- Surface Preparation (SA 2.5 / SSPC)
- Surface Cleanliness Check
- DFT Measurement
- Holiday Test (Low / High Voltage)
- Coating Adhesion Test
- Coating System Verification
Pipe Supports Inspection
- Support Type Verification
- Material & Coating Check
- Dimensional Check
- Installation & Alignment
- Hold Down / Guide / Anchor
- Spring Support Verification
Erection, Hydrotest, Close-out and Safety
Erection Inspection
- Line-up & Alignment
- Level & Slope Check
- Support Installation
- Flange Joint Assembly
- Bolt Tightening (Torque Check)
- Field Joint Fit-up Check
Pre-Hydrotest Inspection
- Hydrotest Package Review
- Line Walkdown
- Temporary Supports
- Blind Installation
- Weld Repair Verification
- Instrument & Equipment Check
Hydrotesting Inspection
- Hydrotest Procedure Review
- Pressure Gauge Calibration
- Test Pressure Calculation
- Filling, Venting & Draining
- Holding Time Monitoring
- Leakage & Pressure Drop Check
Punch List & Close Out
- Punch List Preparation
- Punch Clearance Verification
- Re-Inspection
- Dossier Preparation
- As-Built & Redline Review
- Handover to Client
Safety for the QA/QC Inspector
- HSE Responsibilities
- PTW & LOTO
- Working at Height
- Confined Space
- Gas Testing
- PPE Requirements
Practical Tools, Records and Final Project
ITP & Checklists (Sample)
| Activity | Hold | Witness | Record | Reference |
|---|---|---|---|---|
| Material Receiving | H | W | IR Check Sheet | SAES-QP-50 |
| Fit-up | H | W | Fit-up Check Sheet | ASME B31.3 |
| Welding | H | W | Weld Inspection Sheet | API 1104 |
| NDT | – | W | NDT Report | ASME B31.3 |
| PWHT | H | W | PWHT Chart | SAES-QP-60 |
| Hydrotest | H | W | Hydrotest Report | SAES-QP-70 |
| Painting | – | W | Coating Report | SSPC / SAES |
| Final Inspection | H | W | Final Insp. Report | Project Spec |
H = Hold point | W = Witness point. Sample only; references vary by client and project.
Common Defects & Acceptance Criteria
- Cracks
- Porosity
- Lack of Fusion
- Incomplete Penetration
- Undercut
- Excess Reinforcement
- Spatter
- Ovality / Misalignment
Tools & Equipment for the Inspector
- Vernier Caliper
- Micrometer
- Bevel Gauge
- Welding Gauge
- Thickness Gauge (UT)
- DFT Meter
- Holiday Detector
- Torque Wrench
- Endoscope
Quality Records & Reports
- Inspection Request (IR)
- Inspection Report (IRR)
- Daily Inspection Report (DIR)
- NDT Reports
- Material Test Certificates (MTC)
- Calibration Certificates
- Non-Conformance Report (NCR)
- Final Dossier
Final Project – Case Study
- Complete piping system inspection from receiving to handover
- Real project drawings
- ITP preparation
- Inspection planning
- Defect identification
- Reporting & close out
Client standards covered
Learn how international codes are applied through client-specific requirements.
Saudi Aramco (SAES / SAEP)
- SAEP-331 – Welding
- SAEP-134 – Inspection
- SAEP-105 – Piping System
- SAES-P-010 – Carbon Steel Piping
- SAES-P-020 – Stainless Steel Piping
- SAES-A-008 – Bolting
- SAES-O-003 – Coating
- SAES-O-004 – Insulation
- SAES-QP-50 / 60 / 70 – Inspection Procedures
SABIC Standards
- Eng. Standard ENG-003
- Piping Spec. 001
- Welding Spec. 002
- Inspection Standard 003
- Coating Standard 004
- Bolting Standard 005
- Material Specification 006
ADNOC Standards
- Process Piping Standard
- Inspection Standard
- Welding Standard
- Material Specification
- Coating & Painting Standard
- Bolting Standard
- Hydrotest Standard
PDO Technical Standards
- Engineering Standard
- Piping Specification
- Welding Specification
- Inspection & Testing Standard
- Material Specification
- Coating Standard
- Hydrotest Standard
International and Indian standards you will work with
A piping inspector on an EPC project moves between ASME and API codes, ISO and EN references, and Indian standards for domestic and statutory work. The course teaches how to find the right requirement and apply it.
International standards
ASME, API, ASTM, MSS, NACE, ISO, EN- ASME B31.3Process piping design, fabrication, examination and testing
- ASME B16.5 / B16.9 / B16.11 / B16.34Flanges, butt-weld and forged fittings, valves
- ASME B36.10M / B36.19MDimensions of welded and seamless steel and stainless pipe
- ASME Sections II, V and IXMaterials, non-destructive examination, welding qualification
- API 570 / 574 / 598 / 6D / 1104Piping inspection, valve testing, pipeline valves, pipeline welding
- ASTM A106 / A53 / A333 / A312 / A335 / A105 / A182Pipe, forgings and fittings material specifications
- MSS SP-6 / SP-58 / SP-97Flange face finish, pipe supports, branch outlet fittings
- NACE MR0175 / ISO 15156Materials for sour (H2S) service
- ISO 9001Quality management systems
- ISO 9606-1 / ISO 15614-1Welder qualification and welding procedure qualification
- ISO 5817Quality levels for imperfections in fusion welds
- ISO 17636 / ISO 17640Radiographic and ultrasonic testing of welds
- ISO 8501-1 / SSPCSurface preparation grades before coating
- EN 10204 (3.1 / 3.2)Types of material inspection certificates
BIS: Indian Standards
Bureau of Indian Standards (IS codes)- IS 1239 (Part 1)Mild steel tubes, tubulars and other wrought steel fittings
- IS 3589Steel pipes for water and sewage
- IS 2062 / IS 1161Structural steel and steel tubes for pipe supports and structures
- IS 2825Code for unfired pressure vessels
- IS 814 / IS 7280Welding electrodes and bare wire electrodes
- IS 817 / IS 7307Training and testing of metal arc welders, welding procedure approval tests
- IS 823 / IS 9595Manual metal arc welding of mild steel and carbon manganese steels
- IS 2595 / IS 4853Radiographic testing of welds and pipe butt joints
- IS 3658 / IS 3703 / IS 4260Penetrant, magnetic particle and ultrasonic testing of welds
- IS 1363 / IS 1367Hexagon head bolts and nuts, threaded steel fasteners
- IS 2379Colour code for identification of pipelines
- IS 5822Laying of welded steel pipes for water supply
Indian statutory and industry
Regulations and safety bodies- Indian Boiler Regulations (IBR)Boiler and steam piping, approved materials and inspection
- OISD standardsOil Industry Safety Directorate guidelines, including work permit system
- PESOPetroleum and Explosives Safety Organisation statutory requirements
- 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 and client specification. Inspectors are trained to confirm the governing document before inspection.
Course content at a glance
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What you get
What you will learn
- End-to-end piping QA/QC inspection
- Interpretation of P&IDs and drawings
- Inspection techniques and NDT
- Use of codes and standards
- Documentation and reporting
- Quality control in EPC projects
- Practical field examples
Who should attend
- QA/QC Inspectors
- Piping Supervisors
- Mechanical Engineers
- Quality Engineers
- Construction Engineers
- Commissioning Engineers
Course deliverables
- Video Lectures & e-Books
- Inspection Checklists
- QA/QC Formats
- Real Project Case Studies
- P&ID, Isometric and GA Drawing Samples
- Quizzes & Assessments
- Certificate of Completion
Training features
- Industry expert trainers
- Practical field examples
- Real project documents
- Case-study based learning
- Lifetime access to materials
Key benefits
- Understand international and client standards
- Perform inspections confidently
- Reduce rework and avoid defects
- Improve quality and safety
- Enhance career opportunities
Build your career as a piping QA/QC inspector
Prepare yourself for QA/QC Inspector and Piping Inspector positions with top Oil & Gas EPC companies worldwide.
Quality is not an act, it is a habit. Build it right, inspect it right.