Piping and Mechanical Quality Control (QC) Inspector Course

Why Select this Training Course?

A Piping and Mechanical QC (Quality Control) Inspector is an essential component of a team whose objective is to develop the integrity and dependability of piping and mechanical installation. The essential part of this job is to review piping systems, mechanical machines, and related components to ensure compliance with appropriate codes, standards, and project specifications.

The Rcademy Piping and Mechanical Quality Control (QC) Inspector Course offers a structured approach to developing proficiency in piping and mechanical quality control, drawing from international standards, industry prerequisites, and a systematic exploration of QA/QC practices. Through the Rcademy training course, participants gain comprehensive knowledge encompassing heat treatments, metallurgical assessments, identification of damage mechanisms, and the proper selection of alloys to mitigate potential issues. Additionally, the course provides insights into prevalent national and international piping construction codes, piping inspection protocols, piping design principles, and procedures for piping repairs and modifications.

As a Piping and Mechanical Quality Control Inspector, the primary responsibility is to offer on-site expertise in quality control and assurance. This entails conducting frequent inspections to confirm code adherence, testing protocols, and material standards. Additionally, ensuring strict compliance with the company’s Quality Management System is a crucial aspect of the role. Key duties encompass:

• Adhering to the QA/QC management system at project sites.
• Independently performing all piping and mechanical inspection tasks with minimal supervision.
• Ensuring compliance with piping and mechanical Inspection Test Plan (ITP) stages.
• Facilitating communication and training related to quality control.
• Developing inspection and testing protocols.
• Assessing product materials, weld quality, and testing procedures to ensure alignment with relevant codes, standards, specifications, and Quality Control Measures (QCM).
• Verifying that supplies and external services meet the quality control standards established by the company.

What is the difference between quality assurance and quality control inspectors?

Quality Assurance (QA) inspectors are focused on preventing defects and keeping quality consistent from cycle to cycle for the project or production. They are responsible for implementing and maintaining quality management systems, policies, and standards that support compliance with customer requirements and specific regulations. The QA inspectors oversee the production or project lifecycle during all stages, including compliance with necessary standards and regulations. They emphasise continuous improvement that allows the optimisation of processes and elevates the overall quality performance.

On the other hand, the job of the Quality Control (QC) inspector is to find defects by using inspection, testing, and evaluation methods for products or processes. They inspect finished products, components, or materials to verify compliance with the prescribed specifications and primarily correct the errors they detect as soon as they can. QC inspection personnel keep records of inspection and test results, findings, deviations, and actions taken, including sampling procedures and statistical analysis to gauge the overall quality level.

Who Should Attend?

The Rcademy Piping and Mechanical Quality Control (QC) Inspector Course would be suitable for:

• Mechanical engineers who oversee the design and operation of mechanical systems, including piping networks.
• Metallurgical engineers specialising in the properties and behaviour of metals used in piping construction.
• Production engineers who manage the manufacturing processes involved in producing piping components.
• Chemical engineers who ensure the compatibility and safety of materials used in piping systems.
• Quality inspectors responsible for assessing the adherence of piping components to quality standards and specifications.
• Welding inspectors and welding QA/QC inspectors who ensure the quality and integrity of welded joints in piping systems.
• Inspection supervisor/inspectors overseeing the inspection processes for piping installations.
• Fabrication supervisor/inspectors managing the fabrication of piping components and assemblies.
• Technicians providing technical support for the inspection and maintenance of piping systems.
• Engineering supervisors overseeing engineering activities related to piping design, construction, and maintenance.
• Welding supervisors managing welding processes and personnel involved in piping fabrication.
• Quality supervisors who ensure Quality Control Procedures are implemented and followed in piping projects.
• NDE (Non-Destructive Evaluation) inspectors who use various techniques to assess the integrity of piping components without causing damage.

What are the Course Objectives?

Upon completing the Rcademy Piping and Mechanical Quality Control (QC) Inspector Course successfully, participants will:

• Understand how to design and make process piping according to the code.
• Recognise different types of piping connections, like raised neck flange, socket weld, threaded, and seal welds, and know the right sizes for welding.
• Develop the expertise to choose the correct class of flanged fittings for different conditions such as corrosion, erosion, high temperature, and pressure, and understand testing requirements.
• Gain knowledge about control valves like globe, slide, swing check, and butterfly valves, including how to maintain and inspect them.
• Understand filler metals, welding electrodes, and the variables involved in welding.
• Learn more about post-weld heat treatment, preheating, and different heat treatments for metals.
• Discover non-destructive testing methods like Ultrasonic, Magnetic, Penetrant, Eddy Current, Thermography, and Radiography.
• Learn about piping and welding codes.

How will this Course be Presented?

The Rcademy Piping and Mechanical QC (Quality Control) Inspector Course is designed to cater to participants’ needs and enhance their knowledge and skills. It incorporates various practical methods to ensure active learning throughout the course. Experienced professionals in the field deliver the course content, which is based on thorough research.

Participants engage in both theoretical and practical learning through slides, lecture notes, case studies, video presentations, and real-life scenarios. They also participate in quizzes, seminars, and mock sessions. Additionally, a feedback platform is provided to ensure participants’ satisfaction and address any concerns they may have.

What are the Topics Covered in this Course? 

Module 1: Roles and Responsibilities of QA/QC Piping Engineer

• Understanding the duties and responsibilities of a QA/QC piping engineer
• Role in ensuring compliance with codes, standards, and project specifications
• Collaboration with project management and other stakeholders

Module 2: Overview of Classification of Pipes, Fittings, Flanges, and Valves

• Types and classifications of pipes, fittings, flanges, and valves
• Understanding the purpose and application of different components in piping systems

Module 3: Piping Materials and Material Receiving Inspection

• Types of piping materials and their properties
• Material selection criteria for various applications
• Procedures for material receiving inspection and verification

Module 4: Tools and Equipment

• Inspection tools and equipment
• Manufacturing and processing discontinuities
• Bolting and fastener inspections

Module 5:  Types of Inspection

• Piping and Tubing Inspections
• Valve Inspections
• Pump Inspections
• Vessel and Tank Inspections
• Hanger and Support Inspections

Module 6: Piping Engineering

• Introduction of Piping
• Piping drawing
  • Isometric
  • P and ID
  • GA
• Equipment drawing and structural drawing
• Piping material and material standard
• Pipe support
• Pipe Fittings/Flanges and Valves
• Torque and bolts/ gaskets
• BOM preparation
• Pipe fit-up and cutting terminology
• Piping codes and standard
• Pipe fabrication/erection and hydrostatic testing
• Documentation related to piping and inspection
• Pipe insulation and painting
• Introduction of air tubing and hook-up drawing

Module 7: QA/QC Engineering

• Introduction of the welding process
• Weld terminology
• Material inspection, material codes and standard
• WPS and PQR
• Welding drawing/weld map
• Weld symbols
• Welding defects
• Destructive testing
• Non-Destructive Testing
  • NDT Level 1
  • NDT Level 2
• Repair of weld joint
• Heat treatment
• Four factors and weldability
• Document preparation related to the inspection

Module 8: Non-destructive Testing Level I and II

• Visual Testing
• DYE Penetrant Testing
• Magnetic Particle Testing
• Ultrasonic Testing
• Radiographic Testing
• Radiographic Film Interpretation
• Documentation of the testing

Module 9: Plans, Codes and Standards

• Preparation of Inspection Test Plans (ITP)
• Pressure Vessel and Storage Tank
• ASME Codes and Standards
• ASNT Level 2 NDT
• QC in Welding Inspection

Module 10: Drawings and Diagrams Analyses

• Process Flow Diagrams and Isometric Drawings
• P and ID Diagrams

Module 11: QA/QC Documentation

• Functional inspections and tests
• Reporting inspection results
• Operating experience

Module 12: Quality Control Procedures

• Quality control plans and procedures
• Inspection checklists and forms
• Record-keeping and documentation requirements
• Corrective and preventive actions

Module 13: Emerging Technologies

• Remote inspection technologies
• Augmented Reality (AR) for inspection guidance
• Machine Learning for defect recognition
• Quality Management Systems (QMS) integration