Piping Fabrication L4

STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN (NATIONAL OCCUPATIONAL SKILLS STANDARD)

STANDARD PRACTICE, STANDARD CONTENT & CURRICULUM of COMPETENCY UNIT FOR

PIPING FABRICATION MANAGEMENT (OIL, GAS & PETROCHEMICAL)

PENGURUSAN FABRIKASI PERPAIPAN (MINYAK, GAS & PETROKIMIA) LEVEL 4 TAHAP 4

JABATAN PEMBANGUNAN KEMAHIRAN KEMENTERIAN SUMBER MANUSIA, MALAYSIA

Copyright © DSD 2012 Department of Skills Development (DSD) Federal Government Administrative Centre 62530 PUTRAJAYA, MALAYSIA

STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN (NATIONAL OCCUPATIONAL SKILL STANDARD)

STANDARD PRACTICE, STANDARD CONTENT & CURRICULUM of COMPETENCY UNIT

FOR

PIPING FABRICATION MANAGEMENT (PENGURUSAN FABRIKASI PAIP)

LEVEL 4 (TAHAP 4)

First Published 2012

All rights reserved No part of this publication may be produced, stored in data base, retrieval system, or in any form by any means, electronic, mechanical, photocopying, recording or otherwise without prior written permission from Department of Skills Development (DSD)

TABLE OF CONTENTS

No.

Pages

Contents

1.

Introduction

1

2.

Occupational Structure

3

3.

Definition Of Competency Levels

5

4.

Malaysian Skill Certification

6

5.

Job Competencies

6

6.

Working Conditions

6

7.

Employment Prospects

7

8.

Training, Industrial/Professional Recognition, Other Qualifications and

9

Advancements

9.

10

Sources of Additional Information

10. Acknowledgement

12

11. Validation

12

12. Literature References

13

13.

Abbreviations

13

14.

Committee Members for Development of Standard Practice (SP), Competency Profile Chart (CPC), Competency Profile (CP) and Curriculum

15

of Competency Unit (CoCU 15.

Competency Profile Chart (CPC)

17

16.

Competency Profile (CP)

17.

Curriculum of Competency Unit (CoCU): Health, Safety & Environment

18 - 52

(HSE) Compliance Supervision 18.

Curriculum of Competency Unit (CoCU): Piping FabricationProject Materials Storage & Control

19.

Curriculum of Competency Unit (CoCU): Piping Fabrication Operation Supervision

54 - 61

62 - 76

77 - 94

20.

Curriculum of Competency Unit (CoCU): Piping Fabrication Quality Control

95 - 110

21.

Curriculum of Competency Unit (CoCU): Piping Fabrication Document

111-117

Control 22.

Curriculum of Competency Unit (CoCU): Shop Drawing Preparation

23.

Training Hour Summary

118-129 130

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STANDARD PRACTICE NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR PIPING FABRICATION MANAGEMENT LEVEL 4

1. INTRODUCTION This NOSS document outlines the standards and curriculum for Piping Fabrication Management (Level 4) in the Oil, Gas and Petrochemical Sector.

Piping fabrication is the process of manufacturing and fabricating predesigned piping systems for various uses.

Piping fabrication is usually required at large

industrial facilities such as offshore facilities (drilling platform), oil refineries plants, shipyards, residential irrigation, HVAC (Heating, Ventilation & Air Conditioning) and utility facilities.

Based on the Occupational Analysis (OA) of the Oil, Gas & Petrochemical sector, the Oil and Gas industry consists of a total process starting from the oil or gas field and runs all the way to the sending of processed hydrocarbon to the final user1. The industry is divided into two major components namely upstream and downstream. The upstream component is further divided into areas such as exploration, appraisal and engineering.

Engineering includes piping, structure,

instrumentation and control and civil. Piping fabrication is one of the job areas identified for piping.

The piping fabrication personnel are part of a piping fabrication team responsible for pipe fabrication, installation, maintenance, modification and repair of damages or breakdowns of the piping systems. Piping fitters and fabricators fabricate pipes at the operational level. Piping fabrication supervisors ensure that fabrication and installation work are carried out efficiently in accordance with piping and project specifications and standards. Piping supervisors assist the piping superintendents in managing the fabrication process and production team to ensure that completion dates, budgets, safety and quality requirements are met.

Quality in piping fabrication is addressed by a number of standards, specifications, and codes issued by bodies such as American National Standards Institute (ANSI), American Society of Mechanical Engineers (ASME), American Petroleum Institute (API), British Standard Institution (BSI) and International Organisation for Standardisation (ISO).

These standards, specifications and codes govern the

1 1 Department of Skills Development. 2011. Occupational Structure, Oil, Gas andPetrochemical Industry.

selection of piping materials, design, dimensions and tolerances, welding requirements, installation as well as inspection and testing procedures.

Piping

fabrication is a major activity in the construction of offshore facilities which must strictly adhere to established standards and health, safety and environment (HSE) requirements. In Malaysia, with the Oil, Gas and Energy sector as one of the twelve National Key Economic Areas, Oil and Gas service providers will continue to enjoy a sustained growth.

According to PEMANDU, the Oil & Gas sector would enable the industry

to contribute to an incremental Gross National Income (GNI) of RM131.5bil and 52,000 jobs by 20202.

This will also boost the demand for piping fabrication

personnel. Currently Oil and Gas Sector employs a significant number of foreign workers due to lack of trained local workers. It is hoped that concerted effort in training local expertise will open up opportunities for Malaysians to specialise in this sector and gain from the NKEA outcomes.

Therefore, this National Occupational Skills Standard (NOSS) document is developed for generating competent personnel in this specified occupational area. Pre-requisite The minimum requirements proposed by the industrial experts for those interested to enrol in this course are as follows: • Possesses minimum SKM 3 in Piping Fabrication Operation • Medically fit with good eyesight • Able to speak and write in Bahasa Malaysia or English

2 2PEMANDU. ETP Report : Oil, Gas and Energy 2011

2.

OCCUPATIONAL STRUCTURE

Piping fabrication comes under the Oil, Gas & Petrochemical Sector. The related sub-sector, area and job area as well as the structured career path are as shown in Figure 1and Figure 2.

SECTOR

OIL, GAS & PETROCHEMICAL

SUBSECTOR AREA

ENGINEERING

JOB AREA

PIPING

LEVEL 8 LEVEL 7 LEVEL 6 LEVEL 5 LEVEL 4

UPSTREAM

PIPING CUSTODIAN PRINCIPAL PIPING DESIGN PIPING MATERIAL PIPING STRESS SPECIALIST SPECIALIST SPECIALIST PIPING TECHNOLOGIST PIPING FABRICATION SUPERINTENDENT PIPING FABRICATION SUPERVISOR

PIPING DESIGNER PIPING SENIOR DRAFTER

LEVEL 3

PIPING FABRICATOR

PIPING DRAFTER

LEVEL 2

PIPING SENIOR FITTER

PIPING JUNIOR DRAUGHTER

LEVEL 1

PIPING FITTER

DRAUGHTSMAN

Figure 1 Occupational Profile Chart for Piping Fabrication Personnel

3

SECTOR


SUB-SECTOR

UPSTREAM (ENGINEERING)

AREA

PIPING FABRICATION

L8 L7

N/A

L6 L5

PIPING FABRICATION MANAGEMENT

L4


L3

PIPING FABRICATION OPERATION

L2

PIPING FABRICATION OPERATION

L1

N/A

Figure 2 Occupational Area Analysis (OAA) Chart for Piping Fabrication Personnel

4

3.

DEFINITION OF COMPETENCY LEVELS The NOSS is developed for various occupational areas. Candidates for certification must be assessed and trained at certain levels to substantiate competencies. Below is a guideline of each NOSS Level as defined by the Department of Skills Development, Ministry of Human Resources, Malaysia. Competent in performing a range of varied work activities, most of which are routine and predictable. Competent in performing a significant range of varied work activities, performed in a variety of contexts. Some of the activities are non-routine and required individual responsibility and autonomy. Competent in performing a broad range of varied work activities, performed in a variety of contexts, most of which are complex and non-routine. There is considerable responsibility and autonomy and control or guidance of others is often required. Competent in performing a broad range of complex technical or professional work activities performed in a wide variety of contexts and with a substantial degree of personal responsibility and autonomy. Responsibility for the work of others and allocation of resources is often present. Competent in applying a significant range of fundamental principles and complex techniques across a wide and often unpredictable variety of contexts. Very substantial personal autonomy and often significant responsibility for the work of others and for the allocation of substantial resources features strongly, as do personal accountabilities for analysis, diagnosis, planning, execution and evaluation.

Malaysia Skills Certificate Level 1: (Operation Level) Malaysia Skills Certificate Level 2: (Operation Level)

Malaysia Skills Certificate Level 3: (Supervisory Level)

Malaysia Skills Diploma Level 4: (Executive Level)

Malaysia Skills Advanced Diploma Level 5: (Managerial Level)

5

4. MALAYSIAN SKILL CERTIFICATION Candidates after being assessed and verified and fulfilled Malaysian Skill Certification requirements shall be awarded with Malaysia Skills Diploma (DKM) Piping Fabrication Management (Level 4).

5. JOB COMPETENCIES Piping Fabrication Management (Level 4) personnel are competent in performing the following core competencies: •

Piping Fabrication Health, Safety & Environment Compliance Supervision

•

Piping Fabrication Project Materials Storage & Control

•

Piping Fabrication Operation Supervision

•

Piping Fabrication Quality Control

•

Piping Fabrication Document Control

Optionally, the Piping Fabrication Management (Level 4) personnel are also competent in performing the following elective competency:•

Shop Drawing Preparation

6. WORKING CONDITIONS Piping fabrication can be accomplished in several ways namely shop fabricate and field installed, or field fabricate and installed, or combinations of both.

In shop fabrication, metal is fabricated and assembled into structures at the fabricator’s facility and then transported to the site for erection.

Shop fabrication allows the

fabrication personnel to work under controlled environment.

In field fabrication, metal is fabricated at site fabrication yards which are usually well equipped and organized to ensure efficient work flow. The pipes are then hooked-up or modified as required on site.

Working conditions at offshore sites may be unpredictable and personnel may have to work under pressure and in hazardous conditions. Working in an open air structure will require protection from weather conditions such as rain, wind and cold. .

6

Piping fabrication personnel are also required to complete their job within allocated time and usually work in a team which consists of workers from all levels. Safety is a major issue to all fabricator personnel. Thus, compliance with occupational safety and health is everyone’s responsibility at all times.

7. EMPLOYMENT PROSPECTS Malaysia is rich in both renewable and non-renewable sources of energy suchas petroleum. The rapid growth of the Oil and Gas Industry opens up plenty of job opportunities in this sector. The industry currently faces a shortage of skilled and experienced workforce in piping fabrication. Piping Fabrication Operation experts are highly sought after in various sectors other than the Oil, Gas and Petrochemical sector. While this sector offers many job opportunities, any sector involved in piping have great need for fabricators. This is especially true in the development sector where large upcoming piping projects such as the SCORE (Sarawak Corridor Renewal Energy) project in Bintulu, Sarawak and the Iskandar project in Johor will ensure plentiful opportunities for piping fabricators and management personnel in the near and foreseeable future. Resourceful and experienced piping fabricators and management personnel may also commercialise their skills and knowledge widely including taking up job offers abroad.. Well skilled and experienced fabricators are highly sought after in regions such as the Middle East. Other than the oil and gas industry, piping fabrication personnel can also work in the construction, marine and shipbuilding industries.

Listed below are the major companies in Malaysia involved in Piping Fabrication (Oil and Gas):

7

Table 1

Piping Fabrication Companies Company

Malaysia Marine and Heavy Engineering Holdings Berhad

SapuraKencana Petroleum Bhd

Sime Darby Energy & Utilities

TH Heavy Engineering Sdn Bhd

Brooke Dockyard and Engineering Works Corporation

Address Level 31, Menara Dayabumi, Jalan Sultan Hishamuddin, 50050 Kuala Lumpur, Malaysia Tel: 603 22730266 Fax: 603 22738916 Website: www.mhb.com.my Level 6, Menara SapuraKencana Petroleum 1, Jalan Dutamas 1, Solaris Dutamas, 50480 Kuala Lumpur Tel: 603 6200 8800 Fax: 603 6209 5683 Website: www.sapurakencana.com Kompleks Sime Darby Persiaran Kewajipan USJ7 47600 Subang Jaya Selangor Darul Ehsan, Malaysia Tel: 603 5891 8555 Fax: 603 5638 1911 Website: www.simedarbyenergyutilities.com Level 23, Tower B, Menara UOA Bangsar No. 5, Jalan Bangsar Utama 1 59000 Kuala Lumpur Tel:(+603) 2787 9000 Fax:(+603) 2787 9001 Website: www.thhe.com.my Sublot 47, 48 & 49, Block A, 1st-3rd Flr, Demak Laut Commercial Centre Phase 3, Jalan Bako, Petra Jaya, Kuching, Sarawak, Malaysia. Tel: 6082-439732 Website: www.brookedockyard.com

PFCE Engineering Sdn Bhd

Level 22, Maju Tower 1001 Jalan Sultan Ismail 50250 Kuala Lumpur, Malaysia Tel: +603 277287777 Fax: +603 27728780 Website: www.pfce.com.my

Labuan Shipyard & Engineering Sdn Bhd

Km9 Jalan Ranca-Ranca P.O. Box 81210 87031 F.T. Labuan Tel: +087 451888 Fax: +087 451777 Website: www.labuanship.com

8

Table 1

Piping Fabrication Companies (continue) Company

8.

Address

Dialog Group Berhad

109, Block G, Phileo Damansara 1, No. 9, Jalan 16/11, 46350 Petaling Jaya, Selangor Darul Ehsan, Malaysia Tel: 603 7955 1199 Fax: 603 7955 8989 Website: www.dialogasia.com

Boustead Heavy Industries Group

17th Floor, Menara Boustead 69, Jalan Raja Chulan 50200 Kuala Lumpur Tel: (+6)03-20787770 Fax: (+6)03-20316089 Website: www.bhic.com.my

TRAINING, INDUSTRIAL RECOGNITION, OTHER QUALIFICATION AND ADVANCEMENT Most piping fabricators develop their competencies on the job and through in-house certification. Management positions are acquired through years of working experience in the field. Training is currently also provided by public and private training centers. Many piping fabricators have their basic training in welding and develop their fabrication skills later on the job. In addition, the National Dual Training System also offers apprenticeship programme. With additional training in management and human resource development, piping fabricators can advance to become supervisors and superintendents at the fabrication site.Further certification and experience may advance them further as piping technologists or material specialists.

9

9. SOURCES OF ADDITIONAL INFORMATION LOCAL SOURCES •

DEPARTMENT OF OCCUPATIONAL SAFETY AND HEALTH (DOSH) Level 2, 3 & 4, Block D3, Complex D Federal Government Administrative Centre 62530 Wilayah Persekutuan Putrajaya

•

Phone

.: 603-8886 5000

Fax

: 603-8889 2443

Website

: http://www.dosh.gov.my

CONSTRUCTION INDUSTRY DEVELOPMENT BOARD MALAYSIA (CIDB) 7th Floor, Grand Season Avenue 72, Jalan Pahang 53000 Kuala Lumpur, Wilayah Persekutuan

•

Phone

.: 603-2617 0200

Fax

: 603-2617 0220

Website

: http://cidb.gov.my

INSTITUTION OF ENGINEERS, MALAYSIA (IEM) Bangunan Ingenieur, Lot 60/62 Jalan 52/4, Peti Surat 223 (Jalan Sultan) 46720 Petaling Jaya, Selangor Darul Ehsan, Malaysia.

•

Phone

.: 603-7968 4001

Fax

: 603-7957 7678

Website

: http://myiem.org.my

PERFORMANCE MANAGEMENT & DELIVERY UNIT (PEMANDU) Prime Minister’s Department 3rd Floor, East Block, Perdana Putra Building, Federal Government Administrative Centre, 62502 Putrajaya Phone

: 03-88727237

Fax

: 03 8888 7107

Website

: www.pemandu.gov.my

10

INTERNATIONAL SOURCES • AMERICAN WELDING SOCIETY (AWS) 550 Northwest 42nd Avenue Miami, FL 33126, United States Phone

:(305) 443-9353

Website

: http://www.aws.org

• AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) Three Park Avenue New York, NY 10016-5990 Phone

:973-882-1170 (outside North America)

Website

: http://www.asme.org

• AMERICAN PETROLEUM INSTITUTE (API) # 900, 1220 L Street Northwest Washington, DC 20005, United States Phone

:(202) 682-8000

Website

: http://www.api.org

• INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) ISO Central Secretariat 1, ch. de la Voie-Creuse CP 56 CH-1211 Geneva 20 Switzerland Phone

:+41 22 749 01 11

Website

: www.iso.org

• PIPE FABRICATION INSTITUTE USA Office 511 Ave. of America's, # 601 New York, NY 10011 Phone

: (514) 634-3434

Website

: [email protected]

11

10.

ACKNOWLEDGEMENT The Director General of DSD would like to extend his gratitude to the organisations and individuals involved in developing this standard. Special acknowledgement is given to the team of experts in piping fabrication who have generously shared their knowledge and experience for the documentation of this standard. Appreciation is also extended to the DSD NOSS team who provides guidance and direction in the development of this standard with ample patience and commitment.

11.

VALIDATION This standard has been checked by the Standard Technical Evaluation Committee (STEC), DSD and validated by the members of Skills Development Advisory Committee (SDAC) on …………………………..

The SDAC members as listed

below have agreed in consensus to this standard:

VALIDATION COMMITTEE PIPING FABRICATION MANAGEMENT

LEVEL 4

1.

En Azdi Abass

Managing Director Octagon Petroleum Technology Sdn Bhd

2.

Tuan Haji Arshad Ahmad

General Manager Sime Darby

3.

En Awaludin Mohd Arif

Managing Director Industrial Testing & Engineering

4.

En Baharuddin bin Mamat

Deputy Director Department of Occupational Safety and Health, Johor CHAIRMAN

1.

Principal Asst Director DSD, Cyberjaya, Selangor

En Ab Halim bin Hasan

VALIDATION OFFICER 1.

Tuan Syed Mahathir bin Syed Azman Shah

Asst Director DSD, Cyberjaya, Selangor

12

12.

LITERATURE REFERENCES 1.

PEMANDU. 2011 ETP Report: Oil, Gas and Energy. 2011. etp.pemandu.gov.my/.../upload/ENG_NKEA_Oil_Gas_Energy.pdf (20 June 2012: 17.30pm )

2.

Department of Skills Development. 2011. Occupational Structure, Oil, Gas and Petrochemical Industry. Department of Skills Development, Malaysia (23 June 2012: 20.30pm)

3.

Malaysia. 2010. Tenth Malaysia Plan 2011 - 2015. Malaysia (18 June 2012: 1800)

4.

Malaysian German Chamber of Commerce (MGCC). 2012. Market Watch 2012: The Malaysian Petrochemical Industry. Malaysia http://www.malaysia.ahk.de/fileadmin/ahk_malaysia/Market_reports/The_Malaysi an_Petrochemical_Industry.pdf (22 June 2012: 18.30pm)

13.

ABBREVIATIONS

ANSI

American National Standards Institute

API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

AWS

American Welding Society

CoCU

Curriculum of Competency Unit

CPC

Competency Profile Chart

DSD

Department of Skills Development

GA

General Arrangement (Drawing)

ISO

International Organisation for Standardisation

ITP

Inspection Test Plan

JSA

Job Safety Analysis

NDT

Non-destructive Testing

MT

Magnetic Particle Test

MTO

Material Take-Off

NKEA

National Key Economic Area

OA

Occupational Analysis

13

Abbreviations (cont) OAA

Occupational Area Analysis

OGSP

Oil & Gas Safety Passport

OSHA

Occupational Safety and Health Act

PEMANDU

Performance Management and Delivery Unit

P & ID

Piping & Instrumentation Diagram

PPE

Personal Protective Equipment

PTW

Permit To Work

PWHT

Post Weld Heat Treatment

WPS

Welding Procedure Specification

WQT

Welder Qualification Test

14

14.

COMMITTEE MEMBERS FOR DEVELOPMENT OF STANDARD PRACTICE (SP), COMPETENCY PROFILE CHART (CPC), COMPETENCY PROFILE (CP) AND CURRICULUM of COMPETENCY UNIT (CoCU)


LEVEL 4

PANEL Lecturer Advance Technology Training Centre (ADTEC) Construction & Project Management Supervisor Brooke Dockyard and Engineering works Corporation Sdn Bhd

1. Mohamad Yashar bin Hj Bujang 2.

Francis Kujat

3. Tuan Azam Bin Tun Mamat

Project Manager Dimet Wasser (M) Sdn Bhd

4. Sham Kwai Yau

Consultant Dimet Wasser (M) Sdn Bhd

5. Ten Wai Keong

Piping & Layout Engineer Samsung Engineer Corporation Limited

6. Maziyatunnur Adam

Piping Engineer KNM Process System Sdn Bhd

7. Sim Kwang Teck

Engineering Manager PFCE Offshore World Sdn Bhd

8. Jaffari Lee Ariffin

Principal Engineer Petroliam Nasional Berhad FACILITATOR

1.

Training Consultant Gemilang Offshore Engineering Company (M) Sdn Bhd

Nabilah Ooi Binti Abdullah

CO-FACILITATORS 1.

Raihan Tahir

2.

Eva Hoo Seet Yoong

Training Consultant Gemilang Offshore Engineering Company (M) Sdn Bhd Manager Gemilang Offshore Engineering Company (M) Sdn Bhd

15

STANDARD CONTENT NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR:

PIPING FABRICATION MANAGEMENT (PENGURUSAN FABRIKASI PERPAIPAN) LEVEL 4 (TAHAP 4)

16

COMPETENCY PROFILE CHART (CPC) SECTOR


SUB SECTOR


JOB AREA


JOB LEVEL

LEVEL FOUR (4)

COMPETENCY

CORE

ELECTIVE

JOB AREA CODE

COMPETENCY UNIT HEALTH, SAFETY & ENVIRONMENT COMPLIANCE SUPERVISION

PIPING FABRICATION PROJECT MATERIALS STORAGE & CONTROL

PIPING FABRICATION OPERATION SUPERVISION

SHOP DRAWING PREPARATION

17

PIPING FABRICATION QUALITY CONTROL

PIPING FABRICATION DOCUMENT CONTROL

Sub Sector


Job Area


Level

FOUR (4)

CU Title

1. Health, Safety &

CU Code

CU Descriptor

CU Work Activities

Performance Criteria

The primary objective of

1. Supervise safety of working

1.1 Safety signage and JSA

Environment

Health, Safety, and

Compliance

Environment initiatives is to

Supervision

reduce overall risk, to comply

environment

are visibly displayed at designated areas

1.2 Potential hazards

with legislative requirements,

(physical, chemical,

and to create a safe yet

biological, ergonomical)

efficient working

are identified and

environment. HSE

mitigation actions are

compliance supervision

taken as per HSE

ensures that these initiatives

requirements

are integrated with day-to-

1.3 Safety equipment (such as

day operations management.

fire extinguisher) are

The person competent in this

checked to ensure

CU shall be able to supervise

equipment are in good

safety of working

working condition

environment, supervise

1.4 Erection and dismantling

safety check of tools and

of scaffolding are

18

CU Title

CU Code

CU Descriptor

CU Work Activities


equipment and supervise

supervised in accordance

usage of PPE.

with HSE requirements

The outcome of this

1.5 Sufficient ventilation and

competency is efficient and

lighting are ensured in

effective supervision of

confined space

working environment, tools

1.6 Cleanliness of working

and equipment, and usage of

environment is monitored

PPE in compliance with HSE

as per housekeeping

requirements.

practices

2.1 Tools and equipment are inspected (visually and

2. Supervise safety check of tools and equipment

using instruments) and test run according to manufacturer’s specifications

2.2 Green tag are marked on tools and equipment which are tested and safe to be used

2.3 Load certificates for lifting equipment and gear are

19

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria checked to ensure working condition as per lifting plan

2.4 Magnetic Particle Test (MT) for cracks on shackle by qualified technician is arranged and witnessed

2.5 Colour coding on tools and equipment are periodically checked according to HSE requirements

2.6 Random daily test on tools and equipment is conducted according to HSE requirements

2.7 Non-compliant tools and equipment are sent for servicing and re-inspected

2.8 .Safe-for-use certification expiry dates are monitored to identify reinspection dates

20

CU Title

CU Code

CU Descriptor

CU Work Activities


3.1 Personal protective equipment are selected, checked and used in accordance with HSE requirements

3. Supervise usage of PPE

3.2 PPE with expiry dates (such as helmet & safety shoes) are replaced at regular intervals

3.3 Appropriate actions are taken in cases of noncompliance, if applicable

21

CU Title

2. Piping Fabrication

CU Code

CU Descriptor

CU Work Activities


Piping fabrication project

1. Identify project materials

1.1 Types of piping

Project Materials

materials storage & control

storage & control

fabrication materials

Storage & Control

refers to the activities of

requirements

required are identified as

receiving, storing, issuing and .

per contract design

distribution of piping

specifications

materials to production

1.2 Quantity of piping

stations from the secondary

fabrication materials

storage area at the

required are identified as

fabrication site. This CU

per production

outlines the requirements for

requirements

the systematic control of

1.3 Piping material codes &

piping materials held under

standards are identified

shop and site conditions such

as per piping material

as to prevent damage or

specifications

deterioration or loss of

1.4 Piping material storage &

identity.

control procedures are


established in

CU shall be able to identify

accordance with material

piping materials storage and

storage and handling

control requirements, monitor

requirements

piping materials stock level, follow up to expedite

1.5 Roles of personnel responsible for the

22

CU Title

CU Code

CU Descriptor

CU Work Activities


procurement activities,

operation of project

supervise storage area,

materials storage and

receive piping materials and

control are clearly

supervise materials handling,

defined

storage, issuance and

,

distribution to production

2.1

areas.

Piping material par stock level is identified to

The outcome of this

2. Monitor project materials

competency is the efficient and systematic management

stock level

ensure availability and optimise storage area

2.2 Stock level at store and

of piping fabrication material

production line is

storage and control in the

monitored to ensure

field of oil and gas industry.

continuous availability

2.3 Recommendations for additional materials procurement is given to purchaser based on stock level and production requirements

2.4 Piping materials stock records are updated regularly

23

CU Title

CU Code

CU Descriptor

CU Work Activities


3.1 Piping materials timely delivery is monitored as per expected delivery date and required on site

3. Follow up to expedite procurement activity

(ROS)

3.2 Expediting actions are taken to ensure timely delivery

3.3 Recommendations are provided, if applicable, to overcome delay in delivery

4.1 Storage lay out area is planned based on production lay out and types and specifications of piping materials

4. Supervise project materials storage area

4.2 Specific storage areas are allocated for different types of piping materials according to

24

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria manufacturer’s recommendations

4.3 Signage installation is monitored to ensure compliance with HSE requirements

4.4 Storage area climatic condition (including temperature and relative humidity) control is monitored to prevent material deterioration and damage

4.5 Storage area cleanliness is monitored in accordance with housekeeping practices

5.1 Received piping materials are received and checked in accordance with related

25

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria Mill Certificate and product catalogue

5.2 Non-compliant items are segregated,recorded in

5. Receive Verify project materials received from store as per production request

material non-compliance report and replacement is requested, if applicable

5.3 Personal protective equipment is used in accordance with HSE requirements

5.4 Receiving records and documentations are updated in a timely manner

6.1 Piping materials handling is monitored to ensure compliance with manufacturer’s specifications and HSE requirements

26

CU Title

CU Code

CU Descriptor

CU Work Activities


6.2 Material handling tools and equipment are used in accordance with manufacturer’s

6. Supervise project materials handling & storage

specifications and HSE requirements

6.3 Piping materials are stored at designated areas according to storage layout plan

6.4 Labels and signage display are monitored to ensure efficient accessibility and control

6.5 Welding consumables are marked or colourcoded for easy recognition

6.6 Storage records are updated in a timely manner

6.7 Personal protective 27

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria equipment is used in accordance with HSE requirements

7.1 Piping materials request from production team is verified against project requirements and schedule

7.2 Piping materials are issued according to production requirements

7.3 Piping materials distribution is monitored as per production requirements

7.4 Usage of tools and 7.

Supervise project materials

equipment for distribution

issuance and distribution to

is monitored in

production related teams

accordance with manufacturer’s specifications and HSE

28

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria requirements

7.5 Personal protective equipment is used in accordance with HSE requirements

7.6 Issuance and distribution records are updated in a timely manner

3. Piping Fabrication Operation Supervision

Supervision covers many

1. Review piping fabrication

functions including work

1.1

scope of work

Fabrication tasks are identified according to

planning and delegation,

project scope of work

work flow coordination,

1.2

Related documents( such

provision of technical

as P &ID, isometric

assistance and support as

drawing, contract design

well as resolving problems

specification, inspection

within the work unit

test plan, WPS-PQR &

supervised.

WQT) are reviewed to

This CU describes

identify piping fabrication

supervision in the daily piping

standards and

fabrication operation activities

specifications

29

CU Title

CU Code

CU Descriptor

CU Work Activities

in the oil and gas industry.


1.3

Projected quantity and

The person who is competent

production capacities

in this CU shall be able to

are reviewed in

review piping fabrication

accordance with project

scope of work, organise

master plan

piping fabrication activities,

1.4

HSE requirements are

supervise spool fabrication

identified according to

and installation work, piping

Job Safety Analysis

fabrication work progress,

(JSA) and client

production team and prepare

requirements

production progress reports. The outcome of this CU is the

2.1

development of

Fabrication tasks are prioritised and

competencies required by a supervisor in enhancing work

2. Organise piping fabrication

sequenced according to

activities production process

the overall production

productivity and job quality in accordance with piping

schedule

2.2

fabrication and project

Fabrication tasks are delegated to qualified

specifications for the oil and

personnel according to

gas industry.

job specifications and project requirements

2.3 30

Welders qualification is

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria checked (using WQT as per client approved WPS) to ensure only qualified welders are used for piping welding

2.4

Welding consumables are as stipulated in WPS approved by client

2.5

Work areas are organised to optimise space utilisation and prevent congestion

2.6

Production organisation complies with HSErequirements

3.1

Pipe marking and cutting are checked to ensure compliance with cutting plan

3. Supervise spool fabrication

3.2

Fit-up spools are visually inspected prior

31

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria to any welding

3.3

Tack-weld is inspected to ensure compliance with WPS

3.4

Pre-Heating is verified in accordance with WPS pre-heating requirements (such as ASME B31.3)

3.5

Post heating is verified in accordance with WPS

3.6

Welded pipe spool are visually inspected (VI) prior to NDT

3.7

Work place is ensured of adequate ventilation prior to any purging of pipe works

3.8

Piping welding repair work is supervised to ensure compliance with

32

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria project requirements, welding repair procedures and WPS standards (such as ASTM A488 or ASME IX)

3.9

Post Weld Heat Treatment (PWHT) is verified in accordance with WPS

4.1

Pipe spools are released for NDT, hydrotest, blasting and painting prior to assembly and installation

4.2

33

Handling and

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria movement of pipes are supervised for

4. Supervise piping installation work (piping spool

compliance with HSE

installation, piping system

requirements

installation)

4.3

Pipe lifting complies with lifting standard operating procedures

4.4

Pipe and pipe fitting installation are supervised for compliance with isometric drawings

4.5

Pipe supports installation is in accordance with IFC pipe support arrangement drawings

4.6

Flange connections to equipment are checked for alignment

4.7

Pipe spool installation adheres to HSE

34

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria requirements

5.1

Project production progress measurement is reviewed to identify expected progress

5.2

Work progress is monitored against project production progress measurement to ensure target is achieved

5.3 5. Supervise piping fabrication

Completion times of tasks/jobs are

work progress

monitored and scheduling is adjusted as appropriate

5.4

Corrective actions are taken to resolve delayed work activities to ensure project timeline meets target

35

CU Title

CU Code

CU Descriptor

CU Work Activities


5.5

Assistance is provided when required to meet operational targets

6.1

Roles and responsibilities of production team members are clearly communicated in accordance with job specifications

6.2

Required standard is explained to team members to ensure understanding of allotted task

6.3

Operational targets are set and checked at

6. Supervise production team

regular intervals

(pipe fitters, pipe welders)

6.4

Feedback and recommendations are provided for

36

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria performance improvement as necessary

6.5

Compliance of HSE requirements is strictly enforced

6.6

Training needs are identified and training proposed or conducted as necessary

7.1 Mark-cut progress, fit-up progress and welding progress records are updated with specific data including quantities, dates and descriptions

7.2 Hydro-test/ leak test/ pneumatic test records are updated

7.3 Variations from production plan are recorded with

37

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria appropriate details

7.4 Reports are produced and submitted in a timely manner

7. Prepare production progress reports

4. Piping Fabrication Quality Control (QC)

Quality control refers to the control of production process

1. Review piping fabrication QC requirements

1.1 Quality Manual is perused to identify quality

using a planned and

standards and

systematic sequence of

requirements for each

actions which provide the

phase of the fabrication

confidence that all work

process (such as ASME

carried out will meet and

B31.3, ASME IX)

satisfy the project and piping

1.2 Client quality specifications

specifications.. This CU

are perused to identify QC

covers in-process QC which


is conducted before the


actual audit by the QA/QC

process

personnel. The objective is to confirm that all work is

1.3 Inspection Test Plan (ITP) is perused to identify QC

38

CU Title

CU Code

CU Descriptor

CU Work Activities


produced in compliance with

requirements and

the project scope of work as

schedule

well as to identify non-

1.4 In-process QC procedures

compliance for rectification.

and schedules are

The person who is competent

established in accordance

in this CU shall be able to

with QA/QC requirements

review piping fabrication QC

1.5 QA/QC audit requirements

requirements, conduct in-

are identified to assist in

process QC, liaise with

inspection preparation

QA/QC personnel and client

1.6 QC requirements are

on inspection work and

communicated to

provide information for the

fabrication crew to ensure

preparation of QA/QC

accurate interpretation and

reports.

compliance of fabrication

The outcome of this CU is the

standards

development of competencies for conducting

2.1 Preparations for in-

in-process QC in accordance

process quality

with ITP to ensure that piping fabrication work adheres with project and piping fabrication specifications in the oil and

2. Conduct in-process QC

inspection is carried out in accordance with inprocess QC procedures

2.2 Inspection and data 39

CU Title

CU Code

CU Descriptor

CU Work Activities

gas industry.

Performance Criteria checklist are prepared in accordance with ITP

2.3 Hold points are identified for inspection purposes in accordance with QA/QC specifications

2.4 Processes and items for in-process QC are selected in accordance with quality sampling methods

2.5 Acceptance criteria (including tolerances for dimensions and distortions) are established in accordance with piping standards and isometric drawings

2.6 Project materials are inspected for compliance with piping standard and

40

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria isometric drawing

2.7 Weld preparations, parameters and consumables are inspected for compliance with WPS

2.8 Fit-up configuration, dimension and orientation are checked for compliance with WPS and isometric drawing

2.9 Spool and sub spool identification are checked in accordance with isometric drawing

2.10 Removal of pipe surface contaminants is checked in accordance with piping and ITP requirements

2.11 All completed welds are visually checked prior to NDT

41

CU Title

CU Code

CU Descriptor

CU Work Activities


2.12 Corrective actions are taken to rectify noncompliance

2.13 Inspection and tests are conducted in accordance with in-process QC procedures and HSE requirements

2.14 Inspection results are documented in accordance with QC format

3.1

Hydrotest package is perused to identify hydrotest requirements

3.2

Pipe spools are identified as per hydrotest package

3.3

Pipe spools and hydrotest equipment are set up as per hydrotest package

42

CU Title

CU Code

CU Descriptor

CU Work Activities


3. Coordinate hydrotest

3.4

Hydrotest is supervised to ensure compliance with HSE requirements

4.1

QA/QC Inspection schedule is identified from Inspection Test Plan

4.2

Preparation for QA/QC audit is arranged in accordance with QA/QC procedures

4.3

QA/QC inspection sessions are

4. Liaise with QA/QC on

coordinated in

inspection work

accordance with QA/QC procedures

4.4

Assistance and support is provided to QA/QC personnel to facilitate efficient audit

43

CU Title

CU Code

CU Descriptor

CU Work Activities


5.1

Client inspection schedule is identified from ITP and client requirements

5.2

Preparation for client inspection is arranged in accordance with ITP and client requirements

5.3

Inspection session is coordinated to facilitate efficient client inspection

5. Liaise with client on

5.4

inspection work as per ITP

Assistance and clarification is provided to client during inspection session if necessary

5.5

Inspection procedures adhere to HSE requirements

6.1 44

Compliance and non-

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria compliance are recorded according to QA/QC format (NDT report, hydrotest report)

6.2

Information on compliance and noncompliance is made accessible to QA personnel for the preparation of QA/QC reports

6.3

Recommendations for process improvement are

6. Provide information for the preparation of QA/QC report

5. Piping Fabrication Document Control

Document control refers to

provided where applicable

1. Control fabrication drawings 1.1 Fabrication drawings are

the systematic procedure of

(P &ID, isometric, piping

received, acknowledged

checking and approving

plan drawing, pipe support

and compiled in

documents prior to release to

arrangement)

accordance with

ensure drawings and

documentation procedure

documents released are of

1.2 Drawings are distributed

the latest revision. It

to production floor

45

CU Title

CU Code

CU Descriptor

CU Work Activities


prevents the unintended use

according to

of obsolete documents and

documentation

drawings in the fabrication

distribution procedure

process.

1.3 Old drawings are


superseded and

CU shall be able to control

destroyed according to

fabrication drawings and

document control

related documents, and

procedures

compile lessons learnt for

1.4 Revised drawings are

production team.

distributed to production

The outcome of this CU is the

floors to ensure the latest

development of

revised drawings are

competencies for controlling

referred for all fabrication

release of document

work

revisions to ensure fabrication process is based

2.1 WPS is distributed to

on latest revised drawings

production floor

and documentation.

2.

Control related fabrication

according to document

documents (WPS, ITP

control procedure

2.2 Non-destructive test procedure is distributed to production foreman

46

CU Title

CU Code

CU Descriptor

CU Work Activities


2.3 Hydrotest package is distributed and briefed to production foreman

2.4 Contract design specifications are distributed and briefed to production foreman

2.5 ITP is distributed and briefed to production foreman

2.6 Process standard is distributed and briefed to production foreman

3.1 Lessons learnt compilation format is established in accordance with documentation

3. Compile lessons learnt for production team (postmortem)

guidelines

3.2 Lessons learnt records and reports are gathered from production team

47

CU Title

CU Code

CU Descriptor

CU Work Activities


3.3 Lessons learnt are categorised for easy reference

3.4 Lessons learnt compilation is regularly updated, verified and made accessible to production team for continuous improvement

6. Shop Drawings

Shop drawings are prepared

Preparation

to provide information which

1. Identify

shop

requirements

drawings 1.1 Shop drawing format and presentations are identified

assists in confirmation of the

as per shop detail drawings

intent of the design and to

presentation guidelines or

provide suppliers, fabricators

fabricator’s shop drawings

or manufacturers with

procedures and guidelines.

information which assists

1.2 Specification and

them in making and providing

requirements for fabrication,

the required material

material, shop procedures,

components. It shows in

inspection, cleaning and

detail (1) the proposed

painting are identified as

fabrication and assembly of

per structure standard

structural elements and (2)

details requirements.

48

CU Title

CU Code

CU Descriptor

CU Work Activities


the installation of materials for the equipment. It includes drawings, diagrams, layouts, schematics, descriptive

2.1 Structure components such 2. Identify shop drawings information

as I-beams, girder, plates, channels etc are identified

literature, illustrations,

according to project

schedules, and any data

requirements as generated

intended to illustrate details

in cutting plan and detailed

of the work that is required by

design drawings.

the contract.

2.2 Drawings and specifications

The competent person will be

are identified and reviewed

able to ensure shop drawings

as per engineering

are prepared as per

specifications.

requirements.

2.3 Materials are identified as

The CU covers activities like

per manufacturer’s

identifying shop drawings

specifications or catalogue.

requirements and

2.4 Yard machines and

information, preparing shop drawings and confirming

equipment capacity are identified according to shop

shop drawings prepared.

drawings requirements.

The outcome of this CU is the development of

2.5 Variations orders on shop drawings from the contract

competencies to prepare

are identified and

49

CU Title

CU Code

CU Descriptor

CU Work Activities

shop drawings.

Performance Criteria described.

2.6 Information to fabrication process such as dimensions or special fabrication instructions is identified as per contract.

3.1 General information such as location of all items, general shape and size, stationing at supports, field

3. Prepare shop drawings

welded items and weld symbols and etc are shown according to erection framing plan.

3.2 Shop drawings are prepared according to assembly diagrams requirements.

3.3 Horizontal and vertical dimensions, bolt and hole diameters, edge distances

50

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria on crossframe components, thickness and width of crossframe connections and etc are identified as per shop detail drawings presentation guidelines.

3.4 Product details are included in shop drawings as per project requirements.

4.1 Drawings are consolidated and reviewed for accuracy, completeness and compliance with contract requirements prior to fabrication.

4. Confirm shop drawings prepared

4.2 Materials specified are checked so that they conform to the contract documents.

4.3 Weld symbols on shop detail drawings are ensured

51

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria that they are compatible with joints on the plans.

4.4 Dimensions, material and connection properties on shop detail drawings are checked as per approved checklist.

4.5 Shop drawings prepared are checked against cutting plan output to ensure cut off materials is within specified supplied piece.

4.6 Drawing details such as numbers and revision numbers, BOM/MTO, all dimensions, bolt and hole size, cutting plans, welding symbols, installation sequence and etc are indicated on the shop drawings as per shop drawings guidelines and

52

CU Title

CU Code

CU Descriptor

CU Work Activities

Performance Criteria requirements.

4.7 Details such as yard layout, equipment and fabrication equipment are included as per requirements.

4.8 Quality and quantity of information provided is in accordance with company format, standards and procedures.

53

CURRICULUM of COMPETENCY UNIT (CoCU) FOR:

NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR:

PIPING FABRICATION MANAGEMENT (PENGURUSAN FABRIKASI PAIP) LEVEL 4 (TAHAP 4)

54

CURRICULUM of COMPETENCY UNIT (CoCU)

Sub Sector


Job Area


Competency Unit Title

Health, Safety and Environment Compliance Supervision The person who is competent in this CU shall be able to supervise HSE compliance in piping fabrication daily operations. Upon completion of this competency unit, trainees will be able to:-

Learning Outcomes

•

Supervise safety of work environment

•

Supervise safety check of tools and equipment

•

Supervise usage of personal protective equipment (PPE)

Competency Unit ID

Level

Work Activities

Related Knowledge

1. Supervise safety

i Types of hazards in oil and

4

Applied Skills

Training Duration

150

Credit Hours

15

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

30

Lecture

i

Potential

of work

gas fabrication activities

Group discussion

hazards

environment

•

Shop talk

(physical,

Physical (working at height, dropping

chemical,

objects)

biological,

Chemical (to add in

ergonomical)

examples)

are identified

•

Biological

and mitigation

•

Health

actions are

•

Fire

taken as per

•

55

Work Activities

Related Knowledge •

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria HSE

Ergonomical

requirements

ii Hazards mitigation actions ii

iii Structure Fabrication

Safety

working environment HSE

equipment

requirements

(such as fire

•

Safety equipment

extinguisher)

•

Safety signage

are checked to

•

Scaffolding

ensure

•

Ventilation

equipment are

•

Lighting

in good working condition

iv Housekeeping practices iii

such as: •

Site clearning

•

Storage

•

Segregation of

Safety signage and JSA are visibly displayed at designated areas

garbage iv

v Security

Sufficient ventilation and

i.

ii.

Determine types of hazards

HSE

Determine mitigation

requirements

actions for different

iii.

i. Comply with

ii. Ensure safe

types of hazards

and clean

Check safety

working

equipment

environment

56

30

lighting are

Demonstration

ensured in

Project

confined space v

Cleanliness of working environment is monitored as

Work Activities

Related Knowledge

Applied Skills iv.

v.

Display safety signage

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

iii. Practise IIF

per

and JSA at designated

culture (incident

housekeeping

areas

& injury free

practices

Determine ventilation

culture)

and lighting requirements for confined space 2. Supervise safety

i

30

Importance of safety

i Tools and

check of tools

check for tools and

equipment are

and equipment

equipment

inspected

ii

Safety check procedures

(visually and

iii

Test-run procedures

using

iv

Equipment safe-for-use

instruments)

tagging procedures

and test run

Safe working load for

according to

lifting equipment

manufacturer’s

Magnetic Particle Test

specifications

v

vi

(MT) procedures vii

viii

ix

ii Green tag are

Colour coding for tools

marked on tools

and equipment

and equipment

Tools and equipment

which are

random and periodical

tested and safe

inspection procedures

to be used

Non-compliance and

iii Load

actions to be taken

certificates for

57

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria lifting equipment and gear are checked to ensure working

i

Check safety of tools

i

Comply with

and equipment

HSE

ii

Test run equipment

requirements

iii

Mark tools and

iv

v

ii

equipment with safety-

and

for-use tags

equipment are

Interpret load

safe and in

certificates

good working

Arrange MT inspection

condition iii

for shackles vi

vii

Practise IIF

Check colour coding

culture

on tools and

(incident &

equipment

injury free

Apply random daily

culture)

condition as per lifting plan iv Magnetic Particle Test (MT) for shackle by qualified technician is arranged and witnessed v Colour coding on tools and equipment are periodically checked according to

test procedures viii

Ensure tools

30

Take actions for noncompliant tools and

HSE requirements vi Random daily

equipment

test on tools and equipment

58

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria is conducted according to HSE requirements vii Non-compliant tools and equipment are sent for servicing and re-inspected viii Safe-for-use certification expiry dates are monitored to identify reinspection dates

3. Supervise usage of PPE

i Types of PPE

15

i Personal

•

Coverall

protective

•

Safety boots

equipment are

•

Safety helmet

selected,

•

Gloves

checked and

•

Ear plug

used in accordance with

ii PPEexpiry dates (safety

HSE

boots and helmet)

59

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

iii PPE usage procedures

requirements

iv Actions for non-compliance

ii PPE with expiry

in PPE usage

dates (such as i Select PPE

i

ii Check PPE safety condition iii Check PPE usage

ii

iv Take appropriate

Comply with

compliance

iii

shoes) are

requirements

replaced at

Ensure PPE is

regular intervals iii Appropriate

at all times

actions are

Practise IIF

taken in cases

culture

of non-

(incident &

compliance, if

injury free

applicable

culture)

60

helmet & safety

HSE

used correctly

actions for non-

15

Employability Skills Core Abilities

Social Skills

04.09

Prepare work plan

1. Communication skills

04.10

Utilise science and technology to achieve goal

2. Conceptual skills

05.04

Delegate responsibilities and/or authority

3. Interpersonal skills

05.05

Coordinate contract and tender activities

06.08

Identify and analyse effect of technology on the environment

4. Learning skills 5. Leadership skills 6. Multitasking and prioritising 7. Self-discipline 8. Teamwork

Tools, Equipment and Materials (TEM) ITEMS 1. 2. 3. 4. 5. 6. 7. 8. 9.

RATIO (TEM : Trainees)

Occupational Safety and Health Act Safety procedures Company policies Company Rules and Regulations JSA template Log book Stationery PPE (coverall, safety boots, safety helmet, gloves, mask, harness) Safety Passport

1:25 1:25 1:25 1:25 1:1 1:1 1:1 1:1 1:1

61

REFERENCES 1.

Sutton, I. (2012). Offshore Safety Management. ISBN 9781437735246

2.

OSHA. Occupational Safety and Health Act 1994. Malaysia

3.

Industry Code of Practice for Safe Working in a Confined Space 2010; Department of Occupational Safety and Health, Ministry of Human Resources, Malaysia

62


Sub Sector


Job Area



PIPING FABRICATION PROJECT MATERIALS STORAGE & CONTROL The person who is competent in this CU shall be able to perform materials storage and control in accordance with piping and project specifications. Upon completion of this competency unit, trainees will be able to:-

Learning Outcomes

•

Identify project materials storage & control requirements

•

Monitor project materials stock level

•

Follow up to expedite procurement activity

•

Supervise project materials storage area

•

Receive project materials from store as per production request

•

Supervise project materials handling & storage

•

Supervise project materials issuance and distribution to production related teams

Competency Unit ID

Level

Work Activities 1. Identify project

Related Knowledge i.

4

Applied Skills

Types of piping materials

Training Duration

300

Credit Hours

30

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

15

Lecture

i.

Types, quantity

materials storage

•

Carbon steel

Group discussion

and

& control

•

Low-temperature

Shop talk

specifications of

requirements

materials

piping

•

Stainless steel

fabrication

•

Duplex

materials

63

Work Activities

Related Knowledge • ii.

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria required

Super Duplex

identified as

Types of fittings •

Elbow

per project

•

Tee

specification

•

Flange

•

Weldolet

storage &

•

Flangolet

control

•

Nipple

procedures

•

Reducer

ii. Piping material

established in accordance with

iii. Types of welding

store

consumables •

Welding rod

•

Welding wire and

procedures and HSE requirements

electrodes •

iii. Duties of

Argon gas

personnel

iv. Piping material

responsible for

requirement such as

project

• Quantity

materials

• Pipe standards

storage and

(ASME, ANSI, API,

control defined

ISO or equivalent) • Welding consumables standards and colour coding v.

Piping material

64

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

storage requirements • Lighting & ventilation

• Space area • Climatic requirements vi. Piping material storage control principles and procedures vii. Job scope of store personnel

vi.

Identify types, quantity

i. Comply with

and specifications of

piping

piping fabrication

standards

materials required

ii. Comply with

vii. Establish piping

15

Demonstration Project

HSE

material storage & control procedures viii. Define job scope of

requirements iii. Attention to details

personnel responsible for project materials storage and control 2. Monitor project materials stock

i.

Par stock level

6

ii. Stock level monitoring procedure

65

Lecture

i. Stock level at

Group discussion

store and

Shop talk

production line

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

iii. Criteria for requesting

is monitored as

additional materials

per par stock

iv. Stock recording format

level i.

ii.

iii.

Monitor stock level at

i. Alert regarding

store and production

changes of

line

stock level

9

requirement


ii. Recommendati on for additional

Make

materials

recommendations for

procurement

additional materials

given to

procurement

purchaser as

Update piping

required iii. Piping materials

materials stock

stock records

records

periodically updated

3. Follow up to

i. Material delivery schedule

6

Lecture

i.

Piping materials

expedite

ii. Expediting procedure

Group discussion

delivery

procurement

iii. Communication skills

Shop talk

monitored as

Demonstration

per expected

Project

delivery date

activity

i. Monitor piping materials delivery

i. Communicate effectively

ii. Take actions to

follow-up on

expedite materials

delivery

9

ii. Actions taken to expedite material

delivery

delivery by

iii. Take actions to

66

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

overcome delay in

using effective

delivery if applicable

communication

iv. Apply effective

skills

communication skills

iii. Actions taken to overcome delay in delivery if applicable

4. Supervise project materials storage area

30

i. Storage lay out ii. Storage requirements for various types of piping

Lecture

i. Storage lay out

Group discussion

area planned as

Shop talk

per production lay out. types

materials iii. Signage for storage area

and

iv. Storage area climatic

specifications of

condition requirements

piping materials

•

Humidity

and HSE

•

Temperature

requirements ii. Specific storage

v. HSE requirements •

OSHA

areas allocated

•

Housekeeping

for different

practices and

types of piping

requirements

materials

PPE

according to

•

67

Work Activities

Related Knowledge

Applied Skills i. Plan storage lay out area

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

Comply with

30

i.

HSE

ii. Allocate specific storage areas allocated for

requirements ii. Comply with

Demonstration

manufacturer’s

Project

recommendatio ns iii. Signage

different types of piping

manufacturer’s

installation

materials

specifications

monitored to

iii. Monitor signage

iii. Comply with

installation

ensure

storage climatic

compliance with

iv. Monitor storage area

condition

HSE

climatic condition

iv. Keep storage

(including temperature

area clean and

and relative humidity)

dry

v. Monitor storage area cleanliness

requirements iv. Storage area climatic condition (including temperature and relative humidity) control monitored to prevent material deterioration and damage v. Storage area cleanliness monitored in

68

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria accordance with housekeeping practices

5. Verify project

30

i. Mill Certificate

Lecture

i.

Related Mill

materials

•

Material composition

Group discussion

Certificate &

received from

•

Yield strain

Shop talk

product

store as per

•

Tensile strength

catalogue

production

•

Material specifications

reviewed in

request

accordance

ii. Product catalogue

with DIN

information

50049 code

iii. Material verification ii.

procedure

Piping

iv. Compliance and non-

materials

compliance criteria

verified in accordance

v. Material request procedure i.

Review related Mill Certificate & product catalogue Verify piping materials

iii.

Segregate non-

material details

pipe standards iii. Comply with

30

Demonstration

with project

Project

and catalogue specifications, iii.

Non-compliant items

compliant items

HSE

segregated

Request required

requirements

and action

materials if necessary v.

Attention to

ii. Comply with

ii.

iv.

i.

Wear personal

69

iv. Maintain up-to-

taken to

date records

request

Work Activities

Related Knowledge

Applied Skills

vi.

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

protective equipment

required

Update material

materials if

receiving records and

necessary iv.

documentations

Personal protective equipment used in accordance with HSE requirements

v.

Receiving records and documentatio ns updated in a timely manner

70

Work Activities 6. Supervise project


Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

30

Piping materials handling

Lecture

i. Piping materials

procedure

Shop talk

handling

Pipes handling tool and

Group discussion

monitored to

equipment

Problem-based

ensure

iii.

Storage procedures

Learning

compliance with

iv.

Pipe colour coding and

Demonstration

manufacturer’s

materials handling &

Applied Skills

ii.

storage

labelling system

specifications

v.

Storage signage

and HSE

vi.

Storage recording format

requirements

vii.

PPE for store activities

ii. Material i. Monitor piping materials handling

i. Ensure safe usage of

ii. Monitor material handling tools and equipment

designated areas iv. Monitor labelling, colour

Demonstration

handling tools

Project

and equipment

materials

used in

handling tools

accordance with

ii. Comply with

iii. Store piping materials at

30

manufacturer’s

HSE

specifications

requirements

and HSE

iii. Comply with

requirements iii. Piping materials

coding and signage

material colour

display

coding and

stored at

labelling system

designated

v. Update storage records vi. Monitor usage of PPE

iv. Maintain up-todate records

areas according to storage layout plan iv. Labels, colour

71

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria codes and signage display monitored to ensure efficient accessibility and control v. Storage records updated in a timely manner vi. Personal protective equipment used in accordance with HSE requirements

72

Work Activities 7.

Supervise project materials issuance and distribution to production related teams

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

30

i. Material request verification procedure ii. Material issuance

Lecture

i. Piping materials

Group discussion

request from

Shop talk

production team verified against

procedure iii. Material distribution

project requirements

procedure iv. Tools and equipment for

and schedule ii. Piping materials

material distribution v. PPE for material

issued

distribution

according to

vi. Issuance and distribution

production

recording format

requirements i.

Verify piping materials

i. Comply with

request from production

HSE

team

requirements

ii. Issue piping materials according to production requirements

ii. Maintain up-todate records iii. Timely in

iii. Monitor piping materials distribution iv. Monitor usage of tools

30


iii. Piping materials distribution monitored to ensure timeliness iv. Usage of tools

issuing and

and equipment

distributing

for distribution

materials

monitored in

and equipment for

accordance with

distribution

manufacturer’s

requirements

specifications

v. Monitor usage of PPE

73

and HSE

Work Activities

Related Knowledge

Applied Skills vi. Update issuance and distribution records

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria requirements v. Personal protective equipment used in accordance with HSE requirements vi. Issuance and distribution records are updated in a timely manner

74


Social Skills

04.08

Develop and negotiate staffing plans


04.09

Prepare work plan


04.10



05.03

Allocate and record usage of financial and physical resources

05.04


05.05


06.08



75

Tools, Equipment and Materials (TEM) ITEMS

RATIO (TEM: TRAINEES)

1. Computer set

1:1

2. Scientific calculator

1:1

3. Stationery

As required

4. PPE (coverall, safety helmet, safety glass, safety boots, ear-plug,

1:1

hand gloves)

As required

5. Piping materials

As required

6. Welding consumables 7. Sample Documents:

1:25

•

Company Rules and Regulations

1:1

•

Engineering specification sample

1:1

•

Purchase requisition proposal form sample

1:1

•

Material requisition sample

1:1

•

Material issuing form sample

1:1

•

Work Order sample

1:1

•

Project material delivery schedule sample

1:1

•

Work schedule sample

8. First aid kit

1:1 1:25

76

REFERENCES 1.

Sutton, I. 2012. Offshore Safety Management. ISBN 9781437735246

2.

McAllister, E.W. 2009 Pipeline Rules of Thumb Handbook. ISBN 9780750678520

3.

Menon, E.S. 2010. Working Guide to Pump and Pumping Stations. ISBN 9781856178280

4.

Rao, K.R. 2006. Companion Guide to the ASME Boiler & Pressure Vessel Code. ISBN 791802183

5.

B31.3 - 2010 Process Piping (Standard Book). ASME. ISBN 9780791833162

6.

Nayyar, M.L. 2002. Piping Handbook (Book). McGraw-Hill. ISBN 978-0-07-047106-1

7.

Nayyar, M. Piping Databook. McGraw-Hill ISBN 9780071364515

8.

Smith, P. Piping Material Guide.

9.

Menon, S. Piping Calculations Manual.

10.

Lee, R. A. IPT's Pipe Trades Training Manual (Book). IPT Publishing ISBN 9780920855201

11.

Lee, R.A. Pocket Guide for Flanges, Fittings, & Piping Data (Book) ISBN 9780884153108

12.

Pipefitter Estimator (Book). AbeBooks.Com ISBN 9780969989912

ISBN 978-0-7506-7743-1 McGraw-Hill ISBN 978-0071440905

77


Sub Sector


Job Area



PIPING FABRICATION OPERATION SUPERVISION The person who is competent in this CU shall be able to supervise piping fabrication operation in accordance with piping and project specifications. Upon completion of this competency unit, trainees will be able to:-

Learning Outcomes

Review piping fabrication scope of work

•

Organise fabrication activities

•

Supervise spool fabrication

•

Supervise piping installation work

•

Supervise work progress

•

Supervise production team

•

Prepare production progress reports

•

Competency Unit ID

Work Activities 1. Review piping

•

Related Knowledge

Level

3

Applied Skills

i. Fabrication tasks

fabrication scope

•

marking,

of work

•

cutting

•

fit-up

•

welding

Training Duration

480

Credit Hours

48

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

15

Lecture

i

Fabrication

Group discussion

tasks

Shop talk

identified according to project scope

78

Work Activities

Related Knowledge

•

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria of work

installation ii

ii. Piping fabrication drawings

Related

•

P& ID drawing

documents(

•

Isometric drawing

such as:

•

Pipe support

isometric

arrangement

drawing,

•

Piping plan

•

Pipe cutting plan

contract design specification,

iii. Pipe fabrication documents •

inspection test

Contract Design

plan, WPS-

Specification •

PQR & WQT,)


reviewed to

(ITP) •

NDT Matrix

•

Hydrotest package

•

WPS

•

WQT

identify piping fabrication standards and specifications iii

iv. Fabrication specifications •

requirements

Piping standards

identified

(ASME, ISO, API) •

Quantity required

•

Production capacity

HSE

according to Job Safety Analysis (JSA)

v. JSA vi. HSE requirements

79

Work Activities


OSHA

•

Oil and Gas Safety

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

Passport (OGSP) •

PTW

•

Working at height

i.

ii.

Identify fabrication tasks

HSE

Review related

requirements

documents( such as:

piping

drawing, contract

standards

project

WPS-PQR & WQT,)

specifications

Identify piping

Review projected quantity and production capacities

v.

iii. Comply with

inspection test plan,

specifications iv.

ii. Comply with

detail drawing/shop

design specification,

iii.

i. Comply with

Review JSA to identify HSE requirements

80

15


Work Activities 2. Organise piping

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

30

Lecture

i Fabrication

i.

Scheduling procedure

fabrication

ii.

Job delegation procedure

Group discussion

tasks prioritised

activities

iii.

Welders Qualification

Shop talk

and sequenced ii Fabrication

Test (WQT) iv.

WPS (ASME, ISO, API)

tasks delegated

v.

Welding consumables

to qualified

vi.

Work area organisation

personnel according to job

vii. HSE requirements •

OSHA

specifications

•

OGSP

and project

•

PTW

requirements

•

Working at height

•

Housekeeping

as electrodes

Practices

and wires) to be

iii Materials (such

i.

ii.

iii.

Prioritise and

i.

30

Demonstration

utilized for

Project

piping welding

sequence fabrication

HSE

tasks

requirements

as stipulated in

Incorporate

WPS

Delegate fabrication

ii.

iv Work areas

tasks to fabricators

housekeeping

Check welders

practices in

organised to

qualification as per

planning

optimise space

Place

utilisation and

approved WPS

importance on

prevent

Check materials (such

qualified and

congestion

as electrodes and

competent

WQT and client

iv.

Comply with

iii.

81

v Production

Work Activities

Related Knowledge

Applied Skills wires) to be utilized for

v.

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

personnel

organisation

piping welding as

complies with

stipulated in W.P.S

HSE

approved by client

requirements

Organise work areas to optimise space utilisation and prevent congestion

3. Supervise spool fabrication

i.

Isometric Drawing

45

Lecture

i

Pipe marking

•

Weld number

Group discussion

and cutting

•

Spool number

Shop talk

supervised to

•

Piping specifications

ensure

•

MTO

compliance

•

Design temperature

with cutting

•

Operating temperature

plan

•

Piping class

ii

Fit-up spools

ii. Pipe marking procedures

inspected as

iii. Pipe cutting procedures

per WPS iii

iv. WPS

Tack welds

v. Fit-up procedures

inspected to

vi. Pre-Heating Heat

ensure compliance

Treatment procedures

with WPS

vii. Post-Heating procedures iv

viii. Post Weld Heat Treatment

82

Pre-Heating

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

procedures

Heat

ix. Welding repair

Treatment

x. Supervision guidelines and

(PWHT)

procedures

supervised in

xi. HSE requirements

accordance

•

OSHA

with WPS pre-

•

PTW

heating

•

OGSP

requirements

•

Working at height

(such as

•

PPE requirements

ASME B31.3) i.

ii.

iii.

iv.

Check pipe marking

Comply with

45

Demonstration

v

Post Heating supervised in

as per isometric

piping

drawing

standards

accordance

Ensure

with WPS

as per mark-up

workplace

requirements

Inspect fit-up welds as

complies with

per approved WPS

HSE

ensured of

Supervise pre-Heating

requirements

adequate

Practise IIF

ventilation

Supervise pipe cutting

Heat Treatment

v.

i.

ii.

iii.

Project

vi

vii

Work place

Piping welding

(PWHT) is supervised

culture

as per approved WPS

(incident &

repair work

(such as ASME

injury free

supervised to

B31.3)

culture)

ensure

Practise

compliance

effective

with project

Supervise piping welding repair as per

83

iv.

Work Activities

Related Knowledge

Applied Skills

vi.

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

WPS (ASTM A488 or

communicatio

requirements,

ASME IX)

n and

welding repair

Supervise Post Weld

interpersonal

procedures

Heat Treatment

skills

and WPS

Objective and

standards

fair in making

(ASTM A488

judgements

or ASME IX)

(PWHT) as per WPS

v.

viii

Post Weld Heat Treatment (PWHT) supervised in accordance with WPS post-heating requirements

4. Supervise piping

i.

Pipe handling and

installation work

45

Lecture

vi.

Handling and

movement procedures

Group discussion

movement of

Shop talk

pipes

(piping spool

ii.

Pipe lifting procedures

installation, piping

iii.

Pipe fitting installation

supervised for

system

iv.

Pipe support installation

compliance

installation)

v.

Pipe support GA

with HSE

•

Piping plan view

•

Structural frame

•

Pipe routing

requirements vii. Pipe lifting complies with

84

Work Activities


Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria lifting standard

Line number

vi.

Flange connections

operating

vii.

Assembly alignment

procedures viii. Pipe and pipe

viii. HSE requirements •

OSHA

fitting

•

OGSP

installation

•

PTW

supervised for

•

Working at height

compliance

•

PPE requirements

with isometric i.

Supervise handling

i.

Comply with

and movement of

HSE

pipes

requirements

45

drawings


ix.

Pipe supports installation supervised for

ii.

Supervise pipe lifting

iii.

Supervise pipe and

piping

compliance

pipe fitting installation

standards

with GA

iv.

v.

ii. Comply with

drawings

iii. Ensure

Supervise pipe

x.

Flange

supports installation

workplace

Check flange

complies with

connections to

connections to

HSE

equipment

equipment for

requirements

checked for

alignment

alignment

iv. Practise IIF culture (incident

Pipe spool

& injury free

installation

culture)

adheres to

v. Practise

85

xi.

HSE

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

effective

requirements

communication and interpersonal skills vi. Objective and fair in making judgements 5. Supervise piping

i.

work progress ii.

Project production

45

Lecture

i.

Project

progress measurement

Group discussion

production

Work progress monitoring

Shop talk

progress

procedures

measurement

iii.

Scheduling procedures

reviewed to

iv.

Resolving delayed work

identify

procedures

expected progress i. Review project

i. Comply with

production progress

HSE

measurement to identify

requirements

expected progress ii. Monitor work progress against project production progress measurement iii. Monitor completion

86

ii. Comply with

45


ii.

Work progress monitored against project production

piping

progress

standards

measurement

iii. Ensure

to ensure

workplace

target is

complies with

achieved

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

HSE

times of tasks iv. Adjust schedule if

iii.

times of

requirements

applicable

Completion

iv. Practise IIF

tasks/jobs

culture (incident

monitored and

& injury free

scheduling

vi. Provide technical

culture)

adjusted as

assistance when

v. Practise

appropriate

v. Resolve delayed work activities

effective

iv.

Corrective

communication

actions taken

and

to resolve

interpersonal

delayed work

skills

activities to

vi. Objective and

ensure project

fair in making

timeline meets

judgements

target v.

Assistance provided when required to meet operational targets

87

Work Activities 6.

Supervise


Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

Roles and responsibilities

45

Lecture

i. Roles and

production team

of fabrication production

Shop talk

responsibilities

(pipe fitters,

team

Group discussion

of production

ii.

Piping standards

Problem-based

team members

iii.

Operational targets

Learning

clearly

iv.

Feedback skills

Demonstration

communicated

v.

HSE requirements

in accordance

vi.

Training needs

with job

identification

specifications

pipe welders)

vii. Types of training for

ii. Required

fabrication team

standard i. Specify roles and

i. Comply with

responsibilities of

HSE

production team

requirements

ii. Explain required

ii. Comply with

standard to team

piping

members

standards

iii. Set and check

iii. Ensure

operational targets iv. Provide feedback and

team members to ensure understanding of allotted task iii. Operational targets set and

regular intervals

requirements iv. Practise IIF

88

Project

complies with

performance

v. Enforce compliance of

explained to

checked at

HSE

necessary

Demonstration

workplace

recommendations for

improvement as

45

iv. Feedback and recommendatio ns provided for

culture (incident

performance

& injury free

improvement as

Work Activities

Related Knowledge

Applied Skills HSE requirements vi. Identify training needs vii. Propose or conduct

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

culture) v. Practise

necessary v. Compliance of

effective

HSE

training required for

communication

requirements

fabrication team

and

strictly enforced

interpersonal skills

vi. Training needs are identified

vi. Objective and

and training

fair in making

proposed or

judgements

conducted as necessary

89

Work Activities 7. Prepare

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

15

i. Fabrication production

Lecture

i. Fabrication

production

progress reports

Group discussion

supervision

progress reports

•

Shop talk

records are

Pipe mark-cut progress

accurately

Spool fabrication

updated with

progress

specific data

Pipe installation

including

progress

quantities,

ii. Hydrotest/ leak test/

dates and

• •

descriptions

pneumatic test records iii. Report content

ii. Variations from

requirements

production plan

iv. Report format

are accurately

v. Report submission

recorded

procedure

iii. Written reports i. Update fabrication

i.

supervision records

reporting

ii. Update variations from production plan

Comply with

format ii.

Timely in

15

Demonstration

are concise and

Project

conform to specified format

iv. Reports are

iii. Prepare written reports

updating

produced and

iv. Submit reports in a

records and

submitted in a

timely manner

preparing reports iii.

Accurate in reporting

90

timely manner

Employability Skills

Core Abilities

Social Skills

04.08


1.

Communication skills

04.09

Prepare work plan

2.

Conceptual skills

04.10


3.

Interpersonal skills

05.03


4.

Learning skills

05.04


5.

Leadership skills

05.05


6.

Multitasking and prioritising

7.

Self-discipline

06.08


8.

Teamwork

91

Tools, Equipment and Materials (TEM) ITEMS 1.

2.


Fabrication drawings • Isometric drawings

1:1

• P & ID

1:1

• Pipe support arrangement

1:1

• Piping Plan

1:1

• Piping Cutting Plan

1:1

Piping materials • Carbon steel pipe • Stainless steel

As required

• Duplex • Super duplex 3.

Welding consumables • Welding wire and electrode • Argon gas

4.

Marking tools, such as • Chalk • Centre punch • Measuring tape • Pipe strap

5.

As required

Cutting and Grinding equipment such as: • Cutting torch • Grinder • Die pinch grinder • Cold cut machine

As required 1:5 1:5 1:5

1:5 1:5 1:5 1:5 1:5

92

ITEMS 6.


Alignment tools such as: • 12” and 24” L Square

1:5

• Water level

1:5

• Hand tools

1:5

• Pipe Clamp

1:5

• Tapper gauge

1:5

• Theodolite 7.

Pipe support such as: • Trunnion (Dummy) support

As required

• Spring support • Hanging support • Shoe support • Clamp support • Cradle block support 8.

Pipe spool inspection checklist

9.

Pipe spool inspection tools such as: Thickness gauge • 12” and 24” L square • Water level • Tapper gauge

10. Stationery 11. PPE (Coverall, safety boots, safety helmet, gloves, ear-plug)

1:1

1:5 1:5 1:5 1:5

As required 1:1

93

ITEMS


12. Sample Documents: • Engineering specification sample

1:1

• Purchase requisition proposal form sample

1:1

• Material requisition sample

1:1

• Material issuing form sample

1:1

• Work Order sample

1:1

• Project material delivery schedule sample

1:1

• Work schedule sample

1:1

• Work progress measurement chart

1:1

13. First aid kit

1:25

94

REFERENCES 1.


2.


3.


4.


5.

Sherwood, D.R.

6.


7.

Rhea, R.A. Pipe Drafting and Design 2 edition.ISBN

8.


9.

Smith, P. Piping Material Guide. ISBN 978-0-7506-7743-1

10.

Menon, S. Piping Calculations Manual. McGraw-Hill ISBN 978-0071440905

11.

Hamilton, J.E. Facility Piping Systems. ISBN 978-0071358774

12.

Frankel. M. Pipe Fitter's Math Guide. ISBN 962419702

13.

Graves, W.V. The Pipe Fitter Blue Book. ISBN

14.

Frankland. T. The Pipefitter's and Pipe Welder's Handbook. ISBN 9780028025001

15.

Frnakland.T. Pipe Trades Pocket Manual (Book) ISBN 9780028024103

16.

Lee, R.A. IPT's Pipe Trades Handbook (Book).ISBN 978-0920855188

17.

Linsey, F. Pipefitters Handbook (Book).

18.

Bowman, S.D. Selected Piping Problems (Book).

19.

Bowman, S.D. Modern Methods of Pipe Fabrications (Book).

20.

Bowman, S.D. Ordinates for 1000 Pipe Intersections (Book). Claitors Pub Div. ISBN 9781579801724

21.


22.

Lee, R.A. Pocket Guide for Flanges, Fittings, & Piping Data (Book)

23.


24.

Chakrabarti, S. 2005. Handbook Of Offshore Engineering (2 Vol Set ). Elsevier, ISBN 9780080443812

The Piping Guide for the Design and Drafting of Industrial Piping Systems (Book & CD) ISBN

978-0750674393

978-0970832122

ISBN 9780831130190 ISBN 9780875110097 ISBN 9780875110080

ISBN 9780884153108

95

978-091408219


Sub Sector


Job Area



PIPING FABRICATION QUALITY CONTROL The person who is competent in this CU shall be able to perform in-process QC as well as liaise with QA/QC and client pertaining to inspection and testing in accordance with Inspection Test Plan and project spectifications. Upon completion of this competency unit, trainees will be able to:-

Learning Outcomes

•

Review piping fabrication QC requirements

•

Conduct in-process QC

•

Liaise with QA/QC on inspection work

•

Liaise with client on inspection work as per ITP

•

Provide information for preparation of QA/QC reports

Competency Unit ID

Level

Work Activities 1.

Related Knowledge

4

Applied Skills

Training Duration

360

Credit Hours

36

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

Review piping

i.

Quality Manual

fabrication QC

ii.

Piping standards and

Group discussion

reviewed to

codes (ASME, ANSI,

Shop talk

identify quality

requirements

iii. •

15

Lecture

i. Quality Manual

API, ISO or equivalent)

standards and


requirements

(ITP)

for each phase of the

Inspection

96

Work Activities

Related Knowledge

iv.

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

requirements

fabrication

•

Hold points

process (such

•

NDT matrix

as ASME

In-process QC

B31.3, ASME

procedures

1X) i. Review Quality Manual

i. Comply with

to identify quality

QA/QC

standards and

requirements


ii. Comply with

15


ii. Client quality specifications reviewed to identify QC


ITP

requirements

process (such as ASME

specifications

for each phase of the

B31.3, ASME 1X) ii. Review client quality specifications to identify QC requirements for

fabrication process iii. Inspection Test

each phase of the

Plan (ITP)

fabrication process

reviewed to

iii. Review Inspection Test

identify QC

Plan (ITP) to identify

requirements

QC requirements and

and schedule iv. In-process QC

schedule iv. Establish in-process QC

procedures and

procedures and

schedules

schedules

established in

v. Review QA/QC audit

97

accordance with

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

requirements to assist

QA/QC

in inspection

requirements

preparation

v. QA/QC audit

vi. Communicate QC

requirements

requirements to

identified to

fabrication crew

assist in inspection preparation vi. QC requirements communicated to fabrication crew to ensure accurate interpretation and compliance of fabrication standards

2. Conduct in-

i.

process QC

ii.

iii.

In-process QC

60

Lecture

i. Preparations

requirements and

Group discussion

for in-process

procedures

Shop talk

quality

Inspection and data

inspection

checklist

carried out in

Fabrication Drawing

accordance

98

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

•

Isometric Drawing

with in-

•

P&ID Drawing

process QC

•

Pipe Support General

procedures ii. Inspection and

Arrangement •

Piping Plan

data checklist

•

Piping Cutting Plan

prepared in

iv.

Hold points for inspection

accordance

v.

Quality sampling methods

with ITP iii. Hold points

and procedures vi.

identified for

ITP Inspection

inspection

requirements

purposes in

•

Hold points

accordance

•

NDT matrix

•

with QA/QC specifications

vii. Compliance and non-

iv. Processes

compliance criteria

and items for

(dimensions, tolerance,

in-process QC

compliance with piping

selected in

standards)

accordance

viii. Fabrication tasks

with quality

(marking, cutting, fit-up,

sampling

installation) ix.

Pipe spool identification

x.

Piping standards (ASME,

methods v. Acceptance criteria

API, ISO)

99

Work Activities

Related Knowledge xi.

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria (including

WPS

xii. Inspection procedure

tolerances for

xiii. Inspection recording

dimensions and

format xiv. Non-compliance

distortions) established in

rectification procedures xv. HSE requirements

accordance

•

OSHA

with piping

•

PTW

standards and

•

OGSP

isometric

•

Working at height

drawings vi. Project i.

ii.

Carry out preparations for in-process quality

QA/QC

Prepare inspection

requirements

and data checklist iii.

iv.

v.

i. Comply with

ii. Comply with

60

Demonstration

materials

Project

inspected for compliance with piping

Identify hold points for

ITP

standard and

inspection

specifications

AFC drawing

Sample processes

iii. Comply with

vii. Weld

and items for in-

HSE

preparations,

process

requirements

parameters

Establish acceptance

iv. Attention to

and

criteria (including

details during

consumables

tolerances for

inspection

inspected for

v. Objective in

dimensions and

100

compliance

Work Activities

Related Knowledge

Applied Skills

vi.

xii.

Environmental

Hours

Mode

Criteria

judgements

materials for

during

configuration,

compliance with piping

inspection

dimension and

vi. Apply effective

with WPS viii. Fit-up

orientation

isometric drawing

communication

checked for

Inspect weld

and

compliance

preparations,

interpersonal

with WPS and

parameters and

skills

AFC drawing

viii. Fit-up configuration,

xi.

Assessment

Inspect project

compliance with WPS

x.

Delivery

making

consumables for

ix.

Training

distortions)

standard and

vii.

Attitude / Safety /

ix. Spool and sub spool identification

dimension and

checked in

orientation are

accordance

checked for

with AFC

compliance with WPS

drawing

and isometric drawing

x. Removal of

Identify spool and sub

pipe surface

spool

contaminants

Check removal of pipe

checked in

surface contaminants

accordance

Check all completed

with piping

welds visually

and ITP

Rectify non-

requirements

compliance

xi. All completed

101

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

xiii. Document inspection

welds visually

results

checked xii. Corrective actions taken to rectify noncompliance xiii. Inspection and tests conducted in accordance with inprocess QC procedures and HSE requirements xiv. Inspection results documented in accordance with QC format

3. Coordinate hydrotest

i. Hydrotest package

30

Lecture

ii. Hydrotest procedures

Group discussion

iii. HSE requirements

Shop talk

102

i.

Hydrotest requirements

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

iv. Hydrotest equipment

identified from i

ii

Interpret hydrotest

iv

v

vi

Comply with

package information

HSE

Identify pipe spools for

requirements

hydrotest iii

i

ii

30

Demonstration

hydrotest

Project

package

ii.

Pipe spools

Ensure hydro

and

Determine hydrotest

test is carried

hydrotest

procedures

out according to

Determine HSE

test package

requirements for

requirements

hydrotest

and procedures

Determine hydrotest

iii

equipment set up as per hydrotest package

Apply effective

equipment

interpersonal

Arrange set up for

skills

iii.

HSE requirements

hydrotest

are adhered

iv.

Effective interpersonal skills applied

4. Liaise with QA/QC on

i. ITP •

inspection work

30

Lecture

i. QA/QC

Inspection

Group discussion

Inspection

requirements

Shop talk

schedule

•

Hold point

identified from

•

NDT matrix

ITP

103

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria ii. Preparation for

ii. QA/QC audit requirements iii. QA/QC audit procedures

QA/QC audit

iv. HSE requirements

arranged in

•

OSHA

accordance with

•

PTW

QA/QC

•

OGSP

procedures

•

Working at height

iii. QA/QC i.

ii.

iii.

Identify QA/QC

i.

inspection schedule

QA/QC

as per ITP

requirements

Prepare for QA/QC

ii. Comply with

30

Demonstration

inspection

Project

sessions coordinated in accordance with

audit

ITP

QA/QC

Coordinate QA/QC

specifications

procedures

inspection sessions iv.

Comply with

iii. Comply with

iv. Assistance and

Provide assistance

HSE

support

and support to QA/QC

requirements

provided to

personnel to facilitate efficient audit

iv. Apply effective

QA/QC

interpersonal

personnel to

skills

facilitate efficient audit

104

Work Activities 5. Liaise with client on inspection

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

30

i. ITP •

work as per ITP

Lecture

i. Client

Inspection

Group discussion

inspection

requirements

Shop talk

schedule

•

Hold points

identified from

•

NDT matrix

ITP and client

ii. Client inspection

requirements ii. Preparation for

requirements and

client inspection

procedures iii. QA/QC requirements

arranged in

iv. HSE requirements

accordance with

•

OSHA

ITP and client

•

PTW

requirements

•

OGSP

•

Working at height

iii. Inspection session i.

ii.

iii.

Identify client

i. Comply with

inspection schedule

QA/QC

as per ITP

requirements

Prepare for client inspection

ITP

Coordinate Inspection

specifications

session iv.

ii. Comply with

iii. Comply with

Provide assistance

HSE

and clarification is to

requirements

client if necessary

iv. Apply effective communication

105

30


coordinated to facilitate efficient client inspection iv. Assistance and clarification provided to client during inspection session if necessary

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

and

v. Inspection

interpersonal

procedures

skills

adhere to HSE requirements

5. Provide

30

Lecture

i. Compliance and

i.

QA/QC requirements

ii.

Compliance and non-

Group discussion

non-compliance

the preparation of

compliance in piping

Shop talk

recorded

QA/QC report

fabrication

according to

Testing results recording

QA/QC format

information for

iii.

format iv.

ii. Information on

Continuous improvement

compliance and

in piping fabrication

non-compliance i. Record compliance and non-compliance ii. Provide Information on compliance and non-

i. Comply with QA/QC requirements ii. Comply with

30

Demonstration

made

Project

accessible to QA personnel for the

compliance to QA

recording

preparation of

personnel for the

format

QA/QC reports

iii. Apply effective

iii. Recommendati

communication

ons for process

and

improvement

recommendations for

interpersonal

provided where

process improvement

skills

applicable

preparation of QA/QC reports iii. Provide

where applicable

106


Social Skills

04.08



04.09

Prepare work plan


04.10



05.03


05.04


05.05


06.08



107

Tools, Equipment and Materials (TEM) ITEMS 1. Fabrication drawings

2.


• Isometric drawings

1:1

• P & ID

1:1

• Pipe support arrangement

1:1

• Piping Plan

1:1

• Piping Cutting Plan

1:1

Piping materials • Carbon steel pipe • Stainless steel

As required

• Duplex • Super duplex 3.

Welding consumables • Welding wire and electrode • Argon gas

4.

Marking tools, such as • Chalk • Centre punch • Measuring tape • Pipe strap

5.

As required

Cutting and Grinding equipment such as: • Cutting torch • Grinder

As required 1:5 1:5 1:5

1:5 1:5 1:5

• Die pinch grinder

1:5

• Cold cut machine

1:5

108

ITEMS 6. Alignment tools such as:


• 12” and 24” L Square

1:5

• Water level

1:5

• Hand tools

1:5

• Pipe Clamp

1:5

• Tapper gauge

1:5

• Theodolite 7.

Pipe support such as: • Trunnion (Dummy) support

As required

• Spring support • Hanging support • Shoe support • Clamp support • Cradle block support 8.

Pipe spool inspection checklist

9.

Pipe spool inspection tools such as: Thickness gauge • 12” and 24” L square • Water level • Tapper gauge

10. Stationery 11. PPE (Coverall, safety boots, safety helmet, gloves, ear-plug)

1:1

1:5 1:5 1:5 1:5

As required 11

109

ITEMS 12. Sample Documents:


• Quality Plan

1:1

• Engineering specification sample

1:1

• Purchase requisition proposal form sample

1:1

• Material requisition sample

1:1

• Material issuing form sample

1:1

• Work Order sample

1:1

• Project material delivery schedule sample

1:1

• Work schedule sample

1:1


1:1

• Hydrotest package

1:1

13. First aid kit

1:25

110

REFERENCES 1.


2.


3.

Parkash, S. 2003, Refining Processes Handbook. ISBN 978-0750677219

4.


5.


6.

Sherwood, D.R. The Piping Guide for the Design and Drafting of Industrial Piping Systems (Book & CD) ISBN

7.


8.


9.


10.

Smith, P. Piping Material Guide.

11.

Menon, S. Piping Calculations Manual.

12.

Hamilton, J.E. Facility Piping Systems. ISBN 978-0071358774

13.


14.


15.


16.

Frnakland.T. Pipe Trades Pocket Manual (Book)ISBN 9780028024103

17.


18.

Linsey, F. Pipefitters Handbook (Book). ISBN 9780831130190

19.

Bowman, S.D. Selected Piping Problems (Book). ISBN 9780875110097

20.

Bowman, S.D. Modern Methods of Pipe Fabrications (Book).

21.

Bowman, S.D. Ordinates for 1000 Pipe Intersections (Book). Claitors Pub Div. ISBN 9781579801724

22.


23.

Lee, R.A. Pocket Guide for Flanges, Fittings, & Piping Data (Book). ISBN 9780884153108

24.


25.

Chakrabarti, S. 2005. Handbook Of Offshore Engineering (2 Vol Set ). Elsevier, ISBN 9780080443812

978-0750674393

ISBN 978-0-7506-7743-1 McGraw-Hill ISBN 978-0071440905

978-0970832122

ISBN 9780875110080

111

978-091408219


Sub Sector


Job Area



PIPING FABRICATION DOCUMENT CONTROL The person who is competent in this CU shall be able to control relevant documents to ensure latest revisions are released and used in fabrication work. Upon completion of this competency unit, trainees will be able to:-

Learning Outcomes

•

Control fabrication drawings

•

Control related fabrication documents

•

Compile lessons learnt for production team

Competency Unit ID

Level

Work Activities 1. Control fabrication drawings

Related Knowledge

4

Applied Skills

i. Document control

Training Duration

120

ii. Fabrication drawings

12

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

30

procedure

Credit Hours

Lecture

i. Fabrication

Group discussion

drawings

Shop talk

received,

•

Isometric drawing

acknowledged

•

P & ID drawings

and compiled

•

Pipe support GA

in accordance

drawings

with

•

Piping plan

documentation

•

Cutting plan

procedure

iii. Document superseding

ii. Drawings are

112

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

/removal procedure

distributed to

iv. Document distribution

production floor

procedure

according to i. Compile fabrication drawings

i. Comply with

30

document

ii. Distribute drawings to production floor

Demonstration

documentation

Project

distribution procedure

control

iii. Old drawings

procedure

iii. Remove and destroy old drawings iv. Distribute revised drawings to production floors

are superseded

ii. Alert in detecting

and destroyed

changes in

according to

drawings

document control

iii. Ensure

procedures

distribution and

iv. Revised

use of latest revision

drawings are

documents

distributed to production floors to ensure the latest revised drawings are referred for all fabrication work

2. Control related

i.

WPS

fabrication

ii.

NDT procedure

15

Lecture Group discussion

113

i. WPS distributed to

Work Activities documents

Related Knowledge iii.

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria

Contract design

iv. •

Shop talk

production floor

specifications

according to

ITP

document

Inspection

control

requirements

procedure

•

Hold points

•

NDT matrix

ii. Non-destructive test procedure

v.

Process standard

distributed to

vi.

Distribution and briefing

production

procedures

foreman i.

ii.

Distribute WPS to

v.

Demonstration

specifications

Distribute non-

distribution

distributed and

destructive test

procedure

briefed to

ii. Alert in

production foreman

detecting

Distribute and brief on

changes in

contract design

documents iii. Apply effective

Project

iii. Contract design

document

specifications iv.

15

production floor

procedure to

iii.

i. Comply with

production foreman iv. ITP distributed and briefed to production foreman

Distribute and provide

communication

briefing on ITP

and

Distribute and provide

interpersonal

standard

briefing on process

skills

distributed and

v. Process

briefed to

standard

production

114

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria foreman

3. Compile lessons learnt for production team

15

i. Importance of lessons learnt ii. Continuous improvement

Lecture

i. Lessons learnt

Group discussion

compilation

Shop talk

format

iii. Recording format for

established in

lessons learnt

accordance with i.

Establish lessons learnt compilation format

ii. Gather lessons learnt records and reports from production team iii. Categorise lessons learnt for easy reference

i.

Comply with recording and reporting format

ii. Alert in

15

Demonstration

documentation

Project

guidelines ii. Lessons learnt records and

identifying

reports

situations for

gathered from

learning

production team

iii. Demonstrate

iii. Lessons learnt

interest in

categorised for

compilation production

continuous

easy reference

team for continuous

improvement

iv. Provide lessons learnt

iv. Lessons learnt compilation

improvement

made accessible to production team

115

Work Activities

Related Knowledge

Applied Skills

Attitude / Safety /

Training

Delivery

Assessment

Environmental

Hours

Mode

Criteria for continuous improvement

Employability Skills

Core Abilities

Social Skills

04.08



04.09

Prepare work plan


04.10



05.03


05.04


05.05


06.08



116

Tools, Equipment and Materials (TEM) ITEMS 1.

2.

3.


Sample Documents: • Quality Plan

1:1

• Engineering specification sample

1:1


1:1

• Inspection Test Plan (ITP)

1:1

• Welding Procedure Specification (WPS)

1:1

Engineering Drawings • Isometric Drawings

1:1

• Piping & Instrumentation Diagram (P&ID)

1:1

• Pipe Support General Arrangement Drawing

1:1

• Piping Plan

1:1

• Cutting Plan

1:1

Stationery

As required

117

REFERENCES 1.


2.


3.


4.

Sherwood, D.R. The Piping Guide for the Design and Drafting of Industrial Piping Systems (Book & CD) ISBN

5.


6.


7.


8.

Smith, P. Piping Material Guide. ISBN 978-0-7506-7743-1

9.


10.


11.


12.

Frnakland.T. Pipe Trades Pocket Manual (Book) ISBN 9780028024103

13.


14.

Linsey, F. Pipefitters Handbook (Book).

15.

Bowman, S.D. Selected Piping Problems (Book). ISBN 9780875110097

16.

Bowman, S.D. Modern Methods of Pipe Fabrications (Book). ISBN 9780875110080

17.


18.

Lee, R.A. Pocket Guide for Flanges, Fittings, & Piping Data (Book )ISBN 9780884153108

978-0750674393

978-0970832122

ISBN 9780831130190

118

978-091408219

CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector


Job Area



SHOP DRAWINGS PREPARATION The person who is competent in this CU shall be able to prepare shop drawings according to drafting standards. Upon completion of this CU, trainees will be able to:-

Learning Outcomes

Competency Unit ID

•

Identifyshop drawings requirements

•

Identifyshop drawings information

•

Prepare shop drawings

•

Confirm shop drawings prepared

Work Activities

Related Knowledge

1. Identifyshop

i.

drawings requirements

Level

SD-XXX-X

Applied Skills

Attitude / Safety / Environmental

Project

Training Duration Training Hours 15

requirements ii.

4

Types of shop drawings • Erection

180 hours

Credit Hours

Delivery Mode Lecture Tutorial Group discussion Case study

18 Assessment Criteria

i.

Project requirements are identified and adhered to.

ii.

Drawings are

drawings-

coordinated and

sequence

reviewed for

• Sea fastening

accuracy, completeness and

shop drawings • Component

compliance with contract

design drawings • Fabrication

requirements.

119

Work Activities

Related Knowledge

Applied Skills


Training Hours

Delivery Mode

drawings

Assessment Criteria iii. Variations on shop

• Standard

drawings from the

connections,

contract are

components or

identified,

equipment

described and finalised.

iii. Drawing

iv. Shop drawings are

information such as • Quantities

ensured that they

• Weldings and

are checked

test codes and

verified prior

procedures

approval and fabrication

iv. Drafting standards v.

and codes v.

Information are

Engineering

included on shop

standards

drawings as per fabrication, erection

vi. Submission

and load out

procedures i.

ii.

Interpret and apply

i.

Compliance with

30

Practical Demonstration

requirements. vi. Shop drawing

project

client’s and

requirements

company’s rules

schedule prepared

Check to ensure

and regulations

as per project

Comply with

requirements

that types of shop

ii.

drawings are

Occupational,

identified and

Safety and

differentiated

Health Act

120

Work Activities

Related Knowledge

Applied Skills iii. Check to ensure


Training Hours

Delivery Mode

Assessment Criteria

(OSHA) and

shop drawing

company

information

requirements

furnished met design specifications and detailed drawings. iv. Check to ensure drafting standards and codes are applied v.

Check to ensure engineering codes applied as identified in the requirements.

vi. Check to ensure submission procedures are applied. 2. Identify

i.

offshore structure shop drawings information

Contractual

15

document ii.

Project requirements

iii. Structure

Lecture Tutorial Group discussion Case study

i.

Cutting plan is identified and analysed.

ii.

Components are identified from

121

Work Activities

Related Knowledge

Applied Skills


Training Hours

Delivery Mode

Assessment Criteria

components such

cutting plan and

as

detailed design

•

I-Beam

•

Girder

iii. Related information

•

Plates

on drawings and

•

Channels

specifications are

drawings.

identified and

iv. Yard equipment

v.

and capacities

reviewed as per

Drawing

engineering

information such as

specifications. iv. Materials

•

Designed loads

•

Quantities

information are

•

Welding and

identified and

test codes

obtained from

procedures

various resources. v.

vi. Drafting standards

Variation order are followed.

and codes

vi. Yard machines and

vii. Engineering

equipment capacity

standards

are identified

viii. Submission

according to shop

procedures

drawings

ix. Variation order i.

Identify project requirements

ii.

i.

Compliance with client’s and

Identify structure

122

30


requirements. vii. Project requirements are

Work Activities

Related Knowledge

Applied Skills


Training Hours

Delivery Mode

Assessment Criteria

company’s rules

components to be fabricated

identified. viii. Types of drawings

and regulations

to be prepared are

iii. Identify information from various types of shop drawings iv. Identify various

v.

ii.

Comply with

identified.

legislative

ix. Information to be furnished on

requirements

drawing information

various drawings

Review cutting plan

prepared is

generated

identified. x.

vi. Identify related

Submission

drafting standards

procedure for shop

and codes

drawings identified.

vii. Identify types of yard equipment viii. Differentiate equipment capacity ix. Identify special instruction to be applied 3. Prepare shop

i.

drawings

Project

15

requirements ii.

Types of shop drawings •


i.

requirements identified are applied ii.

Erection

Project

Information furnished on

drawings,

123

Work Activities

Related Knowledge

•

Applied Skills


load out

prepared followed

methods

drawing standards

Sea fastening

and codes. iii. Erection framing plan are followed.

Component

iv. Assembly diagrams

drawings

requirements are

General

adhered to. v.

arrangement •

•

Assessment Criteria various drawings

design •

Delivery Mode

sequence and

shop drawings •

Training Hours

Shop detail

drawings

drawings

Fabrication/

presentation

detailed

guidelines are

drawings

identified and

Standard

adhered to. vi. Product details are

connections, components or

included in shop

equipment

drawings.

iii. Drawing information such as •

Designed loads

•

Quantities

•

Welding and test codes procedures

124

Work Activities

Related Knowledge

Applied Skills


Apply project

i.

Training Hours

Delivery Mode

iv. Drafting standards and codes v.

Engineering standards

vi. Submission and quality procedures i.

ii.

Comply with

requirements

client’s and

Identify and

company’s rules

differentiate various

and regulations

types of shop drawings iii. Furnish shop

ii.

Comply with legislative requirements

drawing information according to design specifications and detailed drawings. iv. Apply drafting standards and codes v.

Apply engineering codes as identified in the requirements.

vi. Apply submission

125

30


Assessment Criteria

Work Activities

Related Knowledge

Applied Skills


Training Hours

Delivery Mode

Assessment Criteria

procedures.

4. Confirm shop

i.

drawings prepared

Project

15

requirements ii.

Types of shop drawings • •

• •


i.

checked to confirm that project requirements ii.

Erection

Shop drawings are

drawings

checked to ensure

Component

that shop drawings

design

are prepared as

drawings

requirements.

Fabrication/det

iii. Shop drawings are

ailed drawings

checked to ensure

Standard

product details are

connections,

included in shop

components or

drawings iv. Shop drawings are

equipment

checked to ensure

iii. Drawing information

drawing numbers

•

Quantities

and revision

•

Codes

numbers are indicated on the

iv. Drafting standards

shop drawings.

and codes v.

Shop drawings are

v.

Engineering

Shop drawings are checked to ensure

standards

126

Work Activities

Related Knowledge

Applied Skills


Training Hours

Delivery Mode

Assessment Criteria

vi. Submission

details as per

procedures

standards are i.

ii.

Check to ensure

i.

Comply with

30


included in shop drawings.

project

client’s and

requirements are

company’s rules

applied

and regulations

checked to ensure

Comply with

that details such as

that types of shop

legislative

sea fastening

drawings are

requirements

layout

Check to ensure

ii.

vi. Shop drawings are

identified and

arrangement,

differentiated

equipment,

iii. Check to ensure

installation and

shop drawing

load out method

information

are included as per

furnished met

shop drawings

design

requirements.

specifications and

vii. Shop drawings are

detailed drawings.

checked to ensure that quality and

iv. Check to ensure

v.

drafting standards

quantity of

and codes are

information

applied

contained on shop

Check to ensure

drawings conform

engineering codes

to drawings

applied as

specifications,

127

Work Activities

Related Knowledge

Applied Skills


Training Hours

Delivery Mode

identified in the

company standards

requirements.

and procedures.

vi. Check to ensure submission procedures are applied.

Employability Skills Core Abilities 01.07 01.08 01.10 01.11 02.10 02.11 03.10

Assessment Criteria

Social Skills

Utilize database applications to locate and process information Utilize spreadsheets applications to locate and process information Apply a variety of mathematical techniques Apply thinking skills and creativity Prepare reports and instructions Convey information and ideas to people Provide consultation and counselling

128

1. 2. 3. 4. 5. 6. 7. 8.

Communication skills Interpersonal skills Multitasking and prioritizing Self-discipline Teamwork Compliance Diligence Cooperation

Tools, Equipment and Materials (TEM) ITEMS

RATIO (TEM : Trainees)

1. Compliance documents • Contractual agreement • Client’s requirements • Final design requirements • Design specifications • Design guidelines • Company’s procedures • Drawing quality checklist • Drawings convention • Drawings standards and codes • Welding and test standards and codes 2. Drawings • Technical • Engineering • FEED (for building purposes) • Conceptual (for building purposes) • Detailed design drawings • Drawings from other discipline o Piping o Pipeline o Electrical o Mechanical o Process o Equipment

1:25

1:25

1:25

129

ITEMS

RATIO (TEM : Trainees) 1:1

3. Drawing Equipment and Accessories • CAD software such as o PDMS (Plant Design Management System) o AVEVA o BOCAD TEKLA Structures X-Steel o Smart Marine 3D • Computer hardware to support 2D and 3D design application • Computer peripherals o Mouse, o Spaceball, • Drafting tools • Drawing stationeries

REFERENCES

1. R.R. Young (2006), Project Requirements: A Guide to Best Practices ISBN 1-56726-169-8 2. McMorrough, Julia ; Materials, Structures and Standards: All the Details Architects Need to Know But Can Never Find ,Rockport Publishers.Inc (2006)., ISBN 1-59253-193-8

3. MacLaughlin .David C & H.Estrada; Structural Steel Design Drafting and Design , 2nd Edition (2009) Nelson Ed. Ltd.;ISBN 978-1-4018-9032-2 4. Mike W.Lin , Wiley(1993), Drawing and Designing with Confidence: A Step-by-Step Guide, ISBN 978-0471283904 5. Heino Engel, Hatje Cantz; 3rd Edition (February 1, 2007), Structure System, ISBN-978-3775-71876-9 6. James Ambrose, Wiley(2007), Simplified Design of Concrete Structures (Parker/Ambrose Series of Simplified Design Guides), ISBN 978-0470044148

7. Fritz Drury, Prentice Hall; (2008), Drawing: Structure and Vision, ISBN 978-0130896025 8. T. Schmidt; Strategic Project Management Made Simple: Practical Tools for Leaders and Teams, John Wiley & Sons, Inc.,(2009), ISBN: 978-0470-41158-2

130

TRAINING HOURS SUMMARY

: OIL, GAS & PETROCHEMICAL

SECTOR : SUB SECTOR

UPSTREAM :

AREA

ENGINEERING :

JOB AREA

PIPING FABRICATION MANAGEMENT :

JOB LEVEL CU ID

FOUR (4) Competency Unit

Training Hours

HEALTH, SAFETY AND ENVIRONMENT COMPLIANCE SUPERVISION

150

PIPING FABRICATION PROJECT MATERIALS STORAGE & CONTROL

300

PIPING FABRICATION OPERATION SUPERVISION

480

PIPING FABRICATION QUALITY CONTROL

360

PIPING FABRICATION DOCUMENT CONTROL

120

SHOP DRAWING PREPARATION

180

Total Training Programme Hours

1590

131

Piping Fabrication L4

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