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.
Contents Introduction Occupational Structure Definition Of Competency Levels Malaysian Skill Certification Job Competencies Working Conditions Employment Prospects Training, Industrial/Professional Recognition, Other Qualifications and Advancements
Pages 1 3 5 6 6 6 7 9
1. 2. 3. 4. 5. 6. 7. 8. 9.
Sources of Additional Information
10 12 12 13 13
10. Acknowledgement 11. Validation 12. Literature References

13. 14. Abbreviations Committee Members for Development of Standard Practice (SP), Competency Profile Chart (CPC), Competency Profile (CP) and Curriculum of Competency Unit (CoCU 15. 16. 17. Competency Profile Chart (CPC) Competency Profile (CP) Curriculum of Competency Unit (CoCU): Health, Safety & Environment (HSE) Compliance Supervision 18. Curriculum of Competency Unit (CoCU): Piping FabricationProject Materials Storage & Control 19. Curriculum of Competency Unit (CoCU): Piping Fabrication Operation Supervision 20. 21. Curriculum of Competency Unit (CoCU): Piping Fabrication Quality Control Curriculum of Competency Unit (CoCU): Piping Fabrication Document Control 22. 23. Curriculum of Competency Unit (CoCU): Shop Drawing Preparation Training Hour Summary
15
17 18 - 52 54 - 61
62 - 76
77 - 94 95 - 110 111-117
118-129 130
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 SUBSECTOR AREA JOB AREA LEVEL 8 LEVEL 7 LEVEL 6 LEVEL 5 LEVEL 4 LEVEL 3 LEVEL 2 LEVEL 1
OIL, GAS & PETROCHEMICAL UPSTREAM ENGINEERING PIPING PIPING CUSTODIAN PRINCIPAL PIPING DESIGN PIPING MATERIAL PIPING STRESS SPECIALIST SPECIALIST SPECIALIST PIPING TECHNOLOGIST PIPING FABRICATION SUPERINTENDENT PIPING FABRICATION SUPERVISOR PIPING FABRICATOR PIPING SENIOR FITTER PIPING FITTER PIPING DESIGNER PIPING SENIOR DRAFTER PIPING DRAFTER PIPING JUNIOR DRAUGHTER DRAUGHTSMAN
Figure 1 Occupational Profile Chart for Piping Fabrication Personnel
SECTOR SUB-SECTOR AREA L8 L7 L6 L5 L4 L3 L2 L1
OIL, GAS & PETROCHEMICAL UPSTREAM (ENGINEERING) PIPING FABRICATION
N/A
PIPING FABRICATION MANAGEMENT PIPING FABRICATION MANAGEMENT PIPING FABRICATION OPERATION PIPING FABRICATION OPERATION N/A
Figure 2 Occupational Area Analysis (OAA) Chart for Piping Fabrication Personnel
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. Malaysia Skills Certificate Level 1: (Operation Level) Malaysia Skills Certificate Level 2: (Operation Level) 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 3: (Supervisory Level)
Malaysia Skills Diploma Level 4: (Executive Level)
Malaysia Skills Advanced Diploma Level 5: (Managerial Level)
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 fabricators 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. .
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 everyones 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):
Table 1
Piping Fabrication Companies Company 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 Level 22, Maju Tower 1001 Jalan Sultan Ismail 50250 Kuala Lumpur, Malaysia Tel: +603 277287777 Fax: +603 27728780 Website: www.pfce.com.my Km9 Jalan Ranca-Ranca P.O. Box 81210 87031 F.T. Labuan Tel: +087 451888 Fax: +087 451777 Website: www.labuanship.com
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
PFCE Engineering Sdn Bhd
Labuan Shipyard & Engineering Sdn Bhd
Table 1
Piping Fabrication Companies (continue) Company Address 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 17th Floor, Menara Boustead 69, Jalan Raja Chulan 50200 Kuala Lumpur Tel: (+6)03-20787770 Fax: (+6)03-20316089 Website: www.bhic.com.my
Dialog Group Berhad
Boustead Heavy Industries Group
8.
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. 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 Fax Website .: 603-8886 5000 : 603-8889 2443 : 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 Fax Website .: 603-2617 0200 : 603-2617 0220 : 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 Fax Website .: 603-7968 4001 : 603-7957 7678 : http://myiem.org.my
PERFORMANCE MANAGEMENT & DELIVERY UNIT (PEMANDU) Prime Ministers Department 3rd Floor, East Block, Perdana Putra Building, Federal Government Administrative Centre, 62502 Putrajaya Phone Fax Website : 03-88727237 : 03 8888 7107 : www.pemandu.gov.my
10
INTERNATIONAL SOURCES AMERICAN WELDING SOCIETY (AWS) 550 Northwest 42nd Avenue Miami, FL 33126, United States Phone Website :(305) 443-9353 : http://www.aws.org
AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) Three Park Avenue New York, NY 10016-5990 Phone Website :973-882-1170 (outside North America) : http://www.asme.org
AMERICAN PETROLEUM INSTITUTE (API) # 900, 1220 L Street Northwest Washington, DC 20005, United States Phone Website :(202) 682-8000 : 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 Website :+41 22 749 01 11 : www.iso.org
PIPE FABRICATION INSTITUTE USA Office 511 Ave. of America's, # 601 New York, NY 10011 Phone Website : (514) 634-3434 : pfi@pfi-institute.org
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 .. below have agreed in consensus to this standard: The SDAC members as listed
VALIDATION COMMITTEE PIPING FABRICATION MANAGEMENT 1. 2. 3. 4. En Azdi Abass Tuan Haji Arshad Ahmad En Awaludin Mohd Arif En Baharuddin bin Mamat LEVEL 4
Managing Director Octagon Petroleum Technology Sdn Bhd General Manager Sime Darby Managing Director Industrial Testing & Engineering Deputy Director Department of Occupational Safety and Health, Johor CHAIRMAN
1.
En Ab Halim bin Hasan
Principal Asst Director DSD, Cyberjaya, Selangor 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 API ASME AWS CoCU CPC DSD GA ISO ITP JSA NDT MT MTO NKEA OA
American National Standards Institute American Petroleum Institute American Society of Mechanical Engineers American Welding Society Curriculum of Competency Unit Competency Profile Chart Department of Skills Development General Arrangement (Drawing) International Organisation for Standardisation Inspection Test Plan Job Safety Analysis Non-destructive Testing Magnetic Particle Test Material Take-Off National Key Economic Area Occupational Analysis
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Abbreviations (cont) OAA OGSP OSHA PEMANDU P & ID PPE PTW PWHT WPS WQT Occupational Area Analysis Oil & Gas Safety Passport Occupational Safety and Health Act Performance Management and Delivery Unit Piping & Instrumentation Diagram Personal Protective Equipment Permit To Work Post Weld Heat Treatment Welding Procedure Specification 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)
PIPING FABRICATION MANAGEMENT
LEVEL 4
PANEL 1. Mohamad Yashar bin Hj Bujang 2. Lecturer Advance Technology Training Centre (ADTEC) Construction & Project Management Supervisor Brooke Dockyard and Engineering works Corporation Sdn Bhd Project Manager Dimet Wasser (M) Sdn Bhd Consultant Dimet Wasser (M) Sdn Bhd Piping & Layout Engineer Samsung Engineer Corporation Limited Piping Engineer KNM Process System Sdn Bhd Engineering Manager PFCE Offshore World Sdn Bhd Principal Engineer Petroliam Nasional Berhad FACILITATOR 1. Nabilah Ooi Binti Abdullah Training Consultant Gemilang Offshore Engineering Company (M) Sdn Bhd CO-FACILITATORS 1. Raihan Tahir Eva Hoo Seet Yoong Training Consultant Gemilang Offshore Engineering Company (M) Sdn Bhd Manager Gemilang Offshore Engineering Company (M) Sdn Bhd
Francis Kujat
3. Tuan Azam Bin Tun Mamat 4. Sham Kwai Yau 5. Ten Wai Keong 6. Maziyatunnur Adam 7. Sim Kwang Teck 8. Jaffari Lee Ariffin
2.
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 OIL, GAS & PETROCHEMICAL UPSTREAM (ENGINEERING) PIPING FABRICATION MANAGEMENT LEVEL FOUR (4) JOB AREA CODE
COMPETENCY
HEALTH, SAFETY & ENVIRONMENT COMPLIANCE SUPERVISION
COMPETENCY UNIT
PIPING FABRICATION PROJECT MATERIALS STORAGE & CONTROL PIPING FABRICATION OPERATION SUPERVISION PIPING FABRICATION QUALITY CONTROL PIPING FABRICATION DOCUMENT CONTROL
CORE
ELECTIVE
SHOP DRAWING PREPARATION
17
Sub Sector Job Area Level CU Title
UPSTREAM (ENGINEERING) PIPING FABRICATION MANAGEMENT FOUR (4) CU Code CU Descriptor The primary objective of Health, Safety, and Environment initiatives is to reduce overall risk, to comply with legislative requirements, and to create a safe yet efficient working environment. HSE compliance supervision ensures that these initiatives are integrated with day-today operations management. The person competent in this CU shall be able to supervise safety of working environment, supervise safety check of tools and CU Work Activities Performance Criteria
1. Health, Safety &

Environment Compliance Supervision
1. Supervise safety of working

environment
1.1 Safety signage and JSA

are visibly displayed at designated areas
1.2 Potential hazards

(physical, chemical, biological, ergonomical) are identified and mitigation actions are taken as per HSE requirements
1.3 Safety equipment (such as

fire extinguisher) are checked to ensure equipment are in good working condition
1.4 Erection and dismantling

of scaffolding are
18
CU Title
CU Code
CU Descriptor equipment and supervise usage of PPE. The outcome of this competency is efficient and effective supervision of working environment, tools and equipment, and usage of PPE in compliance with HSE requirements.
CU Work Activities
Performance Criteria supervised in accordance with HSE requirements
1.5 Sufficient ventilation and

lighting are ensured in confined space
1.6 Cleanliness of working

environment is monitored as per housekeeping 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 manufacturers 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
Performance Criteria
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
CU Code
CU Descriptor Piping fabrication project materials storage & control refers to the activities of
CU Work Activities
2. Piping Fabrication
Project Materials Storage & Control
1. Identify project materials

storage & control requirements
1.1 Types of piping

fabrication materials required are identified as per contract design specifications
receiving, storing, issuing and . distribution of piping materials to production stations from the secondary storage area at the fabrication site. This CU outlines the requirements for the systematic control of piping materials held under shop and site conditions such as to prevent damage or deterioration or loss of identity. The person competent in this CU shall be able to identify piping materials storage and control requirements, monitor piping materials stock level, follow up to expedite
1.2 Quantity of piping

fabrication materials required are identified as per production requirements
1.3 Piping material codes &

standards are identified as per piping material specifications
1.4 Piping material storage &

control procedures are established in accordance with material storage and handling requirements
1.5 Roles of personnel

responsible for the
22
CU Title
CU Code
CU Descriptor procurement activities, supervise storage area, receive piping materials and supervise materials handling, storage, issuance and distribution to production areas. The outcome of this competency is the efficient and systematic management of piping fabrication material storage and control in the field of oil and gas industry.
CU Work Activities
Performance Criteria operation of project materials storage and control are clearly defined
2.1
Piping material par stock level is identified to
2. Monitor project materials

stock level
ensure availability and optimise storage area
2.2 Stock level at store and

production line is monitored to ensure 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
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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
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CU Title
CU Code
CU Descriptor
CU Work Activities
Performance Criteria manufacturers 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 material non-compliance report and replacement is requested, if applicable
5. Receive Verify project

materials received from store as per production request

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 manufacturers 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 manufacturers
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 issuance and distribution to production related teams equipment for distribution is monitored in accordance with manufacturers specifications and HSE
28
CU Title
CU Code
CU Descriptor
CU Work Activities
Performance Criteria requirements

equipment is used in accordance with HSE requirements
7.6 Issuance and distribution

records are updated in a timely manner
Operation Supervision
Supervision covers many functions including work planning and delegation, work flow coordination, provision of technical assistance and support as well as resolving problems within the work unit supervised. This CU describes supervision in the daily piping fabrication operation activities
1. Review piping fabrication

scope of work
1.1
Fabrication tasks are identified according to project scope of work
1.2
Related documents( such as P &ID, isometric drawing, contract design specification, inspection test plan, WPS-PQR & WQT) are reviewed to identify piping fabrication standards and specifications
29
CU Title
CU Code
CU Descriptor in the oil and gas industry. The person who is competent in this CU shall be able to review piping fabrication scope of work, organise piping fabrication activities, supervise spool fabrication and installation work, piping fabrication work progress, production team and prepare production progress reports. The outcome of this CU is the development of competencies required by a supervisor in enhancing work productivity and job quality in accordance with piping fabrication and project specifications for the oil and gas industry.
CU Work Activities
1.3
Projected quantity and production capacities are reviewed in accordance with project master plan
1.4
HSE requirements are identified according to Job Safety Analysis (JSA) and client requirements
2.1 2. Organise piping fabrication

activities production process
Fabrication tasks are prioritised and sequenced according to the overall production schedule
2.2
Fabrication tasks are delegated to qualified personnel according to 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
Handling and
33
CU Title
CU Code
CU Descriptor
CU Work Activities
Performance Criteria movement of pipes are
4. Supervise piping installation

work (piping spool installation, piping system installation)
supervised for compliance with HSE requirements
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

work progress
Completion times of tasks/jobs are 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 6. Supervise production team

(pipe fitters, pipe welders)
Operational targets are set and checked at regular intervals
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
Quality Control (QC)
Quality control refers to the control of production process using a planned and systematic sequence of actions which provide the confidence that all work carried out will meet and satisfy the project and piping specifications.. This CU covers in-process QC which is conducted before the actual audit by the QA/QC personnel. The objective is to confirm that all work is
1. Review piping fabrication QC

requirements
1.1 Quality Manual is perused

to identify quality standards and requirements for each phase of the fabrication process (such as ASME B31.3, ASME IX)
1.2 Client quality specifications

are perused to identify QC requirements for each phase of the fabrication process
1.3 Inspection Test Plan (ITP)

is perused to identify QC
38
CU Title
CU Code
CU Descriptor produced in compliance with the project scope of work as well as to identify noncompliance for rectification. The person who is competent in this CU shall be able to review piping fabrication QC requirements, conduct inprocess QC, liaise with QA/QC personnel and client on inspection work and provide information for the preparation of QA/QC reports. The outcome of this CU is the development of competencies for conducting in-process QC in accordance with ITP to ensure that piping fabrication work adheres with project and piping fabrication specifications in the oil and
CU Work Activities
Performance Criteria requirements and schedule
1.4 In-process QC procedures

and schedules are established in accordance with QA/QC requirements
1.5 QA/QC audit requirements

are identified to assist in inspection preparation
1.6 QC requirements are

communicated to fabrication crew to ensure accurate interpretation and compliance of fabrication standards
2.1 Preparations for inprocess quality inspection is carried out in accordance with inprocess QC procedures
2. Conduct in-process QC
2.2 Inspection and data 39
CU Title
CU Code
CU Descriptor gas industry.
CU Work Activities
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 3.3
Pipe spools are identified as per hydrotest package 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 4. Liaise with QA/QC on

inspection work
QA/QC inspection sessions are coordinated in 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

inspection work as per ITP
5.4
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 6. Provide information for the

preparation of QA/QC report
Recommendations for process improvement are provided where applicable
Document Control
Document control refers to the systematic procedure of checking and approving documents prior to release to ensure drawings and documents released are of the latest revision. It
1. Control fabrication drawings 1.1 Fabrication drawings are

(P &ID, isometric, piping plan drawing, pipe support arrangement) received, acknowledged and compiled in accordance with documentation procedure
1.2 Drawings are distributed

to production floor
45
CU Title
CU Code
CU Descriptor prevents the unintended use of obsolete documents and drawings in the fabrication process. The person competent in this CU shall be able to control fabrication drawings and related documents, and compile lessons learnt for production team. The outcome of this CU is the development of competencies for controlling release of document revisions to ensure fabrication process is based on latest revised drawings and documentation.
CU Work Activities
Performance Criteria according to documentation distribution procedure
1.3 Old drawings are

superseded and destroyed according to document control procedures
1.4 Revised drawings are

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

production floor according to document control procedure
2.
Control related fabrication documents (WPS, ITP
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
Preparation
Shop drawings are prepared to provide information which assists in confirmation of the intent of the design and to provide suppliers, fabricators or manufacturers with information which assists them in making and providing the required material components. It shows in detail (1) the proposed fabrication and assembly of structural elements and (2)
1. Identify
shop
drawings 1.1 Shop drawing format and presentations are identified as per shop detail drawings presentation guidelines or fabricators shop drawings procedures and guidelines.
requirements
1.2 Specification and

requirements for fabrication, material, shop procedures, inspection, cleaning and painting are identified as per structure standard details requirements.
48
CU Title
CU Code
CU Descriptor the installation of materials for the equipment. It includes drawings, diagrams, layouts, schematics, descriptive literature, illustrations, schedules, and any data intended to illustrate details of the work that is required by the contract. The competent person will be able to ensure shop drawings are prepared as per requirements. The CU covers activities like identifying shop drawings requirements and information, preparing shop drawings and confirming shop drawings prepared. The outcome of this CU is the development of competencies to prepare
CU Work Activities
2.1 Structure components such 2. Identify shop drawings

information as I-beams, girder, plates, channels etc are identified according to project requirements as generated in cutting plan and detailed design drawings.
2.2 Drawings and specifications

are identified and reviewed as per engineering specifications.
2.3 Materials are identified as

per manufacturers specifications or catalogue.
2.4 Yard machines and

equipment capacity are identified according to shop drawings requirements.
2.5 Variations orders on shop

drawings from the contract are identified and
49
CU Title
CU Code
CU Descriptor shop drawings.
CU Work Activities
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
UPSTREAM (ENGINEERING) PIPING FABRICATION MANAGEMENT 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
Training Duration
150
Credit Hours
15
Work Activities 1. Supervise safety of work environment
Related Knowledge i Types of hazards in oil and gas fabrication activities Physical (working at height, dropping objects) Chemical (to add in examples) Biological Health Fire
Applied Skills
Attitude / Safety / Environmental
Training Hours 30
Delivery Mode Lecture Group discussion Shop talk i
Assessment Criteria Potential hazards (physical, chemical, biological, ergonomical) are identified and mitigation actions are taken as per
55
Work Activities
Related Knowledge Ergonomical
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria HSE requirements ii Safety equipment (such as fire extinguisher) are checked to ensure equipment are in good working condition iii Safety signage and JSA are visibly displayed at designated areas iv Sufficient ventilation and
ii Hazards mitigation actions iii Structure Fabrication working environment HSE requirements Safety equipment Safety signage Scaffolding Ventilation Lighting
iv Housekeeping practices such as: Site clearning Storage Segregation of garbage v Security
i.
Determine types of hazards
i. Comply with HSE requirements ii. Ensure safe and clean working environment
30
Demonstration Project v
lighting are ensured in confined space Cleanliness of working environment is monitored as
ii.
Determine mitigation actions for different types of hazards
iii.
Check safety equipment
56
Work Activities
Related Knowledge iv.
Applied Skills Display safety signage and JSA at designated areas v. Determine ventilation and lighting requirements for confined space
Attitude / Safety / Environmental iii. Practise IIF culture (incident & injury free culture)
Training Hours
Delivery Mode
Assessment Criteria per housekeeping practices
2. Supervise safety check of tools and equipment
Importance of safety check for tools and equipment
30
i Tools and equipment are inspected (visually and using instruments) and test run according to manufacturers specifications ii Green tag are marked on tools and equipment which are tested and safe to be used iii Load certificates for
ii iii iv
Safety check procedures Test-run procedures Equipment safe-for-use tagging procedures
Safe working load for lifting equipment
vi
Magnetic Particle Test (MT) procedures
vii
Colour coding for tools and equipment
viii
Tools and equipment random and periodical inspection procedures
ix
Non-compliance and actions to be taken
57
Work Activities
Related Knowledge
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria lifting equipment and gear are checked to ensure working
Check safety of tools and equipment
Comply with HSE requirements
30
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 HSE requirements vi Random daily test on tools and equipment
ii iii
Test run equipment Mark tools and equipment with safetyfor-use tags ii
Ensure tools and equipment are safe and in good working condition
iv
Interpret load certificates
Arrange MT inspection for shackles iii
Practise IIF culture (incident & injury free culture)
vi
Check colour coding on tools and equipment
vii
Apply random daily test procedures
viii
Take actions for noncompliant tools and equipment
58
Work Activities
Related Knowledge
Applied Skills
Training Hours
Delivery Mode
Assessment 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 Coverall Safety boots Safety helmet Gloves Ear plug
15
i Personal protective equipment are selected, checked and used in accordance with HSE
ii PPEexpiry dates (safety boots and helmet)
59
Work Activities
Related Knowledge iii PPE usage procedures iv Actions for non-compliance in PPE usage
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria requirements ii PPE with expiry dates (such as
i Select PPE ii Check PPE safety condition iii Check PPE usage iv Take appropriate actions for noncompliance
Comply with HSE requirements
15
helmet & safety shoes) are replaced at regular intervals iii Appropriate actions are taken in cases of noncompliance, if applicable
ii
Ensure PPE is used correctly at all times
iii
Practise IIF culture (incident & injury free culture)
60
Employability Skills Core Abilities 04.09 04.10 05.04 05.05 06.08 Prepare work plan Utilise science and technology to achieve goal Delegate responsibilities and/or authority Coordinate contract and tender activities Identify and analyse effect of technology on the environment Social Skills 1. Communication skills 2. Conceptual skills 3. Interpersonal skills 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. 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 RATIO (TEM : Trainees) 1:25 1:25 1:25 1:25 1:1 1:1 1:1 1:1 1:1
61
REFERENCES 1. 2. 3. Sutton, I. (2012). Offshore Safety Management. ISBN 9781437735246 OSHA. Occupational Safety and Health Act 1994. Malaysia Industry Code of Practice for Safe Working in a Confined Space 2010; Department of Occupational Safety and Health, Ministry of Human Resources, Malaysia
62
UPSTREAM (ENGINEERING) PIPING FABRICATION MANAGEMENT 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: 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
Learning Outcomes
Competency Unit ID
Level
Training Duration
300
Credit Hours
30
Work Activities 1. Identify project materials storage & control requirements i.
Related Knowledge Types of piping materials Carbon steel Low-temperature materials Stainless steel Duplex
Applied Skills
Training Hours 15
Delivery Mode Lecture Group discussion Shop talk i.
Assessment Criteria Types, quantity and specifications of piping fabrication materials
63
Work Activities ii.
Related Knowledge Super Duplex Types of fittings Elbow Tee Flange Weldolet Flangolet Nipple Reducer
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria required identified as per project specification ii. Piping material storage & control procedures established in accordance with store procedures and HSE requirements iii. Duties of personnel responsible for project materials storage and control defined
iii. Types of welding consumables Welding rod Welding wire and electrodes Argon gas
iv. Piping material requirement such as Quantity Pipe standards (ASME, ANSI, API, ISO or equivalent) Welding consumables standards and colour coding v. Piping material
64
Work Activities
Related Knowledge storage requirements Lighting & ventilation
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria
Space area Climatic requirements

vi. Piping material storage control principles and procedures vii. Job scope of store personnel
vi.
Identify types, quantity and specifications of piping fabrication materials required
i. Comply with piping standards ii. Comply with HSE requirements iii. Attention to details
15
Demonstration Project
vii. Establish piping material storage & control procedures viii. Define job scope of personnel responsible for project materials storage and control 2. Monitor project materials stock i. Par stock level
Lecture Group discussion Shop talk
i. Stock level at store and production line
ii. Stock level monitoring procedure
65
Work Activities
Related Knowledge iii. Criteria for requesting additional materials iv. Stock recording format i.
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria is monitored as per par stock level
Monitor stock level at store and production line
i. Alert regarding changes of stock level
requirement ii. Recommendati on for additional materials procurement given to purchaser as required iii. Piping materials stock records periodically updated
ii.
Make recommendations for additional materials procurement
iii.
Update piping materials stock records
3. Follow up to expedite procurement activity
i. Material delivery schedule ii. Expediting procedure iii. Communication skills i. Monitor piping materials delivery ii. Take actions to expedite materials delivery iii. Take actions to i. Communicate effectively follow-up on delivery
i.
Piping materials delivery monitored as per expected delivery date
ii. Actions taken to expedite material delivery by
66
Work Activities
Related Knowledge
Applied Skills overcome delay in delivery if applicable iv. Apply effective communication skills
Training Hours
Delivery Mode
Assessment Criteria using effective communication skills iii. Actions taken to overcome delay in delivery if applicable
4. Supervise project materials storage area
i. Storage lay out ii. Storage requirements for various types of piping materials iii. Signage for storage area iv. Storage area climatic condition requirements Humidity Temperature
30
i. Storage lay out area planned as per production lay out. types and specifications of piping materials and HSE requirements ii. Specific storage areas allocated for different types of piping materials according to
v. HSE requirements OSHA Housekeeping practices and requirements PPE
67
Work Activities
Related Knowledge
Applied Skills i. Plan storage lay out area ii. Allocate specific storage areas allocated for different types of piping materials iii. Monitor signage installation iv. Monitor storage area climatic condition (including temperature and relative humidity) v. Monitor storage area cleanliness
Attitude / Safety / Environmental i. Comply with HSE requirements ii. Comply with manufacturers specifications iii. Comply with storage climatic condition iv. Keep storage area clean and dry
Training Hours 30
Delivery Mode Demonstration Project
Assessment Criteria manufacturers recommendatio ns iii. Signage installation monitored to ensure compliance with HSE 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
Training Hours
Delivery Mode
Assessment Criteria accordance with housekeeping practices
5. Verify project materials received from store as per production request
i. Mill Certificate Material composition Yield strain Tensile strength Material specifications
30
i.
Related Mill Certificate & product catalogue reviewed in accordance with DIN 50049 code
ii. Product catalogue information iii. Material verification procedure iv. Compliance and noncompliance criteria v. Material request procedure i. Review related Mill Certificate & product catalogue ii. iii. Verify piping materials Segregate noncompliant items iv. Request required materials if necessary v. Wear personal i. Attention to material details ii. Comply with pipe standards iii. Comply with HSE requirements iv. Maintain up-todate records iii. 30 Demonstration Project ii.
Piping materials verified in accordance with project and catalogue specifications, Non-compliant items segregated and action taken to request
69
Work Activities
Related Knowledge
Applied Skills protective equipment vi. Update material receiving records and documentations
Training Hours
Delivery Mode
Assessment Criteria required materials if necessary iv. 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 materials handling & storage iii. iv. ii. i.
Related Knowledge Piping materials handling procedure Pipes handling tool and equipment Storage procedures Pipe colour coding and labelling system v. vi. vii. Storage signage Storage recording format PPE for store activities
Applied Skills
Training Hours 30
Delivery Mode Lecture Shop talk Group discussion Problem-based Learning Demonstration
Assessment Criteria i. Piping materials handling monitored to ensure compliance with manufacturers specifications and HSE requirements ii. Material
i. Monitor piping materials handling ii. Monitor material handling tools and equipment iii. Store piping materials at designated areas iv. Monitor labelling, colour coding and signage display v. Update storage records vi. Monitor usage of PPE
i. Ensure safe usage of materials handling tools ii. Comply with HSE requirements iii. Comply with material colour coding and labelling system iv. Maintain up-todate records
30
handling tools and equipment used in accordance with manufacturers specifications and HSE requirements iii. Piping materials stored at designated areas according to storage layout plan iv. Labels, colour
71
Work Activities
Related Knowledge
Applied Skills
Training Hours
Delivery Mode
Assessment 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 i. Material request verification procedure ii. Material issuance procedure iii. Material distribution procedure iv. Tools and equipment for material distribution v. PPE for material distribution vi. Issuance and distribution recording format i.
Applied Skills
Training Hours 30
Delivery Mode Lecture Group discussion Shop talk
Assessment Criteria i. Piping materials request from production team verified against project requirements and schedule ii. Piping materials issued according to production requirements
Verify piping materials request from production team
i. Comply with HSE requirements ii. Maintain up-todate records iii. Timely in issuing and distributing materials
30
iii. Piping materials distribution monitored to ensure timeliness iv. Usage of tools and equipment for distribution monitored in accordance with manufacturers specifications and HSE
ii. Issue piping materials according to production requirements iii. Monitor piping materials distribution iv. Monitor usage of tools and equipment for distribution requirements v. Monitor usage of PPE
73
Work Activities
Related Knowledge
Applied Skills vi. Update issuance and distribution records
Training Hours
Delivery Mode
Assessment Criteria requirements v. Personal protective equipment used in accordance with HSE requirements vi. Issuance and distribution records are updated in a timely manner
74
Employability Skills Core Abilities 04.08 04.09 04.10 05.03 05.04 05.05 06.08 Develop and negotiate staffing plans Prepare work plan Utilise science and technology to achieve goal Allocate and record usage of financial and physical resources Delegate responsibilities and/or authority Coordinate contract and tender activities Identify and analyse effect of technology on the environment Social Skills 9. Communication skills 10. Conceptual skills 11. Interpersonal skills 12. Learning skills 13. Leadership skills 14. Multitasking and prioritising 15. Self-discipline 16. Teamwork
75
Tools, Equipment and Materials (TEM) ITEMS 1. Computer set 2. Scientific calculator 3. Stationery 4. PPE (coverall, safety helmet, safety glass, safety boots, ear-plug, hand gloves) 5. Piping materials 6. Welding consumables 7. Sample Documents: Company Rules and Regulations Engineering specification sample Purchase requisition proposal form sample Material requisition sample Material issuing form sample Work Order sample Project material delivery schedule sample Work schedule sample 1:25 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:25 1:1 1:1 As required 1:1 As required As required RATIO (TEM: TRAINEES)
8. First aid kit
76
REFERENCES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Sutton, I. 2012. Offshore Safety Management. ISBN 9781437735246 McAllister, E.W. 2009 Pipeline Rules of Thumb Handbook. ISBN 9780750678520 Menon, E.S. 2010. Working Guide to Pump and Pumping Stations. ISBN 9781856178280 Rao, K.R. 2006. Companion Guide to the ASME Boiler & Pressure Vessel Code. ISBN 791802183 B31.3 - 2010 Process Piping (Standard Book). ASME. ISBN 9780791833162 Nayyar, M.L. 2002. Piping Handbook (Book). McGraw-Hill. ISBN 978-0-07-047106-1 Nayyar, M. Piping Databook. McGraw-Hill ISBN 9780071364515 Smith, P. Piping Material Guide. ISBN 978-0-7506-7743-1 McGraw-Hill ISBN 978-0071440905
Menon, S. Piping Calculations Manual.
Lee, R. A. IPT's Pipe Trades Training Manual (Book). IPT Publishing ISBN 9780920855201 Lee, R.A. Pocket Guide for Flanges, Fittings, & Piping Data (Book) ISBN 9780884153108 Pipefitter Estimator (Book). AbeBooks.Com ISBN 9780969989912
77
UPSTREAM (ENGINEERING) PIPING FABRICATION MANAGEMENT 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: 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
Learning Outcomes
Competency Unit ID
Level
Training Duration
480
Credit Hours
48
Work Activities 1. Review piping fabrication scope of work
Related Knowledge i. Fabrication tasks
Applied Skills
Training Hours 15
Delivery Mode Lecture Group discussion Shop talk i
Assessment Criteria Fabrication tasks identified according to project scope
marking, cutting fit-up welding
78
Work Activities
Related Knowledge
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria of work ii Related documents( such as: isometric drawing, contract design specification, inspection test plan, WPSPQR & WQT,) reviewed to identify piping fabrication standards and specifications iii HSE requirements identified according to Job Safety Analysis (JSA)
v. JSA
installation
ii. Piping fabrication drawings P& ID drawing Isometric drawing Pipe support arrangement Piping plan Pipe cutting plan
iii. Pipe fabrication documents Contract Design Specification Inspection Test Plan (ITP) NDT Matrix Hydrotest package WPS WQT
iv. Fabrication specifications Piping standards (ASME, ISO, API) Quantity required Production capacity
vi. HSE requirements
79
Work Activities
Related Knowledge OSHA Oil and Gas Safety Passport (OGSP) PTW Working at height
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria
i.
Identify fabrication tasks
i. Comply with HSE requirements ii. Comply with piping standards iii. Comply with project specifications
15
ii.
Review related documents( such as: detail drawing/shop drawing, contract design specification, inspection test plan, WPS-PQR & WQT,)
iii.
Identify piping specifications
iv.
Review projected quantity and production capacities
v.
Review JSA to identify HSE requirements
80
Work Activities 2. Organise piping fabrication activities i. ii. iii.
Related Knowledge Scheduling procedure Job delegation procedure Welders Qualification Test (WQT) iv. v. vi. WPS (ASME, ISO, API) Welding consumables Work area organisation
Applied Skills
Training Hours 30
Assessment Criteria i Fabrication tasks prioritised and sequenced ii Fabrication tasks delegated to qualified personnel according to job specifications and project requirements iii Materials (such as electrodes and wires) to be
vii. HSE requirements OSHA OGSP PTW Working at height Housekeeping Practices i. Prioritise and sequence fabrication tasks ii. Delegate fabrication tasks to fabricators iii. Check welders qualification as per WQT and client approved WPS iv. Check materials (such as electrodes and iii. ii. i. Comply with HSE requirements Incorporate housekeeping practices in planning Place importance on qualified and competent 30 Demonstration Project
utilized for piping welding as stipulated in WPS iv Work areas organised to optimise space utilisation and prevent congestion v Production
81
Work Activities
Related Knowledge
Applied Skills wires) to be utilized for piping welding as stipulated in W.P.S approved by client v. Organise work areas to optimise space utilisation and prevent congestion
Attitude / Safety / Environmental personnel
Training Hours
Delivery Mode
Assessment Criteria organisation complies with HSE requirements
3. Supervise spool fabrication
i.
Isometric Drawing Weld number Spool number Piping specifications MTO Design temperature Operating temperature Piping class
45
Pipe marking and cutting supervised to ensure compliance with cutting plan
ii
Fit-up spools inspected as per WPS
ii. Pipe marking procedures iii. Pipe cutting procedures iv. WPS v. Fit-up procedures vi. Pre-Heating Heat Treatment procedures vii. Post-Heating procedures viii. Post Weld Heat Treatment iv iii
Tack welds inspected to ensure compliance with WPS Pre-Heating
82
Work Activities
Related Knowledge procedures ix. Welding repair x. Supervision guidelines and procedures xi. HSE requirements OSHA PTW OGSP Working at height PPE requirements i.
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria Heat Treatment (PWHT) supervised in accordance with WPS preheating requirements (such as ASME B31.3)
Check pipe marking as per isometric drawing
i.
Comply with piping standards
45
Post Heating supervised in accordance with WPS requirements
ii.
Supervise pipe cutting as per mark-up
ii.
Ensure workplace complies with HSE requirements vi
iii.
Inspect fit-up welds as per approved WPS
Work place ensured of adequate ventilation
iv.
Supervise pre-Heating Heat Treatment (PWHT) is supervised as per approved WPS (such as ASME B31.3) iii.
Practise IIF culture (incident & injury free culture) vii
Piping welding repair work supervised to ensure compliance with project
v.
Supervise piping welding repair as per
iv.
Practise effective
83
Work Activities
Related Knowledge
Applied Skills WPS (ASTM A488 or ASME IX) vi. Supervise Post Weld Heat Treatment (PWHT) as per WPS
Attitude / Safety / Environmental communicatio n and interpersonal skills v. Objective and fair in making judgements
Training Hours
Delivery Mode
Assessment Criteria requirements, welding repair procedures and WPS standards (ASTM A488 or ASME IX) viii Post Weld Heat Treatment (PWHT) supervised in accordance with WPS post-heating requirements
4. Supervise piping installation work (piping spool installation, piping system installation)
i.
Pipe handling and movement procedures
45
vi.
Handling and movement of pipes supervised for compliance with HSE requirements
ii. iii. iv. v.
Pipe lifting procedures Pipe fitting installation Pipe support installation Pipe support GA Piping plan view Structural frame Pipe routing
vii. Pipe lifting complies with
84
Work Activities vi. vii.
Related Knowledge Line number Flange connections Assembly alignment
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria lifting standard operating procedures viii. Pipe and pipe fitting installation supervised for compliance with isometric
viii. HSE requirements OSHA OGSP PTW Working at height PPE requirements i. Supervise handling and movement of pipes ii. iii. Supervise pipe lifting Supervise pipe and pipe fitting installation iv. Supervise pipe supports installation v. Check flange connections to equipment for alignment i. Comply with HSE requirements ii. Comply with piping standards iii. Ensure workplace complies with HSE requirements iv. Practise IIF culture (incident & injury free culture) v. Practise 45 Demonstration Project
drawings ix. Pipe supports installation supervised for compliance with GA drawings x. Flange connections to equipment checked for alignment xi. Pipe spool installation adheres to HSE
85
Work Activities
Related Knowledge
Applied Skills
Attitude / Safety / Environmental effective communication and interpersonal skills vi. Objective and fair in making judgements
Training Hours
Delivery Mode
Assessment Criteria requirements
5. Supervise piping work progress
i.
Project production progress measurement
45
i.
Project production progress measurement reviewed to identify expected progress
ii.
Work progress monitoring procedures
iii. iv.
Scheduling procedures Resolving delayed work procedures
i. Review project production progress measurement to identify expected progress ii. Monitor work progress against project production progress measurement iii. Monitor completion
i. Comply with HSE requirements ii. Comply with piping standards iii. Ensure workplace complies with
45
ii.
Work progress monitored against project production progress measurement to ensure target is achieved
86
Work Activities
Related Knowledge
Applied Skills times of tasks iv. Adjust schedule if applicable v. Resolve delayed work activities vi. Provide technical assistance when
Attitude / Safety / Environmental HSE requirements iv. Practise IIF culture (incident & injury free culture) v. Practise effective communication and interpersonal skills vi. Objective and fair in making judgements
Training Hours
Delivery Mode iii.
Assessment Criteria Completion times of tasks/jobs monitored and scheduling adjusted as appropriate iv. Corrective actions taken to resolve delayed work activities to ensure project timeline meets target v. Assistance provided when required to meet operational targets
87
Work Activities 6. Supervise production team (pipe fitters, pipe welders) ii. iii. iv. v. vi. i.
Related Knowledge Roles and responsibilities of fabrication production team Piping standards Operational targets Feedback skills HSE requirements Training needs identification vii. Types of training for fabrication team
Applied Skills
Training Hours 45
Delivery Mode Lecture Shop talk Group discussion Problem-based Learning Demonstration
Assessment Criteria i. Roles and responsibilities of production team members clearly communicated in accordance with job specifications ii. Required standard
i. Specify roles and responsibilities of production team ii. Explain required standard to team members iii. Set and check operational targets iv. Provide feedback and recommendations for performance improvement as necessary v. Enforce compliance of
i. Comply with HSE requirements ii. Comply with piping standards iii. Ensure workplace complies with HSE requirements iv. Practise IIF culture (incident & injury free
45
explained to team members to ensure understanding of allotted task iii. Operational targets set and checked at regular intervals iv. Feedback and recommendatio ns provided for performance improvement as
88
Work Activities
Related Knowledge
Applied Skills HSE requirements vi. Identify training needs vii. Propose or conduct training required for fabrication team
Attitude / Safety / Environmental culture) v. Practise effective communication and interpersonal skills vi. Objective and fair in making judgements
Training Hours
Delivery Mode
Assessment Criteria necessary v. Compliance of HSE requirements strictly enforced vi. Training needs are identified and training proposed or conducted as necessary
89
Work Activities 7. Prepare production progress reports
Related Knowledge i. Fabrication production progress reports Pipe mark-cut progress Spool fabrication progress Pipe installation progress ii. Hydrotest/ leak test/ pneumatic test records iii. Report content requirements iv. Report format v. Report submission procedure
Applied Skills
Training Hours 15
Assessment Criteria
i. Fabrication
supervision records are accurately updated with specific data including quantities, dates and descriptions
ii. Variations from

production plan are accurately recorded
iii. Written reports

i. Update fabrication supervision records ii. Update variations from production plan iii. Prepare written reports iv. Submit reports in a timely manner ii. i. Comply with reporting format Timely in updating records and preparing reports iii. Accurate in reporting 15 Demonstration Project are concise and conform to specified format
iv. Reports are

produced and submitted in a timely manner
90
Employability Skills
Core Abilities 04.08 04.09 04.10 05.03 05.04 05.05 06.08 Develop and negotiate staffing plans Prepare work plan Utilise science and technology to achieve goal Allocate and record usage of financial and physical resources Delegate responsibilities and/or authority Coordinate contract and tender activities Identify and analyse effect of technology on the environment
Social Skills 1. 2. 3. 4. 5. 6. 7. 8. Communication skills Conceptual skills Interpersonal skills Learning skills Leadership skills Multitasking and prioritising Self-discipline Teamwork
91
Tools, Equipment and Materials (TEM) ITEMS 1. Fabrication drawings Isometric drawings P & ID Pipe support arrangement Piping Plan Piping Cutting Plan 2. Piping materials Carbon steel pipe Stainless steel 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. Cutting and Grinding equipment such as: Cutting torch Grinder Die pinch grinder Cold cut machine As required 1:5 1:5 1:5 As required As required 1:1 1:1 1:1 1:1 1:1 RATIO (TEM: TRAINEES)
1:5 1:5 1:5 1:5 1:5
92
ITEMS 6. Alignment tools such as: 12 and 24 L Square Water level Hand tools Pipe Clamp Tapper gauge Theodolite 7. Pipe support such as: Trunnion (Dummy) support Spring support Hanging support Shoe support Clamp support Cradle block support 8. 9. Pipe spool inspection checklist 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)
RATIO (TEM: TRAINEES)
1:5 1:5 1:5 1:5 1:5
As required
1:1
1:5 1:5 1:5 1:5
As required 1:1
93
ITEMS 12. Sample Documents: Engineering specification sample Purchase requisition proposal form sample Material requisition sample Material issuing form sample Work Order sample Project material delivery schedule sample Work schedule sample Work progress measurement chart 13. First aid kit
RATIO (TEM: TRAINEES)
1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:25
94
REFERENCES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Sutton, I. 2012. Offshore Safety Management. ISBN 9781437735246 McAllister, E.W. 2009 Pipeline Rules of Thumb Handbook. ISBN 9780750678520 Rao, K.R. 2006. Companion Guide to the ASME Boiler & Pressure Vessel Code. ISBN 791802183 B31.3 - 2010 Process Piping (Standard Book). ASME. ISBN 9780791833162 Sherwood, D.R. The Piping Guide for the Design and Drafting of Industrial Piping Systems (Book & CD) ISBN 978-091408219
Nayyar, M.L. 2002. Piping Handbook (Book). McGraw-Hill. ISBN 978-0-07-047106-1 Rhea, R.A. Pipe Drafting and Design 2 edition.ISBN 978-0750674393
Nayyar, M. Piping Databook. McGraw-Hill ISBN 9780071364515 Smith, P. Piping Material Guide. ISBN 978-0-7506-7743-1 Menon, S. Piping Calculations Manual. McGraw-Hill ISBN 978-0071440905 Hamilton, J.E. Facility Piping Systems. ISBN 978-0071358774 Frankel. M. Pipe Fitter's Math Guide. ISBN 962419702 Graves, W.V. The Pipe Fitter Blue Book. ISBN 978-0970832122
Frankland. T. The Pipefitter's and Pipe Welder's Handbook. ISBN 9780028025001 Frnakland.T. Pipe Trades Pocket Manual (Book) ISBN 9780028024103 Lee, R.A. IPT's Pipe Trades Handbook (Book).ISBN 978-0920855188 Linsey, F. Pipefitters Handbook (Book). ISBN 9780831130190 ISBN 9780875110097 ISBN 9780875110080
Bowman, S.D. Selected Piping Problems (Book).
Bowman, S.D. Modern Methods of Pipe Fabrications (Book).
Bowman, S.D. Ordinates for 1000 Pipe Intersections (Book). Claitors Pub Div. ISBN 9781579801724 Lee, R. A. IPT's Pipe Trades Training Manual (Book). IPT Publishing ISBN 9780920855201 Lee, R.A. Pocket Guide for Flanges, Fittings, & Piping Data (Book) Pipefitter Estimator (Book). AbeBooks.Com ISBN 9780969989912 Chakrabarti, S. 2005. Handbook Of Offshore Engineering (2 Vol Set ). Elsevier, ISBN 9780080443812 ISBN 9780884153108
95
UPSTREAM (ENGINEERING) PIPING FABRICATION MANAGEMENT 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: 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
Learning Outcomes
Competency Unit ID
Level
Training Duration
360
Credit Hours
36
Work Activities 1. Review piping fabrication QC requirements i. ii.
Related Knowledge Quality Manual Piping standards and codes (ASME, ANSI, API, ISO or equivalent) iii. Inspection Test Plan (ITP) Inspection
Applied Skills
Training Hours 15
Assessment Criteria i. Quality Manual reviewed to identify quality standards and requirements for each phase of the
96
Work Activities
Related Knowledge requirements iv. Hold points NDT matrix In-process QC procedures
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria fabrication process (such as ASME B31.3, ASME 1X)
i. Review Quality Manual to identify quality standards and requirements for each phase of the fabrication process (such as ASME B31.3, ASME 1X) ii. Review client quality specifications to identify QC requirements for each phase of the fabrication process iii. Review Inspection Test Plan (ITP) to identify QC requirements and schedule iv. Establish in-process QC procedures and schedules v. Review QA/QC audit
i. Comply with QA/QC requirements ii. Comply with ITP specifications
15
ii. Client quality specifications reviewed to identify QC requirements for each phase of the fabrication process iii. Inspection Test Plan (ITP) reviewed to identify QC requirements and schedule iv. In-process QC procedures and schedules established in accordance with
97
Work Activities
Related Knowledge
Applied Skills requirements to assist in inspection preparation vi. Communicate QC requirements to fabrication crew
Training Hours
Delivery Mode
Assessment Criteria QA/QC requirements v. QA/QC audit requirements identified to assist in inspection preparation vi. QC requirements communicated to fabrication crew to ensure accurate interpretation and compliance of fabrication standards
2. Conduct inprocess QC
i.
In-process QC requirements and procedures
60
i. Preparations for in-process quality inspection carried out in accordance
ii.
Inspection and data checklist
iii.
Fabrication Drawing
98
Work Activities iv. v.
Related Knowledge Isometric Drawing P&ID Drawing Pipe Support General Arrangement Piping Plan Piping Cutting Plan Hold points for inspection Quality sampling methods and procedures vi. ITP Inspection requirements Hold points NDT matrix
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria with inprocess QC procedures ii. Inspection and data checklist prepared in accordance with ITP iii. Hold points identified for inspection purposes in accordance with QA/QC specifications iv. Processes and items for in-process QC selected in accordance with quality sampling methods v. Acceptance criteria
vii. Compliance and noncompliance criteria (dimensions, tolerance, compliance with piping standards) viii. Fabrication tasks (marking, cutting, fit-up, installation) ix. x. Pipe spool identification Piping standards (ASME, API, ISO)
99
Work Activities xi.
Related Knowledge WPS
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria (including tolerances for dimensions and distortions) established in accordance with piping standards and isometric drawings vi. Project
xii. Inspection procedure xiii. Inspection recording format xiv. Non-compliance rectification procedures xv. HSE requirements OSHA PTW OGSP Working at height
i.
Carry out preparations for in-process quality
i. Comply with QA/QC requirements ii. Comply with ITP specifications iii. Comply with HSE requirements iv. Attention to details during inspection v. Objective in
60
materials inspected for compliance with piping standard and AFC drawing vii. Weld preparations, parameters and consumables inspected for compliance
ii.
Prepare inspection and data checklist
iii.
Identify hold points for inspection
iv.
Sample processes and items for inprocess
v.
Establish acceptance criteria (including tolerances for dimensions and
100
Work Activities
Related Knowledge
Applied Skills distortions) vi. Inspect project materials for compliance with piping standard and isometric drawing vii. Inspect weld preparations, parameters and consumables for compliance with WPS viii. Fit-up configuration, dimension and orientation are checked for compliance with WPS and isometric drawing ix. Identify spool and sub spool x. Check removal of pipe surface contaminants xi. Check all completed welds visually xii. Rectify noncompliance
Attitude / Safety / Environmental making judgements during inspection vi. Apply effective communication and interpersonal skills
Training Hours
Delivery Mode
Assessment Criteria with WPS viii. Fit-up configuration, dimension and orientation checked for compliance with WPS and AFC drawing ix. Spool and sub spool identification checked in accordance with AFC drawing x. Removal of pipe surface contaminants checked in accordance with piping and ITP requirements xi. All completed
101
Work Activities
Related Knowledge
Applied Skills xiii. Document inspection results
Training Hours
Delivery Mode
Assessment Criteria welds visually 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 ii. Hydrotest procedures iii. HSE requirements
30
i.
Hydrotest requirements
102
Work Activities
Related Knowledge iv. Hydrotest equipment
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria
identified from
i Interpret hydrotest package information ii Identify pipe spools for hydrotest iii Determine hydrotest procedures iv Determine HSE requirements for hydrotest v Determine hydrotest equipment vi Arrange set up for hydrotest iii ii i Comply with HSE requirements Ensure hydro test is carried out according to test package requirements and procedures Apply effective interpersonal skills 30 Demonstration Project
hydrotest package
ii.
Pipe spools and hydrotest equipment set up as per hydrotest package
iii.
HSE requirements are adhered
iv.
Effective interpersonal skills applied
4. Liaise with QA/QC on inspection work
i. ITP Inspection requirements Hold point NDT matrix
30
i. QA/QC Inspection schedule identified from ITP
103
Work Activities
Related Knowledge ii. QA/QC audit requirements iii. QA/QC audit procedures iv. HSE requirements OSHA PTW OGSP Working at height i.
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria ii. Preparation for QA/QC audit arranged in accordance with QA/QC procedures iii. QA/QC
Identify QA/QC inspection schedule as per ITP
i.
Comply with QA/QC requirements
30
inspection sessions coordinated in accordance with QA/QC procedures iv. Assistance and support provided to QA/QC personnel to facilitate efficient audit
ii.
Prepare for QA/QC audit
ii. Comply with ITP specifications iii. Comply with HSE requirements iv. Apply effective interpersonal skills
iii.
Coordinate QA/QC inspection sessions
iv.
Provide assistance and support to QA/QC personnel to facilitate efficient audit
104
Work Activities 5. Liaise with client on inspection work as per ITP
Related Knowledge i. ITP Inspection requirements Hold points NDT matrix
Applied Skills
Training Hours 30
Assessment Criteria i. Client inspection schedule identified from ITP and client requirements ii. Preparation for client inspection arranged in accordance with ITP and client requirements iii. Inspection session
ii. Client inspection requirements and procedures iii. QA/QC requirements iv. HSE requirements OSHA PTW OGSP Working at height i. Identify client inspection schedule as per ITP ii. Prepare for client inspection iii. Coordinate Inspection session iv. Provide assistance and clarification is to client if necessary i. Comply with QA/QC requirements ii. Comply with ITP specifications iii. Comply with HSE requirements iv. Apply effective communication 30 Demonstration Project
coordinated to facilitate efficient client inspection iv. Assistance and clarification provided to client during inspection session if necessary
105
Work Activities
Related Knowledge
Applied Skills
Attitude / Safety / Environmental and interpersonal skills
Training Hours
Delivery Mode
Assessment Criteria v. Inspection procedures adhere to HSE requirements
5. Provide information for the preparation of QA/QC report
i. ii.
QA/QC requirements Compliance and noncompliance in piping fabrication
30
i. Compliance and non-compliance recorded according to QA/QC format ii. Information on compliance and non-compliance
iii.
Testing results recording format
iv.
Continuous improvement in piping fabrication i. Record compliance and non-compliance ii. Provide Information on compliance and noncompliance to QA personnel for the preparation of QA/QC reports iii. Provide recommendations for process improvement where applicable i. Comply with QA/QC requirements ii. Comply with recording format iii. Apply effective communication and interpersonal skills 30 Demonstration Project
made accessible to QA personnel for the preparation of QA/QC reports iii. Recommendati ons for process improvement provided where applicable
106
Employability Skills Core Abilities 04.08 04.09 04.10 05.03 05.04 05.05 06.08 Develop and negotiate staffing plans Prepare work plan Utilise science and technology to achieve goal Allocate and record usage of financial and physical resources Delegate responsibilities and/or authority Coordinate contract and tender activities Identify and analyse effect of technology on the environment Social Skills 1. Communication skills 2. Conceptual skills 3. Interpersonal skills 4. Learning skills 5. Leadership skills 6. Multitasking and prioritising 7. Self-discipline 8. Teamwork
107
Tools, Equipment and Materials (TEM) ITEMS 1. Fabrication drawings Isometric drawings P & ID Pipe support arrangement Piping Plan Piping Cutting Plan 2. Piping materials Carbon steel pipe Stainless steel 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. Cutting and Grinding equipment such as: Cutting torch Grinder Die pinch grinder Cold cut machine As required 1:5 1:5 1:5 As required As required RATIO (TEM: TRAINEES) 1:1 1:1 1:1 1:1 1:1
1:5 1:5 1:5 1:5 1:5
108
ITEMS 6. Alignment tools such as: 12 and 24 L Square Water level Hand tools Pipe Clamp Tapper gauge Theodolite 7. Pipe support such as: Trunnion (Dummy) support Spring support Hanging support Shoe support Clamp support Cradle block support 8. 9. Pipe spool inspection checklist 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)
RATIO (TEM: TRAINEES) 1:5 1:5 1:5 1:5 1:5
As required
1:1
1:5 1:5 1:5 1:5
As required 11
109
ITEMS 12. Sample Documents: Quality Plan Engineering specification sample Purchase requisition proposal form sample Material requisition sample Material issuing form sample Work Order sample Project material delivery schedule sample Work schedule sample Work progress measurement chart Hydrotest package 13. First aid kit
RATIO (TEM: TRAINEES) 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:25
110
REFERENCES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Sutton, I. 2012. Offshore Safety Management. ISBN 9781437735246 McAllister, E.W. 2009 Pipeline Rules of Thumb Handbook. ISBN 9780750678520 Parkash, S. 2003, Refining Processes Handbook. ISBN 978-0750677219 Rao, K.R. 2006. Companion Guide to the ASME Boiler & Pressure Vessel Code. ISBN 791802183 B31.3 - 2010 Process Piping (Standard Book). ASME. ISBN 9780791833162 Sherwood, D.R. The Piping Guide for the Design and Drafting of Industrial Piping Systems (Book & CD) ISBN Nayyar, M.L. 2002. Piping Handbook (Book). McGraw-Hill. ISBN 978-0-07-047106-1 Rhea, R.A. Pipe Drafting and Design 2 edition.ISBN 978-0750674393 978-091408219
Nayyar, M. Piping Databook. McGraw-Hill ISBN 9780071364515 Smith, P. Piping Material Guide. Menon, S. Piping Calculations Manual. ISBN 978-0-7506-7743-1 McGraw-Hill ISBN 978-0071440905
Hamilton, J.E. Facility Piping Systems. ISBN 978-0071358774 Frankel. M. Pipe Fitter's Math Guide. ISBN 962419702 Graves, W.V. The Pipe Fitter Blue Book. ISBN 978-0970832122
Frankland. T. The Pipefitter's and Pipe Welder's Handbook. ISBN 9780028025001 Frnakland.T. Pipe Trades Pocket Manual (Book)ISBN 9780028024103 Lee, R.A. IPT's Pipe Trades Handbook (Book).ISBN 978-0920855188 Linsey, F. Pipefitters Handbook (Book). ISBN 9780831130190 Bowman, S.D. Selected Piping Problems (Book). ISBN 9780875110097 Bowman, S.D. Modern Methods of Pipe Fabrications (Book). ISBN 9780875110080
Bowman, S.D. Ordinates for 1000 Pipe Intersections (Book). Claitors Pub Div. ISBN 9781579801724 Lee, R. A. IPT's Pipe Trades Training Manual (Book). IPT Publishing ISBN 9780920855201 Lee, R.A. Pocket Guide for Flanges, Fittings, & Piping Data (Book). ISBN 9780884153108 Pipefitter Estimator (Book). AbeBooks.Com ISBN 9780969989912 Chakrabarti, S. 2005. Handbook Of Offshore Engineering (2 Vol Set ). Elsevier, ISBN 9780080443812
111
UPSTREAM (ENGINEERING) PIPING FABRICATION MANAGEMENT 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
Training Duration
120
Credit Hours
12
Work Activities 1. Control fabrication drawings
Related Knowledge i. Document control procedure ii. Fabrication drawings Isometric drawing P & ID drawings Pipe support GA drawings Piping plan Cutting plan
Applied Skills
Training Hours 30
Assessment Criteria i. Fabrication drawings received, acknowledged and compiled in accordance with documentation procedure ii. Drawings are
iii. Document superseding
112
Work Activities
Related Knowledge /removal procedure iv. Document distribution procedure
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria distributed to production floor according to
i. Compile fabrication drawings ii. Distribute drawings to production floor iii. Remove and destroy old drawings iv. Distribute revised drawings to production floors
i. Comply with document control procedure ii. Alert in detecting changes in drawings iii. Ensure distribution and use of latest revision documents
30
documentation distribution procedure iii. Old drawings are superseded and destroyed according to document control procedures iv. Revised drawings are distributed to production floors to ensure the latest revised drawings are referred for all fabrication work
2. Control related fabrication
i. ii.
WPS NDT procedure
15
Lecture Group discussion
i. WPS distributed to
113
Work Activities documents iii.
Related Knowledge Contract design specifications iv. v. vi. ITP Inspection requirements Hold points NDT matrix Process standard Distribution and briefing procedures i.
Applied Skills
Training Hours
Delivery Mode Shop talk
Assessment Criteria production floor according to document control procedure ii. Non-destructive test procedure distributed to production foreman
Distribute WPS to production floor
i. Comply with document distribution procedure ii. Alert in detecting changes in documents iii. Apply effective communication and interpersonal skills
15
iii. Contract design specifications distributed and briefed to production foreman iv. ITP distributed and briefed to production foreman v. Process standard distributed and briefed to production
ii.
Distribute nondestructive test procedure to production foreman
iii.
Distribute and brief on contract design specifications
iv.
Distribute and provide briefing on ITP
v.
Distribute and provide briefing on process standard
114
Work Activities
Related Knowledge
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria foreman
3. Compile lessons learnt for production team
i. Importance of lessons learnt ii. Continuous improvement iii. Recording format for lessons learnt i. Establish lessons learnt compilation format ii. Gather lessons learnt records and reports from production team iii. Categorise lessons learnt for easy reference iv. Provide lessons learnt compilation production team for continuous improvement i. Comply with recording and reporting format ii. Alert in identifying situations for learning iii. Demonstrate interest in continuous improvement
15
i. Lessons learnt compilation format established in accordance with
15
documentation guidelines ii. Lessons learnt records and reports gathered from production team iii. Lessons learnt categorised for easy reference iv. Lessons learnt compilation made accessible to production team
115
Work Activities
Related Knowledge
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria for continuous improvement
Core Abilities 04.08 04.09 04.10 05.03 05.04 05.05 06.08 Develop and negotiate staffing plans Prepare work plan Utilise science and technology to achieve goal Allocate and record usage of financial and physical resources Delegate responsibilities and/or authority Coordinate contract and tender activities
Social Skills 1. Communication skills 2. Conceptual skills 3. Interpersonal skills 4. Learning skills 5. Leadership skills 6. Multitasking and prioritising 7. Self-discipline
Identify and analyse effect of technology on the environment
8. Teamwork
116
Tools, Equipment and Materials (TEM) ITEMS 1. Sample Documents: Quality Plan Engineering specification sample Work progress measurement chart Inspection Test Plan (ITP) Welding Procedure Specification (WPS) 2. Engineering Drawings Isometric Drawings Piping & Instrumentation Diagram (P&ID) Pipe Support General Arrangement Drawing Piping Plan Cutting Plan 3. Stationery 1:1 1:1 1:1 1:1 1:1 As required 1:1 1:1 1:1 1:1 1:1 RATIO (TEM: TRAINEES)
117
REFERENCES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Sutton, I. 2012. Offshore Safety Management. ISBN 9781437735246 McAllister, E.W. 2009 Pipeline Rules of Thumb Handbook. ISBN 9780750678520 B31.3 - 2010 Process Piping (Standard Book). ASME. ISBN 9780791833162 Sherwood, D.R. The Piping Guide for the Design and Drafting of Industrial Piping Systems (Book & CD) ISBN Nayyar, M.L. 2002. Piping Handbook (Book). McGraw-Hill. ISBN 978-0-07-047106-1 Rhea, R.A. Pipe Drafting and Design 2 edition.ISBN 978-0750674393 978-091408219
Nayyar, M. Piping Databook. McGraw-Hill ISBN 9780071364515 Smith, P. Piping Material Guide. ISBN 978-0-7506-7743-1 Frankel. M. Pipe Fitter's Math Guide. ISBN 962419702 Graves, W.V. The Pipe Fitter Blue Book. ISBN 978-0970832122
Frankland. T. The Pipefitter's and Pipe Welder's Handbook. ISBN 9780028025001 Frnakland.T. Pipe Trades Pocket Manual (Book) ISBN 9780028024103 Lee, R.A. IPT's Pipe Trades Handbook (Book).ISBN 978-0920855188 Linsey, F. Pipefitters Handbook (Book). ISBN 9780831130190
Bowman, S.D. Selected Piping Problems (Book). ISBN 9780875110097 Bowman, S.D. Modern Methods of Pipe Fabrications (Book). ISBN 9780875110080 Lee, R. A. IPT's Pipe Trades Training Manual (Book). IPT Publishing ISBN 9780920855201 Lee, R.A. Pocket Guide for Flanges, Fittings, & Piping Data (Book )ISBN 9780884153108
118
CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector Job Area Competency Unit Title
UPSTREAM (ENGINEERING) PIPING FABRICATION MANAGEMENT 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
Identifyshop drawings requirements Identifyshop drawings information Prepare shop drawings Confirm shop drawings prepared
Competency Unit ID
SD-XXX-X
Level
Training Duration Training Hours

15
180 hours Delivery Mode

Lecture Tutorial Group discussion Case study
Credit Hours
18 Assessment Criteria
Work Activities
1. Identifyshop drawings requirements
Related Knowledge
i. Project requirements ii. Types of shop drawings Erection drawingssequence Sea fastening shop drawings Component design drawings Fabrication
Applied Skills
i.
Project requirements are identified and adhered to.
ii.
Drawings are coordinated and reviewed for accuracy, completeness and compliance with contract requirements.
119
Work Activities
Related Knowledge
drawings Standard connections, components or equipment iii. Drawing information such as Quantities Weldings and test codes and procedures iv. Drafting standards and codes v. Engineering standards vi. Submission procedures i.
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria
iii. Variations on shop drawings from the contract are identified, described and finalised. iv. Shop drawings are ensured that they are checked verified prior approval and fabrication v. Information are included on shop drawings as per fabrication, erection and load out
Interpret and apply project requirements
i.
Compliance with clients and companys rules and regulations
30
Practical Demonstration
requirements. vi. Shop drawing schedule prepared as per project requirements
ii.
Check to ensure that types of shop drawings are identified and differentiated ii.
Comply with Occupational, Safety and Health Act
120
Work Activities
Related Knowledge
Applied Skills
iii. Check to ensure shop drawing information 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.

(OSHA) and company requirements
Training Hours
Delivery Mode
Assessment Criteria
2. Identify offshore structure shop drawings information
i.
Contractual document
15
ii.
Project requirements
i.
Cutting plan is identified and analysed.
ii.
Components are identified from
iii. Structure
121
Work Activities
Related Knowledge
components such as I-Beam Girder Plates Channels
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria
cutting plan and detailed design drawings. iii. Related information on drawings and specifications are identified and reviewed as per engineering specifications. iv. Materials information are identified and obtained from various resources. v. Variation order are followed. vi. Yard machines and equipment capacity are identified according to shop drawings
iv. Yard equipment and capacities v. Drawing information such as Designed loads Quantities Welding and test codes procedures vi. Drafting standards and codes vii. Engineering standards viii. Submission procedures ix. Variation order i. Identify project requirements ii. Identify structure i. Compliance with clients and 30 Practical Demonstration
requirements. vii. Project requirements are
122
Work Activities
Related Knowledge
Applied Skills
components to be fabricated iii. Identify information from various types of shop drawings iv. Identify various drawing information v. Review cutting plan generated vi. Identify related drafting standards and codes vii. Identify types of yard equipment viii. Differentiate equipment capacity ix. Identify special instruction to be applied

companys rules and regulations ii. Comply with legislative requirements
Training Hours
Delivery Mode
Assessment Criteria
identified. viii. Types of drawings to be prepared are identified. ix. Information to be furnished on various drawings prepared is identified. x. Submission procedure for shop drawings identified.
3. Prepare shop drawings
i.
15
ii.
Types of shop drawings Erection drawings,
i.
Project requirements identified are applied
ii.
Information furnished on
123
Work Activities
Related Knowledge
sequence and load out methods Sea fastening shop drawings Component design drawings General arrangement drawings Fabrication/ detailed drawings Standard connections, components or equipment iii. Drawing information such as Designed loads Quantities Welding and test codes procedures
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria
various drawings prepared followed drawing standards and codes. iii. Erection framing plan are followed. iv. Assembly diagrams requirements are adhered to. v. Shop detail drawings presentation guidelines are identified and adhered to. vi. Product details are included in shop drawings.
124
Work Activities
Related Knowledge
iv. Drafting standards and codes v. Engineering standards vi. Submission and quality procedures i.
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria
Apply project requirements
i.
Comply with clients and companys rules and regulations
30
ii.
Identify and differentiate various types of shop drawings ii.
Comply with legislative requirements
iii. Furnish shop 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
Work Activities
Related Knowledge
Applied Skills
procedures.
Training Hours
Delivery Mode
Assessment Criteria
4. Confirm shop drawings prepared
i.
15
ii.
Types of shop drawings Erection drawings Component design drawings Fabrication/det ailed drawings Standard connections, components or equipment
i.
Shop drawings are checked to confirm that project requirements
ii.
Shop drawings are checked to ensure that shop drawings are prepared as requirements.
iii. Shop drawings are checked to ensure product details are included in shop drawings iv. Shop drawings are checked to ensure drawing numbers and revision numbers are indicated on the shop drawings. v. Shop drawings are checked to ensure
iii. Drawing information Quantities Codes
iv. Drafting standards and codes v. Engineering standards
126
Work Activities
Related Knowledge
vi. Submission procedures i.
Applied Skills
Training Hours
Delivery Mode
Assessment Criteria
details as per standards are
Check to ensure project requirements are applied
i.
Comply with clients and companys rules and regulations
30
included in shop drawings. vi. Shop drawings are checked to ensure that details such as sea fastening layout arrangement, equipment, installation and load out method are included as per shop drawings requirements. vii. Shop drawings are checked to ensure that quality and quantity of information contained on shop drawings conform to drawings specifications,
ii.
Check to ensure that types of shop drawings are identified and differentiated
ii.
Comply with legislative requirements
iii. Check to ensure shop drawing information 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
127
Work Activities
Related Knowledge
Applied Skills
identified in the requirements. vi. Check to ensure submission procedures are applied.
Training Hours
Delivery Mode
Assessment Criteria
company standards and procedures.
Core Abilities 01.07 01.08 01.10 01.11 02.10 02.11 03.10 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 Social Skills 1. 2. 3. 4. 5. 6. 7. 8. Communication skills Interpersonal skills Multitasking and prioritizing Self-discipline Teamwork Compliance Diligence Cooperation
128
Tools, Equipment and Materials (TEM)

ITEMS 1. Compliance documents Contractual agreement Clients requirements Final design requirements Design specifications Design guidelines Companys 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 RATIO (TEM : Trainees) 1:25
1:25
1:25
129
ITEMS 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
RATIO (TEM : Trainees)

1:1
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
TRAININGHOURSSUMMARY
: SECTOR : SUBSECTOR : AREA : JOBAREA : JOBLEVEL CUID PIPINGFABRICATIONOPERATIONSUPERVISION PIPINGFABRICATION0UALITYCONTROL PIPINGFABRICATIONDOCUMENTCONTROL SHOPDRA3INGPREPARATION To!'4T&'%"%"(P&o(&'mm Ho)&* +,5- +/- +2- .1- 4/- FOUR(4) Comp ! "#$U"%! HEALTH,SAFETYANDENVIRONMENTCOMPLIANCE SUPERVISION PIPINGFABRICATIONPROJECTMATERIALSSTORAGE& CONTROL T&'%"%"( Ho)&* +,- .-- PIPINGFABRICATIONMANAGEMENT ENGINEERING UPSTREAM OIL,GAS&PETROCHEMICAL
131

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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

STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN (NATIONAL OCCUPATIONAL SKILL STANDARD)

STANDARD PRACTICE, STANDARD CONTENT & CURRICULUM of COMPETENCY UNIT

PIPING FABRICATION MANAGEMENT (PENGURUSAN FABRIKASI PAIP)

First Published 2012

Sources of Additional Information

10. Acknowledgement 11. Validation 12. Literature References

Figure 1 Occupational Profile Chart for Piping Fabrication Personnel

SECTOR SUB-SECTOR AREA L8 L7 L6 L5 L4 L3 L2 L1

OIL, GAS & PETROCHEMICAL UPSTREAM (ENGINEERING) PIPING FABRICATION

Malaysia Skills Certificate Level 3: (Supervisory Level)

Malaysia Skills Diploma Level 4: (Executive Level)

Malaysia Skills Advanced Diploma Level 5: (Managerial Level)

4. MALAYSIAN SKILL CERTIFICATION

fabrication personnel to work under controlled environment.

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

PFCE Engineering Sdn Bhd

Labuan Shipyard & Engineering Sdn Bhd

Dialog Group Berhad

Boustead Heavy Industries Group

9. SOURCES OF ADDITIONAL INFORMATION LOCAL SOURCES

En Ab Halim bin Hasan

Principal Asst Director DSD, Cyberjaya, Selangor VALIDATION OFFICER

Tuan Syed Mahathir bin Syed Azman Shah

Asst Director DSD, Cyberjaya, Selangor

PIPING FABRICATION MANAGEMENT

STANDARD CONTENT NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR:

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

SHOP DRAWING PREPARATION

Sub Sector Job Area Level CU Title

1. Health, Safety &

1. Supervise safety of working

1.1 Safety signage and JSA

1.2 Potential hazards

1.3 Safety equipment (such as

1.4 Erection and dismantling

Performance Criteria supervised in accordance with HSE requirements

1.5 Sufficient ventilation and

1.6 Cleanliness of working

2.1 Tools and equipment are

2. Supervise safety check of

using instruments) and test run according to manufacturers specifications

2.2 Green tag are marked on

2.3 Load certificates for lifting

Performance Criteria checked to ensure working condition as per lifting plan

2.4 Magnetic Particle Test

2.5 Colour coding on tools and

2.6 Random daily test on tools

2.7 Non-compliant tools and

2.8 .Safe-for-use certification

3.1 Personal protective

3. Supervise usage of PPE

3.2 PPE with expiry dates

3.3 Appropriate actions are

1. Identify project materials

1.1 Types of piping