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1.QUALITY CONTROL ENGINEER (QC)



A. Introduction

In the current educational field due to emerging of vast number of engineering colleges & technical institutions akin to them release a great number of students who are essentially in need of specialized training certifications besides the professional qualifications they are issued by the concerned colleges. Axionz is delivering innovative and reliable training on various methods in virtual ambiance by the trainers who have hand on experience in Refineries ,Aerospace ,Aircraft ,Marine , Petrochemical ,Oil and GAS etc.

B. Course contents

The QUALITY CONTROL ENGINEERING is a certification cum training program for engineers. In addition to quality control we are also offering training in NON DESTRUCTIVE TESTING(NDT) In this course Axionz are covering the sections mentioned below

                AXIONZ THEORY ORIENTED QA/QC SYLLABUS

CHAPTER 01- INTRODUCTION

a)About oil field industries
b)Oil wells
c)Offshore terminology
d)Onshore
e)Natural gas
f)Oil exploration
g)Oil production
h)Oil refinery
i)Common process units found in

CHAPTER 02- DUTIES AND RESPONSIBILITIES

a)Main responsibilities (code compliance, workmanship control, documentation control)
b) Personal attributes (honesty, integrity, knowledge, good communicator, physical fitness, good eye sight)
c)Welding inspection (before ,during, after welding)
d)Welding inspectors equipments
e)Summary of duties (observe, record, compare)

CHAPTER 03- WELD TERMINOLOGY

a)What is weld and types of welds (butt weld, fillet weld, spot weld, edge weld, plug weld, compound weld)
b) Joint and types of joint (edge, lap, open and closed corner, tee, butt, cruciform)
c) Weld zone terminology
d) Joint design (bevel angle, included angle, root face, root gap) and weld preparation (single Vee, double Vee, single J, double J etc.)
e) Welding positions (1G, 2G, 3G, 4G, 6G, 1F, 2F, 3F, 4F etc.)

CHAPTER 04- WELDING IMPERFECTIONS

a)Cracks
b)Lamellar tearing
c)Gas cavities
d)Crater pipe
e)Solid inclusion
f)Lack of fusion
g)Weld root imperfections
h)Undercut
i)Surface and profile
j)Overlap
k) Set up irregularities l)Incomplete groove
m)Oxide root
n)Miscellaneous imperfections
o)Mechanical damage

CHAPTER 05- DESTRUCTIVE TESTING

a)Quantitative tests (tensile test, hardness test, charpy v notch impact test)
b) Qualitative tests (bent tests, macro tests, fillet fracture, nick-break tests)
c)Welding procedure qualification testing

CHAPTER 06- WELDING PROCEDURE QUALIFICATION

a)What is the test trying to show
b)Essential variable and Non essential variable
c) Additional variable
d) Preliminary welding procedure specification(PWPS)
e) Welding procedure approval record (WPAR)
f) Welding procedure specification (WPS)
g) Welder qualification

CHAPTER 07- MATERIAL INSPECTION , CODES AND STANDARDS

a)Pipe inspection (corrosion , damage, wall thickness ovality, lamination and seams)
b) Plate inspection (corrosion, mechanical damage, laps, bands and lamination)
c)Parent material imperfections
d)Difference between standard and code

CHAPTER 08- WELDING SYMBOL

a)advantage and disadvantage of symbolic representation
b) symbolic representation
c) elementary symbol
f)BS EN 22553 symbols
g)AWS welding symbols

CHAPTER 09- INTRODUCTION TO WELDING PROCESS AND CONSUMABLES

a) Classifications of welding m/c by principles (welding transformers, welding rectifiers, welding generators, alternator, inverter technology)
b) butt welding
c) fillet welding
d) welding process (SMAW AND TIG) C) Welding consumables (covered electrodes, filler wires and electrode wires, shielding gases, separately supplied fluxes, fusible

CHAPTER 10-WELD REPAIRES

a)Production repairs and in-service repairs
b)Authorization and procedure for repair
c) Removal of material and preparation for repair
d)Monitoring of repair weld
e)Testing of repair-visual and NDT
f) Weld repair and related problems

CHAPTER 11-RESIDUAL STRESS AND DISTORTION

a)Stresses (normal stress, shear stress, hoop stress)
b)Residual stress ( along the weld, through the weld, across the weld)
c) Types of distortion (angular distortion, transverse distortion, bowing distortion, longitudinal distortion)
d)distortion prevention methods
e)distortion corrective techniques

CHAPTER 12-HEAT TREATMENT

a)Why?
b) How?
c) Types of heat treatment (preheat, annealing, normalising, quench hardening, temper, stress relief)

CHAPTER 13-FOUR FACTORS AND WELD ABILITY

a)fusion
b)atmospheric protection
c)surface protection
d)adequate properties
e) steel alloying elements
f)classification of steels
g)carbon equivalent formula
h) heat input
i) weld decay

CHAPTER 14-NON DESTRUCTIVE TESTING

a) visual testing
b)magnetic particle testing
c)ultrasonic testing
d)radiographic testing
e)dye Penetrant testing
f)radiographic film inter pretation

                AXIONZ SITE ORIENTED QA/QC SYLLUBUS

CHAPTER 01-ENGINEERING DRAWINGS

a)Title block b) Drawing scale c)Grid system d) Revision changes e)Drawing sizes f)Notes and legents

1)PROCESS AND INSTRUMENT DIAGRAM

It is a schematic representation of the complete process in sequence, which include the main process, the major equipment, the control details and the major instruments (almost all) of the total construction. In P & ID Axionz cover the following sections a)Drawing sizes
b)Piping coordination systems
c)Line numbering
d)Information in the title column
e)Other information in P&ID
f)Interpreting original plant drawings

2)NDT ISOMETRIC /FABRICATION DRAWING

Isometric drawings are the industry’s means of communicating detailed and accurrate information on how to fabricate, assemble and install a pipe line or piping system. In Isometric drawing Axionz cover the following sections
a)Title block
b)Technical data section
c)Graphic section
d)Bill of material section
e)interpretation of fabrication drawing

3)EQUIPMENT DRAWING

Equipment is the basic process item in any oilfield, refineries, chemical plant etc. there are two classifications for equipment used in the oilfield and related industries. One is the static and other is rotary. In Equipment drawing Axionz cover the following sections
a)Pressure vessel drawing
b)Tanks
c)Heat exchanger
d)sphere
e)Interpreting Fabrication drawing

4) STRUCTURAL DRAWING

There are civil structures and mechanical structures in the oil field, mechanical structures are constructed with metal and construction activities such as gas cutting, grinding, welding, bolting, NDT and DT etc. are involved in it. In Structural drawing Axionz cover the following sections
a)I beam
b)Channels
c)Angle and flat

CHAPETR 02-CONSTRUCTION MATERIALS

1)PIPE & PLATE

In Pipes & plates Axionz cover the following sections
a)Basic categories of tubular products
b)materials of construction
c)pipe sizes
d)weight
e)wall thickness and schedule number
e)length
f)methods of manufacture
g) ASTM A106 and ASTM A312 pipes and test requirements
h)ASTM A515 and ASTM A516 plates and their test requirements
i)ASTM A 240 plates(Type 304, 304L, 304H, 304N, 316, 309 )

2)FITTINGS (IN LINE, ON LINE AND CLOSURES)

In Elbows Axionz cover the following sections
a)Five basic version of elbows(90degree long radius elbow, 45degree long radius, 90degree short radius, long radius reducing elbow, long radius 180degree elbow
b) dimension methods of elbow

4) TEES & REDUCERS

In tees & reducers Axionz cover the following sections
a)Equal and un equal tees and dimensional differences
b)concentric and eccentric reducers
c)dimensional methods
d)reducer coupling
d) swage nipple reducer

5)END CAPS, MITERS, STUB IN(STUB ON), R.F PAD

6) O-LET FITTINGS

In O lets Axionz cover the following sections
a)weld o let
b)sock o let
c)thread o let
d) latrolet
e) elbowlet,
f) nip o let
g) flange o let
h) sweepolet i)couplet.

7)FLANGES

In Flanges Axionz cover the following sections
a)Materials of construction
b) Forged steel and cast iron flange ratings
c)flange dimensions d)bolt hole location
d)Types of flanges( weld neck, slip on, socket weld, screwed, lap joint, stub end etc.)
e) Special flange types (expander flanges, reducing flanges, orifice flanges)
f) flange faces (raised face, flat face, ring type joint)
g)flange face finish (stock finish, spiral serrated, concentric serrated, smooth finish)

8) GASKETS & BOLTS

In gaskets Axionz cover the following sections
a) Semi metallic gaskets
b) metallic gaskets
c)non-metallic gaskets
d)often used semi- metallic gaskets
e)Stud bolts
f)cap crews
g)machine bolts

9)VALVES & RUPTURE DISK

In Valves Axionz cover the following sections
a)Gate, globe, ball, butterfly, needle valve, diaphragm valve, plug valve, check valve, control valve, valve actuator, safety relief valve

10)STRINERS & BLINDS

In strainers Axionz cover the following sections
a)Bucket strainer
b)Y-type strainer
c)conical strainer

11)BLEED RING & EXPANSION JOINT

CHAPTER 03-PIPING TERMINOLOGY

1) COATING AND WRAPPING & HYDRO TEST

In Hydro test, Coating and wrapping Axionz cover the following sections
a)surface preparation
b)application of primer
c)wrapping of tape
d)High points vent and low point drains
e)Hydro-static test
f)Procedure

2)HEAT TRACING & ORIFICE RUN

In Heat tracing Axionz covering these all sections a)supplemental heat application for process piping system b)jacketing c)commodity tracing c)electric tracing

3)ORIFICE PLATE & PIPE CLEANING PIGS

4)PIPE SPACING & FITTING TO FITTING & PUP PIECE

5)OFFSETS & CAF(Compressed aramid fiber)GASKET

6)TORQUE & U-BOLT

In Piping terminology Axionz cover the following sections
a)pressure regulator control valve
b)bolt thread protrusion
c)pump cavitations
d) cathodic protection
e)end weld preparation
f) hot bolting
g) nozzles and manholes

CHAPTER 4-PIPE SUPPORTS

In support system Axionz cover the following sections
a)Primary pipe support(Materials of construction and fabrication method)
b) secondary supports (anchors, pipe legs, anchor guides, base supports, cradles, directional anchor, dummy leg support, field support, guides, pipe shoes, riser supports, load distribution pads, hanger rods)

CHAPTER 5-SCAFFOLDING

In scaffolding Axionz cover the following sections
a)guard rails
b)swivel coupler
c)joint pin
d)right-angle coupler
d)putlog coupler

CHAPTER 6-CONSTRUCTION STANDARDS

CHAPTER 7-NON DESTRUCTIVE TESTING

1)VISUAL TESTING

2)DYE PENETRANT TESTING

3) MAGNETIC PARTICLE TESTING

4) ULTRASONIC PARTICLE TESTING

5)RADIOGRAPHIC TESTING

6) RADIOGRAPHIC FILM INTERPRTATION

Add on Certification

PIPING ENGINEERING

• Basics of piping • Joints,pipes,flanges,elbows etc Provides 100 hours practical classes on all methods in NDT and QC.(Saturday and Sunday special classes will be scheduled if the students demand)

COURSE DURATION:

Three months (Covers QC section, NDT LEVEL 1 & 2, Piping engineering) M-tech/ME, BE/B-tech in Mechanical, Aeronautical Engineering etc Those who are waiting for final semester result as well as those who have to attend supplementary examinations may also apply.

ABOUT EXAMINATION

Examinations are CONDUCTED IN BOTH ONLINE AND OFFLINE METHODS.
1.General
2.Specific examinations
3. Practical
4.Viva
1.All General Examination will be Objective Type Examinations .
2.Specific Examinations are Objective Exams based on a given reference specific Codes which will be allowed to refer during the examination time.
3.Practical Examinations are held in suitable specimens and record in the respective reports.
4.Viva is conducted as a part of practical examination

ABOUT CERTIFICATION

Internationally recognized Certificates of QUALITY CONTROL ENGINEER(QC),FIVE METHODS IN NDT AND A PIPING ENGINEERING will be awarded to candidates by the authorized certification body ASNT(American Society for Non Destructive Testing Inc.colombo) (refer admission in home page)
• For Course Fees kindly contact the office.
• A new batch will be starting in first week of each month.
• A PC TAB will be given to students with 20 % discount of the actual price.
• All students should bring scientific calculators to the class daily.
• Study materials will be provided in soft and hard copies to the candidates
• Vision certificate should be submitted during the time of Admission.