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
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
i
No.
Contents
Pages
1.
Introduction
1
2.
Occupational Structure
3
3.
Definition Of Competency Levels
5
4.
Malaysian Skill Certification
6
5.
Job Competencies
6
6.
Working Conditions
6
7.
Employment Prospects
7
8.
Training, Industrial/Professional Recognition, Other Qualifications and
Advancements
9
9.
Sources of Additional Information
10
10.
Acknowledgement
12
11.
Validation
12
12.
Literature References
13
13. Abbreviations
13
14. Committee Members for Development of Standard Practice (SP),
Competency Profile Chart (CPC), Competency Profile (CP) and Curriculum
of Competency Unit (CoCU
15
15. Competency Profile Chart (CPC)
17
16. Competency Profile (CP)
18 - 52
17. Curriculum of Competency Unit (CoCU): Health, Safety & Environment
(HSE) Compliance Supervision
54 - 61
18. Curriculum of Competency Unit (CoCU): Piping FabricationProject
Materials Storage & Control
62 - 76
19. Curriculum of Competency Unit (CoCU): Piping Fabrication Operation
Supervision
77 - 94
20. Curriculum of Competency Unit (CoCU): Piping Fabrication Quality Control
95 - 110
21. Curriculum of Competency Unit (CoCU): Piping Fabrication Document
Control
111-117
22. Curriculum of Competency Unit (CoCU): Shop Drawing Preparation
118-129
1
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 user
1.
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
2
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 2020
2. 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
3
Piping fabrication comes under the Oil, Gas & Petrochemical Sector. The related
sub-sector, area and job area as well as the structured career path are as shown in
Figure 1and Figure 2.
SECTOR
OIL, GAS & PETROCHEMICAL
SUB-SECTOR
UPSTREAM
AREA
ENGINEERING
JOB AREA
PIPING
LEVEL 8
PIPING CUSTODIAN PRINCIPAL
LEVEL 7
PIPING DESIGN
SPECIALIST
PIPING MATERIAL
SPECIALIST
PIPING STRESS
SPECIALIST
LEVEL 6
PIPING TECHNOLOGIST
LEVEL 5
PIPING FABRICATION
SUPERINTENDENT
PIPING DESIGNER
LEVEL 4
PIPING FABRICATION
SUPERVISOR
PIPING SENIOR DRAFTER
LEVEL 3
PIPING FABRICATOR
PIPING DRAFTER
LEVEL 2
PIPING SENIOR FITTER
PIPING JUNIOR DRAUGHTER
LEVEL 1
PIPING FITTER
DRAUGHTSMAN
4
SUB-SECTOR
UPSTREAM (ENGINEERING)
AREA
PIPING FABRICATION
L8
N/A
L7
L6
L5
PIPING FABRICATION MANAGEMENT
L4
PIPING FABRICATION MANAGEMENT
L3
PIPING FABRICATION OPERATION
L2
PIPING FABRICATION OPERATION
L1
N/A
Figure 2 Occupational Area Analysis (OAA) Chart for Piping Fabrication
Personnel
5
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)
Competent in performing a range of varied
work activities, most of which are routine
and predictable.
Malaysia Skills Certificate Level 2:
(Operation Level)
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.
Malaysia Skills Certificate Level 3:
(Supervisory Level)
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.
Malaysia Skills Diploma Level 4:
(Executive Level)
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.
Malaysia Skills Advanced Diploma
Level 5: (Managerial Level)
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.
6
Candidates after being assessed and verified and fulfilled Malaysian Skill
Certification requirements shall be awarded with Malaysia Skills Diploma (DKM)
Piping Fabrication Management (Level 4).
5. JOB COMPETENCIES
Piping Fabrication Management (Level 4) personnel are competent in performing the
following core competencies:
•
Piping Fabrication Health, Safety & Environment Compliance Supervision
•
Piping Fabrication Project Materials Storage & Control
•
Piping Fabrication Operation Supervision
•
Piping Fabrication Quality Control
•
Piping Fabrication Document Control
Optionally, the Piping Fabrication Management (Level 4) personnel are also
competent in performing the following elective competency:-
•
Shop Drawing Preparation
6. WORKING CONDITIONS
Piping fabrication can be accomplished in several ways namely shop fabricate and
field installed, or field fabricate and installed, or combinations of both.
In shop fabrication, metal is fabricated and assembled into structures at the fabricator’s
facility and then transported to the site for erection. Shop fabrication allows the
fabrication personnel to work under controlled environment.
In field fabrication, metal is fabricated at site fabrication yards which are usually well
equipped and organized to ensure efficient work flow. The pipes are then hooked-up
or modified as required on site.
Working conditions at offshore sites may be unpredictable and personnel may have to
work under pressure and in hazardous conditions. Working in an open air structure
will require protection from weather conditions such as rain, wind and cold.
7
time and usually work in a team which consists of workers from all levels. Safety is a
major issue to all fabricator personnel. Thus, compliance with occupational safety
and health is everyone’s responsibility at all times.
7. EMPLOYMENT PROSPECTS
Malaysia is rich in both renewable and non-renewable sources of energy suchas
petroleum. The rapid growth of the Oil and Gas Industry opens up plenty of job
opportunities in this sector. The industry currently faces a shortage of skilled and
experienced workforce in piping fabrication.
Piping Fabrication Operation experts are highly sought after in various sectors other
than the Oil, Gas and Petrochemical sector. While this sector offers many job
opportunities, any sector involved in piping have great need for fabricators. This is
especially true in the development sector where large upcoming piping projects such
as the SCORE (Sarawak Corridor Renewal Energy) project in Bintulu, Sarawak and
the Iskandar project in Johor will ensure plentiful opportunities for piping fabricators
and management personnel in the near and foreseeable future.
Resourceful and experienced piping fabricators and management personnel may
also commercialise their skills and knowledge widely including taking up job offers
abroad.. Well skilled and experienced fabricators are highly sought after in regions
such as the Middle East.
Other than the oil and gas industry, piping fabrication personnel can also work in the
construction, marine and shipbuilding industries.
Listed below are the major companies in Malaysia involved in Piping Fabrication (Oil
and Gas):
8
Table 1
Piping Fabrication Companies
Company
Address
Malaysia Marine and Heavy
Engineering Holdings Berhad
Level 31, Menara Dayabumi, Jalan
Sultan Hishamuddin, 50050 Kuala
Lumpur, Malaysia
Tel: 603 22730266
Fax: 603 22738916
Website: www.mhb.com.my
SapuraKencana Petroleum Bhd
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
Sime Darby Energy & Utilities
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
TH Heavy Engineering Sdn Bhd
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
Brooke Dockyard and Engineering
Works Corporation
Sublot 47, 48 & 49, Block A, 1st-3rd Flr,
Demak Laut Commercial Centre Phase
3, Jalan Bako, Petra Jaya, Kuching,
Sarawak, Malaysia.
Tel: 6082-439732
Website: www.brookedockyard.com
PFCE Engineering Sdn Bhd
Level 22, Maju Tower
1001 Jalan Sultan Ismail
50250 Kuala Lumpur, Malaysia
Tel: +603 277287777
Fax: +603 27728780
Website: www.pfce.com.my
Labuan Shipyard & Engineering Sdn
Bhd
Km9 Jalan Ranca-Ranca
P.O. Box 81210
87031 F.T. Labuan
Tel: +087 451888
Fax: +087 451777
Website: www.labuanship.com
9
Company
Address
Dialog Group Berhad
109, Block G, Phileo Damansara 1,
No. 9, Jalan 16/11, 46350 Petaling Jaya,
Selangor Darul Ehsan, Malaysia
Tel: 603 7955 1199
Fax: 603 7955 8989
Website: www.dialogasia.com
Boustead Heavy Industries Group
17th Floor, Menara Boustead
69, Jalan Raja Chulan
50200 Kuala Lumpur
Tel: (+6)03-20787770
Fax: (+6)03-20316089
Website: www.bhic.com.my
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.
10
LOCAL SOURCES
•
DEPARTMENT OF OCCUPATIONAL SAFETY AND HEALTH (DOSH)
Level 2, 3 & 4, Block D3, Complex D
Federal Government Administrative Centre
62530 Wilayah Persekutuan Putrajaya
Phone
.: 603-8886 5000
Fax
: 603-8889 2443
Website
: http://www.dosh.gov.my
•
CONSTRUCTION INDUSTRY DEVELOPMENT BOARD MALAYSIA (CIDB)
7th Floor, Grand Season Avenue
72, Jalan Pahang
53000 Kuala Lumpur, Wilayah Persekutuan
Phone
.: 603-2617 0200
Fax
: 603-2617 0220
Website
: http://cidb.gov.my
•
INSTITUTION OF ENGINEERS, MALAYSIA (IEM)
Bangunan Ingenieur, Lot 60/62
Jalan 52/4, Peti Surat 223 (Jalan Sultan)
46720 Petaling Jaya,
Selangor Darul Ehsan, Malaysia.
Phone
.: 603-7968 4001
Fax
: 603-7957 7678
Website
: http://myiem.org.my
•
PERFORMANCE MANAGEMENT & DELIVERY UNIT (PEMANDU)
Prime Minister’s Department
3rd Floor, East Block, Perdana Putra Building,
Federal Government Administrative Centre,
62502 Putrajaya
Phone
: 03-88727237
Fax
: 03 8888 7107
11
•
AMERICAN WELDING SOCIETY (AWS)
550 Northwest 42nd Avenue Miami, FL 33126, United States
Phone
:(305) 443-9353
Website
: http://www.aws.org
•
AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)
Three Park Avenue
New York, NY 10016-5990
Phone
:973-882-1170 (outside North America)
Website
: http://www.asme.org
•
AMERICAN PETROLEUM INSTITUTE (API)
# 900, 1220 L Street Northwest
Washington, DC 20005, United States
Phone
:(202) 682-8000
Website
: http://www.api.org
•
INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)
ISO Central Secretariat
1, ch. de la Voie-Creuse
CP 56
CH-1211 Geneva 20
Switzerland
Phone
:+41 22 749 01 11
Website
: www.iso.org
•
PIPE FABRICATION INSTITUTE
USA Office
511 Ave. of America's, # 601
New York, NY 10011
Phone
: (514) 634-3434
Website
: [email protected]
12
The Director General of DSD would like to extend his gratitude to the organisations
and individuals involved in developing this standard. Special acknowledgement is
given to the team of experts in piping fabrication who have generously shared their
knowledge and experience for the documentation of this standard. Appreciation is
also extended to the DSD NOSS team who provides guidance and direction in the
development of this standard with ample patience and commitment.
11.
VALIDATION
This standard has been checked by the Standard Technical Evaluation Committee
(STEC), DSD and validated by the members of Skills Development Advisory
Committee (SDAC) on ……….. The SDAC members as listed
below have agreed in consensus to this standard:
VALIDATION COMMITTEE
PIPING FABRICATION MANAGEMENT LEVEL 4
1.
En Azdi Abass
Managing Director
Octagon Petroleum Technology Sdn Bhd
2.
Tuan Haji Arshad Ahmad
General Manager
Sime Darby
3.
En Awaludin Mohd Arif
Managing Director
Industrial Testing & Engineering
4.
En Baharuddin bin Mamat
Deputy Director
Department of Occupational Safety and
Health, Johor
CHAIRMAN
1.
En Ab Halim bin Hasan
Principal Asst Director
DSD, Cyberjaya, Selangor
VALIDATION OFFICER
1.
Tuan Syed Mahathir bin Syed
Azman Shah
Asst Director
13
1. PEMANDU. 2011 ETP Report: Oil, Gas and Energy. 2011.
etp.pemandu.gov.my/.../upload/ENG_NKEA_Oil_Gas_Energy.pdf (20 June
2012: 17.30pm )
2. Department of Skills Development. 2011. Occupational Structure, Oil, Gas and
Petrochemical Industry. Department of Skills Development, Malaysia (23 June
2012: 20.30pm)
3. Malaysia. 2010. Tenth Malaysia Plan 2011 - 2015. Malaysia (18 June 2012:
1800)
4. Malaysian German Chamber of Commerce (MGCC). 2012. Market Watch 2012:
The Malaysian Petrochemical Industry. Malaysia
http://www.malaysia.ahk.de/fileadmin/ahk_malaysia/Market_reports/The_Malaysi
an_Petrochemical_Industry.pdf (22 June 2012: 18.30pm)
13.
ABBREVIATIONS
ANSI
American National Standards Institute
API
American Petroleum Institute
ASME
American Society of Mechanical Engineers
AWS
American Welding Society
CoCU
Curriculum of Competency Unit
CPC
Competency Profile Chart
DSD
Department of Skills Development
GA
General Arrangement (Drawing)
ISO
International Organisation for Standardisation
ITP
Inspection Test Plan
JSA
Job Safety Analysis
NDT
Non-destructive Testing
MT
Magnetic Particle Test
MTO
Material Take-Off
NKEA
National Key Economic Area
14
OAA
Occupational Area Analysis
OGSP
Oil & Gas Safety Passport
OSHA
Occupational Safety and Health Act
PEMANDU
Performance Management and Delivery Unit
P & ID
Piping & Instrumentation Diagram
PPE
Personal Protective Equipment
PTW
Permit To Work
PWHT
Post Weld Heat Treatment
WPS
Welding Procedure Specification
15
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
Lecturer
Advance Technology Training Centre
(ADTEC)
2.
Francis Kujat
Construction & Project Management
Supervisor
Brooke Dockyard and Engineering works
Corporation Sdn Bhd
3. Tuan Azam Bin Tun Mamat
Project Manager
Dimet Wasser (M) Sdn Bhd
4. Sham Kwai Yau
Consultant
Dimet Wasser (M) Sdn Bhd
5. Ten Wai Keong
Piping & Layout Engineer
Samsung Engineer Corporation Limited
6. Maziyatunnur Adam
Piping Engineer
KNM Process System Sdn Bhd
7. Sim Kwang Teck
Engineering Manager
PFCE Offshore World Sdn Bhd
8. Jaffari Lee Ariffin
Principal Engineer
Petroliam Nasional Berhad
FACILITATOR
1.
Nabilah Ooi Binti Abdullah
Training Consultant
Gemilang Offshore Engineering Company
(M) Sdn Bhd
CO-FACILITATORS
1.
Raihan Tahir
Training Consultant
Gemilang Offshore Engineering Company
(M) Sdn Bhd
2.
Eva Hoo Seet Yoong
Manager
Gemilang Offshore Engineering Company
(M) Sdn Bhd
16
STANDARD CONTENT
NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS) FOR:
PIPING FABRICATION MANAGEMENT
(PENGURUSAN FABRIKASI PERPAIPAN)
LEVEL 4
(TAHAP 4)
17
CORE
HEALTH,
SAFETY &
ENVIRONMENT
COMPLIANCE
SUPERVISION
PIPING
FABRICATION
PROJECT
MATERIALS
STORAGE &
CONTROL
PIPING
FABRICATION
OPERATION
SUPERVISION
PIPING
FABRICATION
QUALITY
CONTROL
PIPING
FABRICATION
DOCUMENT
CONTROL
ELECTIVE
SHOP
DRAWING
PREPARATION
COMPETENCY PROFILE CHART (CPC)
SECTOR
OIL, GAS & PETROCHEMICAL
SUB SECTOR
UPSTREAM (ENGINEERING)
JOB AREA
PIPING FABRICATION MANAGEMENT
JOB LEVEL
LEVEL FOUR (4)
JOB AREA CODE
COMPETENCY UNIT
COMPETENCY
18
Job Area
PIPING FABRICATION MANAGEMENT
Level
FOUR (4)
CU Title
CU Code
CU Descriptor
CU Work Activities
Performance Criteria
1.
Health, Safety &
Environment
Compliance
Supervision
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-to-day operations management.
The person competent in this
CU shall be able to supervise
safety of working
environment, supervise
safety check of tools and
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
19
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.
2.
Supervise safety check of
tools and equipment
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
using instruments) and test
run according to
manufacturer’s
specifications
2.2
Green tag are marked on
tools and equipment which
are tested and safe to be
used
2.3
Load certificates for lifting
equipment and gear are
20
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
21
3.
Supervise usage of PPE
3.1
Personal protective
equipment are selected,
checked and used in
accordance with HSE
requirements
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
non-compliance, if applicable
22
2.
Piping Fabrication
Project Materials
Storage & Control
Piping fabrication project
materials storage & control
refers to the activities of
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.
Identify project materials
storage & control
requirements
.
1.1
Types of piping
fabrication materials
required are identified as
per contract design
specifications
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
23
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.
,
2.
Monitor project materials
stock level
operation of project
materials storage and
control are clearly
defined
2.1
Piping material par stock
level is identified to
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
24
3.
Follow up to expedite
procurement activity
4.
Supervise project materials
storage area
3.1
Piping materials timely
delivery is monitored as
per expected delivery
date and required on site
(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
4.2
Specific storage areas are
allocated for different types
of piping materials
25
manufacturer’s
recommendations
4.3
Signage installation is
monitored to ensure
compliance with HSE
requirements
4.4
Storage area climatic
condition (including
temperature and relative
humidity) control is
monitored to prevent
material deterioration and
damage
4.5
Storage area cleanliness is
monitored in accordance
with housekeeping
practices
5.1
Received piping
materials are received
and checked in
26
5.
Receive Verify project
materials received from
store as per production
request
Mill Certificate and
product catalogue
5.2
Non-compliant items are
segregated,recorded in
material non-compliance
report and replacement is
requested, if applicable
5.3
Personal protective
equipment is used in
accordance with HSE
requirements
5.4
Receiving records and
documentations are
updated in a timely
manner
6.1
Piping materials handling
is monitored to ensure
compliance with
manufacturer’s
specifications and HSE
requirements
27
6.
Supervise project materials
handling & storage
6.2
Material handling tools
and equipment are used
in accordance with
manufacturer’s
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
colour-coded for easy
recognition
6.6
Storage records are
updated in a timely
manner
28
7.
Supervise project materials
issuance and distribution to
production related teams
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
equipment for distribution
is monitored in
accordance with
manufacturer’s
29
requirements
7.5
Personal protective
equipment is used in
accordance with HSE
requirements
7.6
Issuance and distribution
records are updated in a
timely manner
3.
Piping Fabrication
Operation Supervision
Supervision covers many
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
30
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.
2.
Organise piping fabrication
activities production process
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
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
31
3.
Supervise spool fabrication
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
3.2
Fit-up spools are
visually inspected prior
32
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
33
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
34
4.
Supervise piping installation
work (piping spool
installation, piping system
installation)
movement of pipes are
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
35
5.
Supervise piping fabrication
work progress
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
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
36
6.
Supervise production team
(pipe fitters, pipe welders)
5.5
Assistance is provided
when required to meet
operational targets
6.1
Roles and
responsibilities of
production team
members are clearly
communicated in
accordance with job
specifications
6.2
Required standard is
explained to team
members to ensure
understanding of allotted
task
6.3
Operational targets are
set and checked at
regular intervals
6.4
Feedback and
recommendations are
provided for
37
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
38
7.
Prepare production progress
reports
appropriate details
7.4
Reports are produced and
submitted in a timely
manner
4.
Piping Fabrication
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
39
produced in compliance with
the project scope of work as
well as to identify
non-compliance for rectification.
The person who is competent
in this CU shall be able to
review piping fabrication QC
requirements, conduct
in-process 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
2.
Conduct in-process QC
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
in-process quality
inspection is carried out
in accordance with
in-process QC procedures
40
gas industry.
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
41
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
42
2.12
Corrective actions are
taken to rectify
non-compliance
2.13
Inspection and tests are
conducted in accordance
with in-process QC
procedures and HSE
requirements
2.14
Inspection results are
documented in
accordance with QC
format
3.1
Hydrotest package is
perused to identify
hydrotest requirements
3.2
Pipe spools are identified
as per hydrotest package
3.3
Pipe spools and
hydrotest equipment are
set up as per hydrotest
package
43
3.
Coordinate hydrotest
4.
Liaise with QA/QC on
inspection work
3.4
Hydrotest is supervised
to ensure compliance
with HSE requirements
4.1
QA/QC Inspection
schedule is identified
from Inspection Test
Plan
4.2
Preparation for QA/QC
audit is arranged in
accordance with QA/QC
procedures
4.3
QA/QC inspection
sessions are
coordinated in
accordance with QA/QC
procedures
4.4
Assistance and support
is provided to QA/QC
personnel to facilitate
efficient audit
44
5.
Liaise with client on
inspection work as per ITP
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
5.4
Assistance and
clarification is provided
to client during
inspection session if
necessary
5.5
Inspection procedures
adhere to HSE
requirements
non-45
6.
Provide information for the
preparation of QA/QC report
compliance are recorded
according to QA/QC
format (NDT report,
hydrotest report)
6.2
Information on
compliance and
non-compliance is made
accessible to QA
personnel for the
preparation of QA/QC
reports
6.3
Recommendations for
process improvement are
provided where
applicable
5.
Piping Fabrication
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
(P &ID, isometric, piping
plan drawing, pipe support
arrangement)
1.1
Fabrication drawings are
received, acknowledged
and compiled in
accordance with
documentation procedure
1.2
Drawings are distributed
to production floor
46
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.
2.
Control related fabrication
documents (WPS, ITP
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
2.2
Non-destructive test
procedure is distributed to
production foreman
47
3.
Compile lessons learnt for
production team
(post-mortem)
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
guidelines
3.2
Lessons learnt records
and reports are gathered
from production team
48
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
requirements
1.1
Shop drawing format and
presentations are identified
as per shop detail drawings
presentation guidelines or
fabricator’s shop drawings
procedures and guidelines.
1.2
Specification and
requirements for fabrication,
material, shop procedures,
inspection, cleaning and
painting are identified as
per structure standard
details requirements.
49
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
2.
Identify shop drawings
information
2.1
Structure components such
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 manufacturer’s
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
50
shop drawings.
3.
Prepare shop drawings
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
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
51
4.
Confirm shop drawings
prepared
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.
4.2
Materials specified are
checked so that they
conform to the contract
documents.
4.3
Weld symbols on shop
detail drawings are ensured
52
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
53
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.
54
CURRICULUM of COMPETENCY UNIT (CoCU)
FOR:
NATIONAL OCCUPATIONAL SKILLS STANDARD (NOSS)
FOR:
PIPING FABRICATION MANAGEMENT
(PENGURUSAN FABRIKASI PAIP)
LEVEL 4
(TAHAP 4)
55
CURRICULUM of COMPETENCY UNIT (CoCU)
Sub Sector UPSTREAM (ENGINEERING)
Job Area PIPING FABRICATION MANAGEMENT
Competency Unit Title Health, Safety and Environment Compliance Supervision
Learning Outcomes
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:-
• Supervise safety of work environment
• Supervise safety check of tools and equipment
• Supervise usage of personal protective equipment (PPE)
Competency Unit ID Level 4 Training Duration 150 Credit Hours 15
Work Activities Related Knowledge Applied Skills Attitude / Safety /
Environmental Training Hours Delivery Mode Assessment Criteria 1. Supervise safety of work environment
i Types of hazards in oil and gas fabrication activities • Physical (working at
height, dropping objects)
• Chemical (to add in examples) • Biological • Health • Fire 30 Lecture Group discussion Shop talk i Potential hazards (physical, chemical, biological, ergonomical) are identified and mitigation actions are taken as per
56
Work Activities Related Knowledge Applied Skills Attitude / Safety /
Environmental Training Hours Delivery Mode Assessment Criteria • Ergonomical
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 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 lighting are ensured in confined space v Cleanliness of working environment is monitored as i. Determine types of hazards
ii. Determine mitigation actions for different types of hazards iii. Check safety
equipment
i. Comply with HSE
requirements ii. Ensure safe
and clean working environment
30 Demonstration Project
57
Work Activities Related Knowledge Applied Skills Attitude / Safety /
Environmental Training Hours Delivery Mode Assessment Criteria iv. Display safety signage
and JSA at designated areas
v. Determine ventilation and lighting
requirements for confined space
iii. Practise IIF culture (incident & injury free culture) per housekeeping practices 2. Supervise safety check of tools and equipment i Importance of safety check for tools and equipment
ii Safety check procedures iii Test-run procedures iv Equipment safe-for-use
tagging procedures v 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 30 i Tools and equipment are inspected (visually and using instruments) and test run according to manufacturer’s specifications ii Green tag are
marked on tools and equipment which are tested and safe to be used iii Load
58
Work Activities Related Knowledge Applied Skills Attitude / Safety /
Environmental Training Hours Delivery Mode Assessment Criteria lifting equipment and gear are checked to ensure working 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 i Check safety of tools
and equipment ii Test run equipment iii Mark tools and
equipment with safety-for-use tags
iv Interpret load certificates
v Arrange MT inspection for shackles
vi Check colour coding on tools and
equipment
vii Apply random daily test procedures viii Take actions for
non-compliant tools and equipment i Comply with HSE requirements ii Ensure tools and equipment are safe and in good working condition iii Practise IIF
culture (incident & injury free culture)
