Industrial Piping Course

Lesson 1 • Industry Standards and Codes Overview

Surveys the regulatory framework governing design, fabrication, and inspection of piping. Establishes compliance awareness as a professional baseline.

Lesson 2 • Fluid Mechanics Fundamentals

Introduces pressure, flow rate, velocity, and viscosity as they apply to pipe flow. These principles underpin sizing, selection, and troubleshooting throughout the course.

Lesson 3 • Piping System Components Overview

Identifies pipes, fittings, valves, flanges, and supports as the building blocks of any system. Connects component knowledge to system assembly logic.

Lesson 1 • Material Selection Decision Process

Applies a structured methodology to match materials to fluid service, temperature, and pressure conditions. Integrates corrosion, cost, and availability into a defensible selection.

Lesson 2 • Metallic Pipe Materials

Examines carbon steel, stainless steel, alloy steel, and cast iron for industrial service. Material properties are linked to selection decisions made in later design chapters.

Lesson 3 • Non-Metallic and Lined Pipe Materials

Covers thermoplastics, fiberglass-reinforced plastic, and lined pipe for corrosive or low-pressure service. Expands material selection beyond metals for specialised applications.

Lesson 1 • Industrial Valve Types and Functions

Distinguishes gate, globe, ball, butterfly, check, and control valves by function and application. Valve selection directly affects flow control, isolation, and system safety.

Lesson 2 • Pipe Fittings Classification and Use

Covers elbows, tees, reducers, couplings, and caps with their pressure ratings and end connections. Correct fitting selection prevents leaks and structural failures.

Lesson 3 • Flanges, Gaskets, and Bolting

Teaches flange face types, pressure classes, gasket materials, and bolt torque requirements. Proper assembly prevents fugitive emissions and joint failures.

Lesson 1 • Piping Layout and Routing Principles

Establishes rules for economical, maintainable, and safe pipe routing in plant environments. Good layout minimises stress, support costs, and operational interference.

Lesson 2 • Pipe Support Design and Spacing

Determines support span, type, and load for sustained and occasional loading conditions. Proper support prevents excessive deflection, vibration, and stress concentration.

Lesson 3 • Pipe Sizing and Pressure Drop Calculation

Uses flow rate, fluid properties, and allowable velocity to determine pipe diameter and pressure loss. Accurate sizing prevents under- or over-designed systems.

Lesson 4 • Thermal Expansion and Flexibility Analysis

Quantifies thermal growth and designs expansion loops, offsets, and anchors to absorb movement. Prevents fatigue failures caused by cyclic thermal loading.

Lesson 1 • Reading and Interpreting P&IDs

Develops systematic methods for tracing process flow, identifying control loops, and extracting line data. Accurate interpretation prevents construction and commissioning errors.

Lesson 2 • P&ID Symbols and Notation

Introduces standardised symbols for equipment, piping, valves, and instruments used on P&IDs. Symbol literacy is the prerequisite for all diagram interpretation tasks.

Lesson 3 • P&ID Development and Review

Covers the lifecycle of a P&ID from conceptual to as-built, including HAZOP and interdisciplinary review. Students participate effectively in design review sessions.

Lesson 1 • Welding Processes for Piping

Compares SMAW, GTAW, GMAW, and FCAW processes for their suitability in piping applications. Process selection affects weld quality, productivity, and position capability.

Lesson 2 • Spool Fabrication and Dimensional Control

Covers isometric drawing interpretation, spool assembly sequence, and dimensional tolerance verification. Accurate spools reduce field fit-up problems and rework costs.

Lesson 3 • Pipe Cutting and Preparation Methods

Teaches flame cutting, plasma cutting, sawing, and beveling for weld joint preparation. Proper preparation is the first step toward a sound, code-compliant weld.

Lesson 4 • Post-Weld Heat Treatment

Addresses when and how post-weld heat treatment is required to relieve residual stress and restore toughness. Correct PWHT prevents stress corrosion cracking and brittle fracture.

Lesson 1 • Pressure Testing Procedures

Teaches hydrostatic and pneumatic pressure testing requirements, test pressures, and hold times. Pressure testing is the final verification of system integrity before service.

Lesson 2 • Quality Control Documentation and Records

Establishes the documentation system for material certifications, NDE reports, and test records. Complete records demonstrate code compliance and support future maintenance.

Lesson 3 • Non-Destructive Examination Methods

Covers visual, radiographic, ultrasonic, magnetic particle, and liquid penetrant examination for welds. NDE method selection depends on weld geometry, material, and code requirements.

Lesson 1 • Field Installation Practices

Covers rigging, alignment, field welding, and bolted joint assembly for safe and accurate pipe erection. Correct installation prevents misalignment stress and premature failures.

Lesson 2 • Piping Inspection and Maintenance Programmes

Establishes risk-based inspection intervals, corrosion monitoring, and preventive maintenance tasks. Proactive programmes extend service life and reduce unplanned shutdowns.

Lesson 3 • Piping Repair and Modification Procedures

Covers hot-tap, freeze plug, clamp repair, and formal modification procedures for in-service piping. Safe repair methods maintain system integrity without full shutdown.

Lesson 4 • Commissioning and Start-Up Procedures

Guides the systematic introduction of process fluid, valve sequencing, and initial operating parameter verification. Structured commissioning prevents equipment damage and process upsets.