Pipefitting Training Course

Lesson 1 • Reading Pipe System Drawings

Teaches isometric and plan-view piping diagrams, symbols, and notation standards. Enables accurate interpretation of system layouts before fieldwork begins.

Lesson 2 • Pipe Materials and Properties

Covers metal, plastic, and composite pipe materials and their mechanical properties. Establishes material selection criteria used throughout all maintenance tasks.

Lesson 3 • Pipe Fittings and Connections

Identifies elbows, tees, reducers, couplings, and flanges and their installation roles. Prepares students to recognise connection types during inspections.

Lesson 4 • Pipe System Classifications

Distinguishes pressure, gravity, and process piping systems by function and design. Provides context for selecting appropriate maintenance strategies.

Lesson 1 • Personal Protective Equipment

Covers PPE selection, fit, inspection, and disposal for pipe maintenance tasks. Ensures students choose correct protection for each specific hazard type.

Lesson 2 • Regulatory Standards and Documentation

Reviews occupational safety regulations, environmental discharge rules, and maintenance recordkeeping. Connects compliance obligations to daily maintenance documentation practices.

Lesson 3 • Hazard Identification in Pipe Work

Identifies physical, chemical, and biological hazards specific to pipe maintenance. Builds the risk-awareness foundation required before any hands-on procedure.

Lesson 4 • Lockout and Tagout Procedures

Details energy isolation steps for hydraulic, pneumatic, and electrical systems. Prevents accidental energisation during pipe repair and replacement work.

Lesson 1 • Pressure and Flow Testing

Explains hydrostatic pressure testing, flow measurement, and leak detection methods. Validates system integrity after repairs and during routine condition checks.

Lesson 2 • Non-Destructive Testing Fundamentals

Introduces ultrasonic, magnetic particle, and dye penetrant testing for pipe wall evaluation. Enables defect detection without removing pipe from service.

Lesson 3 • Condition Grading and Reporting

Applies standardised grading scales to inspection findings and produces actionable maintenance reports. Bridges field data collection to maintenance scheduling decisions.

Lesson 4 • Visual Inspection Methods

Covers external and internal visual inspection procedures, defect recognition, and documentation. Forms the baseline assessment skill applied before advanced diagnostics.

Lesson 1 • Surface Preparation for Repair

Details abrasive blasting, grinding, and solvent wiping to achieve required surface cleanliness. Directly prepares pipe surfaces for lining, coating, and joint repair.

Lesson 2 • Mechanical Cleaning Methods

Covers rodding, pigging, and rotary cutting tools for removing blockages and deposits. Establishes hands-on cleaning skills used before inspection and repair operations.

Lesson 3 • High-Pressure Water Jetting

Teaches jetting equipment setup, nozzle selection, and safe operating procedures for pipe cleaning. Connects jetting parameters to effective removal of grease, scale, and sediment.

Lesson 4 • Cleaning Verification and Documentation

Uses post-cleaning inspection and flow testing to confirm cleaning effectiveness. Ensures cleaning outcomes meet specifications before repair or lining work begins.

Lesson 1 • Pipe Section Replacement

Details cut-out, spool fabrication, and reinstallation procedures for damaged pipe sections. Builds competency in full-section replacement across multiple pipe materials.

Lesson 2 • Welding and Brazing Repairs

Teaches weld repair procedures for steel and copper pipe, including joint preparation and inspection. Connects welding quality to long-term repair durability and pressure rating.

Lesson 3 • Repair Quality Control

Applies visual, pressure, and NDT checks to verify repair integrity before returning pipe to service. Ensures all repairs meet design pressure and service life requirements.

Lesson 4 • Point Repair Methods

Covers clamp, patch, and epoxy injection repairs for localised defects. Provides fast, cost-effective solutions for isolated cracks, holes, and joint failures.

Lesson 1 • Internal Lining Systems

Covers cement mortar, epoxy, and polyurethane internal linings for corrosion and flow protection. Connects lining selection to fluid chemistry and operating temperature.

Lesson 2 • Coating Inspection and Maintenance

Uses holiday detection, adhesion testing, and visual survey to assess coating condition. Identifies coating failures early to prevent accelerated corrosion damage.

Lesson 3 • External Coating Systems

Details fusion-bonded epoxy, coal tar, and polyethylene wrap coatings for buried and exposed pipe. Addresses surface preparation requirements for each coating type.

Lesson 4 • Cathodic Protection Systems

Explains sacrificial anode and impressed current cathodic protection for buried metallic pipe. Integrates corrosion protection with coating systems for maximum service life.

Lesson 1 • Maintenance Performance Metrics

Tracks mean time between failures, maintenance cost per unit, and system availability as KPIs. Enables continuous improvement of the maintenance programme through data-driven review.

Lesson 2 • Failure Mode and Effects Analysis

Applies FMEA methodology to identify pipe failure modes, causes, and maintenance countermeasures. Prioritises maintenance tasks based on failure severity and detection difficulty.

Lesson 3 • Condition Monitoring Technologies

Introduces vibration analysis, acoustic emission, and inline sensor monitoring for pipe health. Enables early detection of developing faults before failure occurs.

Lesson 4 • Maintenance Strategy Fundamentals

Compares reactive, preventive, and predictive maintenance approaches and their cost-benefit profiles. Provides the decision framework for building a balanced maintenance programme.

Lesson 1 • Advanced Leak Detection Techniques

Covers correlator-based acoustic detection, tracer gas, and ground-penetrating radar for buried pipe leaks. Reduces non-revenue water loss and prevents infrastructure damage.

Lesson 2 • Root Cause Analysis Methods

Uses fishbone diagrams, fault tree analysis, and the five-whys method to identify pipe failure root causes. Prevents recurrence by addressing systemic causes rather than symptoms.

Lesson 3 • Asset Life Cycle Management

Applies remaining useful life estimation, replacement cost analysis, and capital planning to pipe assets. Aligns maintenance investment with long-term infrastructure sustainability goals.

Lesson 4 • Hydraulic System Modelling

Introduces pipe network modelling software to simulate flow, pressure, and velocity under varying conditions. Identifies hydraulic bottlenecks and supports system upgrade planning.