Month 1: Fundamentals of Steel & Pipe Manufacturing
- Week 1: Introduction to Steel
- Types of steel (carbon steel, alloy steel, stainless steel, etc.)
- Steelmaking processes (BOF, EAF, secondary refining)
- Mechanical properties (strength, toughness, ductility)
- Week 2: Pipe Manufacturing Methods
- Seamless vs. welded pipes
- Pipe forming processes (ERW, LSAW, SSAW, seamless extrusion)
- Heat treatment basics (normalizing, quenching, tempering)
- Week 3: Pipe Classifications & Applications
- API, ASTM, ASME, and other classification standards
- Uses in oil & gas, construction, and other industries
- Differences between casing, tubing, line pipe, and structural pipe
- Week 4: Pipe Coatings & Protection
- Anti-corrosion methods (galvanizing, 3LPE, FBE coatings)
- Internal coatings for flow efficiency
- Cathodic protection and field joint coatings
Month 2: Pipe Specifications & Standards
- Week 5: API SPEC 5CT (OCTG) & API SPEC 5L (Line Pipe)
- Pipe grades, chemical composition, and mechanical properties
- Differences between J55, K55, N80, L80, P110, etc.
- H40 vs. X42, X52, X60, X70, and beyond
- Week 6: ASTM & ASME Standards
- ASTM A53, A106, A333, A335
- ASME B31.3 (Process Piping), B31.8 (Gas Transmission)
- Week 7: Pipe Dimensions & Tolerances
- Outer diameter (OD), wall thickness (WT), and schedules
- Pipe end types (beveled, plain, threaded)
- Week 8: Pipe Mechanical & Chemical Testing
- Tensile, impact, hardness, and flattening tests
- Chemical analysis (spectroscopy, PMI testing)
Month 3: Heat Treatment & Metallurgy
- Week 9: Steel Microstructure & Phases
- Ferrite, pearlite, bainite, martensite
- Grain size and its impact on mechanical properties
- Week 10: Heat Treatment Processes
- Normalizing, annealing, quenching & tempering (Q&T)
- Effect of heat treatment on pipe properties
- Week 11: Pipe Defects & Failure Analysis
- Common defects (laminations, cracks, inclusions)
- Root cause analysis of failures (corrosion, fatigue, hydrogen embrittlement)
- Week 12: Welding & Pipe Joining
- Types of welding (SMAW, GMAW, GTAW, SAW)
- Weld quality control and NDT methods
Month 4: Pipe Inspection & Testing
- Week 13: Non-Destructive Testing (NDT) Methods
- Ultrasonic Testing (UT), Radiographic Testing (RT)
- Magnetic Particle Testing (MT), Liquid Penetrant Testing (PT)
- Week 14: Hydrostatic Testing & Pressure Testing
- Test pressure calculations
- Failure criteria and acceptance limits
- Week 15: Quality Control & Certification
- Mill Test Reports (MTRs)
- Third-party inspection and traceability
- Week 16: Pipe Handling, Storage & Logistics
- Safe handling practices
- Storage conditions to prevent corrosion
Month 5: Advanced Applications & Industry Insights
- Week 17: Pipe Selection for Different Environments
- High-temperature, high-pressure, sour service applications
- Week 18: Pipeline Engineering Basics
- Pipe laying methods (onshore, offshore)
- Bending, welding, and testing in pipeline construction
- Week 19: Pipe Coatings & Insulation for Extreme Conditions
- Deep-sea pipelines, cryogenic applications
- Week 20: Real-World Case Studies & Problem-Solving
- Reviewing failures and industry best practices
Month 6: Mastery & Certification Preparation
- Week 21: ASNT & API Certifications Overview
- API 570 (Piping Inspector), API 653 (Tank Inspector)
- ASNT Level 1 & 2 in NDT
- Week 22: Mock Exams & Practical Applications
- Hands-on case studies
- Solving real industry challenges
- Week 23: Industry Trends & Future Technologies
- Smart pipes, IoT monitoring, AI-based inspections
- Week 24: Final Review & Mastery Validation
- Conduct self-assessment
- Prepare for professional certification exams