#quality inspector

Insulation can be used for several purposes in residential, commercial, or industrial locations. To better understand the purpose of insulation, you first need to understand how industry standards define insulation.

The next paragraph in the article defines the insulation in accordance with the definition provided by British Standard, also known as BS, and the International Organization for Standardization, also known as ISO.

How the Industry Standards Define the Insulation

BS and ISO are the two most popular standard publishing bodies in the world, and when you carefully read and understand their defined definitions of insulation, you will come to know that the main purpose of insulation is to restrict the transfer of heat or sound.

A material or system that has the property of resisting the transfer of heat or sound (BS 3533).

Process of reducing heat transfer through a system, or description of a product, component, or system that performs this function (ISO 9229).

What are the fundamental requirements of the insulation

The two fundamental requirements of thermal insulation material are:

Trapping air or inert gas

Being non-conductive

Thermal insulation is a poor conductor of heat and has low thermal conductivity. Insulation includes anything that conducts heat slowly. Insulation not only slows down the rate of heat flow, but also slows down the sound, and prevents electricity from passing through it.

Thermal insulation materials keep hot things hot, and cold things cool. Sectors, such as industrial, commercial, residential, and more, use insulation for the several purposes described below.

How to Empower knowledge about insulation and its Purpose or Use

There are various books, practices, and standards available to empower thermal insulation knowledge. One of the books that you can read out to gain more understanding and knowledge about thermal insulation is Insulation Inspector Book - IOGS/CII.

The IOGS/CII book covers all the necessary information you need to know about the thermal insulation, these include:

Purpose of insulation

Heat transfer

Insulation materials

Properties and Characteristics

Good storage practice

Installation requirements

Inspection and quality control

Applicable standards and manuals, etc.

Apart from gaining knowledge from the books and other resources available, you can also study the thermal insulation online by taking one of the following courses offered by The Institute for Oil & Gas Sector (IOGS).

Insulation Inspector Level 2

Insulation Inspector Level 3

Diploma in Thermal Insulation

Corrosion Under Insulation (CUI)

Conclusion

Insulation, more specifically thermal insulation, is known to save energy, we lose thermal energy when we don't use the insulation or when the insulation is improperly used or installed. There are various insulation materials that are used to store thermal energy and/or meet specific thermal needs.

Being an insulation professional, you must first understand insulation and its purpose so that you can select the appropriate insulation material and/or design an insulation system to address a specific heat loss/gain challenge.

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Pipe and Equipment Insulation

Heat is a form of thermal energy that can move or transfer within an object, from one or more objects, or from an object to its surroundings, we can reduce the heat transfer or restrict the heat movement by the use of thermal insulation.

In this article, you will learn how heat transfer takes place in a refinery or industrial process plant, by what means heat can transfer, and what is required for the heat to transfer?

Mediums of Heat Transfer

Heat can travel from one place to another in three ways:

Convection

Conduction

Radiation

Convection occurs in liquids or gasses, whereas conduction occurs in solids, and radiation occurs through electromagnetic waves.

Understanding the Heat

To better understand heat as a concept, it is crucial to understand what heat is in its essential form. Heat is a form of thermal energy, and the temperature is the medium to measure the hotness or coldness of a surface or body.

You can measure heat in degrees Celsius (˚C), degrees Fahrenheit (˚F), or Kelvin (K). There are devices available to measure the temperature of a surface, some of the frequently used devices are as follows:

Whirling hygrometer

Contact thermometer

Dew point meter

Any surface with a temperature higher than its surrounding environment is hot, whereas any surface with a temperature lower than its surrounding environment is cold.

How heat travel

Since heat is a form of thermal energy, it can travel within an object, between one or more objects, or from an object to its surroundings. But heat can only begin to travel when temperature differences between the surfaces or its surrounding exist. In fact, when temperature differences are greater, the rate of heat transfer is faster.

Heat always transfers from the part that is hot to the part that is cold. Whenever two different temperatures exist, the heat transfers until it reaches thermal equilibrium.

Heat transfer example 1

An example of heat transfer can better illustrate the concepts discussed above. First, consider a cup of hot coffee is kept on a table in a room. The temperature of the hot coffee is 100˚C, and the normal room temperature is 21˚C. We can assume that it would only take a few seconds or minutes for the coffee’s temperature to turn colder.

This is a result of the temperature differences that exist between the coffee and the room, as the heat from the coffee in the cup transfers to the temperature of the surrounding room.

The heat transfer from the cup will only stop when the coffee’s temperature matches the room temperature, which is known as thermal equilibrium.

How heat transfer from piping and equipment in the refinery or process plant

Next, let's illustrate an example of how heat transfer takes place from piping or from the equipment of a refinery or industrial process plant.

It is customary to install a pipe or equipment in an oil refinery or industrial process plant outdoor. Let’s assume that the normal outdoor temperature ranges from 30˚C and 40˚C, and during the plant operation, the operating temperature of the piping or equipment will be approximately 570˚C.

What will happen without the use of Insulation

Thus, when the plant is in operation, the surface temperature of the pipe or equipment will be hotter than its surrounding temperature, and as previously mentioned, heat requires two different temperatures to move. Thus, the heat of the hot surface—in this case, the piping or equipment—will transfer to its surrounding environment as soon as the plant starts its operation.

A similar situation will occur when the piping or equipment has a lower surface temperature than the surrounding environment (ex. -10˚C). In this situation, the cold surface of the pipe or equipment will gain heat from the surrounding environment.

What is required to control the movement of heat

Moreover, when it is necessary to maintain or control the temperatures within a mechanical component, piping and equipment that carry fluid with temperatures that differ from their surrounding environment are insulated. All such surfaces are insulated using appropriate material and thickness to reduce the heat movement to a minimum.

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أعلنت شركة الخريف الصناعية (Alkhorayef Industries Company) عن توفر وظيفة شاغرة بمسمى مراقب جودة (Quality Inspector) للعمل في مدينة جدة، وذلك ضمن وظائف القطاع الصناعي في السعودية، مع بيئة عمل احترافية وفرص تطوير مهني مميزة. وتُعد هذه الفرصة من أفضل وظائف الجودة في السعودية 2026، خاصة للباحثين عن عمل في مجالات التفتيش الصناعي وضبط الجودة. المسمى الوظيفي مراقب جودة (Quality Inspector) مكان…

In the intricate dance of modern manufacturing, quality control isn't a single checkpoint at the finish line; it's a continuous rhythm that pulses throughout the entire production process. While Pre-Production Inspection (PPI) lays the groundwork, and Pre-Shipment Inspection (PSI) provides the final seal of approval, a crucial, often underestimated, phase of quality assurance occurs during production. This is where During Production Inspection (DPI) or In-Process Inspection takes center stage, acting as a dynamic quality gatekeeper that ensures consistency and adherence to standards as your product takes shape.

QC-Easy LTD. understands that achieving impeccable product quality requires a multi-faceted approach. In this comprehensive blog post, we'll delve into the profound impact of During Production Inspection, outlining eight compelling benefits that make it an indispensable part of your quality control strategy.

What is During Production Inspection?

During Production Inspection, also known as In-Process Inspection or DUPRO, is a quality control procedure performed when a portion of your order, typically between 10% to 20%, has been completed. It involves an on-site evaluation of the production line, partially completed goods, and sometimes, even the packed finished products. Unlike a PPI, which focuses on readiness, or a PSI, which is a final verification, DPI is about monitoring the ongoing manufacturing process to catch deviations early.

Think of it as a quality auditor observing the chef in the kitchen while the meal is being prepared, rather than just inspecting the raw ingredients or tasting the final dish. This real-time oversight allows for immediate adjustments and prevents minor issues from snowballing into significant problems.

Benefits of During Production Inspection

Integrating DPI into your quality control framework offers a wealth of advantages, transforming your production process into a more efficient, reliable, and quality-driven operation.

1. Early Detection of Defects and Non-Conformities

This is arguably the most significant benefit of DPI. By inspecting products as they are being manufactured, you can identify defects, deviations from specifications, or quality issues before a large batch of products is affected. Imagine if a machine is miscalibrated or a worker is making a repetitive error – without DPI, hundreds or thousands of units could be produced incorrectly before the problem is spotted at the final inspection stage. Early detection means smaller batches of rejected goods, significantly reducing waste and rework.

2. Prevention of Mass Production of Defective Goods

Building on the first point, early detection is directly linked to prevention. If a critical defect is found during DPI, the production line can be stopped or adjusted immediately. This prevents the costly scenario of mass-producing thousands of defective items that would then need to be scrapped, reworked, or even recalled. The financial and reputational implications of such an event can be devastating. DPI acts as a crucial safety net, mitigating this risk.

3. Verification of Production Progress and Schedule Adherence

DPI isn't just about quality; it's also about production efficiency. During the inspection, the inspector can assess the actual production output against the planned schedule. This provides valuable insights into whether the manufacturer is on track to meet delivery deadlines. If delays are identified, proactive measures can be taken, such as increasing shifts, addressing bottlenecks, or re-evaluating the timeline, thus preventing last-minute surprises and potential penalties for late delivery.

4. Continuous Monitoring of Quality Standards and Processes

Unlike a one-off inspection, DPI offers a snapshot of the ongoing quality control measures at the factory. The inspector can verify if the manufacturer is consistently adhering to the agreed-upon quality standards, work instructions, and internal QC procedures. This includes checking things like:

✅ Worker adherence to processes: Are employees following the correct assembly steps, using the right tools, and handling materials properly?

✅ Calibration of machinery: Is equipment still properly calibrated and maintained?

✅ Environmental conditions: Are temperature, humidity, and cleanliness levels maintained as required for the product? This continuous monitoring reinforces a culture of quality within the factory.

5. Timely Implementation of Corrective Actions

When issues are identified during DPI, there's a unique window of opportunity for immediate corrective action. Instead of waiting for a final report that might come days or weeks after the defects have piled up, the manufacturer can make adjustments on the spot. This could involve retraining staff, repairing or recalibrating machinery, or sourcing alternative materials. The agility afforded by DPI significantly reduces the time and resources needed for problem resolution.

6. Minimization of Rework, Waste, and Associated Costs

Rework is expensive. It consumes valuable labor hours, ties up machinery, and can lead to material waste. By catching errors mid-production, DPI drastically reduces the amount of rework required. Less rework means lower production costs, faster lead times, and a higher overall profit margin. It also contributes to a more sustainable manufacturing process by minimizing waste.

7. Enhanced Transparency and Communication with Manufacturers

The presence of an independent inspector during production fosters greater transparency. It encourages manufacturers to maintain high standards throughout the entire process, knowing that their operations are being actively monitored. Furthermore, the DPI report provides objective data that facilitates clear and constructive communication between the buyer and the manufacturer regarding quality expectations and performance. This collaborative approach can strengthen the relationship and lead to long-term improvements.

8. Increased Confidence in Product Quality Before Shipment

For the buyer, DPI provides a significant boost in confidence. Knowing that the production process has been actively monitored and that quality issues have been addressed proactively throughout the manufacturing cycle instills a higher level of assurance that the final product will meet specifications. This peace of mind translates into fewer surprises during Pre-Shipment Inspection and ultimately, greater satisfaction for the end customer.

The DPI Process: What to Expect

While every DPI is tailored to the specific product and requirements, a typical During Production Inspection by QC-Easy LTD. would involve:

✅ Review of Production Plans: Confirming the production schedule, material sourcing, and internal quality checks.

✅ Inspection of Partially Completed Goods: Checking the quality, dimensions, materials, and workmanship of products as they are being assembled or processed.

✅ Assessment of Production Line: Observing the manufacturing process, verifying work instructions are followed, and assessing equipment functionality.

✅ Random Check of Raw Materials/Components (if applicable): Ensuring materials being fed into the line meet specifications.

✅ Verification of Packing and Labeling (if applicable): For items already packed, checking packaging materials, labeling, and shipping marks.

✅ On-Site Testing: Performing basic on-site tests (e.g., visual checks, basic functionality tests, carton drop tests).

✅ Identification of Deviations: Documenting any non-conformities, defects, or issues observed.

✅ Immediate Feedback to Manufacturer: Providing real-time observations and recommendations for corrective actions.

✅ Detailed Report: Issuing a comprehensive report with findings, photos, and a summary of the inspection.

When to Schedule Your During Production Inspection?

The ideal time for a DPI is typically when 10% to 20% of the order has been produced. This allows enough time for a substantial portion of the order to be completed, revealing any recurring issues, but also leaves sufficient time for the manufacturer to implement corrective actions without significant delays to the overall production schedule. The exact percentage depends on the complexity of the product and the production lead time.

Conclusion

By implementing During Production Inspection, you're not just performing a check; you're actively safeguarding your investment, protecting your brand, and ensuring that your products reach your customers with the quality they expect and deserve.

At QC-Easy LTD., we understand that robust quality control is the backbone of successful international trade. Our highly trained inspectors, coupled with our rigorous methodologies and commitment to transparent reporting, make us the ideal partner for your During Production Inspection needs.

We empower businesses to:

✅ Minimize risks: Catching problems early reduces financial exposure and brand damage.

✅ Improve efficiency: Preventing rework and delays streamlines your supply chain.

✅ Ensure consistent quality: Delivering products that consistently meet customer expectations.

Corrosion Definition

Corrosion describes the deterioration of metal due to chemical reactions between the metal and the environment. The reaction between the metal and its environment starts as soon as the water and the oxygen in the environment come into contact with the metal. The water acts as the electrolyte for the corrosion to start on the metal surface. The extent and type of deterioration due to corrosion depend on the metal type and the environmental conditions where the metal is exposed to.

The Nature of the Metals

Metals in their natural forms are found as ore, ore is extracted from the ground through mining and is processed to make it useful for various purposes. Metals, that are extracted from the ground are divided into two categories, i.e. less noble (i.e. ignoble) and more noble. Ignoble means a material can react with its surrounding environment when exposed to it.

Almost all metals are prone to corrosion attack, due to their tendency to react with the surrounding atmosphere, but the rate of corrosion differs based on the metal’s nobility. For instance, mild steel or carbon steel is less noble than stainless steel, thus the corrosion rate on mild steel is faster than stainless steel. Why stainless steel corrodes slowly is that it is a combination of metal and other alloys, this combination makes the stainless steel nobler than mild steel, and this is why it is often preferred to other available metals like mild steel.

Some other small groups of noble metals like silver, gold, platinum, etc. are less reactive to the surrounding atmosphere and are the only metal we use in their pure form, these metals rarely corrode; hence they are usually more valuable when compared with the other alternate metals and are very costly.

There are various causes of metal corrosion. Some of these causes can be prevented by combining pure metal with alloys. In other cases, a strategic combination of metals or the effective management of the metal’s environment can also prevent corrosion.

Here are the 2 common forms of corrosion

General Corrosion

This is a common type of corrosion that attacks the entire surface of a metal structure. This type of corrosion occurs on the metal due to electrochemical or chemical reactions. When this happens, the metal thickness eventually reduces to a point where the metals break down or fail to perform an intended work for which it was designed for. This form of corrosion is predictable, so it is easy to plan and manage the attack.

Localized Corrosion

As the name suggests, this type of corrosion attacks specific parts of a metal structure. It comes in three different forms and may cause catastrophic failure of a structure or equipment.

Pitting, which occurs on the localized area and creates small holes in the metal surface.

Crevice corrosion, which occurs on a metal surface at, or immediately adjacent to, the gap or crevice between two joining surfaces, including the hidden areas under gaskets.

Filiform corrosion, also known as under film corrosion, is a special form of corrosion that occurs under some thin coatings when water penetrates a coating.

Galvanic Corrosion

Commonly termed as bimetallic or dissimilar corrosion, takes place when there are two different metals connected in an electrolyte. When this happens, one of the metal which is less noble than other become the anode and start corroding, however, the other metal which becomes nobler being unaffected from corrosion.

Corrosion is responsible for about $2.5 trillion in revenue loss every year. Adopting well-researched and properly executed prevention techniques can help prevent up to 25% of this loss. Preventing corrosion will also help to preserve people’s health and safety. Corroded ships, buildings, bridges, and other metal structures all come with injury and death risks.

What is Corrosion? Corrosion of Iron — Corrosion of Metal — How Corrosion Occurs in Metals 2021

You may learn more on what is corrosion and the various methods used to control the corrosion; checkout the following courses;

Corrosion Control by Coating

Corrosion Prevention Under Thermal Insulation

The oil and gas refineries are highly sophisticated industrial facilities transforming crude oil into valuable products used in an array of applications. Mechanical systems, such as; piping, chimney stacks, steel columns, and vessels are an important part of any refinery.

The oil and gas refineries are highly sophisticated industrial facilities transforming crude oil into valuable products used in an array of applications. Mechanical systems, such as; piping, chimney stacks, steel columns, and vessels are an important part of any refinery.

These mechanical systems carry a stream of liquids or gases between the large chemical processing units for the crude oil separation process. Thermal insulation is needed throughout the entire facility in order to aid with the processing of the crude oil as each step in the separation process requires careful monitoring and temperature resistance or control.

A medium-sized oil refinery contains 465 miles of insulated piping and 1.8 million square feet of insulated equipment.

You can expand your knowledge on Thermal Insulation by joining online and/or classroom-based courses. Click Here for the List of Available Courses

If you are looking forward to starting your career in the oil refinery and industrial process plant, then choosing your career in thermal insulation field could be the best fit for you. The following two options that are available for you to work in the thermal insulation field are:

Quality Control

Construction

Before you apply for any available job in the thermal insulation work field, you should first need to acquire knowledge in the thermal insulation by taking up the thermal insulation courses. If you select the quality control work field of thermal insulation you would have to take up quality control inspector courses, and if you decide to work for the thermal insulation construction field (i.e. installation, fabrication, maintenance, designing, etc.) the Diploma in Thermal Insulation course will be the best fit for you.

1. Quality Control Inspector - Thermal Insulation

2. Diploma in Thermal Insulation

The Institute for Oil and Gas Sector (IOGS) offers courses in both categories online as well as in the classroom environment.

Before diving into why you should go for the thermal insulation courses in the above two categories, let's discuss what thermal Insulation is all about!

What is insulation?

Brief on Thermal Insulation

The insulation, or more correctly Thermal Insulation, is a material or system that has the property of resisting the transfer of heat or sound. Insulation plays a major role in conserving the heat energy of a refinery or process plant. A medium-sized oil refinery contains 465 miles of insulated piping and 1.8 million square feet of insulated equipment.

Low thermal conductivity and high thermal resistance are the two most desirable properties expected from thermal insulation material. The following 5 major reasons why an oil refinery or industrial process plant requires its mechanical system to be insulated are:

Energy conservation

Condensation control

Process control

Personnel Protection

Noise Control

A mechanical system, when insulated improperly, can have a various negative impact on a refinery or process plant, some of such impacts are listed below:

Energy loss

Catastrophic failure due to CUI

Large maintenance budget required due to CUI

Carbon emission

Downtime

How the training on Thermal Insulation can be benefited you?

There is a trend in the industry to hiring a skilled and well-trained workforce for each work categories that the industry is having. The industrial companies only hire skilled employees who hold the necessary qualifications to perform their role, and they consistently go above and beyond in the performance of their duties. Skilled workers are known to be an asset for any organization and/or industry as they play a large role in developing the reputation and ongoing success of the organization/industry.

The following qualification/training courses offered by the Institute for Oil & Gas Sector (IOGS) will make you eligible to apply and grab the work opportunities available in the thermal insulation field.

Quality Control Inspector Courses

Insulation Inspector Level 2 - Online Course

Course Code: IOGS/CII

Click Here for More Details

Online learning is certainly a more effective option for continual professional development and/or to learn new skills.

IOGS is offering its prospective student to improve their current skill by learning online. This is a very suitable online program for working individuals in the industry and the students. (Beginners and fresher are most welcomed). This online course is offered through the IOGS Learning Management System (LMS). You can access the course through LMS at any time and place. The maximum duration of this online course is 30 days following a web-based online exam. The successful candidates are awarded the Insulation Inspector Level 2 certification.

The course is most suitable for those who may not have the time or resources to participate in a traditional classroom-based course. The diversified course is covering the thermal Insulation topic as a whole. You will get interactive quizzes, videos, inspection documents that will add to your skill for future prospects.

Insulation Inspector Level 3 - Classroom Course

Course Code: IOGS/CII

Click Here for More Details

It is a 4-days course, headed by the experts of IOGS on a scheduled date, location, and time. Level 3 is ideal if you are currently working in the thermal insulation field and have some relevant knowledge and skills, usually from a role where you've been supervised, and you have time and resources available in participating the course on the scheduled location and date/time.

The attendees receive hands out theoretical and practical training on the relevant subject for 3 days. On the fourth day of the course, you seat for a closed book examination. The successful candidates are awarded IOGS/CII Level 3 Insulation Inspector certification/qualification.

If you do not decide to jump into the Quality Control work field of Thermal Insulation, you should take up the Diploma in Thermal Insulation course to grab an opportunity for working in the Thermal Insulation installation and/or construction work field.

Diploma in Thermal Insulation - Classroom Course

Course Code: IOGS/DTI

Click Here for More Details

This is a 30-Days course where the students are given priority to read, learn, and explore everything about thermal insulation, installation, inspection, and quality control. Preparation and assessment of the ongoing courses and generating reports, writing necessary documents such as: specifications, ITP, etc. all are taught in this course. The successful candidates are awarded the completion certificate.

Effectiveness of the Thermal Insulation courses

All the three courses from The Institute for Oil & Gas Sector are promising, and are designed to improve your technical skills. You will surely gain a lot of knowledge, and your skills in the thermal insulation field would be to the next level.

The demand for skilled, trained, and/or certified workforce level programs are high in the industry. Once you grab the required knowledge in this field, you can indisputably work as Quality Control Inspector, Supervisor, Manager, or Applicator in an oil refinery and industrial process plant.

Get enrolled today to your preferred course on thermal insulation at www.iogs.org and enjoy life long skill enhancement and professional development career benefits.