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DIPLOMA IN OIL AND GAS ENGINEERING
COURSE CONTENTS
CODES & STANDARDS
Familiarization of different codes and standards used in Oil and Gas industry and Petrochemical Industry. Codes and standards provide a robust framework that enables the oil and gas industry to operate safely, efficiently, and responsibly, both locally and globally. They are continuously updated and improved to reflect advancements in technology, changes in regulations, and lessons learned from past experiences, making them a critical aspect of the industry’s success.
- ASME Boiler and Pressure Vessel Code
- ASME Section I: Power Boilers
- ASME Section II: Materials
- ASME Section III: Nuclear Power Plant Components
- ASME Section V: Non-destructive Examination
- ASME Section VIII: Pressure Vessels
- ASME Section IX: Welding and Brazing Qualifications
- ASME Section XI: Rules for In-Service Inspection of Nuclear Power
Plant Components
- ASME B31.1: Power Piping Code
- ASME B31.3: Process Piping
- ASME B31.4: Liquid Transportation Systems for Hydrocarbons
- ASME B31.5: Refrigeration Piping
- ASME B31.8: Gas Transmission and Distribution Piping Systems
- AWS, ANSI, API, ASTM Codes and Specifications
INDUSTRIAL SAFETY
Industrial safety is of paramount importance in the oil and gas industry due to the high-risk nature of its operations. The sector involves complex and hazardous processes, including drilling, exploration, production, refining, and transportation of hydrocarbons.
- Site Awareness session.
- Operational safety- Personal Safety Equipment PPE.
- Working at height
- Chemical safety
- Heat stress
- Confined space safety training
- Electrical safety training
- Excavation safety
- Radiography safety
- Permit system, duties, and responsibilities of WPR.
- Lifting safety precautions.
- Safety equipment.
- Importance of Toolbox Talk, Work delegation, Awareness classes and
Safety Drills.
ONSITE RESPONSIBILITIES OF QA/QC ENGINEER
The QAQC (Quality Assurance and Quality Control) Mechanical Engineer in an oil and gas plant plays a critical role in ensuring that the mechanical aspects of the facility adhere to the highest standards of quality and safety. Their primary focus is on monitoring, inspecting, and verifying that mechanical systems, equipment, and materials meet the required specifications and industry regulations.
A QAQC Mechanical Engineer in an oil and gas plant is responsible for maintaining the quality, safety, and reliability of mechanical systems and equipment through diligent inspection, testing, documentation, and adherence to industry standards and project requirements.
- Inspection and Testing
- Material Inspection
- Documentation and Reporting
- Quality Assurance
- Vendor/Supplier Evaluation
- Welding Inspection
- Non-Destructive Testing (NDT)
- Compliance and safety
- Corrective and preventive actions
- Pre-commissioning and commissioning support
- Training and auditing’
- Root cause analysis
CRUDE OIL EXCTRATION: (OFFSHORE & ONSHORE)
The oil and gas extraction process involves locating, drilling, and producing oil and natural gas from underground reservoirs. It is a complex operation that requires a combination of engineering, geology, and environmental expertise. In the oil and gas industry, the term “upstream” refers to the exploration and production (E&P) activities that take place at the beginning of the oil and gas supply chain. Upstream activities involve locating, extracting, and producing crude oil and natural gas from underground reserves. These activities are crucial for the industry as they are responsible for bringing the hydrocarbons to the surface and making them available for further processing and distribution
Upstream: Drilling and retrieval
• Oceanographic exploration and 3D mapping.
• Blow off preventors.
• Well- heads
• Manifolds
• Gathering and storage
• Settlement processes
• Metering, storage and export.
• Utility systems and operations
• Marine offloading
• Types of rigs and platforms
• Well completion
Midstream: Oil processing & Gas processing
• Pipelines
• Chemical processes
• Cracking and converting
• Liquefaction and vaporization
• Refining
• Separators
• Heat exchangers
• Compressors
• Turbine
• Scrubbers
• Boilers
• Acid removal, Nitrogen removal, NGL recovery,
• Fractional distillation
MATERIAL INSPECTION & EVALUATION
- Inspection of Material based on ASME Sec II
- Types of Materials
- Material Classifications
- Material Test Certificate Verification
- PMI Testing
- Documentation
PIPING INSPECTION & IN-SERVICE INSPECTION OF PIPING
The Piping and Mechanical Quality Control Inspector offers on- site knowledge in quality control and assurance related to all piping activities performed. Responsibilities include conducting routine inspections to ensure code, testing and material compliance of services and products and the standard of strike’s
Quality Management System.
Piping In-service Inspection Code is an inspection code developed and published by the American Petroleum Institute (API). The inspection code covers in-service inspection, rating repair and alteration of metallic and fiberglass-reinforced plastic (FRP) piping systems and their respective pressure relieving devices.
Duties & Responsibilities of Piping Inspector
• Safety
• Piping Components & Fittings (Types of Valves, Elbows, Flanges, Tees etc.)
• Elbow centre calculations, Thickness calculations
• Isometric Drawings (Interpretation, Fabrication and Inspection based on drawings)
• P & ID Drawings (Interpretation and Inspection)
• In-service Piping Inspection based on API 570 (In-service Classifications, Damage mechanisms in Piping, Inspection of buried piping, In-service repairs, Permanent and Temporary repairs, Piping Classifications, Remaining Life calculations)
• MAWP Calculation (Calculations based on Bar Lo Equation)
• Piping Thickness Calculations (Based on ASME B 31.3)
• Pressure Testing (Pneumatic, Hydrostatic calculations)
• Calculations based on ASME B 31.3 (Impact Test requirements, Thermal expansion calculations etc.)
• Calculations based on ASME 16.5 (Flange Selection, Pound rating calculations, Flange Dimensions etc.)
• Documentation
EQUIPMENT INSPECTION
STATIC EQUIPMENT
In the oil and gas industry, static equipment refers to mechanical equipment that does not have moving parts during its normal operation. These pieces of equipment are designed to handle various processes and functions in the industry, such as storage, separation, and heat exchange. Static equipment is crucial for the safe and efficient processing of oil, gas, and other hydrocarbons. Static equipment is designed and fabricated to withstand high pressures, extreme temperatures, and corrosive environments commonly found in the oil and gas industry. Regular inspection, maintenance, and adherence to industry standards and codes are essential to ensure the safe and efficient operation of these critical components.
- Heat Exchanger Installation Inspection
- Final Vessel Closure
- Special Equipment Inspection
- Auxiliary Equipment Index Miscellaneous Items
- Fired Heater Installation Inspection
- Fired Boiler Inspection
- Storage Tank Inspection
- Heat Exchanger Installation Inspection
ROTATING EQUIPMENT
In the oil and gas industry, rotating equipment refers to machinery that has moving parts and operates by converting energy into mechanical motion. These types of equipment are crucial for various processes involved in exploration, production, transportation, refining, and distribution of oil and gas. Rotating equipment is used to drive pumps, compressors, turbines, and other devices essential for the industry’s operations. The proper maintenance and operation of rotating equipment are crucial for the reliability and efficiency of oil and gas operations. Regular inspections, monitoring, and adherence to safety standards are essential to prevent downtime, ensure optimal performance, and enhance the safety of personnel and the environment.
- Alignment Inspection
- Equipment Flange Alignment
- Compressor Inspection
- Pump Inspection
- Fan & Blower Inspection
- Electrical Motor Inspection
- Centrifugal Compressor
- Gear Box
- Pump Motor Running Test
- Centrifugal Separator Static Test
- Compressor Running
- Coupling Alignment
- Centrifugal Separator
WELDING INSPECTION / WPS / PQR QUALIFICATIONS
Weld quality assurance is the use of technological methods and actions to test or assure the quality of welds and secondarily to confirm the presence, location, and coverage of welds. Welding Inspector ensures the quality of the weld through inspection at various stages. A Welding Procedure Specification (WPS) is the formal written document describing welding procedures, which provides direction to the welder or welding operators for making sound and quality production welds as per the code requirements. The purpose of the document is to guide welders to the accepted procedures so that repeatable and trusted welding techniques are used. A WPS is developed for each material alloy and for each welding type used. Specific codes and/or engineering societies are often the driving force behind the development of a company’s WPS. A WPS is supported by a Procedure Qualification Record (PQR or WPQR). A PQR is a record of a test weld performed and tested (more rigorously) to ensure that the procedure will produce a good weld. Individual welders are certified with a qualification test documented in a Welder Qualification Test Record (WQTR) that shows they have the understanding and demonstrated ability to work within the specified WPS.
- Codes & Standards
- Duties of Welding Inspector
- Welding & Cutting Process (SMAW, GMAW, FCAW, GTAW, SAW / OFC, CAC-A, PC)
- Welding Symbols (Types of Joints, Butt weld symbols and different joint Identifications)
- Welding Metallurgy (Iron Carbon diagram, Phase changes during welding, Metallurgical considerations, Types of alloying, Sensitization)
- Types of Heating (Pre-heating, Inter-pass Heating, Post Heating & PWHT)
- Welding Defects (Types of Cracks, Incomplete Fusion, Porosity, Underfill, Arc Strike etc)
- Inspection Methods (Bridge Cam Gauge, Undercut Gauge, Fillet weld Gauge etc.)
- Welding Procedure Qualifications
- Welder Qualifications
- Documentation
NON DESTRUCTIVE TESTING (NDT)
MAGNETIC PARTICLE TESTING
Magnetic Particle Inspection (MPI) is a Non-Destructive Testing (NDT) process for detecting surface and shallow sub-surface discontinuities in ferromagnetic materials and their alloys. The process puts a magnetic field into the part to find out the imperfection
- Basic Principle of Magnetic Particle Testing
- Principles of magnets and magnetic fields
- Characteristics of magnetic fields
- Magnetic Particle Testing Equipments
- Inspection Materials
- Types of Magnetizations
- Types of Magnetic Particle Testing
- Selection of proper method of Magnetization
- Types of Magnetic Powders
- Demagnetization
- Technique/Calibrations
- Safety
- Practical/ Hands on Training
LIQUID PENETRANT TESTING
Dye Penetrant Inspection (DP), also called Liquid Penetrate Inspection (LPI) or penetrant testing (PT), is a widely applied and low-cost inspection method used to check surface-breaking defects in all non-porous materials (metals, plastics, or ceramics)
- Principles of Liquid Penetrant Process
- Liquid Penetrant Processing
- Equipments /Materials Required
- Types of Penetrant Testing
- Types of Developers
- Methods of Measurement
- Lighting requirements for Penetrant Testing
- Factors affecting the Indications.
- Testing and Maintenance of Materials
- Types of Indications from Discontinuities
- Relevant and Non-Relevant Indications
- Codes / Standards & Specifications
- Interpretation/Evaluation
- Safety
- Documentation
- Practical/ Hands on Training
ULTRASONIC TESTING (UT)
Ultrasonic testing (UT) is a non-destructive testing (NDT) technique used to detect internal flaws or defects in materials, primarily metals and composites. It relies on the transmission of high-frequency sound waves into the material and the analysis of the reflected waves to evaluate the internal structure and detect any discontinuities, such as cracks, voids, inclusions, or thickness variations.
- Basic Principle of Ultrasonic Testing
- Equipment’s Required
- Types of Probes
- Near Field and Far Field (Calculations)
- Sensitivity Calculation
- Attenuation/Loss of Energy
- IIWV1 Calibration
- IIWV2 Calibration
- Plotting of DAC Curve
- Weld Scanning
- Advantages and Disadvantage’s
- Safety
- Documentation
- Practical’s/Hands on Training
COATING INSPECTION
Radiography testing is a non-destructive testing (NDT) method used to inspect the internal structures of an object or material using X-rays or gamma rays. It is commonly used to examine the integrity, quality, and defects of welds, castings, and other components in various industries, including aerospace, automotive, manufacturing, and oil and gas.
- Basic Principle of Radiographic Testing
- Equipment’s Required/ Methods
- Types of Radiation
- Calculations based on HVT and TVT
- Geometric Un Sharpness
- SFD & SOD Calculations
- Image Quality Indicator Types
- IQI Selection & Sensitivity
- of RT Films
- Radiographic Techniques
- Safety
- Types of Indications
RADIOGRAPHIC FILM INTERPRETATION
Interpreting radiography test films is a crucial aspect of radiographic testing. It requires a skilled and trained radiographer who can analyse the radiographic images (radiographs) to identify any defects, discontinuities, or anomalies within the material being inspected. Radiography test film interpretation requires expertise and attention to detail. Accurate and reliable interpretation plays a vital role in ensuring the safety, quality, and integrity of inspected materials and components.
- Understand the basic principles of the radiographic inspection procedure
- Understand the radiographic film processing procedures
- Recognise limitations in exposure quality
- Density requirement’s using IQI
- Understand potential causes of processing artifacts
- Assess radiographic quality
- Interpret radiographic codes and specifications
- Write reports based on code requirements
- Locate and recognise radiographic images of defects with a high probability of detection
VISUAL TESTING
Visual inspection is a fundamental and widely used method in the oil and gas industry for evaluating the condition and integrity of various equipment, structures, and components. It involves direct observation and examination of surfaces and features to identify visible defects, corrosion, wear, or any other issues that may impact the safe and efficient operation of facilities. Visual inspection can be performed both onshore and offshore and is often part of routine maintenance, pre-commissioning, and integrity assessment processes.
- Fundamentals
- Vision and light requirements
- Ambient Conditions
- Magnifiers/Microscopes
- Joining Processes
- Dimensional requirements
- Surface comparators
- Application and requirements
- Variable affecting results of Interpretation
- Requirements
- Temperature Indicating devices
- Discontinuity and defects
- Process for reporting visual Indications
- Documentation
- Safety
PRESSURE TESTING- QA
Pressure testing is a crucial process used to assess the integrity, strength, and reliability of pressure vessels, pipelines, and other equipment that operate under pressure in various industries, including oil and gas, petrochemical, manufacturing, and aerospace. The objective of pressure testing is to ensure that the equipment can safely handle the intended pressure without any leakage or failure. Pressure testing is a critical safety measure to ensure that pressurecontaining equipment can operate safely and efficiently without posing any risk to personnel or the environment. Properly conducted pressure testing helps identify potential issues early on and ensures compliance with industry standards and regulations. Qualified and experienced personnel should carry out pressure testing to guarantee accurate and reliable results.
- Hydrostatic Test
- Pneumatic Test
- Calculations
- Pipework Pre-Test Checklist
- Hydrostatic Test Report
- Pipework Post Test Check List
COATING INSPECTION
A coating inspector checks industrial equipment to ensure protective coatings were correctly applied and minimize corrosion risk. They go through rigorous training to learn how to identify problems in coating applications and to suggest which types of coatings will protect the materials from corroding. Manufacturing plants, roadway projects such as bridges and other major industries that utilize paint need coating inspectors for quality assurance..
- Corrosion basics (Types of corrosion, Galvanic Series, Methods of Protection, Corrosion Effects)
- Environmental Testing (Surface Temperature, Dew Point, RH Calculations, and its acceptance criteria)
- Surface Preparation (Types of preparation, NACE, ISO, SSPC standards)
- Types of Blasting (Dry grit abrasive blasting, Centrifugal blasting, Water blasting, Water jetting)
- Types of Abrasives (Abrasive selection criteria, Abrasive replenishment, Sieve Analysis, Vial Test etc.)
- Coating Fundamentals (Paint Ingredients, Modes of protection, VOC etc.)
- Coating Application (Conventional, Air Assisted Airless, Plural Component, Airless application etc.)
- WFT & DFT Calculations
- Coating Defects (Blushing, Blister, Delamination, Sagging, Voids etc.)
- Types of Linings (Types of Liquid Applied Linings, Surface Preparation, Coating Application etc.)
- Pipeline Coatings (FBE Coatings, Epoxy Coatings, Concrete Coatings, Surface Preparation, Coating Application, Field joint coatings etc.)
- Special Coating Process (Antifouling Coatings, Heat Resistant coatings etc.)
- Galvanizing (Hot Dip Galvanizing, Surface Preparation, Coating Application, Inspection etc.)
- WFT & DFT Calculations
- Documentation
MECHANICAL ERECTION
The mechanical erection procedure in the oil and gas industry refers to the systematic process of assembling and installing various mechanical components and equipment required for the construction of oil and gas facilities, such as refineries, petrochemical plants, pipelines, and offshore platforms. This procedure ensures that all mechanical equipment is installed correctly, safely, and in compliance with industry standards and project specifications
- Preparation and Planning
- Site preparation
- Equipment and material inspection
- Foundation and base plate installation
- Lifting and rigging
- Alignment and levelling
- Bolt torquing
- Piping installation
- Electrical and instrumentation installation
- Testing and commissioning
- Documentation
- Safety measures
DOCUMENTATION
- Non-Conformance Report
- Fit Up Report
- Weld Visual Inspection Report
- Spool Fabrication Report (Daily/Weekly)
- Dimensional Inspection Report
- Spool Clearance Report
- Spool Cleanliness Report
- Electrode Baking Log
- PWHT Report
- Hardness Report
- PMI Inspection Report
- Material Identification Report
- Hydro Test Report
- Ferrite Measurement Report
- NDT Request
- Visual Inspection Report
- Liquid Penetrant Inspection Report
- Magnetic Particle Testing Report
- Ultrasonic Inspection Report
- Radiographic Inspection Report
- Paint Storage Report
- Environmental Testing Report
- Surface Profile Inspection Report
- Surface Contamination Test Report
- DFT Report
- Coating Summary Reports