The oil and gas industry is one of the most complex and capital-intensive sectors in the world. Accurate estimation and costing are crucial for the successful planning, execution, and management of oil and gas projects. This comprehensive online course is designed to equip professionals with the knowledge and skills required to perform detailed estimations and manage projects effectively within the oil and gas sector.
Covering a broad spectrum of topics, the course delves into the intricacies of estimating costs for various components of oil and gas plants, including piping systems, pressure vessels, heat exchangers, and civil infrastructure. It also emphasizes project management principles, cost control techniques, and contingency planning to address unforeseen challenges.
By the end of this course, participants will have a thorough understanding of the estimation processes for both mechanical and civil aspects of oil and gas projects, enabling them to contribute significantly to project success and profitability.
Who Should Enroll
- Engineers (Mechanical, Civil, Chemical, Electrical) seeking to specialize in cost estimation within the oil and gas industry.
- Project Managers aiming to enhance their skills in budgeting, cost control, and project planning.
- Estimators and Cost Engineers looking to deepen their understanding of oil and gas plant components and civil works.
- Procurement and Finance Professionals interested in the financial aspects of project management.
- Construction Professionals involved in the erection and commissioning of oil and gas facilities.
Course Objectives
- Understand the fundamental processes of oil and gas plants, including upstream, midstream, and downstream operations.
- Master various estimation methodologies and apply them to real-world scenarios.
- Analyze the costs associated with mechanical equipment such as pumps, compressors, and heat exchangers.
- Estimate civil and structural works, including foundations, earthworks, and infrastructure development.
- Implement project management principles to manage timelines, resources, and costs effectively.
- Develop contingency plans to address unforeseen expenses and risks.
- Utilize cost control and monitoring techniques to ensure projects remain within budget.
Course Modules
Module 1: Introduction to Oil and Gas Plant Estimation
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Overview of Oil and Gas Facilities
- Understanding the different types of oil and gas plants.
- The role of estimation in project planning and execution.
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Key Estimation Principles and Objectives
- Importance of accurate cost estimation.
- Objectives of cost estimation in project management.
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Scope and Limitations of Estimations in the Sector
- Challenges in estimating costs for complex projects.
- Factors influencing estimation accuracy.
Module 2: Understanding Oil and Gas Plant Processes
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Upstream, Midstream, and Downstream Processes
- Exploration, production, transportation, refining, and distribution.
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Process Flow Diagrams (PFD) and Piping and Instrumentation Diagrams (P&ID)
- Interpreting diagrams for estimation purposes.
- Identifying key components and systems.
Module 3: Cost Estimation Basics for Oil and Gas Projects
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Types of Cost Estimates
- Conceptual, feasibility, and detailed estimates.
- When and how to use each type.
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Costing Methodologies
- Unit rate, material take-off (MTO), and parametric estimating.
- Advantages and limitations of each method.
Module 4: Piping Systems Estimation
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Pipe Materials
- Characteristics and costs of carbon steel, stainless steel, and exotic alloys.
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Pipe Fittings, Valves, Flanges, and Gaskets
- Estimating quantities and costs.
- Selection criteria based on process requirements.
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Welding and Insulation Costs
- Labor and material costs for welding.
- Insulation types and their cost implications.
Module 5: Estimation of Pressure Vessels
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Types of Pressure Vessels
- Separators, scrubbers, and knock-out drums.
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Design and Fabrication Costs
- Material selection and thickness calculations.
- Fabrication processes and associated costs.
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Testing and Certification Costs
- Non-destructive testing (NDT) methods.
- Compliance with industry standards.
Module 6: Heat Exchangers Estimation
Module 7: Pumps and Compressors Estimation
Module 8: Storage Tanks and Spheres Estimation
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Types of Storage Tanks
- Fixed-roof, floating-roof, and spherical tanks.
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Material and Construction Costs
- Steel plate requirements and welding volumes.
- Erection methodologies and associated costs.
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Painting, Coating, and Cathodic Protection
- Surface preparation techniques.
- Protective coatings and their cost implications.
Module 9: Pipeline Estimation
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Onshore and Offshore Pipeline Materials
- Selection of pipeline materials based on environmental factors.
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Pipeline Routing, Trenching, and Laying Costs
- Route selection and survey costs.
- Installation techniques and equipment requirements.
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Pigging, Testing, and Commissioning Expenses
- Pipeline cleaning and inspection costs.
- Hydrostatic testing procedures.
Module 10: Electrical Systems Estimation
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Substations, Transformers, and Switchgear
- Electrical distribution requirements.
- Equipment sizing and cost estimation.
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Cables, Cable Trays, and Conduits
- Calculating lengths and sizes.
- Material and installation costs.
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Earthing and Lightning Protection Systems
- Compliance with safety standards.
- Cost factors for protective systems.
Module 11: Instrumentation and Control Systems Estimation
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Sensors, Transmitters, and Controllers
- Selection based on process parameters.
- Quantity estimation and costing.
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Distributed Control Systems (DCS) and SCADA
- System architecture and component costs.
- Integration expenses.
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Calibration and Testing Expenses
- Procedures for ensuring accuracy.
- Cost implications of maintenance and testing.
Module 12: Civil and Structural Works Estimation
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Foundations for Equipment and Buildings
- Load calculations and design considerations.
- Material take-off for concrete and steel.
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Structural Steel for Pipe Racks and Platforms
- Estimating steel quantities.
- Fabrication and erection costs.
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Concrete Works and Finishing
- Formwork, reinforcement, and pouring costs.
- Surface finishing techniques.
Module 13: Rotating Equipment Estimation
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Turbines, Engines, and Blowers
- Selection criteria based on process needs.
- Cost factors including efficiency and capacity.
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Maintenance Access and Auxiliary Systems
- Designing for accessibility.
- Additional equipment requirements.
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Installation and Alignment Costs
- Precision alignment procedures.
- Labor and equipment costs.
Module 14: Static Equipment Estimation
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Reactors, Absorbers, and Columns
- Design considerations for pressure and temperature.
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Internal Fittings and Packing Materials
- Estimating costs for trays, packings, and internals.
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Erection and Safety Features
- Installation challenges.
- Compliance with safety regulations.
Module 15: Utility Systems Estimation
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Boilers, Chillers, and Cooling Towers
- Sizing based on plant requirements.
- Capital and operational costs.
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Air Separation Units (ASU)
- Producing industrial gases.
- Cost implications of cryogenic equipment.
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Power Generation and Distribution Costs
- Onsite power generation options.
- Grid connection expenses.
Module 16: Fire Protection Systems Estimation
Module 17: Insulation and Painting Works Estimation
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Thermal Insulation for Piping and Equipment
- Materials like mineral wool, foam glass, and perlite.
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Surface Preparation and Coating Systems
- Sandblasting and priming costs.
- Protective coatings for corrosion prevention.
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Estimation of Scaffolding Requirements
- Access needs for elevated work.
- Rental and labor costs.
Module 18: Safety and Environmental Systems Estimation
Module 19: Construction and Erection Estimation
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Mobilization and Demobilization Costs
- Transportation of equipment and personnel.
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Labor Productivity and Wage Rates
- Regional labor rates.
- Factors affecting productivity.
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Heavy Lifting and Crane Operations
- Selection of cranes based on load requirements.
- Rental and operation costs.
Module 20: Project Management and Contingency Estimation
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Estimation of Project Timelines and Resource Allocation
- Scheduling techniques.
- Resource leveling and allocation strategies.
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Contingency Planning for Unforeseen Costs
- Risk identification and mitigation.
- Budgeting for contingencies.
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Cost Control and Monitoring Techniques
- Key performance indicators (KPIs).
- Earned value management (EVM).
Module 21: Foundation Works Estimation
Module 22: Paving and Road Works Estimation
Module 23: Structural Steel Estimation
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Supporting Equipment Foundations
- Beams, columns, and trusses design.
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Fabrication, Welding, and Erection Costs
- Workshop vs. onsite fabrication.
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Coating and Painting Requirements
- Protective coatings for structural steel.
Module 24: Temporary Structures Estimation
Module 25: Underground Utilities Estimation
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Drainage Systems, Sewage Lines, and Stormwater Management
- Design and material selection.
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Earthworks for Trenches and Utility Tunnels
- Excavation volumes and support systems.
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Pipe Bedding and Backfilling Costs
- Material specifications and quantities.
Module 26: Buildings and Administrative Infrastructure
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Design and Construction of Control Rooms, Substations, and Offices
- Architectural considerations.
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HVAC and Electrical Systems
- Sizing and cost estimation.
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Civil Finishes
- Flooring, roofing, and wall treatments.
Module 27: Concrete and Formwork Estimation
Module 28: Earthworks and Soil Improvement
Module 29: Retaining Structures Estimation
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Retaining Walls for Ground Stability
- Design and material estimation.
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Reinforced Concrete or Gabion Structures
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Waterproofing and Drainage Layers
- Material selection and costs.
Module 30: Construction Safety Provisions
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Safety Measures during Excavation and Foundation Works
- Shoring and trench support systems.
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Temporary Walkways, Guardrails, and Signage
- Compliance with safety regulations.
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Cost Allocation for Safety Equipment and Supervision
- Personal protective equipment (PPE).
- Safety training expenses.
Equipment and Components Covered
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Major Equipment
- Pumps, compressors, heat exchangers, boilers, turbines, reactors, and storage tanks.
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Piping Components
- Pipes, fittings, valves, flanges, gaskets, and insulation materials.
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Instrumentation
- Sensors, control panels, analyzers, DCS/PLC systems.
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Electrical Components
- Cables, transformers, switchgear, motor control centers.
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Safety Systems
- Firewater pumps, sprinklers, foam systems, and detection units.
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Civil Works Materials
- Concrete, steel reinforcement, structural steel.
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Pipeline Materials
- Pipes, coatings, cathodic protection systems.
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Utility Equipment
- Cooling towers, chillers, and air compressors.
Integration of Civil and Mechanical Estimation
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Foundation Design for Heavy Equipment
- Collaborating between civil and mechanical engineers for load calculations and material specifications.
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Structural Steel for Pipe Racks
- Integrating piping design with structural support requirements.
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Underground Utility Coordination
- Synchronizing civil works with piping and electrical layouts.
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Construction Sequencing
- Planning civil works to align with equipment installation schedules.
Learning Outcomes
By the end of the course, participants will be able to:
- Perform detailed cost estimations for various components of oil and gas plants.
- Understand the interplay between civil and mechanical elements in project estimation.
- Apply project management techniques to control costs and manage resources effectively.
- Develop comprehensive contingency plans to mitigate risks.
- Utilize industry-standard tools and methodologies for estimation and cost control.
Course Format
- Duration: 12 weeks (Flexible learning pace)
- Mode: Online lectures, interactive sessions, and practical assignments.
- Resources: Access to downloadable materials, case studies, and software tools.
- Assessment: Quizzes, assignments, and a final project.
Enrollment Information
- Prerequisites: Basic understanding of engineering principles.
- Certification: Certificate of Completion upon fulfilling course requirements.
- Support: Dedicated instructors and support staff available for guidance.
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