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Module 1: Introduction to Quality Control and Assurance in Oil & Gas Projects
• Importance of QC/QA in the oil and gas industry.
• Key differences between QC and QA.
• Overview of oil and gas projects in GCC and India.
• International standards and frameworks (ISO, ASME, API, etc.).
Module 2: Quality Management Systems for Oil & Gas Projects
• Fundamentals of a Quality Management System (QMS).
• Developing a QMS for oil and gas plant projects.
• Documentation and standard operating procedures (SOPs).
• Role of leadership in implementing QMS.
Module 3: Material Quality Control and Assurance
• Selection of materials for pipelines, storage tanks, and process equipment.
• Material inspection and testing (NDT methods such as UT, RT, PT, and MT).
• International material standards (ASTM, API 5L, etc.).
• Material traceability and certification.
Module 4: Welding and Fabrication Quality Control
• Welding processes and techniques used in oil and gas plants.
• Weld inspection methods and quality standards (ASME Section IX, API 1104).
• Common welding defects and remedies.
Module 5: Piping and Pipeline Quality Assurance
• Piping systems: fabrication, installation, and testing.
• Pipeline QA requirements: hydrostatic testing, pigging, and stress analysis.
• Ensuring compliance with API 570 and ASME B31.3 standards.
• Inspection techniques for buried pipelines.
Module 6: Mechanical Equipment and Rotating Machinery QC/QA
• Quality standards for compressors, pumps, turbines, and heat exchangers.
• Inspection and testing of mechanical equipment during procurement and installation.
• Alignment, vibration analysis, and performance testing.
• Equipment maintenance and quality records.
Module 7: Electrical and Instrumentation Quality Assurance
• Standards for electrical installations (IEC, NEC).
• Testing of electrical systems: insulation resistance, loop impedance, etc.
• Quality checks for instrumentation systems.
• Calibration and validation of control systems.
Module 8: QA/QC for Civil and Structural Works
• Foundation quality checks for heavy equipment.
• Structural steel and concrete quality requirements.
• Inspection methods for tanks and pressure vessels.
• Compliance with Indian and GCC civil engineering standards.
Module 9: HSE Integration with QA/QC
• Importance of Health, Safety, and Environment (HSE) in QA/QC processes.
• QA/QC measures to prevent accidents and ensure environmental compliance.
• Integrating safety audits with QA procedures.
• Case studies of QA/QC-related HSE failures.
Module 10: Project Documentation and Audit
• Documentation requirements for quality assurance.
• Preparing and reviewing quality control plans (QCP) and Inspection Test Plans (ITP).
• Conducting internal and external quality audits.
• Best practices for maintaining compliance with GCC and Indian regulations.
1. Mechanical Tests
1.1 Pressure Tests
1.2 Valve Testing
2. Non-Destructive Testing (NDT)
2.1 Radiographic Testing (RT)
2.2 Ultrasonic Testing (UT)
2.3 Magnetic Particle Testing (MPT)
2.4 Dye Penetrant Testing (DPT)
2.5 Visual Testing (VT)
2.6 Eddy Current Testing (ECT)
3. Electrical and Instrumentation Tests
3.1 Electrical Tests
3.2 Instrumentation Tests
4. Process and Commissioning Tests
4.1 Pre-Commissioning Tests
4.2 Commissioning Tests
5. Safety Systems Testing
5.1 Fire and Gas Detection System Tests
5.2 Emergency Shutdown System (ESD) Tests
5.3 Safety Instrumented System (SIS) Tests
6. Environmental and Emissions Testing
6.1 Emissions Monitoring
6.2 Noise Level Testing
7. Material and Metallurgical Tests
7.1 Positive Material Identification (PMI)
7.2 Hardness Testing
7.3 Tensile Testing
7.4 Impact Testing (Charpy Test)
8. Welding Tests
8.1 Welder Qualification Tests
8.2 Welding Procedure Qualification Records (PQR)
8.3 Weld Inspections
9. Coating and Painting Tests
9.1 Dry Film Thickness (DFT) Measurement
9.2 Adhesion Testing
9.3 Holiday Detection (Spark Testing)
10. Pipeline Tests
10.1 Pigging Operations
10.2 Pipeline Leak Detection Tests
10.3 Cathodic Protection Testing
11. Rotating Equipment Tests
11.1 Vibration Analysis
11.2 Alignment Checks
11.3 Run-in Tests
12. Static Equipment Tests
12.1 Vessel Inspections
12.2 Internal Inspections
13. HVAC (Heating, Ventilation, and Air Conditioning) Tests
13.1 Airflow Measurements
13.2 Temperature and Humidity Tests
14. Laboratory and Process Fluid Tests
14.1 Oil and Gas Sampling
14.2 Water Quality Testing
15. Operational Tests
15.1 Alarm and Trip Testing
15.2 Performance Monitoring
15.3 Preventive Maintenance Checks
16. Cathodic Protection Tests
16.1 Potential Measurements
16.2 System Functionality Tests
17. Structural Tests
17.1 Load Testing
17.2 Settlement Monitoring
18. Telecommunications and Control Systems Tests
18.1 Network Integrity Tests
18.2 Control System Simulations
19. Fire Protection System Tests
19.1 Sprinkler System Testing
19.2 Fire Pump Performance Tests
20. Emergency Systems Tests
20.1 Uninterruptible Power Supply (UPS) Tests
20.2 Emergency Lighting Tests
21. Environmental Compliance Tests
21.1 Waste Disposal Tests
21.2 Spill Containment Tests
22. Miscellaneous Tests
22.1 Pressure Safety Valve (PSV) Testing
22.2 Lifting Equipment Inspection