Focusing on the Offshore Installations (Offshore Safety Directive) (Safety Case etc.) Regulations 2015 (SCR 2015), this module covers their application to oil and gas operations in offshore waters. It emphasises the importance of preparing a safety case to demonstrate effective major accident risk control, outlining the duties and responsibilities of operators and owners. The module also discusses the verification scheme required under SCR 2015, ensuring safety and environmental critical elements are fit for service.

The module on Engineering Materials provides a high-level understanding of material science, particularly focusing on the materials used in the construction of pressure equipment like steel. It discusses the mechanical properties crucial to pressure equipment performance, including yield strength, tensile strength, toughness, ductility, and hardness. The module discusses materials with an emphasis on common types like carbon, low alloy, and stainless steel.

This module delves into the deterioration of materials due to environmental interactions. The focus is on understanding the various forms of corrosion and their implications on material integrity. It outlines the basic principles of corrosion, emphasising that most metals, being artificially stabilised, are inclined to revert to their natural states, leading to corrosion. The course segments different corrosion types into eight groups, including uniform, localised, galvanic, and environmental cracking, among others, providing insights into their unique characteristics and the conditions under which they occur. Special attention is given to the electrochemical nature of corrosion processes, highlighting the factors influencing corrosion rates and the strategies for mitigation.

This module covers the principles and codes governing the design of static pressure equipment like vessels and piping. It starts by explaining why most pressure containers are cylindrical, leveraging the inherent strength of the shape and the simplicity of its fabrication. The thin shell theory is introduced to understand the stresses within pressure vessels, including longitudinal and circumferential stresses, and how they dictate the vessel’s structural integrity. The module also touches upon design codes and standards, emphasizing their role in ensuring the safety and reliability of pressure equipment.

This module explores the construction of pressure vessels through welded assemblies, adhering to the design code ASME VIII, which delegates specific welding requirements. It delves into the qualification rules for welding, welders, and welding operators, ensuring that personnel and processes meet the stringent standards necessary for maintaining the integrity and safety of pressure vessels. The focus is on understanding the critical aspects of welding in the context of pressure vessel fabrication and repair, emphasising the importance of proper qualifications and adherence to recognised codes.

This module introduces the basic principles of arc welding, highlighting the process of forming an arc between the part and the electrode, melting the parts to form a weld pool, and the use of filler metals. It covers the three most frequently used arc welding processes in the fabrication and repair of refinery and chemical process equipment: Shielded Metal Arc Welding (SMAW), Gas Tungsten Arc Welding (GTAW), and Gas Metal Arc Welding (GMAW). Each process’s advantages and limitations are discussed, providing a foundational understanding of welding techniques applicable to various situations in the industry.

This module on In-Service Inspection emphasises the critical role of ongoing evaluations to maintain the integrity and safety of pressure vessels in operation. It begins with understanding the vessel’s history and current state to plan effective inspections, employing a variety of methods like internal, on-stream, and external inspections to assess the condition comprehensively. A well-developed inspection plan, essential for organising these assessments, should detail inspection intervals, methods, and specific areas of focus based on the vessel’s condition and potential risks.

The module highlights the importance of identifying potential damage mechanisms to form a solid foundation for the inspection plan and risk assessments, aiming to prevent unforeseen deterioration. Factors such as known damage mechanisms, susceptible areas, expected damage rates, and the remaining life of the vessel inform the planning process. The inspection frequency is guided by the ‘corrosion half-life principle,’ ensuring that inspections are timely and contribute to the vessel’s safe continued operation.

This module addresses the methodologies and considerations involved in repairing pressure vessels and piping. It differentiates between temporary and permanent repair methods, such as fillet-welded patches and lap band repairs for temporary fixes, and more permanent solutions like excavating defects, repair welding, and insert patches. The module underscores the importance of adhering to codes like API 510 for guidance on repair techniques, ensuring the integrity and safety of pressure vessels post-repair.