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Field Engineer (Fabrication) Development Program

METHOD OF DELIVERY

The participants are first taught the knowledge and preparation required to work in the oil and gas service industry from the trainers with working experience in respective areas. The concepts are re-enforced through tutorial and industrial-related case studies.

After acquiring pre-requisite domain and working knowledge in the subject area, the participants are then provided with company-specific customised modules, such as various management systems, tools and hardware knowledge. They also receive on-the-job training through industrial attachment with the host companies.

 

LEARNING OUTCOME
  • To provide the necessary technical soft skills for engineers to adapt from the university environment to real life technical working environment. 
  • To equip participants with pre-requisite knowledge required to start working as field engineers in the oil and gas industry. These knowledge are: 
    • Malaysia petroleum industry and services industry 
    • Fabrication and load-out of offshore structures 
    • Installation of offshore projects 
    • Hook-up construction and commissioning of offshore projects 
    • Essential knowledge of project management using PMI PMBOK guide 
  • To equip participants with practical skills of field engineering in the oil and gas industry through company-specific training and industrial attachment arrangement.

COMPETENCY SKILL SETS
  • To be able to read and understand fabrication shop drawings and interpret them
  • To know the various fabrication techniques for steel structures
  • To know the practical aspects of cutting, welding, blasting and painting
  • To know the available erection and assembly techniques
  • To know the types of cranes and lifting equipment and their accessories
  • To know the load-out techniques, preparations and ballasting
  • To be able to read and understand sea-fastening engineering and safely supervise load-outs and sea-fastening
  • To know how to manage and supervise post-fabrication activities and complete them

TRAINING MODULES

Part 1: Soft Skills
Please refer to the common soft skills curriculum for details


Part 2: Technical Essentials

M1: Malaysian Oil & Gas Services Industry and Its Value Chain
  • History 
  • Upstream and downstream value chain 
  • Technical and HSE risks and management 
  • New technologies and innovation 
  • Exploration, drilling and appraisal 
  • Field development and planning 
  • Deepwater developments 
  • Overview of offshore facilities and platform 
  • Process/surface equipment 
  • Design & workpack engineering 
  • Fabrication 
  • Mobilization 
  • Installation 
  • Hook-up and commissioning 
  • Production, operations and maintenance 
  • Regulatory environment 
  • Production sharing contracts (PSC) environment 
  • Decommissioning and abandonment 
  • Downstream, refining and retail activities

M2: Fundamentals of Offshore Structural Engineering
  • General introduction to Offshore Structures and Metocean 
  • Metocean Engineering 
  • Independent Metocean Criteria 
  • Joint Metocean Criteria 
  • 100 year design storm 
  • Data collection and data sources 
  • Fixed Shallow Water and Marginal Field Development 
  • Introduction of Fixed structures 
  • Integrated or multi-structures 
  • Air-gap and its impact 
  • Basic framing and batter design 
  • Air Gap and Batter design exercise 
  • Shallow foundation 
  • Pile foundation 
  • Pile and conductor make-up design, 
  • Pile and conductor fabrication and load-out 
  • Pile and conductor installation 
  • Marginal field - What and why? 
  • Options to consider 
  • Deepwater Field Development
  • Introduction to deepwater
  • Economic limit of fixed structures
  • Typical floating structures
  • Fabrication and installation consideration 
  • Subsea Field Development
  • Offshore Structure design basic according to API RP 2A
  • Typical Shallow Water Structures
  • General Design Considerations
  • Loads on an offshore structure
  • Deepwater fixed structures applicability and typical limits
  • Construction/Fabrication and Load-Out processes
  • Fabrication and erection process
  • Load-out options and considerations

M3: Fabrication and Load-out for Offshore Oil and Gas Projects
  • Project Management and Planning essentials:
    • Fundamentals of project development and Project Management Team (PMT) requirements by clients
    • Project management team organisation for fabrication and load-out (PMT members, HSE engineer and safety officers, interface with clients and regulatory activities
  • Contract Management and Supply Chain for Fabrication:
    • Contracting and Procurement activities and considerations
    • Work scoping and AFC drawings
    • Tendering and ITB processes
    • Authority levels and client approvals
    • Fabrication yard layout, load-out methods, workshops and major equipment types
    • Insurances and commercial matters
  • Engineering and Construction Planning & Scheduling:
    • Fabrication loading considerations, foundation preparation and preliminary works 
    • Fabrication Engineering and Calculations
    • Planning and scheduling overview
    • Typical manpower and fabrication equipment planning and management
    • Fabrication cost-time-resource (CTR) estimating
    • Fabrication, erection and assembly of major structures, substructures
    • Cranes capacity considerations
    • Roll-up of side structures
    • Pipeline procurement, concrete coatings, pipeline load out and transportation
  • Engineering and Construction Activities:
    • Blasting and painting activities
    • Fabrication, erection and assembly of topsides and living quarters modules
    • Skid and Package Equipment Procurement, Factory Acceptance Testing, Delivery, storage and preservation, fabrication installation 
    • QA/QC in Fabrication
    • Weight control and weighing of structures in fabrication 
    • Jacket commissioning, trial fitting and ship loose items management
    • Testing, inspection, NDT, repairs
    • Welding activities
    • Welding and welder qualifications
    • Yard Pre-Commissioning activities
  • Load-Out and Sea-fastening:
    • Load-out process and options (Self-propelled Modular transporter (SPMT), Skidding, Lifting)
    • Transportation processes, barge consideration and guidelines
    • Pile and conductors transportation arrangement consideration and load out 
    • Load-out planning, engineering for substructures and topside
    • Load out execution, ballasting techniques and calculation
    • Insurances and marine surveyor requirements
    • Load-out lifting Engineering and Calculations
    • Slings, hooks and rigging accessories for lifting and load-out
    • Warranty surveyor requirements for lifting and rigging
    • Offshore transportation and installation planning and scheduling (basics)
    • Transportation barge requirements, tow tug requirements, fuel and specifications
    • Weather considerations and transportation
    • Safe refuge considerations and planning
    • Major and support marine vessels, major equipment types

M4: Project Management 101: A Step-by-step Approach Using PMI PMBOK Guide
  • Introduction of projects 
  • The triple constraint 
  • The five project management process group 
  • Project initiating 
  • Project planning 
  • Project executing 
  • Project controlling 
  • Project closing

M5: Hook-up Construction and Commissioning for Offshore Oil & Gas Projects
  • Overview of Field Development Planning (FDP) Project Management team (PMT), roles & responsibilities
  • Workpack process, planning and execution
  • Procurement – cost-plus and overheads
  • Construction and marine crew manpower recruitment & mobilisation
  • Onshore Minor Fabrication
  • HSE training requirements
  • QA/QC project documentation requirements
  • Mobilisation of major and support marine vessels
  • Overview of marine operations
  • Onshore supply base and Load-out activities
  • IPOP/pre-execution reviews
  • Pre-commissioning activities, testing and inspection
  • Commissioning activities
  • Start-up (first oil, first gas) and Hand-over to Operations dept
  • Post-project activities, final documentation

 OR –

M5: Introduction to Ship Conversion and FPSO
  • FPSO – Floating, Production, Storage and Offloading
  • Business justification for FPSO conversion
  • Application of Classification Rules
  • FPSO Hull Design Process and Materials Selection
  • Structural Strength – Lengthening of Vessels
  • Increased Breadth and Depth of Vessels 
  • Mounting of Retractable and Side Thrusters
  • Anchoring Equipment and Steering Arrangement
  • FPSO Conversion Particulars and Documentation Requirements
  • Strengthening for Local Overloading
  • Application of Doublers for Longitudinal Strength
  • General Arrangement, Tank Layout, Turret or Spread Mooring
  • Shear Forces Correction and Environmental Loads
  • Ship Stability – Increased Draft and Major FPSO Conversions
  • Fatigue Criteria and Assessment
  • FPSO Conversions that May Have an Effect on Stability
  • Loadline, Life-saving Appliances, COLREG (Collision Regulations) and ILO (International Labour Organization) Crew Accommodation
  • Topsides Interface, Design Requirements and Weight Control
  • Stress and Buckling Criteria, Deformation Effects
  • Electrical Components – Certification by Classification Society and Testing
  • Fire Safety – Special Arrangement
  • Piping Systems – Application of Classification Rules
  • Use of Marine Software for FPSO
  • Conversion – Hands-on Activity using PCs
  • Application of Statutory Rules and Codes, i.e. SOLAS (Safety of Life at Sea), MARPOL (Marine Pollution), IBC/BCH (International Bulker Codes) and IGC (International Gas Carrier) Codes

Part 3: Company-Specific Customized Modules
Modules to be designed specifically for the host companies