Introduction

This specialized 20-day training program, designed by Global Horizon Training Center, aims to equip professionals working in pipeline operations, safety, and gas/oil facilities with comprehensive knowledge and practical strategies. The program blends daily operational insights with advanced emergency preparedness techniques to ensure participants are fully capable of managing both routine and critical scenarios. Covering key areas such as pipeline systems, scraper activities, plant isolation, and fire response, the program fosters technical expertise, operational discipline, and a strong safety culture.

Objectives

By the end of this training, participants will be able to:

• Understand the full scope of pipeline operations from upstream to downstream.

• Apply advanced safety practices and regulatory requirements in daily operations.

• Master scraper operation and maintenance procedures.

• Develop and execute emergency response plans, including plant isolation under fire or disaster scenarios.

• Perform risk assessments and hazard identification in pipeline and gas plant environments.

• Improve interdepartmental coordination during incidents and shutdowns.

• Apply preventive maintenance and integrity management strategies.

Course Methodology

• Interactive lectures and technical presentations

• Real-world case studies and scenario-based exercises

• Hands-on simulations and group problem-solving

• Discussions on industry best practices

• Multimedia visuals and technical documentation

• Assessment quizzes and feedback sessions

Organizational Impact

• Improved safety culture and operational integrity in pipeline environments

• Minimized downtime through enhanced emergency preparedness

• Enhanced coordination across departments during critical incidents

• Reduced risk of accidents, asset loss, and environmental harm

• Strengthened compliance with international safety standards and protocols

Target Audience

• Safety Advisors in plants, gas, and pipeline operations

• Associate Oil/Gas Operators

• Master Gas Pipeline Operators

• Emergency response team members

• Control room operators and field supervisors

• Professionals in pipeline integrity, maintenance, and operations

• New or mid-level engineers expanding their field expertise

Course Outline

Day 1: Introduction to Pipeline Systems and Industry Overview

• Overview of oil and gas pipeline systems (upstream, midstream, downstream)

• Types of pipelines: crude oil, natural gas, product pipelines

• Key players and functions in the pipeline value chain

• Importance of safety, compliance, and operational discipline

Day 2: Pipeline Components, Design, and Flow Dynamics

• Major components: pipes, valves, pumps, compressors, meters

• Pipeline routing and design considerations

• Flow dynamics: pressure, temperature, viscosity, and turbulence

• Overview of pipeline system layouts and schematics

Day 3: Fundamentals of Pipeline Safety and International Standards

• Safety regulations: API, ASME, OSHA, and other standards

• Pipeline hazard identification and risk classification

• Safety management systems (SMS)

• Role of audits and safety inspections

Day 4: Gas Plant Operations: Roles, Interfaces, and System Interconnectivity

• Structure and functions of a gas processing plant

• Gas compression, dehydration, sweetening, and fractionation processes

• Interfaces between plant operations and pipeline flow

• Coordination between control rooms and field units

Day 5: Daily Operations of Oil & Gas Pipelines

• Monitoring flow rates, pressures, and temperatures

• Use of control systems (DCS, SCADA)

• Routine checks, logging, and reporting

• Pipeline operating procedures and documentation

Day 6: Scraper Activity I – Pigging Basics, Types, and Operational Needs

• What is pigging and why it's important

• Types of pigs: utility, cleaning, intelligent

• Pigging frequency and triggers

• Operational planning for pigging

Day 7: Scraper Activity II – Launchers, Receivers, and Safety Procedures

• Pig launcher and receiver designs and safety features

• Sequence of operations during pigging

• Safety interlocks and precautions

• Common failures and troubleshooting

Day 8: Pipeline Integrity Management

• Corrosion types and prevention methods (coating, cathodic protection)

• In-line inspection tools and data interpretation

• Repair and rehabilitation methods

• Recordkeeping and documentation

Day 9: Plant Isolation Procedures

• Types of isolation: positive, process, and mechanical

• Lock-out/tag-out (LOTO) procedures

• Isolation for maintenance and during emergencies

• Case studies of failed isolations and lessons learned

Day 10: Midterm Case Study – Leak and Isolation Drill

• Scenario-based simulation of a pipeline leak

• Team-based response planning

• Execution of plant isolation and containment

• Post-incident reporting and analysis

Day 11: Fire and Explosion Hazards in Pipelines

• Fire triangle and explosion basics

• Fire hazard zones and classifications

• Sources of ignition and control measures

• Explosion modeling and emergency considerations

Day 12: Emergency Response Strategies

• Emergency response planning and policies

• Activation of emergency response teams (ERT)

• Assembly points, communication flow, and evacuation protocols

• Managing panic and decision-making under pressure

Day 13: Disaster Scenario Management – Plant-Wide Isolation

• Full-plant isolation procedures during disasters

• Decision-making roles: supervisors vs. emergency managers

• Coordination with fire departments and external agencies

• Business continuity and disaster recovery concepts

Day 14: Emergency Communication and Command Chain Structures

• Incident command system (ICS) in pipeline operations

• Communication hierarchy and channels

• Internal vs. external communication during a crisis

• Emergency drills and documentation practices

Day 15: Leak Detection Systems and SCADA Monitoring

• Overview of SCADA systems in pipeline control

• Leak detection technologies: acoustic, pressure drop, and fiber optics

• Alarm and event handling protocols

• SCADA case study and simulated alarm analysis

Day 16: PPE, Firefighting Systems, and Rescue Operations

• Personal protective equipment (PPE) types and usage

• Firefighting systems: foam, dry powder, CO2, hydrants

• Rescue techniques in confined spaces and high-risk areas

• Fire response drills and hands-on demonstrations

Day 17: Post-Incident Reporting and Continuous Improvement

• Structure of incident reports (initial, follow-up, final)

• Root cause analysis (RCA) tools: 5 Whys, Fishbone

• Corrective and preventive actions (CAPA)

• Building a culture of safety learning and improvement

Day 18: Regulatory Compliance and Auditing Practices

• Overview of local and international regulatory bodies

• Inspection and audit readiness

• Documentation control and compliance tracking

• Penalties, violations, and best practices to avoid them

Day 19: Integrated Operations and Safety Simulation Exercise

• Full scenario integrating pigging, fire, isolation, and SCADA alarm

• Team roles and communication flow

• Debriefing and performance assessment

• Lessons learned and suggested improvements

Day 20: Final Review, Feedback, and Certification

• Recap of key learning points from the entire course

• Participant presentations or group review exercise

• Feedback collection and discussion

• Distribution of certificates of completion