Module 1: Introduction to Pressure Vessel Safety

• Definition and purpose of pressure vessels
• Importance of safety in pressure systems
• Overview of incidents and lessons learned

Module 2: Types of Pressure Vessels and Applications

• Boilers, air receivers, gas cylinders, storage tanks, and reactors
• Stationary vs. portable pressure vessels
• Common industrial uses (oil & gas, manufacturing, chemical plants)

Module 3: Hazards Associated with Pressure Vessels

• Overpressure, rupture, explosion, and leakage
• Corrosion, fatigue, and material failure
• Human error and poor maintenance

Module 4: Design and Construction Standards

• ASME Boiler & Pressure Vessel Code
• API, EN, and ISO standards
• Importance of material selection and design pressure

Module 5: Pressure Relief and Safety Devices

• Types of relief valves (spring-loaded, pilot-operated)
• Rupture discs and safety interlocks
• Inspection and testing of relief systems

Module 6: Inspection, Testing, and Certification

• Hydrostatic and pneumatic testing
• Non-destructive testing (NDT) methods
• Role of certified inspectors and documentation

Module 7: Safe Operation and Monitoring

• Operating procedures and limits
• Gauges, alarms, and pressure monitoring systems
• Recognizing warning signs of vessel failure

Module 8: Maintenance and Repairs

• Preventive maintenance schedules
• Weld repairs and re-rating requirements
• Recordkeeping and re-certification protocols

Module 9: Hazard Control and Risk Assessment

• Identifying potential hazards before operation
• Safety interlocks and automatic shutdown systems
• Control of ignition sources and confined space hazards

Module 10: Emergency Response and Incident Management

• Response to pressure vessel leaks or ruptures
• Evacuation procedures and fire control
• Post-incident investigation and reporting

Module 11: Roles, Responsibilities, and Training

• Operator and maintenance personnel duties
• Competency requirements and refresher training
• Management oversight and audit practices

Module 12: Continuous Improvement and Safety Culture

• Incorporating lessons learned into procedures
• Periodic safety reviews and audits
• Promoting awareness through toolbox talks and safety campaigns