Surface Equipment Maintenance and Operation

This is a comprehensive course aims at providing participants with working knowledge in the design considerations., operation and troubleshooting of all processes & equipment used for the handling & treatment of liquid and gaseous effluents coming out from the oil wellheads through gathering centers & booster stations to transmission lines.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

• Define the properties of the oil well products & effluents & their discharge environment constraints
• Learn the principles of gaseous & liquid types flow and to relate these principles to the necessary piping systems designing & materials
• Be aware of well technology, equipment / manifold and artificial lift including the principles of pumps, compressors, separators, heat exchangers & valves
• Understand the fundamental principles of processes in gathering centers such as oil /gas/water separation, well testing, water injection, produced water treatment, gas dehydration and sweetening
• Review the appropriate instrumentation and automatic. Control of all these processes and other necessary equipment such as flare system, drains, blowdown, compression, condensate recovery & meeting

Who Should Attend?

This course is intended for maintenance, production and other plant engineers responsible for process equipment.  New graduates will gain essential and integrated knowledge about pressure equipment and piping systems design and the significance of appropriate design, operation and maintenance on their mechanical integrity.

Course Outline

Day 1
Wellhead effluents properties & specifications:

• Crude oil
• Associated gas
• Water discharged

Other effluents discharged to environment:

• Gas flaring
• Produced water
• Displacement water
• Cooling water
• Drill cuttings
• Drain & Water

Wellhead Equipment

• Function
• Safety valves
• Christmas tree
• Chokes
• Operation - Multiple orifices
• Operation - Rotary Choke
• Safety

Day 2
Fluid flow

• Physical properties of hydrocarbon fluids
• Evaluation of friction losses
• Piping & low lines design
• Mam-folds
• Flow rates & pressures - Artificial left

Gas Oil Separation

• The need to separate gases from crude oil
• Demonstration of the separation problem
• Basic concepts underlying gas-oil separation
• Separation Equipment
• Design calculations for sizing gas-oil separators
• Optimum separating pressure for gas-oil separators
• Selection and performance of gas-oil separators

Treatment of Crude Oil - Dehydration

• Forms of water associated with produced oil
• Water-oil emulsions
• Treatment of "Wet" crude oil

Day 3
Desalting of Crude Oil

• Introduction
• Amount of salt and quantity of water found with crude oil
• The arithmetic relationship between volume % of remnant water, its salinity (ppm) and salt content (PTB)
• The desalting process
• Process design considerations

Dual-Purpose Operation: Stabilization and Sweetening of Crude Oil:

• Importance of stabilizing crude oil before storage
• Stabilization of crude oil using fractionation

Storage of Crude Oil and Other Field Facilities:

• Oil storage
• Vapor recovery system
• Pipeline gathering schemes

Day 4
Field Processing and Treatment of Natural Gas:

• Introduction
• Types of gas reservoirs
• Gas specifications and standard conditions
• Dehydration
• Gas sweetening
• Liquid hydrocarbons recovery

Production Operations Equipment

• Pumps
• Compressors
• Separators
• Heat exchangers

Auxiliary Systems & Utilities

• Flame Systems
• Drains
• Relief
• Blowdown
• Water supply & Discharge Systems
• Fire fighting
• Instrument air
• Invert gas
• Fuel Gas System
• Chemical Injection
• Power Generation
• Booster Stations

Day 5
Control Systems

• What to be controlled?
• Types of Control Systems
• Total Distributed Control System
• Automatic / Manual Control

Case Studies/Troubleshooting

Course Methodology

A variety of methodologies will be used during the course that includes:

• (30%) Based on Case Studies
• (30%) Techniques
• (30%) Role Play
• (10%) Concepts
• Pre-test and Post-test
• Variety of Learning Methods
• Lectures
• Case Studies and Self Questionaires
• Group Work
• Discussion
• Presentation

Course Fees

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Course Timings

Daily Course Timings
08:00 - 08:20 Morning Coffee / Tea
08:20 - 10:00 First Session
10:00 - 10:20 Coffee / Tea / Snacks
10:20 - 12:20 Second Session
12:20 - 13:30 Lunch Break & Prayer Break
13:30 - 15:00 Last Session