Oil & Gas Process Facilities Fundamentals Design, Operation & Safety

Duration: 5 Days
Target Audience: Process Engineers, Production Engineers, Facilities Engineers, Operations Staff, Entry-Level Engineers
Delivery Mode: Classroom / Virtual with Practical Exercises, Case Studies, and Facility Design Walkthroughs
Level: Foundation to Intermediate

Course Overview

This course provides a solid foundation in the design, operation, and optimization of oil and gas surface production and processing facilities. Participants will gain an understanding of separation, dehydration, stabilization, compression, storage, and key safety systems used in upstream and midstream facilities.

Day-by-Day Outline

Day 1 – Overview of Oil & Gas Process Facilities

- Upstream, midstream, and downstream overview
- Types of production facilities: onshore, offshore, FPSOs
- Flow of oil and gas from reservoir to processing facilities
- Process flow diagrams (PFDs) and P&IDs basics
- Exercise: Trace a production path from wellhead to export

Day 2 – Oil & Gas Separation Systems

- Principles of phase separation: gravity and centrifugal separators
- Two-phase and three-phase separators: design and internals
- Emulsion treatment and heater treaters
- Sand and solids handling systems
- Workshop: Size a separator for a specific production rate

Day 3 – Gas Processing & Compression

- Gas dehydration systems: glycol and desiccant units
- Gas sweetening basics: amine systems overview
- Gas compression: reciprocating and centrifugal compressors
- Flaring and vent systems
- Exercise: Develop a basic gas compression and dehydration train

Day 4 – Oil Processing, Storage & Measurement

- Crude oil stabilization methods
- Storage tank design and vapor recovery systems
- Custody transfer and metering technologies
- Tank gauging and international standards
- Workshop: Calculate oil storage requirements for a processing facility

Day 5 – Process Safety & Facility Optimization

- HAZOP basics and hazard identification
- Safety instrumented systems (SIS) and emergency shutdowns (ESD)
- Fire and gas detection systems in process facilities
- Debottlenecking strategies and performance improvement
- Capstone Project: Develop a simplified process flow for an integrated oil & gas facility

Expected Learning Outcomes

Understand the main components of oil & gas process facilities
Explain separation, dehydration, stabilization, and compression systems
Read and interpret PFDs and P&IDs
Apply safety best practices in facility design and operation
Identify opportunities for facility optimization and debottlenecking

Training Methods

- Classroom instruction and interactive discussions
- Case studies and exercises with real-world data
- Excel-based economic models and production forecasts
- Software demonstrations

Customization for Regional Needs

- Examples from regional onshore/offshore fields
- English delivery option available
- Integration with national regulatory framework

Trainer Profile

- Multidisciplinary instructors (reservoir, production, drilling)
- Regional NOC/IOC engineering advisors
- Guest speakers from petroleum economics and HSE backgrounds

Certification

Certificate of Completion and individual assessment report provided.