Day-1

The Production Facility

• Facility Description
• Making the Equipment Work
• Process operations
• Operating Procedure
• Process Bottlenecks
• Production Troubleshooting
• Basic System Configuration

Types of wells according to Fluid

• Crude Oil
• Gas
• Condensate

Common Types of Artificial Lift

• Sucker rod pumping
• Gas lift
• Electric submersible pumping (ESP)

Other Types of Artificial Lift

• Hydraulic pumping
• Hydraulic piston pumping
• Hydraulic jet pumping
• Progressive cavity pumping (PCP)

Choice of Artificial Lift

• Production conditions
• Reservoir data
• Fluid properties

Day-2

Monitor Well Productivity

• Pressure
• Temperature
• Specific Gravity
• Salt Content
• Water Cut
• Oil and Gas Ratio
• Gross and Net Volume of Crude Oil
• Basic Sediment and Formation Water
• Well Production Decline and Effect of Well Aging

Manifold and Collector Equipment

• Isolating Valves
• Check Valve
• Chemical Injection Point

Instruments

• A pressure gauge
• A temperature indicator for routine condition checks
• Pressure Relief Valves
• Safety Shutdown Valves (SSV)
• Robot arm SSV
• Piston Action

Wellhead and Manifold

• Well Testing
• Review Production Standards & Procedures

Production Problems

• External Chemical Corrosion
• Internal Chemical Corrosion
• Electrical Corrosion
• Internal Abrasion
• Manufacturing and Welding Defects
• High Internal Pressures
• PSD and ESD Procedures

Day-3

Flow Line Restriction

• Gas Hydrate
• Liquid Slugging
• Paraffin / Asphaltenes
• Scales
• Low Temperatures
• Sand / Erosion
• Corrosion
• Emulsion / Foam
• Failed Mechanical Objects
• Viscous Organics

Oil, Gas and Water Separation

• Principles of Separation
• Phases of Separation
• Stages of Separation & Separators Classification
• Separator Internals
• Multistage Separation
• Centrifugal Separators
• Slug Catchers
• Separator Applications and Performance
• Physical Description
• Phase Separation Theory
• Gravity Settling Principles
• Design Consideration

Sections of a Three-Phase Separator

• Oil/Water Section
• Oil Section
• Gas Section

Factors Affecting Separation

• Difference in Weight of Fluids
• Residence Time in Separator
• Coalescing Surface Area
• Centrifugal Action
• Presence of Solids

Separator Control Points

• Pressure Control
• Level Control (Oil)
• Interface Level Control (Water/Oil)

Common Operating Problems with Separators

• Liquid Carryover in the Outlet Gas Stream
• Inability to Maintain Constant Liquid Level
• Failure of Coalescing Device
• Gas Blow-by
• Solid Deposits
• Foaming

Separator Start-up and Shutdown Procedures

Separators Operation & Troubleshooting

Case Study

Day-4

Crude Oil Treating

Emulsion

• Emulsion Treating Theory
• Forming Emulsions

Emulsifying Agents

• Asphaltic materials
• Resinous substances
• Oil-soluble organic acids
• Sand, carbon, calcium, iron, zinc, aluminum sulfate, iron sulfide, mud and so on

Demulsifiers

Four Important Actions Required of a Demulsifier

• Strong attraction to the oil/water interface
• Flocculation
• Coalescence
• Solid wetting

Emulsion Treating Equipment

• Heater Treaters
• Electrostatic Treaters
• Combinations

Emulsion Breakdown

• Heat
• Chemicals
• Electricity

Crude Oil Desalter

• Purpose
• Crude Oil Salts Chemistry

Types of Desalter

• Natural Desalter
• Chemical Desalter
• Electro Chemical Desalter

Desalting Problems

• Insufficient Attention by Operating Person
• Improper Operating Conditions
• Improper Chemical Dosage
• Inadequate Water Wash Supply, Rate and Quality
• Desalter Start-up and Shutdown Procedures
• Desalter Operation

Troubleshooting Tips

Chemical

• Correct Formulation
• Adequate Mixing
• Correct Injection Points and Rate

Mechanical Malfunction

• Chemical Pump Failure
• Treater Level Control
• Line Leakage
• Flow Splitters
• Metering Valves
• Dump Valves

Production Change

• Desalter Efficiency

Day-5

Pumps

Centrifugal Pumps

• Theory of Operation
• Types of Pumps
• Classifications
• Selection and Sizing of Centrifugal Pumps
• Main Elements and Their Functions in Centrifugal Pumps
• Centrifugal Pump Installation Requirements
• Pump Performance Curve & Head Loss
• Pump Cavitation and NPSH
• Hammering Multistage Pumps and Operation Arrangement Requirement

Pump Problems

• Erosion of the Impeller
• Vibration
• Other Cavitation-Induced Problems
• Maintenance & Troubleshooting

Case Study

Health, Safety & Environment

• Risk Assessment, Hazards Associated with Failure to Control Operation Parameters and Product Specifications in GC
• HSE Problems and Contingency Plans
• Safety Procedures and Implementation