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Oil & Gas Upstream Separation Systems: Design, Operations, and Process Optimization

This training course focuses on the principles, design, and operation of oil and gas separation systems. Participants will gain in-depth knowledge of separation technologies, equipment selection, troubleshooting, and optimization strategies. The course combines theoretical concepts with practical applications, covering everything from basic separation principles to advanced process control and optimization techniques.

Audience

  1. Production Engineers and Operations Personnel
  2. Field Supervisors and Superintendents
  3. Process Engineers and Technicians
  4. Maintenance Engineers and Technicians
  5. Recently graduated engineers transitioning to production operations
  6. Technical professionals seeking to enhance their understanding on O&G processes.

Course objectives

  1. Understand fundamental principles of multiphase separation
  2. Design and optimize separation systems for various process conditions
  3. Evaluate separator performance and efficiency
  4. Troubleshoot common separation problems
  5. Implement best practices in separation operations
  6. Select appropriate separation equipment for specific applications
  7. Apply process safety principles to separation operations

Course contents

Day 1: Fundamentals of Separation

  1. Understand physical principles, fluid properties, and phase equilibrium in multiphase separation.
  2. Explore different separator types, including two-phase, three-phase, FWKO, test separators, and slug catchers.
  3. Learn about separator internals like inlet devices, mist extractors, vane packs, and coalescers.
  4. Focus on control systems for level, pressure, and temperature in separators.

Day 2: Separator Design and Sizing

  1. Master design parameters: retention time, gas/liquid capacity, and efficiency calculations.
  2. Study mechanical design elements: vessel configuration, materials, nozzles, and ASME code requirements.
  3. Address advanced considerations for high pressure, low temperature, sand, foam, and emulsions.
  4. Evaluate real-world design practices to optimize separator performance.

Day 3: Process Control and Instrumentation

  1. Develop control strategies for level, pressure, flow, temperature, and interface level.
  2. Learn about instrumentation for accurate level, pressure, temperature, and flow monitoring.
  3. Explore advanced control strategies like cascade, feed-forward, and ratio control.
  4. Integrate SCADA systems for digital and automated process management.

Day 4: Troubleshooting and Optimization

  1. Identify and address common issues like liquid carry-over, foaming, and sand accumulation.
  2. Optimize separator performance with efficiency improvement and debottlenecking strategies.
  3. Implement preventive maintenance and condition monitoring to improve reliability.
  4. Develop lifecycle management plans to ensure long-term equipment performance.

Day 5: Special Applications and Emerging Technologies

  1. Review offshore, subsea, and compact separation systems for specialized applications.
  2. Explore novel designs and technologies for environmental considerations and efficiency.
  3. Analyze case studies to apply knowledge to real-world scenarios.
  4. Summarize the course, participate in evaluations, and prepare for practical applications