Production Optimization & Process Plant Operational Troubleshooting

10th – 14th February , 2019

Cairo – EGYPT



Upon Completion of The course, Participants will be able to:

Learn and understand the fluid properties

Learn how the process plant work and control

Check data accuracy, system function, report discrepancies to maintenance of valves.

Explain theory behind flow lines ,wellhed  and check valves for preparing and testing according to standard procedures

Understanding  process plant troubleshooting

Understanding the mechanisms ,function of separation process

Explain the theory and mechanisms of emulsion

Understand the production Optimization technique .



Production & Process Engineers and Technicians.




Crude oil properties and compositions

Crude oil types

Crude oil handling problems

Making the Equipment Work, Facility Types

Well flow lines gathering point

Plant layout and integration

 Principles of process operation

Introduction to control systems

GC processes troubleshooting and systems

DCS, system operation and monitoring

PLC systems and operation

UPS systems and monitoring systems

SCADA systems and monitoring techniques.

Control systems using simulator

Principles of calibration of control systems

Precautions during calibration Steps in control systems calibration

Monitoring equipment performance

Routine instrumentation

Controllers checks & reporting defective controls to maintenance

Conducting root cause analysis for all operating parameters

Control system response for ESD

Choosing a Process


Controlling the Process, Operation of a Control Valve, Pressure Control, Level Control, Temperature Control, Flow Control

Basic System Configuration

Wellhead and Manifold, Separation, Oil Treating, Lease Automatic Custody Transfer (LACT), Pumps, Water Treating, Compressors, Gas Dehydrators

 Control types, components

Level control

Pressure Control

Temperature control

Control loops type

Control loop components

Basics of operation on Instrumentation controls (LCV, PCB, transmitter, switches)

Instrumentation functions

Types of instrumentation

Instrumentation locations

Control loop types

Components of instruments

Instrument variable measurement

Control troubleshooting

Sample exercises

  Control Systems

Control systems type

Check data accuracy ,

system function and operate

check control system functions


Performance of control system

Calibration and adjustment

Troubleshooting  of control system and take action

Check for GC equipment as one unit

Operation according to international standard

Operation according to international procedures

Production optimization using check system analysis

Nodal analysis technique

Procedure of appliying Nodal analysis

Oil and Gas Separation 

Factors Affecting Separation

Equipment Description

Horizontal Separators, Vertical Separator

Spherical Separators, Other Configurations


Horizontal vs. Vertical Vessel Selection,

Vessel Internals

Inlet Diverters, Wave Breaker, Defoaming Plates

Vortex Breaker, Mist Extractor

Potential Operating Problems

Foamy Crudes, Paraffin, Sand

Liquid Carryover and Gas Blowby

Troubleshooting  and take action

Settling, Drop Size, Retention Time


Oil and Water Separation 


Equipment Description,

Horizontal Separators, Vertical Separators

Horizontal vs. Vertical Selection

Vessel Internals

Coalescing Plates 143, Sand Jets and Drains



Gas Separation, Oil/Water Settling

Water Droplet Size in Oil, Oil Droplet Size in Water

Retention Time

Separation problems

Troubleshooting  and take action

Crude Oil Treating Systems 

Methods of emulsion treatment


Chemical demulsfiers

Washing water with mixing valve

Electromagnetic field ( dehydration and desalter)

Emulsion Treating Theory

Forming Emulsions, Emulsifying Agent


Gravity Separation,

Coalescence, Viscosity, Temperature Effects

Heat Input Equations, Water Droplet Size and Retention

Time, Coalescing Media Electrostatic Coalescers

Treating Equipment

Vertical Treaters, Horizontal Treaters

Electrostatic Treaters

Troubleshooting  and take action

Produced-Water Treating Systems 


System Description


Gravity Separation, Dispersion, Coalescence, Flotation

Treating Equipment,

Settling Tanks and Skimmer Vessels

Skimmer Sizing Equations, Plate Coalescers

Skimmer/Coalescers, Precipitators/ Coalescing Filters

Free-Flow Turbulent Coalescers (SP Packs)

Flotation Units, Hydrocyclones, Disposal Piles

Skim Pile

Drain Systems

Information Required for Design

Influent Water Quality,

Produced Water, Soluble Oil   Deck Drainage

Equipment Selection Procedure

Equipment Specification

Example: Design the Produced-Water Treating System for the

Data Given

Troubleshooting  and take action

Troubleshooting for separation unit

Troubleshooting for treatment unit

Safety System (Normal & Emergency shutdown System, Fire & Gas detection).

Risk assessment

Safety precaution

Fire and explosion

Loss prevention

Types of hazards

The HAZOP study techniques

Hazards analysis

Preventing fire

Safety culture

The importance of PPE

Safety manage system

The safety procedures and policies

The emergency response

The noise hazard

The leaks and spills

The fumes and volatile vapours

The gas detectors uses and operation

Health and safety related to ranks and tanks farm

Safety Operation of Storage Tanks (Safety related devices)

Course assessment  .

Language : English & Arabic .

Fees : 2850 $

Daily schedule :

Lecture1  9 :  11 Am

Rest  1 11 :  11.15 Am

Lecture2 11.15 :  12.45 Pm

Rest 2 12.45 : 2 Pm

Lecture3 2 :  3 Pm