Oil and Gas Surface Facility Design and Process Optimization Training Course

Course Introduction

Oil and gas surface facilities form the critical connection between subsurface hydrocarbon production and downstream processing, storage, transportation, and export systems. Proper facility design directly influences operational safety, production efficiency, environmental compliance, energy consumption, and long-term profitability. This comprehensive training course provides participants with advanced engineering knowledge of surface facility design, process engineering, equipment selection, production handling systems, utilities, and process optimization. Participants will develop practical competencies for designing, evaluating, and improving integrated oil and gas processing facilities using internationally recognized engineering standards and industry best practices.

Modern upstream developments face increasing challenges associated with complex reservoir fluids, high-pressure and high-temperature production, aging infrastructure, stricter environmental regulations, digital transformation, and the demand for higher operational efficiency. Engineers must integrate process engineering, mechanical design, instrumentation, automation, safety systems, and asset integrity into holistic facility development strategies. This course examines engineering methodologies for designing efficient processing systems that maximize production, reduce operating costs, improve equipment reliability, and support sustainable energy production throughout the facility lifecycle.

The course delivers comprehensive coverage of separation systems, gas processing, crude oil stabilization, produced water treatment, pumping and compression systems, heat exchangers, process simulation, pipeline interfaces, flare systems, storage facilities, instrumentation, utilities, and process control. Participants will explore engineering calculations, equipment sizing techniques, process modeling, debottlenecking methodologies, and optimization strategies through practical exercises and industry-based case studies that reflect real operational challenges in both onshore and offshore facilities.

Special emphasis is placed on process optimization, operational troubleshooting, energy efficiency improvement, asset reliability, maintenance planning, process safety management, HAZOP studies, environmental protection, and production enhancement. Participants will learn how integrated engineering approaches improve facility availability, minimize process bottlenecks, optimize operating costs, reduce emissions, and strengthen production reliability while ensuring compliance with international engineering standards and regulatory requirements.

Emerging technologies including artificial intelligence, machine learning, digital twins, Industrial Internet of Things (IIoT), predictive maintenance, advanced process control, cloud-based asset management platforms, real-time process monitoring, smart instrumentation, robotics, and digital operational excellence are fully integrated into the curriculum. Participants will understand how digital technologies enable intelligent process optimization, automated decision-making, predictive diagnostics, and continuous performance improvement across modern oil and gas surface facilities.

Upon successful completion of this intensive training course, participants will possess advanced competencies in oil and gas surface facility engineering, process optimization, equipment performance evaluation, digital process management, operational excellence, and lifecycle asset optimization. They will be equipped to design efficient processing facilities, optimize production systems, improve equipment reliability, enhance safety performance, and contribute to sustainable, reliable, and economically successful oil and gas operations.

Duration

10 days

Who Should Attend

• Process Engineers

• Petroleum Engineers

• Production Engineers

• Mechanical Engineers

• Chemical Engineers

• Facilities Engineers

• Pipeline Engineers

• Instrumentation and Control Engineers

• Operations Engineers

• Maintenance Engineers

• Asset Integrity Engineers

• HSE Engineers

• Project Engineers

• Plant Supervisors

• Oil and Gas Operations Managers

Course Objectives

• Develop advanced knowledge of oil and gas surface facility engineering principles to design safe, reliable, energy-efficient, and cost-effective production facilities.

• Design integrated surface processing systems incorporating separation, stabilization, gas handling, water treatment, utilities, and export facilities using engineering best practices.

• Apply process simulation, equipment sizing, hydraulic calculations, and engineering analysis techniques to optimize facility performance and production efficiency.

• Evaluate separators, pumps, compressors, heat exchangers, storage systems, pipelines, and process equipment to maximize operational reliability and lifecycle performance.

• Implement advanced process optimization strategies that reduce operating costs, minimize bottlenecks, improve throughput, and increase overall production capacity.

• Integrate process safety management, HAZOP studies, risk assessment, and regulatory compliance into facility design and operational improvement initiatives.

• Utilize artificial intelligence, digital twins, advanced process control, and predictive analytics to optimize plant operations and improve engineering decision-making.

• Assess equipment failures, operational constraints, and process inefficiencies using engineering diagnostics and root cause analysis methodologies.

• Improve energy efficiency through optimized utility systems, heat integration, equipment selection, and sustainable engineering practices across facility operations.

• Strengthen multidisciplinary collaboration between production, process, mechanical, electrical, instrumentation, maintenance, and HSE teams for integrated facility management.

• Evaluate environmental performance, emissions reduction strategies, produced water management, and waste minimization to support sustainable oil and gas operations.

• Enhance practical engineering skills through process simulations, facility design exercises, optimization workshops, and real-world case studies addressing complex operational challenges.

Comprehensive Course Outline

Module 1: Surface Facility Engineering Fundamentals

• Understanding complete oil and gas production facility architecture and operations

• Engineering principles governing upstream surface processing facilities

• Facility lifecycle management from concept through decommissioning

• International design standards and engineering best practices

Module 2: Production Separation Systems

• Design and optimization of two-phase and three-phase separators

• Separator sizing calculations for varying production conditions

• Gas-liquid separation efficiency improvement using advanced technologies

• Troubleshooting separator performance and operational bottlenecks

Module 3: Crude Oil Processing and Stabilization

• Crude stabilization processes for export quality specifications

• Vapor pressure control through optimized stabilization systems

• Heater treaters and electrostatic dehydrator performance optimization

• Product quality assurance and hydrocarbon loss minimization

Module 4: Natural Gas Processing Facilities

• Gas dehydration system design using glycol and solid desiccants

• Gas sweetening technologies for acid gas removal applications

• Hydrocarbon dew point control and gas conditioning processes

• Process optimization for efficient gas treatment operations

Module 5: Produced Water Treatment Systems

• Produced water treatment technologies for environmental compliance

• Oil-water separation equipment design and operational optimization

• Water reinjection system engineering and performance monitoring

• Sustainable water management and discharge quality improvement

Module 6: Pumps, Compressors, and Rotating Equipment

• Pump selection and hydraulic performance optimization methodologies

• Compressor system design for gas gathering and export facilities

• Reliability engineering for rotating equipment lifecycle management

• Condition monitoring and predictive maintenance technologies

Module 7: Heat Transfer and Utility Systems

• Heat exchanger design and thermal performance optimization techniques

• Steam, cooling water, and utility system integration strategies

• Energy recovery and heat integration for improved efficiency

• Utility system reliability and operational performance management

Module 8: Process Simulation and Facility Modeling

• Process simulation using industry-standard engineering software applications

• Mass and energy balance calculations supporting facility optimization

• Debottlenecking methodologies for production capacity improvements

• Simulation validation using operational plant performance data

Module 9: Instrumentation, Automation, and Process Control

• Smart instrumentation supporting accurate process monitoring activities

• Distributed control systems improving operational performance and reliability

• Advanced process control techniques for production optimization

• Industrial communication systems supporting digital facility integration

Module 10: Process Safety and Risk Management

• Hazard identification and HAZOP methodologies for process facilities

• Safety instrumented systems supporting operational risk reduction

• Fire, gas detection, and emergency shutdown system integration

• Regulatory compliance for process safety management programs

Module 11: Asset Integrity and Maintenance Engineering

• Asset integrity management supporting long-term facility reliability

• Reliability-centered maintenance planning for critical process equipment

• Corrosion monitoring and inspection program development strategies

• Lifecycle engineering supporting sustainable operational excellence

Module 12: Digital Transformation and Emerging Technologies

• Artificial intelligence supporting intelligent process optimization decisions

• Digital twins enabling real-time facility performance simulations

• Industrial Internet of Things improving continuous asset monitoring

• Predictive analytics supporting proactive maintenance and operations

Module 13: Energy Efficiency and Environmental Sustainability

• Energy optimization strategies reducing facility operating expenses significantly

• Carbon emission reduction through improved process efficiency initiatives

• Flare minimization and hydrocarbon recovery improvement techniques

• ESG principles supporting sustainable facility engineering practices

Module 14: Offshore and Onshore Facility Design

• Engineering differences between offshore and onshore production facilities

• Modular processing facility design for remote operating environments

• Floating production systems and subsea processing considerations

• Infrastructure optimization supporting future production expansion

Module 15: Operational Excellence and Process Optimization

• Lean operational methodologies improving facility productivity and reliability

• Continuous improvement strategies using operational performance indicators

• Root cause analysis supporting elimination of recurring process failures

• Production optimization through multidisciplinary engineering collaboration

Module 16: Integrated Engineering Case Studies and Practical Applications

• Comprehensive case studies from international oil and gas facilities

• Practical facility design exercises using engineering calculations

• Process optimization workshops addressing complex operational scenarios

• Final integrated project developing a complete optimized surface facility design

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: training@upskilldevelopment.com Tel: +254 721 331 808

Training Venue 

The training will be held at our Upskill Training Centre. We also offer training for a group (at a discount of 10% to 50%) at requested location all over the world. The Onsite course fee covers the course tuition, training materials, two break refreshments, buffet lunch, airport transfers, Upskill gift package, and guided tour.

Visa application, travel expenses, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Upskill certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: training@upskilldevelopment.com, +254 721 331 808

Terms of Payment:

Unless otherwise agreed between the two parties’ payment of the course fee should be done 3 working days before commencement of the training so as to enable us to prepare better.