Arabian American Center Details Training & Development
Program Title:
Crude Oil Process Plant Operational Troubleshooting
16.06.2019 - 20.06.2019
$ 3900


Course Objectives

        By the end of this course ,the Participants  will be able to:

               • To learn and understand the fluid properties

               • To learn how the process plant work and control   

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

               • To explain theory behind flow lines ,wellhed  and check valves for preparing and testing

                   according to standard procedures  

               • Understanding well testing procedures

               • Understanding the mechanisms ,function of separation process

               • To explain the theory and mechanisms of emulsion


Course Methodology

               • Power point presentation

               • Practical exercises

               • Cases studies

               • Open discussion



               • Introduction

                                o Crude oil properties and compositions

                                o Crude oil types

                                o Crude oil handling problems

                                o Making the Equipment Work, Facility Types

                                o Well flow lines gathering point

                                o Plant layout and integration

               • Principles ofprocess operation

                                o Introduction to control systems

                                o GC processes troubleshooting and systems

                                o DCS, system operation and monitoring

                                o PLC systems and operation

               • UPS systems and monitoring systems

                                o SCADA systems and monitoring techniques.

                                o Control systems using simulator

                                o Principles of calibration of control systems

                                o Precautions during calibration Steps in control systems calibration


               • Monitoring equipment performance

                                o Routine instrumentation

                                o Controllers checks & reporting defective controls to maintenance

                                o Conducting root cause analysis for all operating parameters

                                o Control system response for ESD

               • Choosing a Process

                                o Introduction  

                                o Controlling the Process, Operation of a Control Valve, Pressure Control, Level

                                    Control, Temperature Control, Flow Control  

               • Basic System Configuration

                                o Wellhead and Manifold, Separation, Oil Treating, Lease Automatic Custody

                                     Transfer (LACT), Pumps, Water Treating, Compressors, Gas Dehydrators  

                • Control types, components

                                o Level control

                                o Pressure Control

                                o Temperature control

                                o Control loops type

                                o Control loop components

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

                                o Instrumentation functions

                                o Types of instrumentation

                                o Instrumentation locations

                                o Control loop types

                                o Components of instruments

                                o Instrument variable measurement

                                o Control troubleshooting

                                o Sample exercises

               • Control Systems

                                o Control systems type

                                o Check data accuracy ,

                                o System function and operate

                                o Check control system functions

                                o DSC,PLC, SCADA

                                o Performance of control system

                                o Calibration and adjustment

                                o Troubleshooting  of control system and take action

               • Fluid Properties  

                                o Introduction,  

                                o Basic Principles

                                o Specific Gravity and Density, Viscosity   

               • Oil and Gas Separation  

                                o Introduction

                                o Factors Affecting Separation

                                o Equipment Description

                                                 Horizontal Separators, Vertical Separator

                                                 Spherical Separators, Other Configurations

                                                 Scrubbers  

                                o Horizontal vs. Vertical Vessel Selection,  

                                o Vessel Internals

                                                 Inlet Diverters, Wave Breaker, Defoaming Plates  

                                                 Vortex Breaker, Mist Extractor  

                                o Potential Operating Problems  

                                                 Foamy Crudes, Paraffin, Sand

                                                 Liquid Carryover and Gas Blowby  

                                                 Troubleshooting  and take action

                                o Theory  

                                                 Settling, Drop Size, Retention Time

                                                 Re-entrainment  

               • Oil and Water Separation  

                                o Introduction,  

                                o Equipment Description,  

                                                 Horizontal Separators, Vertical Separators

                                                 Horizontal vs. Vertical Selection   


                                o Vessel Internals  

                                                 Coalescing Plates 143, Sand Jets and Drains  

                                o Emulsions

                                o Theory,

                                                 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  

                                o Introduction

                                o Methods of emulsion treatment Heating

                                o Chemical demulsfiers

                                o Washing water with mixing valve

                                o Electromagnetic field ( dehydration and desalter)

                                o Emulsion Treating Theory

                                                 Forming Emulsions, Emulsifying Agent  

                                                 Demulsifiers   

                                o Gravity Separation,  

               • Coalescence, Viscosity, Temperature Effects

               • Heat Input Equations, Water Droplet Size and Retention

               • Time, Coalescing Media Electrostatic Coalescers  

                                o Treating Equipment

               • Vertical Treaters, Horizontal Treaters

               • Electrostatic Treaters Troubleshooting  and take action

               • Produced-Water Treating Systems  

                                o Introduction,  

                                o System Description  

                                o Theory

               • Gravity Separation, Dispersion, Coalescence, Flotation  

               • Treating Equipment,  

                                o Settling Tanks and Skimmer Vessels

                                o Skimmer Sizing Equations, Plate Coalescers

                                o Skimmer/Coalescers, Precipitators/ Coalescing Filters

                                o Free-Flow Turbulent Coalescers (SP Packs)  

                                o Flotation Units, Hydrocyclones, Disposal Piles

                                o Skim Pile  

               • Drain Systems

               • Information Required for Design

               • Influent Water Quality,  

               • Produced Water, Soluble Oil   Deck Drainage  

                                o Equipment Selection Procedure

                                o Equipment Specification

                                o Example: Design the Produced-Water Treating System for the

                                o Data Given Troubleshooting  and take action

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

                                o Risk assessment

                                o Safety precaution

                                o Fire and explosion

                                o Loss prevention

                                o Types of hazards

                                o The HAZOP study techniques

                                o Hazards analysis

                                o Preventing fire

                                o Safety culture

                                o The importance of PPE

                                o Safety manage system

                                o The safety procedures and policies

                                o The emergency response

                                o The noise hazard

                                o The leaks and spills

                                o The fumes and volatile vapours

                                o The gas detectors uses and operation

                                o Health and safety related to ranks and tanks farm

                                o Safety Operation of Storage Tanks (Safety related devices)

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