Oil Process Facilities VIRTUAL TRAINING

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Upcoming Course

Code Start Date End Date Location Cost Instructor Register
PST0423-202101  02 Aug 2021  06 Aug 2021  VIRTUAL TRAINING  USD 2995  Magdi El Naggar   Register

Past Course

Code Start Date End Date Location Cost Instructor Register
        Aaron A. Zick, Ph.D. 

This course is designed to ensure awareness and effective understanding of various phases of production operations fundamentals throughout understanding the functions of various oil field components from the well to processing facilities.

The course also addresses and emphasizes the fundamental understanding of wide range of oilfield production handling and treatment equipment not only “what” but “how” the field fluid treating equipment works. The major objective of this course is to improve communication amongs the technical disciplines across organizations in order to enhance operational and cross functional work perfomance, promote cooperation and team work spirit amongs the team across various organizations, optimize cost and improve production economics. This can be the operator’s best insurance to achieve successful safe and cost effective operations

Module 1 : Introduction and Overview on Oil & Gas

  • Petroleum Geology and Origin of Hydrocarbons
    • Formation of Oil
    • Oil and Gas Reservoirs
    • Reservoir Rock and Fluid properties
  • Exploration and Appraisal
    • Geological and commercial factors necessary for successful exploration and appraisal
    • Seismic surveys
  • Drilling
    • Drilling rigs
    • Equipment and processes involved in drilling a well
    • Completing a well and preparing it for production
    • Horizontal Drilling
    • Well workover operations
  • Oil Recovery Methodologies
    • Reservoir production mechanisms
    • Artificial Lift Systems
    • Well stimulation - fracturing, acidizing and sand control
    • Production and treatment of reservoir fluids
    • Processing the production from oil and gas fields

Module 2 : Surface Facilities

  • Introduction
    • Field Development Overview
    • Why do we need Surface Facilities?
    • Data Required
    • Fluid Characterization
    • Surface Facilities Processes
    • Function of Surface Facilities
    • Hydrocarbon Specification
  • Well Control and Safety System
    • Wellhead, X-mas Tree and Wellhead Equipment
    • Wellhead Control and Safety System
    • Choke Valve (fixed, adjustable)
    • Flow Principles through Chokes
  • Gathering System
    • The manifold function in gathering stations
    • Flowlines
    • Horizontal Pipe Flow patterns
    • Multiphase Flow Fundamental
    • Multiphase Flow Meters
    • Flowlines
    • Surge Phenomenon
    • Manifold
      • Onshore
      • Offshore
      • Subsea
    • Pipelines
    • Monitoring
    • Maintenance
    • Pigging

Module 3 : Oil & Gas Separation System

  • Introduction
    • Oil Field separation Process
    • Principles of separation
    • Phases Separation
    • Stage Separation
    • Separator Configurations
    • Separator Internals
  • Major Components of Process Separators and Vessel Internal
  • Classification of Oil & Gas Separators
    • By Operating Configuration
    • By Function
    • By Operating Pressure
    • By Application
  • Primary Functions of Oil and Gas Separators
    • Removal of Oil from Gas
    • Removal of Gas from Oil
    • Separation of Water from Oil
  • Secondary Functions of Oil and Gas Separators
    • Maintenance of Optimum Pressure on Separator
    • Maintenance of liquid Seal in Separator
    • Removal Methodologies of Oil from Gas in Separators
    • Density Difference (Gravity Separation)
    • Impingement
    • Change of Flow Direction
    • Change of Flow Velocity
    • Centrifugal Force
  • Flow Calibration in Oil and Gas Separators
  • Controls, Valves, Accessories & Safety Features for Oil & Gas Separators
    • Controls
    • Valves
    • Accessories
    • Safety Features
  • Operational and Maintenance Considerations for Oil & Gas Separators
    • Periodic Inspection
    • Installation of Safety Devices
    • Low Temperature
      • Corrosive Fluids
      • Separation Operation problems & troubleshooting

Module 4 : Oil Dehydration System

  • Introduction
  • Emulsions & Emulsion Terminology
  • Emulsion Treatment Equipment
  • Emulsifying Agents
  • Demulsifiers
  • Factors affecting Emulsion Breakdown
  • Emulsion Treatment and Process Description
  • Factors affecting Emulsion Treatment

Module 5 : Gas Dehydration

  • Introduction
  • Definition
  • Water/Hydrocarbon System Behaviors
  • Water content in Natural Gas
  • Water Dew Point
  • Dew Point Depression
  • Hydrates Control in Natural Gas Systems
  • Gas Dehydration System
  • Absorption using Liquid Desiccants (Glycol Dehydration)
  • Process Flow & Components
  • Process Operation & Variables
  • Operational Problems & Troubleshooting
  • Hydrate Inhibitation at Low Temperature Processing Plant

Module 6 : Refrigeration

  • Introduction
  • Liquid Separation Economics
    • Lean Oil Absorption
    • Refrigeration
    • Cryogenic
  • Gas Chilling
  • Cryogenic Process
    • Dehydration
    • Chilling
    • Fractionation
  • Refrigeration Systems
  • Single Component Refrigeration (Propane)
    • Refrigerant
    • Equipment
    • Principle of Operation, Problems and Controls

Module 7 : Equipment & Process System

  • Pipe, Pipe Fittings and Associated Equipment
  • Valves, Control Valves, Actuators & Solenoids
  • Strainers
  • Separators & Vessels
  • Heat & Heat Transfer Equipment; Coolers & Fin Fans
  • Pumps - Centrifugal and Reciprocating
  • Pressure, Temperature, Flow & Level Measurement
  • Turbines
  • Compressors
  • Emergency Generators
  • DCS Basics
  • Process Drawings and Nomenclature - P&IDs, PFDIs

Module 8 : Produced Water Treatment

  • Characteristics of Produced Water, Formation Water, Surface and Sea Water
  • Suspended and Dissolved Material Parameters and Oil in Water Concetration
  • Surface Water, Sea Water and Produced Water Injection Examples Corrosion Problems
  • Water Quality for Injection and Produced Water Quality Rating Methods Guidelines for Produced Water Reinjection
  • Methods and Equipment for Produced Water Treatment before
  • Reinjection and their Operations
  • Pressure Build-up and Confinement Problems and Solutions
  • Practical Application of Produced Water Treating Technology

Module 9 : Chemical Injection & Sampling

  • Basic Production Chemistry
  • Chemical Injection
  • Chemicals Handling Procedures
  • Sampling

Module 10 : Pigging Operations

  • Pigging Operations
  • Pipelines and Pigging Operations
  • Types of Pigs
  • Pigging Facilities
  • Procedures for Pigging Operations
  • Launching and Receiving Utility and Inteligent Tools
  • How to assess a tool’s perfomance
    • Signaling and Pig Location
    • Locating and Reporting Sample Defects
  • Pig Launcher/Pig Receiver P & ID Diagram
  • Why Pigs Get Stuck? How to avoid that?
  • Factors Contributing to Accident during Pigging Operations
  • Site Safety : Procedures and Perfomance
  • Example of Pigging Accidents
  • Safe Pigging Operations

Module 11 : Oil Storage & Shipping Facilities

  • Tanks and Tank Storage Facilities
  • Types of Storage Tanks
  • Associated Hazardous Conditions

Module 12 : HSE Requirement

  • Authorization and Competency of Production Personnel
  • General Safety Procedures
  • Handling Chemicals
  • Understand surface facilities components from well to production station
  • Understand the principles of Oil & Gas Separation
  • Understand the principles of Oil & Gas Dehydration
  • Familiarize with the principles of Fractionation & Operations
  • Familiarize with the principles of Refrigeration Operations
  • Understand and Identify the Operating problems
  • Familiarize with the Pipeline Operations & Maintenance, Problem & Troubleshooting
  • Familiarize with the Pipeline Pigging Operations
  • Familiarize with types of Storage Tanks, Associated Hazards & Safety
  • Familiarize with various equipment and tools and its function
  • Production Engineers
  • Operation Engineers
  • Facilities Engineers
  • Petroleum Engineers
  • Field Production Supervisors
  • Surface Equipment Technicians
  • Field Facility Engineers / Operators

Aaron A. Zick, Ph.D.

Founder and President


President, Zick Technologies (Since 10/93).

Petroleum engineering consulting and software development, specializing in the area of reservoir fluid phase behavior modeling. References available on request. Key achievements:

-Developed numerous equation-of-state and black-oil fluid characterizations for various major oil companies and as a sub-contractor for Pera A/S.

-Recommended phase behavior experimentation and modeling guidelines for several major oil companies.

-Wrote PhazeComp, a new, state-of-the-art program from Zick Technologies for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Wrote Streamz, unique Petrostreamz A/S software for translating, manipulating, and managing vast quantities of fluid stream information.

-Designed and helped write Pipe-It, unique Petrostreamz A/S software for managing and manipulating petroleum resources, processes, and projects.

-Taught numerous industry courses on phase behavior, equations of state, reservoir fluid characterization, and miscible gas injection processes.

-Designed and helped implement a new set of equation-of-state routines for the in-house reservoir simulator of a major oil company.

-Advised the architects of a major commercial reservoir simulator on ways to significantly improve their equation-of-state routines.


Director of Research, Reservoir Simulation Research Corporation (6/91–10/93).

Responsible for the research and development of more efficient, accurate, and reliable techniques for modeling reservoir fluid phase behavior within MORE® (a fully-compositional, equation-of-state reservoir simulator). Also responsible for improving three-dimensional visualization of reservoir simulator output, and for occasional consulting work. Key achievements:

-Designed and implemented new equation-of-state solution algorithms for MORE®, improving both efficiency and robustness while using less memory.

-Developed a powerful and flexible interface between MORE® and TECPLOT™ (three-dimensional surface contouring software from AMTEC Engineering).


Senior Principal Research Engineer, ARCO Oil and Gas Company (9/83–5/91).

Developed expertise in reservoir fluid phase behavior, phase behavior modeling, compositional reservoir simulation, and relative permeability modeling.  Designed and analyzed PVT experiments. Created equation-of-state reservoir fluid characterizations. Developed ARCO’s phase behavior modeling software and relative permeability modeling software. Helped develop several of ARCO’s compositional and limited compositional reservoir simulators. Key achievements:

-Discovered the true, condensing/vaporizing mechanism of oil displace­ment by enriched hydrocarbon gases.

-Represented ARCO on the Prudhoe Bay co-owners’ Enhanced Oil Recovery Task Force for the Prudhoe Bay Miscible Gas Project.

-Designed and analyzed most of the PVT and slim-tube experiments for the Prudhoe Bay Miscible Gas Project.

-Created the equation-of-state reservoir fluid characterization adopted by the operating companies for the Prudhoe Bay Miscible Gas Project.

-Developed the miscibility pressure correlations used by the facility operators for the Prudhoe Bay Miscible Gas Project.

-Developed EOSPHASE, a then state-of-the-art program for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Developed SLIMTUBE, a special-purpose, equation-of-state simulator for slim-tube displacements.

-Developed new, compositionally-consistent, three-phase relative perme­ability models for ARCO’s compositional simulators and wrote data-fitting software for those models.

-Developed the phase behavior and relative permeability routines for a new, limited compositional reservoir simulator and assisted on other aspects of it.

-Continually added improvements to various in-house reservoir simulators.

-Regularly taught in-house courses on the phase behavior of miscible gas displacement processes.



A. A. Zick, “A Combined Condensing/Vaporizing Mechanism in the Displacement of Oil by Enriched Gases,” presented at the 61st Annual Technical Conference and Exhibition of the Society of Petroleum Engineers, New Orleans, LA (October, 1986).

D. E. Tang and A. A. Zick, “A New Limited Compositional Reservoir Simulator,” presented at the 12th SPE Symposium on Reservoir Simulation, New Orleans, LA (March, 1993).