COURSE OVERVIEW:

Debottlenecking and Capacity Improvement for Production Facilities is a strategic engineering course focused on extracting maximum value from existing surface infrastructure. As oil and gas fields evolve, the fluids they produce often change in composition, with increasing water cuts or gas-to-oil ratios that can overwhelm original facility designs. This course provides a structured methodology for identifying the specific components, whether separators, pumps, or compressors—that are restricting total system throughput.

The scope of this training involves the use of process simulation and field data to pinpoint "bottlenecks" and evaluate the feasibility of various expansion options. Participants will learn to distinguish between operational bottlenecks, which can be resolved through setpoint optimization, and physical bottlenecks, which require hardware modifications or replacements. The curriculum emphasizes a holistic approach, ensuring that increasing capacity in one part of the plant does not create a new restriction further downstream.

Coverage includes the evaluation of separation efficiency, the upgrade of fluid handling systems, and the implementation of advanced control strategies to stabilize flow. Attendees will learn how to perform cost-benefit analyses for debottlenecking projects, comparing minor piping modifications against major capital expenditures. By focusing on practical, real-world engineering solutions, this course empowers participants to revitalize aging facilities and accommodate increased production volumes without the need for entirely new installations.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the concept of a "bottleneck" within an integrated production system.
• Utilize process flow diagrams (PFDs) and mass balances to identify capacity limits.
• Evaluate the hydraulic capacity of existing piping and manifolds.
• Identify the limiting factors in three-phase separators and slug catchers.
• Assess the performance of pumps and compressors against their original curves.
• Model the impact of increasing water cut on separation and water treatment capacity.
• Propose low-cost modifications such as vessel internal upgrades to improve throughput.
• Analyze the effect of heat exchanger fouling on facility processing limits.
• Determine the capacity of flare and relief systems for expanded operations.
• Use Nodal Analysis and simulation tools to identify "hidden" bottlenecks.
• Design debottlenecking solutions that minimize production downtime.
• Calculate the Return on Investment (ROI) for various capacity improvement options.
• Implement "Quick-Win" operational changes to stabilize and increase production.

TARGET AUDIENCE:

Process Engineers, Facilities Engineers, Production Supervisors, Project Managers, and Operations Planners responsible for facility optimization and upgrades.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.