Surface Production Facilities Design

Introduction

Surface production facilities design is a critical discipline that directly influences operational efficiency, safety performance, asset reliability, and long-term profitability across energy production value chains. Modern organizations require integrated facility solutions that align engineering excellence with strategic business objectives, ensuring that production targets are achieved within defined technical, financial, and operational constraints. This course provides a structured and results-oriented approach to designing surface production systems, covering essential components such as separation systems, fluid handling, processing units, storage, utilities, and export infrastructure while emphasizing decision-making accuracy, risk mitigation, and lifecycle optimization. Participants will gain practical insight into balancing technical requirements with economic considerations, addressing common industry challenges such as production variability, equipment selection uncertainties, capacity planning, and operational bottlenecks. The program also highlights opportunities for performance optimization through improved system integration, reliability engineering, and process efficiency enhancements. By the end of the course, professionals will be equipped with the competencies needed to design, evaluate, and improve surface production facilities in alignment with measurable performance objectives, organizational priorities, and sustainable operational strategies.

Course Objectives

• Analyze production requirements to determine optimal facility design configurations.

• Evaluate process flow diagrams and piping and instrumentation diagrams with technical accuracy.

• Design separation and processing systems based on fluid characteristics and production profiles.

• Calculate equipment sizing parameters for key surface facility components.

• Assess operational risks and implement mitigation strategies in facility design.

• Optimize facility layouts to improve efficiency, safety, and maintainability.

• Integrate utilities and support systems into overall production infrastructure.

• Apply lifecycle cost analysis to support engineering and investment decisions.

• Develop practical solutions for production bottlenecks and performance challenges.

Target Audience

This program is designed for production engineers, facility engineers, process engineers, project engineers, operations supervisors, maintenance professionals, technical managers, and professionals involved in design, commissioning, and optimization of surface production systems.

Benefits for the Organization

• Improved facility performance and production efficiency.

• Reduced operational risks and downtime.

• Enhanced capital investment decision quality.

• Optimized equipment utilization and lifecycle management.

• Strengthened engineering standardization and best practices.

• Increased operational reliability and safety compliance.

Benefits for the Trainee

• Strong technical competence in facility design principles.

• Improved decision-making confidence in engineering projects.

• Practical skills applicable to real-world production challenges.

• Enhanced career progression opportunities.

• Ability to evaluate and optimize existing facilities.

• Greater understanding of integrated production systems.

Course Outline

Day 1 – Fundamentals of Surface Production Systems

• Overview of surface production facility architecture.

• Production fluid characteristics and implications for design.

• Process flow fundamentals and system integration concepts.

• Introduction to separation technologies and equipment.

• Design standards, codes, and engineering practices.

• Safety considerations in facility design.

Day 2 – Separation and Processing Equipment Design

• Two-phase and three-phase separation principles.

• Separator sizing and selection methodologies.

• Heating, treating, and conditioning systems.

• Produced water handling and treatment concepts.

• Gas handling and compression fundamentals.

• Equipment performance evaluation techniques.

Day 3 – Facility Layout and Infrastructure Integration

• Facility layout planning and optimization.

• Piping systems design considerations.

• Storage systems and tank design fundamentals.

• Utility systems integration and requirements.

• Instrumentation and control system basics.

• Constructability and maintainability considerations.

Day 4 – Operations, Reliability, and Optimization

• Production system bottleneck analysis.

• Reliability engineering principles for facilities.

• Maintenance strategies and asset management.

• Process optimization techniques.

• Energy efficiency and performance improvement.

• Operational troubleshooting methodologies.

Day 5 – Economic Evaluation and Project Implementation

• Capital cost estimation and budgeting principles.

• Lifecycle cost analysis and financial evaluation.

• Project planning and execution strategies.

• Risk assessment and management frameworks.

• Case studies in facility design and optimization.

• Final workshop and integrated design exercise.

Course Duration

Duration: 5 days
Format: Classroom / Online / Blended

Instructor Information

“The training will be delivered by a team of experts specialized in negotiation and professional relationships. They have extensive practical experience in managing complex negotiations, as well as a strong record in delivering leadership and management development programs.”

Conclusion

Designing effective surface production facilities requires a combination of technical precision, strategic thinking, and operational awareness, and organizations that invest in these competencies gain significant advantages in efficiency, safety, and profitability. This course equips professionals with the structured knowledge and applied skills necessary to design robust, scalable, and economically viable production systems while improving cross-functional collaboration and engineering decision quality. Participants will leave with practical tools and confidence to contribute immediately to facility performance improvement initiatives and long-term organizational success.