This training is designed for field operators, console operators, and maintenance personnel working in oil & gas production facilities such as wellheads, flow stations, gas plants, terminals, and FPSOs, and aligns with Advanxis’ technical training approach emphasizing both theory and hands-on practical sessions.

Target Audience:

Field Operators
Console Operators
Instrument Technicians
Production Technicians
Maintenance Personnel
New Graduate Trainees

Training Mode: Classroom + Practical + Simulation + Field Demonstration

TRAINING OBJECTIVES

At the end of this training, participants will be able to:

Interpret and understand P&IDs and process drawings
Understand oil and gas production processes from wellhead to export
Understand process control principles and instrumentation
Safely perform process startup and shutdown
Identify process equipment and their functions
Respond properly to abnormal process conditions
Understand operator responsibilities in safe plant operations

MODULE 1: P&ID (Piping and Instrumentation Diagram)

Objectives

Participants will learn how to read, interpret, and apply P&IDs for safe and effective plant operation.

Topics Covered

1.1 Introduction to Engineering Drawings

Types of drawings:
- PFD (Process Flow Diagram)
- P&ID (Piping and Instrumentation Diagram)
- Isometric Drawings
- General Arrangement Drawings
- Cause & Effect diagrams
Differences between PFD and P&ID

1.2 P&ID Symbols and Identification

Equipment Symbols

Pumps
Compressors
Separators
Heat exchangers
Valves
Tanks and vessels

Instrument Symbols

Pressure Transmitters (PT)
Temperature Transmitters (TT)
Flow Transmitters (FT)
Level Transmitters (LT)
Controllers (PIC, LIC, TIC, FIC)

Valve Types

Control valves
Manual valves
Shutdown valves (ESD)
Check valves
Safety valves (PSV)

1.3 Tag Numbering System

Examples:

PT-101 → Pressure Transmitter
LIC-201 → Level Indicating Controller
FV-301 → Flow Control Valve

Understanding ISA standards

1.4 Line Identification

Understanding pipe information:

Line number
Size
Fluid type
Flow direction
Insulation
Pressure rating

Example:
6”-CRUDE-101-A1

1.5 Control Loops on P&ID

Understanding complete loop:

Process → Transmitter → Controller → Control Valve

Example:
Separator Level Control Loop:
LT → LIC → LV

1.6 Safety Systems on P&ID

Identification of:

ESD Valves
Safety valves (PSV)
Blowdown valves
Emergency shutdown logic

Practical Session

Participants will:

Identify instruments on real P&ID
Trace process flow from wellhead to separator
Identify control loops
Identify shutdown valves

MODULE 2: OIL AND GAS PRODUCTION PROCESS

Objectives

Participants will understand the complete oil and gas production process from wellhead to export.

Topics Covered

2.1 Overview of Oil and Gas Production

Production stages:

Wellhead production
Separation
Treatment
Storage
Export

2.2 Wellhead Equipment

Components:

Christmas tree
Master valve
Wing valve
Choke valve
Pressure gauges

Functions and operation

2.3 Flowlines and Manifolds

Purpose:

Transport fluids
Control flow from multiple wells

Types:

Production manifold
Test manifold

2.4 Separation Process

Purpose:

Separate:

Oil
Gas
Water

Types of separators:

2-phase separator
3-phase separator

Working principle

2.5 Oil Processing System

Includes:

Heater treaters
Electrostatic treaters
Storage tanks
Export pumps

2.6 Gas Processing System

Includes:

Gas scrubbers
Compressors
Gas dehydration units
Gas export systems

2.7 Produced Water Treatment

Includes:

Hydrocyclones
Skimmers
Water injection pumps

Practical Session

Participants will:

Identify production equipment
Trace process from wellhead to export
Understand equipment functions

MODULE 3: PROCESS CONTROL FUNDAMENTALS

Duration: 2 Days

Objectives

Participants will understand how process variables are measured and controlled.

Topics Covered

3.1 Introduction to Process Control

Definition of process control

Why process control is required:

Safety
Stability
Efficiency
Product quality

3.2 Process Variables

Major process variables:

Pressure
Temperature
Flow
Level

Examples in oil and gas plants

3.3 Instrumentation Basics

Types of instruments:

Transmitters
Controllers
Control valves

Signal types:

4-20 mA
Digital communication (HART, Modbus)

3.4 Control Loop Components

Components:

Process
Transmitter
Controller
Control valve

Closed loop vs open loop

3.5 Control Room and SCADA System

Overview:

PLC
DCS
SCADA
HMI

Operator interface

3.6 Alarms and Trips

Types:

High alarm
Low alarm
High-High trip
Low-Low trip

Operator actions during alarm

Practical Session

Participants will:

Identify instruments in field
Observe control loops
Simulate process control using SCADA simulator

MODULE 4: PROCESS STARTUP AND SHUTDOWN

Objectives

Participants will understand safe startup and shutdown procedures.

Topics Covered

4.1 Importance of Proper Startup and Shutdown

Risks of improper startup:

Explosion
Equipment damage
Loss of production

4.2 Types of Startup

Cold startup
Warm startup
Hot startup

4.3 Pre-Startup Checks

Includes:

Equipment inspection
Valve position verification
Instrument readiness
Power availability
Utility availability

4.4 Startup Procedure

Typical startup sequence:

Start utilities
Pressurize system slowly
Open valves gradually
Start pumps and compressors
Stabilize process
Monitor parameters

4.5 Normal Shutdown Procedure

Sequence:

Reduce load
Stop pumps
Close valves
Depressurize system

4.6 Emergency Shutdown (ESD)

Causes:

High pressure
Fire detection
Gas leak detection
Equipment failure

Operator responsibilities

4.7 Safe Isolation Procedure

Includes:

Lockout/Tagout
Depressurization
Isolation verification

Practical Session

Participants will:

Simulate startup using training system
Simulate shutdown procedure
Practice emergency response scenarios

TRAINING DELIVERABLES

Participants will receive:

Training manual
P&ID reference guide
Operator quick reference handbook
Certificate of completion

TRAINING OUTCOME

Participants will be able to:

Read and understand P&IDs
Understand oil and gas production systems
Understand process control systems
Safely start and shutdown process equipment
Respond properly to alarms and process abnormalities

Course Duration 48hrs/4weeks

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