Surface Facilities for Oil & Gas Handling Course | IIT Madras Prof. Abdus Samad
Course Details
| Exam Registration | 134 |
|---|---|
| Course Status | Ongoing |
| Course Type | Core |
| Language | English |
| Duration | 12 weeks |
| Categories | Ocean Engineering |
| Credit Points | 3 |
| Level | Undergraduate/Postgraduate |
| Start Date | 19 Jan 2026 |
| End Date | 10 Apr 2026 |
| Enrollment Ends | 02 Feb 2026 |
| Exam Registration Ends | 20 Feb 2026 |
| Exam Date | 18 Apr 2026 IST |
| NCrF Level | 4.5 — 8.0 |
Surface Facilities for Oil and Gas Handling: Your Gateway to Upstream Operations
The journey of oil and gas from deep within the reservoir to the market involves a critical, yet often overlooked, stage: surface handling. Once the hydrocarbons are brought to the surface, they are a complex mixture of crude oil, natural gas, water, and sand. The systems designed to safely, efficiently, and environmentally separate these components are known as Surface Facilities. A deep understanding of these facilities is paramount for any engineer in the upstream oil and gas sector.
This detailed guide explores a comprehensive 12-week course designed by Prof. Abdus Samad of IIT Madras that delves into the engineering principles, technologies, and design considerations behind these essential installations.
About the Course Instructor: Prof. Abdus Samad
Led by an expert with robust industry and academic credentials, this course offers unparalleled insights. Prof. Abdus Samad holds undergraduate and graduate degrees in Mechanical Engineering from India and South Korea. His practical experience includes a two-year stint with ZiLift Ltd (UK), where he worked on designing novel artificial lift systems. Since joining IIT Madras in 2010, he has been teaching petroleum engineering subjects and conducting extensive research in fluid machinery applications for oil, gas, and renewable energy. With 5 patents and an authored book on fluid machinery, Prof. Samad brings a wealth of knowledge to the subject.
Who is This Course For?
This course is meticulously structured for:
- Undergraduate and Postgraduate students in Petroleum, Mechanical, and Chemical Engineering.
- Professionals seeking to solidify their understanding of midstream surface operations.
- Individuals aiming for careers in upstream oil and gas companies, service providers, or consulting firms.
Prerequisites: A foundation in first-year engineering courses, along with basic concepts of petroleum drilling, completion, and production, is recommended.
Detailed 12-Week Course Layout
The course is structured to build knowledge from fundamental concepts to detailed design, following a logical flow of the surface treatment process.
| Week | Core Topics Covered |
|---|---|
| Week 1 | Introduction to drilling, completion, production, and the role of surface facilities. Fluid properties and units. |
| Week 2 | Fundamentals of separating oil, water, sand, and gas. Coalescence principles, coalescing media, and electrostatic coalescers. |
| Week 3 | Two-phase separators: vertical vs. horizontal designs, internals, and sizing calculations. |
| Week 4 | Three-phase separators, oil-water separation, vessel internals, emulsions, and heater treaters. |
| Week 5 | In-depth look at water-in-oil and oil-in-water separation, droplet size dynamics, and advanced separator sizing. |
| Week 6 | Crude oil treating: heater treaters, gun barrel settlers, desalting processes, and associated calculations. |
| Week 7 | Produced water treating systems: flotation units, hydrocyclones, and offshore disposal standards. |
| Week 8 | Natural gas processing: dehydration and sweetening techniques to meet pipeline specifications. |
| Week 9 | Storage facilities, metering systems, controlling evaporative emissions, and strategic storage concepts. |
| Week 10 | Heat transfer mechanisms in processes, calculating process heat duty, fire-tube heaters, and heat exchanger types/sizing. |
| Week 11 | Pressure vessel design fundamentals: determining wall thickness, line sizing, and essential design calculations. |
| Week 12 | Overview of key rotating equipment: compressors and pumps used on surface facilities, and internal combustion engines. |
Key Learning Outcomes
Upon completion, students will be equipped to:
- Understand the complete workflow of surface facilities from wellhead to sales point.
- Apply fundamental principles to separate oil, gas, water, and sand mixtures.
- Perform basic sizing calculations for separators, treaters, and heat exchangers.
- Comprehend the technologies for produced water treatment and environmentally sound disposal.
- Grasp the essentials of natural gas processing (dehydration & sweetening).
- Recognize the importance of safety, industry standards (API, ASME), and environmental regulations in design and operation.
Essential Reading & Industry Relevance
The course is supported by authoritative texts, ensuring alignment with global industry practices:
Primary Textbooks:
- Stewart, M. & Arnold, K. Surface Production Operations (Vol I & II). Gulf Professional Publishing.
- Stewart, M. Surface Production Operations (Vol III & IV). Gulf Professional Publishing.
Reference Books:
- Lyons, W.C. & Plisga, G.J. Standard Handbook of Petroleum and Natural Gas Engineering.
- Lake, L.W. (Ed.) Petroleum Engineering Handbook, Vol-III. SPE.
- Szilas, A.P. Production and Transportation of Oil and Gas, Part B. Elsevier.
Industry Support: The curriculum is recognized and supported by major industry players like ONGC, Baker Hughes, and other upstream oil and gas companies, highlighting its practical relevance and value for aspiring engineers.
Conclusion
The Surface Facilities for Oil and Gas Handling course provides a critical and comprehensive foundation for engineering the systems that transform raw reservoir fluid into marketable products. Under the guidance of Prof. Abdus Samad, students gain not only theoretical knowledge but also insights grounded in real-world patent work and industry experience. For any student or professional aiming to excel in upstream oil and gas operations, mastering the content of this 12-week journey is an indispensable step.
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