P3700 THREE PHASE SEPARATION TRAINING UNIT

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cussons TECHNOLOGY

Control Engineering

EXPERIMENTAL CAPABILITY

Phase Separator model studies the effect of separation

pressure, feed temperature, and flow/residence time.

Full aspects of Three Phase Separation learning.

Separation basics: Flow vs Residence Time, Flow vs

Composition, Pressure vs Flow, Press v. Compositions,

Temp v. Compositions.

Simulation model providing highly visual representation

of fluid component separation at various flow,

temperature and pressure conditions.

Tuning of PID algorithms for closed loop control.

Practical learning associated with the instrumentation:

PLC and ESD system and DCS controls.

Programmed PLC for safety functionality, valve and

pump responses to HH and LL level sensors, and

depressurisation.

FEATURES

Controlled Pressurisation and Valving for Fluid Movement

to the Separator Mixer.

Integral OMRON PLC.

Steel Vessels Fluid System.

DCS Interface.

Polycarbonate Separation Vessel.

Oil/water ratio to the Separator feed.

Multicomponent Hi-Fidelity Engineering Dynamic Process

Simulation Model.

Model is based on actual equipment in the UK North

Sea.

Typical composition set from an actual oil/gas wellhead.

Dynamic Simulation Model across 10 PCs (classroom

simulation).

INTRODUCTION

A clear separator vessel allows full visualization of the

separation dynamics.

The P3700 have developed this unit to meet the training

requirements of standard curriculums from bodies such as

OPITO, SQA and C&G. The unit is designed around standard

industrial equipment – valves, sensors, transducers and

instrumentation from well-known suppliers such as SMC and

OMRON.

The system requires air at just 2 bar, and all equipment

operates at 24V d.c. for maximum safety. The oil is non-toxic,

fume free, and safe.

An integral OMRON PLC is used to provide signal

conditioning and protective ESD functionality, using

standard ladder code software.

The system is controlled using a PC, running the world

renowned P3700 training DCS interface through an industrial

OPC connection.

The DCS system allows the user to operate all aspects of the

Separator including oil/water/air ratios and the pressure,

level and flow control loops. A DCS based ESD with Cause &

Effects chart allows start-up and shutdown procedures to be

run.

P3700 THREE PHASE SEPARATION TRAINING UNIT

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cussons TECHNOLOGY

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FLUID SYSTEM

Two steel vessels are used for fluid storage, one for distilled

water, the other to contain the special oil used.

Each vessel has:

10 Litre running capacity with 50% spare.

Sight glass with HH, H and LL level switches.

Vent and drain facility.

Controlled pressurisation and valving for fluid movement

to the Separator mixer.

Pumped fluid return with flow measurement.

Variable speed pump, and flow control valve.

SEPARATION VESSEL

The clear polycarbonate Separation Vessel is designed for

maximum visibility of the process. The vessel includes:

upstream section with interface level sensor.

separation weir.

pressure sensor, pressure control valve and relief valve

oil level sensor (dP type).

Water & oil discharge ports and drains.

The vessels are filled and drained using

a simple, clean routine through easily

accessible connectors.

The oil/water ratio to the Separator feed is controlled through

two separator flow control valves, with individual flow meters.

These flow through a shutoff valve into the Separator feed

nozzle.

P3700 THREE PHASE SEPARATION TRAINING UNIT

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cussons TECHNOLOGY

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CONTROL SYSTEM

TSC has provided many of the world’s major oil and gas

exploration companies with DCS-style training material – for

example on a continuous basis for BP over 34 years. For this,

TSC has created emulations of many of the manufacturer’s

DCS styles, and has taken the best features of each style to

create its world renowned generic DCS interface. This runs

under Windows on a standard PC.

A DCS style overview screen includes the following features:

PFD style graphics of the process plant.

Top menu bar selection of access levels, User Guide,

printer and other functions.

Side menu button selection of display screens, Trends,

ESD. and Alarm functions.

Detailed drill-down to each vessel by vessel selection.

Overview graphics of major item status and key process

values.

The P3700Hardware Unit includes a powerful OMRON PLC

with digital and analogue interfacing to all the sensors,

transducers, valves and limit switches. This links using the

industrial standard OPC protocol through a USB lead to the

DCS software on a PC.

In the event of PC disconnection, the PLC is programmed to

carry out all the safety functionality, such as valve and pump

responses to HH and LL level, and to depressurize the P3700

automatically. In normal running, the PC communicates

through the PLC to interface to all functions on the P3700 as

in a standard control room.

Graphically, each of the areas of the plant are expanded

from the overview, and include full details of that area.

Faceplates are displayed for each Pump, Valve and

Controller as appropriate, to enable full control of the

system. The controller and switch faceplates are based on

best DCS practice and allow trainees to migrate easily onto

P3700 THREE PHASE SEPARATION TRAINING UNIT

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cussons TECHNOLOGY

Control Engineering

Head Office

Cussons Technology Limited

102 Great Clowes Street,

Manchester.

M7 1RH England

Tel: + (44)161 833 0036

Fax: + (44)161 834 4688

E-mail: sales@cussons.co.uk

Explore our website!

www.cussons.co.uk

The company may alter specifications as its discretion and without no-

tice, in line with its policy of continuous development

DIMENSIONS AND WEIGHTS

Electrical supply: - 220/240V 50/60Hz single phase

INSTALLATION REQUIREMENTS

Nett

Weight Length Width Height

kg lb m in m in m in

P3700 45 100 1.2 48” O.76 30” 0.70 28”

with case 85 190 1.23 49” 0.82 32” 0.82 32”

Each faceplate is equipped with drop down menus for

setting tuning parameters and noting alarm limits.

The overview and area pages also include button selection

of a powerful Trend Display package with full printout

capability, Alarm handling pages and ESD Trips and Over-

rides pages. The system includes a pop-down User Guide

and trainer - editable Workbooks, from the top line menu

bar.

DYNAMIC PROCESS SIMULATION MODEL

The TSC system takes advantage of the 34 years’ experience

in Dynamic Process Simulation modelling, to provide a full

identical dynamic simulation model of the P3700 which runs

on exactly the same DCS graphics and uses the same

control system.

In this way, the maximum cost effectiveness may be

obtained by mixing the Simulation Model with the P3700

Hardware on a student rota basis.

Example: For a class of 12 trainees

2 off P3700 hardware and PC DCS system.

10 off Dynamic Simulation Model across 10 PCs will allow

each of the curriculum subjects to be learned and fully

understood on a rota basis by the 12 trainees

individually, at an optimised cost.

IN ADDITION

Each set of TSC software, for either the DCS control of P3700,

or for the classroom simulation of the P3700, includes a

multicomponent hi-fidelity engineering dynamic simulation

model of a Three Phase Separator.