p3700 three phase separation training unit · p3700 three phase separation training unit issue 2...
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P3700 THREE PHASE SEPARATION TRAINING UNIT
1 Issue 2 [email protected] / www.cussons.co.uk
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
2 Issue 2 [email protected] / www.cussons.co.uk
cussons TECHNOLOGY
Control Engineering
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
3 Issue 2 [email protected] / www.cussons.co.uk
cussons TECHNOLOGY
Control Engineering
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
4 Issue 2 [email protected] / www.cussons.co.uk
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: [email protected]
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.