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"Mini Plant" Large Scale Three Phase Separator


The primary separation operation for crude oil occurs when the crude stream flows through a vessel of sufficient capacity to allow gravitational separation of the gas, liquid hydrocarbon and water phases. This process trainer blends air, water and refined oil to emulate a crude oil stream. This fluid mixture then flows into a horizontal separator vessel fabricated of clear PVC. Gas flow passes through a secondary vertical 2-phase separator, or knock-out ports to remove any further liquids from the gas stream. The separator is equipped with industry-typical   process instrumentation. The entire trainer is controlled from a distributed control system (DCS).


Process Highlights:

  • Continuously variable flow of process fluids: air, water and oil
  • Liquids are recycled, air is vented
  • Time to reach steady state after a reasonable step change – less than 20 minutes


Equipment Specification Highlights:

  • Clear Acrylic/PVC separator vessels and process piping where possible

  • 2 off 760 x 2150 mm (30” dia. x 84”) Acrylic horizontal separator vessels

  • Electronic process measurement available in 4-20ma, 4-20mA with HART, Profibus PA or
  • Level Measurement (choice of) - Bypass Chamber Magnetic, capacitance, ultrasonic, displacer and guided wave radar
  • Pressure measurement
  • Flow Measurement (choice of) - Vortex, Swirl, Averaging Pitot, DP Orifice, Magflow, Ultrasonic and Turbine meters
  • High level (2 types) and pressure switches
  • Centrifugal pump for water and gear pump for oil, both with variable speed drive
  • On skid oil and water storage tanks
  • Complete unit mounted on a steel structure/skid
  • Completely mounted on a steel structure/skid (3 parts for transport, approx.. 5m x 3m x 3m)
  • Approximate dimensions of assembled process skid – 10m long x 3m wide x 5 m high. Dimensions may be adjusted based on room size and layout
  • Variable speed roots type air blower mounted on skid
  • With ESD system and Flame scanner Fire and Gas System
  • Available in all world voltages / frequencies (customer to specify electrical power available)


Controls Options:

  • Industrial Standard PLC/SCADA or DCS
  • Instruments by specific manufacturers on request


Instrument Air Option:

This trainer can be supplied with a dedicated air compressor/receiver/drier to provide the required instrument quality air on request.



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