Building upon the global success of the DarbyTech 100:3PST Trainer—the standard for process engineering education in universities worldwide—DarbyTech is proud to introduce the 100-3PSR Research Separator.
Designed specifically for advanced laboratory environments and high-level industrial R&D, this rig combines the clarity of our training units with the robust, data-rich capabilities required for cutting-edge research.
This unit is currently deployed by leading Oil & Gas supermajors for advanced separation research, validating its capability to meet the most demanding industrial standards.
Designed specifically for advanced laboratory environments and high-level industrial R&D, this rig combines the clarity of our training units with the robust, data-rich capabilities required for cutting-edge research.
This unit is currently deployed by leading Oil & Gas supermajors for advanced separation research, validating its capability to meet the most demanding industrial standards.
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Key Research & Experimental Capabilities
The Research Separator transforms the standard laboratory environment into a dynamic pilot plant. Going beyond basic steady-state demonstrations, this system offers a fully instrumented platform for researching complex fluid dynamics, separation efficiency, and control strategies under realistic, upset conditions found in live production wells.
The 3PST Research Series is designed to enable researchers to visualise, measure, and optimise separation processes in real-time. |
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Advanced Flow Simulation: Recreating Well-Head Conditions
Real-world production is rarely smooth. To prepare engineers for the reality of field operations, the 3PS-Research rig features advanced control software designed to simulate non-ideal flow regimes, specifically slugging flow. Programmable Slugging Sequences: Utilising variable speed drives (VSD) on the precision NOV Progressive Cavity Feed Pumps, the control system can be programmed to modulate feed rates dynamically. This allows researchers to induce controlled "slugs" of liquid or gas, simulating the erratic surging behaviour typical of long tie-backs or mature wells.
Upset Condition Response:
This feature enables critical research into how separator levels, pressures, and control loops respond to sudden hydraulic shocks, allowing users to test and tune PID parameters for robust stability during process upsets.
Real-Time Water Cut Monitoring & Efficiency Analysis
Quantifying separation efficiency in real-time is critical for validating research models. The 3PSTResearch rig eliminates the latency of manual sampling by integrating industrial-grade online analysis.
Geometric Optimisation & Internals Research
The vessel’s modular design allows for the physical modification of the separation environment, enabling comparative studies on vessel geometry.
*Note: DarbyTech can provide access to published research papers regarding droplet distribution studies performed using DarbyTech equipment, offering a solid academic foundation for your own experimental curriculum
Real-world production is rarely smooth. To prepare engineers for the reality of field operations, the 3PS-Research rig features advanced control software designed to simulate non-ideal flow regimes, specifically slugging flow. Programmable Slugging Sequences: Utilising variable speed drives (VSD) on the precision NOV Progressive Cavity Feed Pumps, the control system can be programmed to modulate feed rates dynamically. This allows researchers to induce controlled "slugs" of liquid or gas, simulating the erratic surging behaviour typical of long tie-backs or mature wells.
Upset Condition Response:
This feature enables critical research into how separator levels, pressures, and control loops respond to sudden hydraulic shocks, allowing users to test and tune PID parameters for robust stability during process upsets.
Real-Time Water Cut Monitoring & Efficiency Analysis
Quantifying separation efficiency in real-time is critical for validating research models. The 3PSTResearch rig eliminates the latency of manual sampling by integrating industrial-grade online analysis.
- Instantaneous Phase Measurement: The system is equipped with high-sensitivity Water Cut meters.
- Water-in-Oil Analysis: Monitors the oil outlet to quantify valuable product loss and separation quality.
- Efficiency Correlation: By cross-referencing these real-time quality measurements with inlet flow rates and vessel residence times, researchers can generate high-fidelity efficiency curves, enabling them to see the impact of changing variables on separation performance.
Geometric Optimisation & Internals Research
The vessel’s modular design allows for the physical modification of the separation environment, enabling comparative studies on vessel geometry.
- Variable Aspect Ratio/ Residence Time Studies: The acrylic vessel features two removable mid-sections. Researchers can physically shorten or lengthen the vessel to alter the length-to- Diameter (L/D) ratio, directly testing the impact of residence time on droplet settling and phase separation.
- Internal Testing: The vessel includes dedicated fixings for coalescing packs, adjustable weir plates, and an inlet distributor. This flexibility allows for the rapid change-out of internal technologies to evaluate their effectiveness in mitigating emulsions or improving droplet coalescence.
- Microscopic Droplet Visualisation*: Specialised mounting points allow for the installation of microscopes and high-speed cameras at various settling zones. This enables the direct observation and statistical analysis of droplet size distribution (DSD) profiles, providing empirical data to validate CFD models and settling theories.
*Note: DarbyTech can provide access to published research papers regarding droplet distribution studies performed using DarbyTech equipment, offering a solid academic foundation for your own experimental curriculum