Separator Control Challenge

SAFESafety status

05:00Time remaining

Not startedScore status

Opening the wellActive disturbance

Challenge deckSelect disturbance scenario

Beginner

Normal operationBeginnerSteady oil and water feed with nominal sensors and dump valves.Oil/water feed stepBeginnerStart hereOnce the vessel is established, total feed rises from 50 to 70 m³/h at 3 minutes.

Intermediate

Slow water-dump actuatorIntermediateA slow water valve must control a higher inlet water fraction.Oil outlet restrictionIntermediateAvailable oil dump-valve capacity falls to 60% once the vessel is established.

Advanced

Water-rich liquid slugAdvancedAt about 3 minutes a liquid slug raises both total feed and the inlet water fraction.Noisy interface sensorAdvancedThe interface sensor sees ±1.5% noise with a 0.5 s sample hold.Gas-oil ratio surgeAdvancedOnce pressure is established, the well starts making far more gas per cubic metre of oil. Needs the gas cap enabled.

Gain notation

The same controller, written the way a control course does or the way a field panel does.

Gas cap and pressure loopTwo loops

Adds a third controller (PIC-101) on the gas outlet valve. The loops become coupled: draining liquid enlarges the gas space and drops pressure.

Well

Playback speed

PID presets

Configure both controllers before starting. Gains are locked during the attempt.

SEP-101 · engineering fallback

Separator process cutaway

Filling: low-level protection bypassed

Total true: 0.0%
Total measured: 0.0%
Total SP: 50.0%
Interface true: 0.0%
Interface measured: 0.0%
Interface SP: 20.0%
Total inlet: Stopped / 0.0 m³/h
Oil outlet: Stopped / 0.0 m³/h
Water outlet: Stopped / 0.0 m³/h
Oil command: 0.0%
Oil actual: 0.0%
Water command: 0.0%
Water actual: 0.0%
Active safety: Filling: low-level protection bypassed

2D engineering fallback · process values and safety logic remain fully active.

LIC-101

Total level / oil valve

Ready to tune

More valve opening → more oil out → lower total level

Total level process value: 0.0%
Total level measured value: 0.0%
Total level setpoint: 50.0%
Oil valve command: 0.0%
Oil valve actual position: 0.0%
P / I / D: 0.0 / 0.0 / 0.0

Total level primary gains

Total level proportional gain

4.0

Response strength. Range 0–10 dimensionless.

Total level integral gain

0.08

Offset removal. Range 0–0.3 s⁻¹.

Total level derivative gain

8.0

Damping and anticipation. Range 0–30 s.

Advanced settings

Total level advanced settingsTotal level sample time sTotal level integral limit % outputTotal level derivative filter s

IIC-101

Interface / water valve

Ready to tune

More valve opening → more water out → lower interface

Interface process value: 0.0%
Interface measured value: 0.0%
Interface setpoint: 20.0%
Water valve command: 0.0%
Water valve actual position: 0.0%
P / I / D: 0.0 / 0.0 / 0.0

Interface primary gains

Interface proportional gain

4.0

Response strength. Range 0–10 dimensionless.

Interface integral gain

0.08

Offset removal. Range 0–0.3 s⁻¹.

Interface derivative gain

8.0

Damping and anticipation. Range 0–30 s.

Advanced settings

Interface advanced settingsInterface sample time sInterface integral limit % outputInterface derivative filter s

Total level0.0%0 mm of liquid · 900 mm to high alarm

Oil/water interface0.0%MAE 0.0% · low 0.0%

Oil valve LV-1010.0%Command 0.0% · travel 0.0%

Water valve WV-1010.0%Command 0.0% · travel 0.0%

Safety envelopeFilling: low-level protection bypassedTotal outside 0.0 s · interface 0.0 s

Control note

Low error is only half the job: watch actual valve travel and saturation too.

Synchronized historian

Live control trends

1 / 900 samples

Total liquid level

Truth, LT-101, SP and protection limits · %

Oil/water interface

Truth, LT-102, SP and protection limits · %

Phase flows

Feed and phase flows · m³/h; water cut · %

Valve response

Commands and actual positions · %

Run details

Deterministic seed: 1002
Residence time: —