Advanced Control Algorithms for a Horizontal Three-Phase Separator in a Hardware in the Loop Simulation Environment

Abstract

The three-phase separator has a fundamental role in oil production, due to its multivariable and nonlinear characteristics, controlling it represents a major challenge. In the engineering training academy, having a real industrial process represents a significant cost, however, thanks to technological advances, providing a virtual industrial process is possible. In this research work, a hardware in the loop simulation (HIL) environment is proposed, which includes a three-phase horizontal separator, and its controllers implemented in a physical control device. The proposed system is flexible enough to perform different control algorithms and implement them in any control device. The design methodology of the proposed system includes three sections. In the first section, the nonlinear multivariable mathematical models of the industrial process are obtained. The second section corresponds to the development of the virtual environment, in which the 3D modeling of the industrial process is performed. In the third section, the control strategies are proposed, designed and implemented in a physical control device. To validate the applicability and performance of the variables to be controlled, two control strategies are implemented: a traditional proportional integral derivative (PID) control, and a multivariable model predictive control (MPC). Finally, a comparison of the implemented controllers performance is made for the controlled variables: water level $$h(t)_w$$ , oil level $$h(t)_l$$ and separator pressure P(t).