Simulation Training Package for Generic Oil & Gas Extraction,
Separation, and Compression Process
The Package
The Oil and Gas Production Training Simulator is
developed as a total integrated system, which
includes a model of the Wellhead System, Separator
System, and the Compressor System. The Crude Oil
and the Gas are the final products from this process.
The simulator model, is based on first principles for
mass and energy balance, and runs in real-time with
an extensive physical property database.
The simulation model has been integrated with an
emulated control system, which includes the generic
continuous control loops and interlocks as defined in
a typical DCS system, a Gas Turbine Control system,
and specific local controls and emergency shutdown
systems, e.g. Wellhead Baker Logic, and ESD
systems in PLCs.
Trainee Station
Ethernet
Printer
Instructor Station
Simulator Hardware Configuration
The package includes the basic hardware
configuration shown above, and also includes pre-
configured training exercises, that can be used with
or without an Instructor.
The Process Model
The process model in the generic simulator
contains the key process unit operations, with
instructor features and training material that will
allow in-depth training of process operators in the
operation of those facilities. Although the facilities
are generic, they are a high-fidelity and include all
the key operations, including the requirements to
bypass interlocks for startup of the facilities. There
are realistic situations all the way from plant start up
to handling process malfunctions, all of which will
train the operators, as well as train the Instructors to
enable them to develop additional training plans.
Included in the simulator project are Instructor tools
that will allow them to construct “performance
scoring” recording of trainee sessions, and the
development of trainee, self-conducted, training
programs.
Trainee Station Options
Additional hardware could be added to the base
configuration to allow for stations for both a field,
and a control room, trainee operator. This would
allow the field operator to work at his field panel
displays, in conjunction with the control room
operator working at his own display. An option for
field panel displays is an interactive large screen
display like the one shown below.
 Crude Oil and Gas Wellhead and Separation Systems The Wellhead System starts from the
sub-sea valves and connects to the
HIC
PI 101
003
FI
ZI vent

separators. The crude oil production

WNV001 001 CHV101 208
2A

PSV201 PIC PIC

MSV001 PV PV To 2nd stage
201B 201A

throughput is dependent on the wellhead

PI PI
005
compressor
001 FI
PSLL1 vent 209
HS E
PALL201 2B
SSV001 IF 103 HS PAHH201

operations, where wellhead pressure,

01 107 ESV201 PIC PIC
PSV202 PV PV To 1st stage
1ST STAGE 202B 202A
HV103 HP Production Manifold BDM compressor
XV107 PI SEPARATOR E
WW001 HIC HS

composition, and the choke valve

201 TI
PI E ESV205
PI 102 109 201
PSLL2 HIC 005 PALL202
004 LIC
104 SP201 PAHH202
ZI HS FI LI 202
2ND STAGE

position are the main factors. The

001 ESV109 LALL201B 202
WNV002 002
CHV102 105 LAHH201B
HV104 HS E
LI LALL201A PI SEPARATOR
PI LAHH201A 202
PI 110 201 FI TI
006
MSV002 202 202
006
HV105 LIC

training simulator provides Instructor

PI
HS FI V201 LV SP202 LIC
002 201 204
106 HS 002 ESV110 ESV203 LV
LI
E V202 ESV204 LALL202B 204
SSV002 108 E E LAHH202B LI

Functions to allow the instructor to select

203 FI LALL202A
HV106 BDM ESV202 204 LAHH202A
IF LP Production Manifold drain
XV108 LV LIC
02 FI V203
201 203
WW002 oily wt V204 ESV207 LV

HS
3rd stage/ Pipeline
HS
212
E

FI
drain
E

the desired wellhead composition,

pressure and temperature for realistic
FI
214 HS
210 suc. 2A ESV206 203
N 213 FI oily wt
scrubbers XV212 210
HV

simulation.
214 HV
V209 PAHH203
P201 LIC
213
PALL203 205
HS
ESV210 HS E 501
3RD STAGE 500
ELEVATED
SEPARATOR TI

Because the Wellhead Baker Logic is

PI HV
203 203 HV
E 501
LI 500
205 P501
SP203 HS
COALESCER

highly interlocked with the plant

PI FI
LALL203A HS E 503
ESV208 LAHH203A 502
501 501
LALL203B LI Crude
LAHH203B 206
CR201 Export
LIC HV LV

emergency shutdown system, proper

E
LV V206 E
HV 503
206
LALL204 502 P502
ESV209 V205 LAHH204
LI
HS
207
FI LIC

wellhead startup procedures require

E
LV HS E 505
oily wt 206 207 V208
504
drain V207 ESV211 drain
ESV212
HV
FI

activating the shutdown inhibit logic. A

oily wt 207
drain HV 505
504 P503

comprehensive ESD logic with emulated

operator station graphic is provided with
HS
the simulator.
PIC Gas Compression 308
301
vent
vent XV308

The Separation Section has HP and LP

vent
FI
303 FV
XV302
HS
HS FI XV304
304

Production Manifolds, which feed a first

PI 302
301 FI 302
PSV305
301
FV vent
PSV301 FV

stage separator and a second stage

PSV303
PALL301 PALL302 PALL303
vent 1ST STAGE vent 2ND STAGE 3RD STAGE FIC
FIC PAHH301 FIC PAHH302 303 PAHH303
301 COMPRESSOR 302 COMPRESSOR SUCTION
PI PI PI
SCRUBBER
303 304 305
3rd stage HS HS HA303

separator. There is an elevated third

TALL301 HS HS
TAHH301 HA302 TALL302
separator 301 TI FI TI 303 TAHH302 TI 305 TALL303 TI 309
HA301 301 305 306 307 TAHH303 308
1C SD301 CP301 TI
SD302 CP302 TI SD303 CP303
FI FI
XV301 XV

stage separator as a final separation and

PV 302 306
E XV 303 307 E XV
303
E
TIC E
TIC 305 TIC 309
1ST LI PSV
TV 301 TV TV 303 3RD STAGE
STAGE 301 302 LI 304 LI
SUCTION 1ST STAGE LIC 302 303 COMPRESSOR

stabilization. The gas leaving the

COOLER SUCTION 301 2ND 3RD PSV
vent 2ND STAGE
SCRUBBER STAGE vent STAGE LIC 306
PSV SUCTION LIC
LALL301 SUCTION 302 SUCTION 303
P301A 302 SCRUBBER V303
V301 LAHH301 COOLER COOLER
HS

separators is dehydrated by contacting

ESV320 LALL303
E vent
To 2nd stage 307 XV LAHH303
1A separator V302 307 drain
E
drain LV
LV 2nd st age
ESV319 LV HS 1B

with TEG.
drain separat or 306
LALL302
To 3rd st age
LAHH302
1B vent separator
P301B XV306

fuel gas

V308
vent
The Gas Compression system has a
single train of four stage compressors.
gas
reinjection
PSV
HS 310
PIC vent
310

The four stages are driven by a single

V311 302
vent FIC
XV 304
310 vent HS XV

two-shaft variable speed gas turbine that

PSV V310 FI
315 315
304
DEHYDRATOR 309 HS
INLET HS
XV 313 FV 318
SCRUBBER 311 PALL305

is controlled by an emulated gas turbine

E
HS TALL305 PAHH305 XV
PALL304 PI PI
PAHH304 313 TAHH305 307 318
XV HS 302 HS HS HS HS
vent 311
PSV FI HA305 TI 314 326 327 328 325

speed controller.
308 HS 309
308 gas
vent 312 SD305 CP304
PSV FI HV326 export
V305 PI TI XV E HV327 PV HV328 FI
307 V307 306 309 PIC ESV325
DEHYDRATOR TALL304 305 314 310
TAHH304 303
INLET DEHYDRATOR E XV PIPELINE
COOLER 312 TIC XV316
HS GAS
305 vent
SD304 DH301 322 PIPELINE COMPRESSOR
SUCTION LI PV
V306 HS

In addition to being a generic simulator

SCRUBBER 305
1st st age HA304 TI
ESV322 PIPELINE 316 HS
304 LIC GAS
separator LI 317
304 305 COOLER
E
TIC glycol reg. vent
TV

and training package in its own right, the

1A syst em
304 LIC ESV324 XV
304 HS 317
V309 To 2nd stage
323 1C
drain E
ESV323 glycol reg. LALL305 separator
LV

process modeling and emulation of

V304 ESV321 syst em drain LAHH305

LALL304
LAHH304
LV

different control packages are examples

of the process simulation technology that
New Operators? - New to Simulation? GSE has to offer its clients for custom
operator training simulators.
The comprehensive simulation package offered here is an ideal entry
point for using simulator training in the Oil & Gas industries. The process
contains key training features, includes training exercises, and
incorporates vital field control actions normally outside of the control
room DCS. There are tools to establish self-training for the trainees if
required, and comprehensive trainee monitoring and evaluation utilities
for the Instructor.

1332 Londontown Blvd., Suite 200

Sykesville, MD 21784 USA

SimSuite Pro™ is a trademark of GSE Systems, Inc. All other Tel: +1.410.970.7800
trademarks are the property of their respective owners. The Fax: +1.410.970.7999
information in this literature is subject to change without
notice and is not to be construed as a warranty. Email: process.simulation@gses.com
www.gses.com
DS.34.VC 03/10