Three-Phase Separator Learning System

8094289 (3535-10)

LabVolt Series

Datasheet

Festo Didactic
en 120 V - 60 Hz
* The product images shown in this document are for illustration purposes; actual products may vary. Please refer to the Specifications section of
each product/item for all details. Festo Didactic reserves the right to change product images and specifications at any time without notice. 10/2021
 Three-Phase Separator Learning System, LabVolt Series

Table of Contents

General Description _________________________________________________________________________________ 2

3535-1 Three-Phase Separator with Instrumentation ______________________________________________________ 4
3535-A Instrumentation Add-On _______________________________________________________________________ 5
Centrifugal Pumps with Control Unit____________________________________________________________________ 6
Rotameters ________________________________________________________________________________________ 7
Inline Mixer ________________________________________________________________________________________ 7
Pressure Gauge ____________________________________________________________________________________ 7
8093315: Back Pressure Regulator_____________________________________________________________________ 8
8093631: Pressure Safety Valve _______________________________________________________________________ 8
Pneumatic Control Valves ____________________________________________________________________________ 9
Monitoring Unit ____________________________________________________________________________________ 9
Differential Pressure Transmitter (HART) with orifice primary element. _______________________________________ 10
Turbine Flow transmitters ___________________________________________________________________________ 10
Vibrating fork level switches _________________________________________________________________________ 11
Pressure Transmitter (HART) _________________________________________________________________________ 11
Multiparameter Guided-Radar Level Transmitter _________________________________________________________ 12
General Specifications ______________________________________________________________________________ 12
Product Dimensions________________________________________________________________________________ 13
Features & Benefits ________________________________________________________________________________ 14
List of Equipment __________________________________________________________________________________ 14
List of Manuals ____________________________________________________________________________________ 15
Optional Equipment ________________________________________________________________________________ 15
Equipment Description _____________________________________________________________________________ 15
Optional Equipment Description ______________________________________________________________________ 18

General Description
The Three‐Phase Separator learning System demonstrates the fundamentals of oil separation when processing
crude oil. Crude oil is a mixture of oil, water, and hydrocarbon gas, that must be separated before oil can be sent
to a refinery. Accurate measurement of the gas and oil ratio is also essential, as it directly impacts production.
The Three-Phase Separator demonstrates the fundamentals of oil separation, such as the effect of gravity, the
effect of layer thickness, viscosity, retention time, density difference, vessel pressure, and oil/water/gas ratio. It
features the similar components and instrumentation that is used in the oil and gas industry. It also replicates
similar operational behavior to the ones that are used in the industry.
The Three-Phase Separator offers two different configurations such as Basic Pneumatic Control for training
operation personal and a second one with Smart Instrumentation for training instrumentation technician as well
as engineers. It is also possible to start with a Basic Pneumatic Control Separator (3535-0) and then add the
Learning System Instrumentation Add-on to make it a Complete Solution.
The Three-Phase Separator operates as an industrial production separator with basic level pneumatic
controllers, or with instrumentation for crude oil characterization. It is part of the LabVolt Series 353X product
family, offering high quality, modular industrial instrumentation and process control training solutions,
supported by unique pedagogical content.
The Three-Phase Separator is part of our oil and gas training program that naturally fit the requirements to
quality technicians and engineers.

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Three-Phase Separator Learning System, LabVolt Series

It is possible to visit our virtual showroom that present a layout of the most popular learning systems at the
following address:
http://www.festo-turnkey-solutions.com/oilandgas/

The Basic Three-Phase separator includes the components used in a real production separator.
It features a Three-phase separator Vessel, two centrifugal pumps, two reservoirs (water and oil), a Pumps
Control Unit with Allen-Braddley variable frequency drives, a Back Pressure Regulator and a Safety Pressure
Relief Valve.

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The control on the oil level and oil-water interface level is performed using pneumatic controllers from well-
known brands such as Norriseal-Wellmark. The Pneumatic level controllers send pneumatic signals to the two
pneumatic control valves.
Ordering numbers:
8094286 120V-60Hz
8099487 230V-50/60Hz

3535-1 Three-Phase Separator with Instrumentation

The Three-Phase Separator with
Instrumentation includes all the
features of the Basic configuration
plus all the smart instruments required
for measuring important parameters
to optimize the separation process,
which reduces operation cost and
maximizes operator and asset safety.
Students get first-hand experience
with Rockwell Automation and
Endress+Hauser technologies, both of
which are used on a large scale in the
oil and gas industry. The system is
monitored using the PlantPAx
Distributed Control System (DCS), as is
usually the case in real world
*Shown with optional Temperature Transmitter and Thermocouple scenarios. The HMI for data
acquisition and alarm management is
performed using a CompactLogix PLC and a large PanelView Plus7 touch panel. The communication between the
PLC and the touch panel uses Ethernet/IP protocol. The Smart Instrumentation features latest technology from
Endress+Hauser including:

• a FMP55 Multiparameter Guided-Radar Level Transmitter

• Absolute Pressure Transmitter (HART)
• Differential-Pressure Transmitter (HART) with an orifice plate for gas flow measurement.
• Three Vibrating Fork Level Switches
• Two Cameron Turbine Flow Transmitters

Ordering numbers:
8094289 120V-60Hz
8099490 230V-50/60Hz

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Three-Phase Separator Learning System, LabVolt Series

3535-A Instrumentation Add-On

The instrumentation Add-On is a turnkey solution that permits previously purchased the Basic Three-Phase
Separator configuration to be upgraded to the same level as the Three-Phase Separator with Instrumentation.
This Add-on includes the following components:

• Instrumentation Module with CompactLogix PLC

• a Large PanelView Plus7 touch panel
• a FMP55 Multiparameter Guided-Radar Level Transmitter
• an Absolute Pressure Transmitter (HART)
• a Differential-Pressure Transmitter (HART) with an orifice plate for gas flow measurement.
• Three Vibrating Fork Switches
• Two Cameron Turbine Flow Transmitters

Ordering numbers:
8094292 120-230V-50/60Hz

Advanced Vessel Design

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Large clear acrylic vessel in order to see the internal components in operation for training purpose.
Pressurized operation with similar safety devices that are used in real industrial separator such as pressure
safety valve. Vessel internal components such as diverter plate, perforated baffle plate, coalescing plate, weir
plate, demister pad. Vortex breakers are also installed to the oil and water outlets to prevent formation of
vortex.
All the internal components inside the Vessel are made of stainless steel to ensure long lasting.
The Vessel includes a rupture disk that is a pressure relief device that protects the system against
overpressurization. The rupture disc burst pressure is 70 kPa (10 psig).

Centrifugal Pumps with Control Unit

Each variable-speed centrifugal pump
has a flow of 0-12 l/min (0-3.2 gal US/
min) and a maximum pressure of 100
kPa, gauge (14.5 psig). Each pump
motor has a rated speed of 3450 rpm
at 60 Hz and 2850 rpm at 50 Hz, with a
power of 0.56 kW (0.75 hp) at 60 Hz
and 0.37 kW (0.5 hp) at 50 Hz.
The Pumps Control Unit includes great
features such as two built-in Powerflex
4M ac drive from Allen-Bradley. This ac
motor drive has an output voltage of
0-230 V ac, an output frequency of
0-240 Hz, and is controlled using a convenient communication interface to configure and monitor all the drive's
parameters.
The nominal current of the Pumps Control Unit is 12 A at 120V 60 Hz and 7 A at 220-240V 50 Hz.
The reservoir of the Oil Pumping Unit has a capacity of 57 l (15 gal US) and the one for the water has a capacity
of 114 l (30 gal US). The water reservoir features an overflow allowing the excess of oil going to the water
reservoir to overflow to the oil reservoir.

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Three-Phase Separator Learning System, LabVolt Series

Rotameters
The three rotameters are variable area
flow meters allow students to adjust
the crude oil mixture ratios by
controlling the flow rates of Oil, Water
and Gas.
The oil and water rotameters have a
range of 0-14 lpm (0-3.5 usgpm) and
the Gas rotameter scale is from 0-110
slpm (0-4.0 scfm).

Inline Mixer
The inline mixer creates an homogeneous three-phase fluid mixture and it can also be bypassed using the hand
valve. It is made of clear plastic to permit the students to see the internal construction and the effect on the
inlet fluid.

Pressure Gauge
The Pressure Gauge provides a direct
reading of the pressure and is filled
with glycerine in order to have a stable
pressure reading. The operating range
is 0-100 kPa (0-15 psig).

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8093315: Back Pressure Regulator

The Fisher Backpressure Valve
maintains a constant pressure into the
separator vessel.
It operates on a pressure range of
14-48 kPa (2-7 psig). A shut-off hand
valve can also be used to prevent the
air going to the vessel.

• Fisher Direct-Operated Industrial Back-

Pressure Regulator
• Size 1/4", NPT Ends, Cast Iron Body, Cast
Iron Spring Case
• 416 Stainless Steal plug & guide, S41600
Stainless Steal disk & seat
• Neoprene Diaphragm
• Outlet pressure range 2 to 7 psig

8093631: Pressure Safety Valve

The Norriseal-Wellmark Industrial
Pressure Safety Valve limit the
pressure inside the Separator Vessel
to enhanced safety as it would do in a
real industrial Separator.
The pressure is limited at 48 kPa (7
psig).

• Pressure Relief valve Diameter: 1 inch

• ASME Coded: “UV” Section VIII Air/Gas
and Liquid
• Enhanced Guided Lift System: Optimum
Performance
• Trim Option: Soft Seat
• Stainless Steel Internals
• Threaded Connections
• Lap Joint Flanges for Easy Alignment

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Pneumatic Control Valves

The two Pneumatic Control Valve are
industrial bronze control globe valve
designed for pressure, flow and level
control applications. This reliable valve
features a durable construction, tight
shutoff, and good control
characteristics. The valve is of the
equal percentage type and is normally
open.
The Valve also feature a bypass
manual valve to permit manual
operation of the separator.

Monitoring Unit
The Monitoring Unit uses a L24
CompactLogix PLC and a Panel View
Plus7 touch panel with the PlantPAx
Distributed Control System (DCS). The
10-inch operator panel permit to the
student to monitor the flow rates, the
fluid levels and the pressure in the
separator vessel.
It is also possible to display an Piping
and Instrumentation Diagram of the
process.
Students learn also about Alarm Management through the standard operation of the system and during
troubleshooting experiments that can be performed after inserting one or many faults on the components.
Measuring units can also be display in metric system or imperial.
Each instrument can quickly and easily to the Monitoring Unit.

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Differential Pressure Transmitter (HART) with orifice primary element.

The differential pressure transmitter is
an instrument that senses a pressure
difference between two points and
converts the pressure to a
standardized electronic signal which
can be sent to a control element. The
transmitter can be configured so that
its signal is either proportional to a
pressure differential, a gas flow rate in
this case. The Low Range version of
the differential pressure transmitter is
designed to operate in a range going
from a difference of 0 kPa (0 psi) to an
absolute difference of 50 kPa (7.3 psi).
As a primary element use to measure
the gas flow rate, an Orifice Plate is used with the Differential Pressure Transmitter. It uses the Venturi effect to
produce a pressure drop from which the flow rate can be inferred. This primary element consists of an orifice
precisely machined in a brass tube. The differential-pressure transmitter directly convert the pressure drop into
a usable flow rate value.

Turbine Flow transmitters

The Cameron Turbine Flow Transmitter
provide accurate measurement of the
fluid flow for the oil and water.

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Three-Phase Separator Learning System, LabVolt Series

Vibrating fork level switches

The three Vibrating Fork Level
Switches are level limit switches used
to detect whether or not the level of
water or oil in the Vessel has reached a
set level. The fork of the switch is
continuously excited at its natural
resonance frequency. When the level
of liquid reaches the fork, the frequency of oscillation changes. This is detected by the device which triggers a
relay. The Vibrating Fork Level Switch allows continuous monitoring and is suitable for overspill-protection
setups.

Pressure Transmitter (HART)

The Pressure Transmitter is a gauge
pressure measurement device for the
fluids in the Separator Vessel. It
convert the Pressure into a 4-20mA
analog signal.
This rugged and reliable device has a
high accuracy and supports HART
communication protocol. The Pressure
Transmitter maximum pressure range
is 1 MPa (150 psig).

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Multiparameter Guided-Radar Level Transmitter

The Levelflex FMP55 guided radar with
SensorFusion offers the first
combination of the capacitance and
guided radar measuring principle in
one device. The Transmitter offer
interface measurement required for
the oil & gas, chemical and
petrochemical industry.
The instrument is configurable using
either local display buttons or HART
communication protocol with the
optional Fieldcare Configuration
Software.

General Specifications

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Product Dimensions

Virtual Showroom for Oil & Gas Training

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Virtual Showroom for Oil & Gas Training

Features & Benefits

• Train operators, instrumentation technicians, and engineers
• Develop industry-relevant skills for successfully performing operation, troubleshooting, and maintenance tasks
• Work with hardware that is commonly used in the oil and gas industry
• Rely on comprehensive learning resources
• Safety is ensured with an industrial pressure relief valve and a rupture disc

List of Equipment
Model
Qty Description
number
1 ______________________________________________________________________________________ 8092028
1 ______________________________________________________________________________________ 8093315
1 ______________________________________________________________________________________ 8093414
1 ______________________________________________________________________________________ 8093416
1 ______________________________________________________________________________________ 8093508
1 ______________________________________________________________________________________ 8093631
1 Orifice Plate (Air- High Flow) _____________________________________________________ 8096149 (46914-A0)
1 Differential-Pressure Transmitter (HART, Low Range) __________________________________ 582410 (46921-00)
2 Turbine Flow Transmitter ________________________________________________________ 8092030 (46925-A0)
1 Pressure Transmitter (HART) ______________________________________________________ 588333 (46928-00)
3 Vibrating Fork Level Switch ______________________________________________________ 8092031 (46933-A0)
1 ____________________________________________________________________________ 8098928 (46937-00)
2 Pneumatic Control Valve ________________________________________________________ 8093322 (46950-F0)
1 Touch Screen Graphic Terminal (Allen-Bradley) - 26.4 cm (10.4 in) ______________________ 8092029 (46973-B0)

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List of Manuals
Manual
Description
number
Three-Phase Separator – Basic Control (Workbook (Instructor)) _____________________________________ 8097886
Three-Phase Separator – Instrumentation (Workbook (Instructor)) __________________________________ 8099616

Optional Equipment
Model
Qty Description
number
1 J-Type Thermocouple ____________________________________________________________ 582406 (46916-00)
1 Electromagnetic Flow Transmitter (HART) ___________________________________________ 582413 (46922-00)
1 Coriolis Flow Transmitter (HART) __________________________________________________ 588323 (46924-00)
1 Temperature Transmitter (HART) __________________________________________________ 582422 (46940-00)
1 HART Software Configurator ______________________________________________________ 588420 (46982-00)

Equipment Description
Orifice Plate (Air- High Flow)
8096149 (46914-A0)
The Orifice Plate (Air - High Fow) is a flow measurement device designed for air applications. It uses the Venturi
effect to produce a pressure drop from which the flow rate can be inferred. This primary element consists of an
orifice precisely machined in a brass tube. The Orifice Plate requires the use of a differential-pressure
transmitter to directly convert the pressure drop into a usable flow rate value.

Differential-Pressure Transmitter (HART, Low Range)

582410 (46921-00)
A differential pressure transmitter is an instrument that senses a
pressure difference between two points and converts the
pressure to a standardized electronic signal which can be sent to
a control element. The transmitter can be configured so that its
signal is either proportional to a pressure differential, a flow
rate, or a level.
The Low Range version of the differential pressure transmitter is
designed to operate in a range going from a difference of 0 kPa
(0 psi) to an absolute difference of 50 kPa (7.3 psi).
This Differential-Pressure Transmitter includes a transmitter
which is compatible with the HART communication protocol.
Available Differential-Pressure Transmitters:

• 46920-0 Differential-Pressure Transmitter (HART, High Range)

• 46920-A Differential-Pressure Transmitter (Fieldbus, High Range)
• 46920-B Differential-Pressure Transmitter (Profibus-PA, High Range)
• 46921-0 Differential-Pressure Transmitter (HART, Low Range)
• 46921-A Differential-Pressure Transmitter (Fieldbus, Low Range)
• 46921-B Differential-Pressure Transmitter (Profibus-PA, Low Range)

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Turbine Flow Transmitter

8092030 (46925-A0)
The Cameron Turbine Flow Transmitter provides a accurate measurement of the flow rate by inserting a turbine
into the flow stream. A sensor measures the velocity of the turbine which is converted into a direct reading of
the flow rate displayed on a remote digital display. The Paddle Wheel Flow Transmitter also features a 4-20 mA
output signal.
The model 46925-B0 offers the same features as this one but is CE marked for 230V- 50/60Hz Learning
Systems.

Pressure Transmitter (HART)

588333 (46928-00)
The Pressure Transmitter is a gauge pressure measurement
device for the fluids in the Pressure, Flow, Level, and
Temperature Process Training Systems. This rugged and reliable
device has a high accuracy and supports one of two
communication protocols: HART or FOUNDATION Fieldbus.
Available Pressure Transmitters:

• 46928-0 Pressure Transmitter (HART)

• 46928-A Pressure Transmitter (FOUNDATION Fieldbus)

Specifications
Parameter Value
Ceramic Sensor
Operating Range -100 to 1000 kPa (-15 to 150 psi)
Physical Characteristics
Dimensions (H x W x D) TBE
Net Weight TBE

Vibrating Fork Level Switch

8092031 (46933-A0)
The Vibrating Fork Level Switch is a level limit switch used to detect whether or not the level of water in the
water or the oil in a vessel has reached a set level. The fork of the switch is continuously excited at its natural
resonance frequency. When the level of liquid reaches the fork, the frequency of oscillation changes. This is
detected by the device which triggers a relay. The Vibrating Fork Level Switch allows continuous monitoring and
is suitable for overspill-protection setups.

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Three-Phase Separator Learning System, LabVolt Series

8098928 (46937-00)

Pneumatic Control Valve

8093322 (46950-F0)
The Pneumatic Control Valve is an industrial bronze control globe valve designed for pressure, flow, level, and
temperature control applications. This reliable valve features a durable construction, tight shutoff, and good
control characteristics. The valve is of the equal percentage type and is normally open.
This model includes a current-to-pressure converter which transforms a 4-20 mA input signal into a pneumatic
output signal sent to the actuator of the control valve.
The Pneumatic Control Valve features a bypass that can be use to control the liquid flow manually.

Touch Screen Graphic Terminal (Allen-Bradley) - 26.4 cm (10.4 in)

8092029 (46973-B0)
The Touch Screen Graphic Terminal consists of an Allen-Bradley PanelView™ Plus 7 1000 with a 26.4 cm (10.4
in) color display. This touch-screen interface allows monitoring and control of some features of the Pressure,
Flow, Level, and Temperature Process Training Systems. The Touch Screen Graphic Terminal is pre-programmed
with a control interface developed with the various components of the system in mind. It features an integrated
EtherNet/IP communication port and one USB port. The Touch Panel requires a 24V-DC power supply that can
be connected using either a terminal block or a M12 quick connector.
The FactoryTalk software, Model 46968, is optional and can be used to design your own visualization and
control interface or modify the interface developped for the Touch Screen Graphic Terminal.

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Optional Equipment Description

J-Type Thermocouple (Optional)
582406 (46916-00)
The J-Type Thermocouple uses the thermoelectric effect to
perform precise measurement of temperature. The model is
provided with a T-shaped connector and a thermowell for
inclusion in the process loop.

Electromagnetic Flow Transmitter (HART) (Optional)

582413 (46922-00)
The Electromagnetic Flow Transmitter is a flow measurement
device relying on the conductive properties of liquids traveling
across a magnetic field to measure the flow in a pipe. The
operating principle of the flowmeter makes it insensitive to
vibrations and causes almost no pressure loss. Temperature
variations of the fluid are automatically compensated by the
device for accurate flow rate measurement.
Due to the specific geometrical design of the apparatus, a
different model (46922-1, -B, or -F) must be used if the
Electromagnetic Flow Transmitter is to be installed on the
second team side of the Process Workstation.
Available Electromagnetic Flow Transmitters:

• 46922-0 Electromagnetic Flow Transmitter (HART)

• 46922-1 Electromagnetic Flow Transmitter (HART, 2nd Team)
• 46922-A Electromagnetic Flow Transmitter (Foundation Fieldbus)
• 46922-B Electromagnetic Flow Transmitter (Foundation Fieldbus, 2nd Team)
• 46922-E Electromagnetic Flow Transmitter (Ethernet)
• 46922-F Electromagnetic Flow Transmitter (Ethernet, 2nd Team)

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Three-Phase Separator Learning System, LabVolt Series

List of Manuals
Manual
Description
number
Electromagnetic Flow Transmitter (Workbook) ___________________________________________585123 (85990-00)
Electromagnetic Flow Transmitter (Workbook (Instructor)) _________________________________585126 (85990-10)

Table of Contents of the Manual(s)

Electromagnetic Flow Transmitter (Workbook) (585123 (85990-00))
• 1 Fundamentals of the Electromagnetic Flowmeters

Coriolis Flow Transmitter (HART) (Optional)

588323 (46924-00)
The Coriolis Flow Transmitter is a flow measurement device using
the Coriolis forces generated when a fluid goes through the
flowmeter to measure the mass flow of liquid in a pipe. Since the
Coriolis Flow Transmitter measures the mass flow, the
measurement is not affected by changes in the temperature,
viscosity, and density of the fluid. In the industry, the Coriolis Flow
Transmitter is useful to measure the flow of liquids containing solid
particles or blend of ingredients.
Available Coriolis Flow Transmitters:

• 46924-0 Coriolis Flow Transmitter (HART)

• 46924-A Coriolis Flow Transmitter (FOUNDATION Fieldbus)

List of Manuals
Manual
Description
number
Coriolis Flow Transmitter (Workbook) __________________________________________________585133 (85995-00)
Coriolis Flow Transmitter (Workbook (Instructor)) ________________________________________585134 (85995-10)

Table of Contents of the Manual(s)

Coriolis Flow Transmitter (Workbook) (585133 (85995-00))
• 1 Fundamentals of the Coriolis Flowmeter

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Temperature Transmitter (HART) (Optional)

582422 (46940-00)
The Temperature Transmitter displays the temperature
measured by up to two devices such as RTDs or thermocouples.
It also outputs either a 4-20 mA signal compatible with the HART
communication protocol or a FOUNDATION Fieldbus
communication signal. The configuration of this transmitter can
only be modified using the Software Configurator, Model 46982.
Available Temperature Transmitters:

• 46940-0 Temperature Transmitter (HART)

• 46940-A Temperature Transmitter (FOUNDATION Fieldbus)

HART Software Configurator (Optional)

588420 (46982-00)
The Software Configurator includes the FieldCare software
necessary to interpret the data related to the different smart
devices and to configure their parameters. The HART version
also includes a communication box for data transfer between a
HART device and a PC with a USB port.
Available versions:

• 46982-0 HART Software Configurator

• 46982-A FOUNDATION Fieldbus Software Configurator
• 46982-B HART/FOUNDATION Fieldbus Software Configurator

List of Manuals
Manual
Description
number
HART Device Configuration (Workbook) ________________________________________________585164 (86050-00)
HART Device Configuration (Workbook (Instructor)) ______________________________________585165 (86050-10)

Table of Contents of the Manual(s)

HART Device Configuration (Workbook) (585164 (86050-00))
• 2-1 Two-Wire Transmitter
• 2-2 Four-Wire Transmitter (Optional)
• 2-3 Output Device (Optional)
• 3-1 HART Multidrop with Multiple Transmitters

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Three-Phase Separator Learning System, LabVolt Series

Specifications
Parameter Value

A currently available personal computer running under one of the following operating systems: Windows® 7 or
Computer Requirements
Windows® 8.

21 © Festo Didactic
 Three-Phase Separator Learning System, LabVolt Series

Reflecting the commitment of Festo Didactic to high quality standards in product, design, development, production,
installation, and service, our manufacturing and distribution facility has received the ISO 9001 certification.

Festo Didactic reserves the right to make product improvements at any time and without notice and is not responsible
for typographical errors. Festo Didactic recognizes all product names used herein as trademarks or registered
trademarks of their respective holders. © Festo Didactic Inc. 2021. All rights reserved.

Festo Didactic SE
Rechbergstrasse 3
73770 Denkendorf
Germany
P. +49(0)711/3467-0
F. +49(0)711/347-54-88500

Festo Didactic Inc.

607 Industrial Way West
Eatontown, NJ 07724
United States
P. +1-732-938-2000
F. +1-732-774-8573

Festo Didactic Ltée/Ltd

675 rue du Carbone
Québec QC G2N 2K7
Canada
P. +1-418-849-1000
F. +1-418-849-1666

www.labvolt.com
www.festo-didactic.com

© Festo Didactic 22