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Aspen Technology, Inc. All rights reserved. Recent webinars on many engineering topics can be viewed on-demand on aspentech.com including: April 2013: Modeling Solids Dryers and Granulators with aspenplus v8.
Aspen Technology, Inc. All rights reserved. Recent webinars on many engineering topics can be viewed on-demand on aspentech.com including: April 2013: Modeling Solids Dryers and Granulators with aspenplus v8.
Aspen Technology, Inc. All rights reserved. Recent webinars on many engineering topics can be viewed on-demand on aspentech.com including: April 2013: Modeling Solids Dryers and Granulators with aspenplus v8.
Compressor Modeling Using Aspen HYSYS Dynamics Glenn Dissinger, Director of Product Management Martyn Blanchard, Global Practice Director
Engineering Collaboration Webinar Series April 23, 2013 2013 Aspen Technology, Inc. All rights reserved |
2 Ongoing Series of Technical Webinars Engineering Webinars for Education and Best Practices UPCOMING WEBINARS: April 30, 2013: Vea lo Nuevo de aspenONE Engineering V8 May 14, 2013: Melhorar o Projeto Conceitual com Modelagem e Fluxo de Trabalho Integrado Usando Aspen Plus May 15, 2013: Utilizing Property Data with Aspen Properties in Aspen Plus May 22, 2013: Integrate Thermal & Mechanical Heat Exchanger Designs to Save Time and Reduce Capital Costs OTHER RECENT WEBINARS: Recent webinars on many engineering topics can be viewed on-demand on aspentech.com including: April 2013: Modeling Solids Dryers and Granulators with Aspen Plus V8 April 2013: Optimize Specialty Chemical Processes with aspenONE Engineering March 2013: The New Aspen HYSYS for Refining
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3 Common Models & Data aspenONE Integration Support Manufacturing & Supply Chain
Aspen Plus Dynamics, ACM & Flare System & Energy Analyzer Aspen Plus Aspen HYSYS Aspen Process Economic Analyzer (APEA) Detailed Engineering Aspen Plus Aspen HYSYS 2013 Aspen Technology, Inc. All rights reserved |
4 aspenONE Engineering V8.0 The New HYSYS Solids Modeling in Aspen Plus Activated Economic Analysis Activated Energy Analysis Integrated Exchanger Design Plant Data View Easy To Adopt Reduce Time to Get Started for New & Occasional Users by 50% Increase Engineering Productivity by 20% Reduce Capital & Energy Costs by 10% Increase Troubleshooting Efficiency by 20% 2013 Aspen Technology, Inc. All rights reserved |
5 aspenONE Engineering V8.0 The New HYSYS Solids Modeling in Aspen Plus Activated Economic Analysis Activated Energy Analysis Integrated Exchanger Design Plant Data View Easy To Adopt 2013 Aspen Technology, Inc. All rights reserved |
6 Compressor Modeling Using Aspen HYSYS Dynamics Glenn Dissinger, Director of Product Management Martyn Blanchard, Global Practice Director
2013 Aspen Technology, Inc. All rights reserved |
7 Disclaimer Aspen Technology may provide information regarding possible future product developments including new products, product features, product interfaces, integration, design, architecture, etc. that may be represented as product roadmaps. Any such information is for discussion purposes only and does not constitute a commitment by Aspen Technology to do or deliver anything in these product roadmaps or otherwise. Any such commitment must be explicitly set forth in a written contract between the customer and Aspen Technology, executed by an authorized officer of each company.
2013 Aspen Technology, Inc. All rights reserved |
8 Outline Overview of HYSYS V8 Compressor Overview Types Whats Important to Consider Surge Modeling Compressors in HYSYS Overview Demo Compressor Trip Case Studies Best Practices Customer Examples AspenTech Global Services & Capabilities Wrap-Up and Q&A 2013 Aspen Technology, Inc. All rights reserved |
9 New Aspen HYSYS: Easier to Use Faster to Learn 2013 Aspen Technology, Inc. All rights reserved |
10 Multiple Views Interactive Analysis Environments Streamlined Workflow & Easier Access Easier to Learn New Aspen HYSYS 2013 Aspen Technology, Inc. All rights reserved |
11 Add Pure or Hypothetical Components from the Same Form Properties Environment Workflow Oriented Ribbon -> Left to Right Navigation Pane to Easily Browse Objects 2013 Aspen Technology, Inc. All rights reserved |
12 Units of Measure Simulation Options Home Ribbon Solver Summary and Reports Analysis Tools Simulation Environment 2013 Aspen Technology, Inc. All rights reserved |
13 Easy Navigation Pane Status Icons One Dockable Model Palette 2013 Aspen Technology, Inc. All rights reserved |
14 Stream Analysis Button in Ribbon One Click to Analyze 2013 Aspen Technology, Inc. All rights reserved |
15 Case Study Button in Ribbon Drag & Drop Variables Results in Table and Plots 2013 Aspen Technology, Inc. All rights reserved |
16 Outline Overview of HYSYS V8 Compressor Overview Types Whats Important to Consider Surge Modeling Compressors in HYSYS Overview Demo Compressor Trip Case Studies Best Practices Customer Examples AspenTech Global Services & Capabilities Wrap-Up and Q&A 2013 Aspen Technology, Inc. All rights reserved |
17 Poll Question 2013 Aspen Technology, Inc. All rights reserved |
18 Compressors Three Typical Types Centrifugal Most common compressor used in industry
Reciprocating Piston Used for very high pressures and low flow rates
Axial Special compressor used for very high flow rates and low pressures Inlet Flow (acfm) 1 0 10 2
10 3
10 4
10 6
10 5
1 10 10 2
10 5 10 3 10 4 Discharge Pressure (psia) Reciprocating Centrifugal Axial Flow Reference Compressor Handbook for the Hydrocarbon Industries, Gulf Publishing Co., 1979 Compressors are mechanical devices commonly used to increase the pressure of a gas and transport it through a pipeline 2013 Aspen Technology, Inc. All rights reserved |
19 Compressors Why Worry? Design Issues Expensive equipment Often customized with long lead times to replace
Operability Issues Very fast dynamics Compressor trips are costly Compressor surge is very hazardous Specialized anti-surge control systems are common From both a design and controllability / operability point of view, compressors provide unique issues and challenges 2013 Aspen Technology, Inc. All rights reserved |
20 What is Surge and Why is it Such a Problem? Results Rapid flow reversals (e.g., surge) Rapid changes in axial thrust High vibration Potential damage to rotor seals and bearings Catastrophic equipment failures and release of gases to atmosphere Surge is the point where a centrifugal compressor cannot add enough energy to overcome the system backpressure 2013 Aspen Technology, Inc. All rights reserved |
21 Outline Overview of HYSYS V8 Compressor Overview Types Whats Important to Consider Surge Modeling Compressors in HYSYS Overview Demo Compressor Trip Case Studies Best Practices Customer Examples AspenTech Global Services & Capabilities Wrap-Up and Q&A 2013 Aspen Technology, Inc. All rights reserved |
22 Two Operating Modes Centrifugal & Reciprocating Operating Mode 2013 Aspen Technology, Inc. All rights reserved |
23 Theory - Efficiencies Isentropic Efficiency = ratio of isentropic (ideal) power required for compression to the actual power required
Efficiency(%) = (Power Required isentropic ) / (Power Required actual ) x 100%
Polytropic Efficiency = Work for a mechanically reversible (polytropic) process W = V dP where W = work V = volume dP = pressure difference
For a polytropic compression of a gas from P 1 to P 2
W = F 1 (MW) (n/(n-1)) CF (P 1 /r 1 ) (P 2 /P 1 ) ((n-1)/n) - 1]
Flow (ACFM) Polytropic Efficiency (%) Centrifugal 2000 69 5000 72 10,000 73 20,000 74 50,000 75 100,000 76 Pressure Ratio Polytropic Efficiency (%) Reciprocating 1.5 73 2.0 79 3.0 83 5.0 85 2013 Aspen Technology, Inc. All rights reserved |
24 Centrifugal Compressor Performance Curves Typically available from the manufacturer as plots of efficiency and head vs. flow capacity of a centrifugal compressor for one or more operating speeds (e.g., RPM) Head vs. Flow Capacity
Decreasing Speed 2013 Aspen Technology, Inc. All rights reserved |
25 Input for Multiple Head and Efficiency Curves The Enable Curves checkbox must be clicked One curve per speed All curves must use the same efficiency definition (Adiabatic or Polytropic) Individual curves may be activated or deactivated Remove any input value for efficiency on the Parameters page 2013 Aspen Technology, Inc. All rights reserved |
26 Input for Multiple Head and Efficiency Curves Able to Add Additional Curves for Other MW Gases Able to add performance curves for the different molecular weights Compressor performance impacted by significant shifts in gas molecular weight, particularly for low pressure compressors 2013 Aspen Technology, Inc. All rights reserved |
27 Centrifugal Compressor Performance Limits Surge Limit Lower Flow Capacity Limit Occurs at the upper end of head vs. flow curve (for a given speed) where the performance curves tangent becomes zero
Stonewall Limit Upper Flow Capacity Limit Maximum flow rate for a given speed due to the approach of sonic flow of the gas within the compressor Occurs at the lower end of head vs. flow curve (for a given speed) Important for capacity control, but not as critical as surge control
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28 Surge and Stonewall Curves 2013 Aspen Technology, Inc. All rights reserved |
29 Handling Inertia of Compressor Impeller & Shaft Used to account for frictional energy loss associated with the impeller and the energy required to accelerate the rotational speed of the shaft
Key Equations
I = MR 2
E I = I II d/dt
E f = f fric I II
I = rotational inertia E I = power to accelerate impeller E f = frictional work = rotational speed M = mass of impeller and rotating shaft R = radius of gyration
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30 Surge Controller Surge controller attempts to maintain a minimum flowrate through the compressor Surge controller takes more aggressive action if compressor is close to surging Parameters for surge controller set on Surge Control page on the Parameters tab 2013 Aspen Technology, Inc. All rights reserved |
31 Modeling Linked Compressors & Expanders Used to model compressors and expanders that are physically connected to the same shaft Operate at the same speed or a specified gear ratio Total Power Loss can be specified
Notion of upstream and downstream links is arbitrary and determined by the user 2013 Aspen Technology, Inc. All rights reserved |
32 Demonstration 2013 Aspen Technology, Inc. All rights reserved |
33 Outline Overview of HYSYS V8 Compressor Overview Types Whats Important to Consider Surge Modeling Compressors in HYSYS Overview Demo Compressor Best Practice & Case Studies Best Practices Customer Examples AspenTech Global Services & Capabilities Wrap-Up and Q&A 2013 Aspen Technology, Inc. All rights reserved |
34 Centrifugal & Axial Compressors Whats Important What power will it absorb and what mechanical design does it have? Back to back casing designs have particular issues Axial compressors are not very rugged Single small wheel high pressure compressors have less issues than multi-wheel ones Surging a 5MW compressor is very different to surging a 40MW one What driver does it have? Gas Turbine Steam Turbine Electric Motor variable speed or fixed speed What arrangement are you looking at: Stages in parallel, series Multiple drivers per train or only one? How is it controlled? What protection is there for high or low pressures, low flows What range of operating conditions will it be expected to cope with? Differing gas molecular weights Differing ambient temperatures (gas turbine driver) Continuous recycle? Special start-up conditions (nitrogen, de-frost gas)
2013 Aspen Technology, Inc. All rights reserved |
35 Best Practices for Modelling Compressors What is Needed in a Dynamic Model Compressor dynamics Accurate modelling of speed lines to at least minimum governed speed (dont just assume the fan laws apply) Inertia of all items on the string, must be related to the same speed (watch the units used) Driver power decay rate Accurate capacities/holdups in all pipelines to/from compressor Return location of the recycle or hot gas bypass line Piping details of the recycle line, both up and down stream in case choking occurs Discharge volume up to the NRV after the compressor and the hot gas bypass or recycle take-off Valve dynamics Size, speed of operation and characteristics of the recycle or hot gas bypass valve Relative timings and delays if these can be assessed Valid Boundary Conditions
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36 Best Practices for Modelling Compressors Compressor Trip Tests on the Dynamic Model Discuss the basis for the trip tests. Possible scenarios are: Trip from design? Trip from the surge line just out of recycle ? Trip at maximum power? Depends on expected operation and possible consequences Examine simulation results with a critical eye First make sure you can trust them If the trajectory isnt very smooth or there seems to be any sign of instability, halve the sample time and repeat it. Continue to do this until there is no discernible difference between results. If you are inexperienced in dynamics you may want to do this in any case. Next gather the facts from the model How long before it enters surge (if it does) What is the power at the time it enters? Does the model predict recovery within a very short period (1 second or so)
2013 Aspen Technology, Inc. All rights reserved |
37 Best Practices for Modelling Compressors Modelling the Compressor under Surge Conditions The only details you can rely on are the time and power of entry into surge No commercially available dynamic compressor model accurately predicts behavior in surge You may draw some tentative conclusions from the time spent in surge according to the model Less than 0.5 seconds on a HYSYS Dynamics model is often unlikely to be real based on feedback from operations Always discuss with the Compressor Vendor, in the end it is their decision on whether action needs to be taken Ideally surge should be totally prevented in all cases
2013 Aspen Technology, Inc. All rights reserved |
38 Best Practices for Modelling Compressors Possible Design Changes to Avoid Surge Minimize the discharge volume Increase the recycle valve size (within the limits of controllability) Increase the speed of opening of the recycle valve Consider a parallel cold gas bypass valve around the recycle valve Consider a hot gas bypass valve Considerations such as leakage, vibration etc. often make this an unattractive option
2013 Aspen Technology, Inc. All rights reserved |
39 Best Practices for Modelling Compressors Modelling the Anti-Surge Control System Surge control systems are designed to detect the imminent start of surging, and prevent the compressor from reaching this operating condition Basic Strategy Open a surge recycle valve that will allow outlet flow from the compressor to recycle back to the compressor inlet, thus providing a flow rate through the compressor above the minimum surge limit. For conceptual and FEED studies, use the HYSYS Anti-Surge controller For detailed design, there may be a need to use a proprietary system: CCC, Dresser Rand, Man-Turbo, Solar, Triconex etc Most of these systems use multiple control lines, linking between serial and parallel units, surge protection by moving lines, various characterizers, algorithm selection etc. and can be quite complex to set up In some cases the Vendor will provide software (at a cost) or an emulator; in others just the algorithms are used and settings
2013 Aspen Technology, Inc. All rights reserved |
40 Challenge Solution Results Challenge Liquefied Natural Gas (LNG) plant revamp design verification Ensure compressor anti-surge system will provide adequate protection from the risk of damage under all scenarios Verify controllability of the compressors during unit upsets, start-up, shutdown and normal operation scenarios Check the start-up and shutdown procedures for compressors Verify compressor systems and equipment design conditions
Ref: Siti Rafidah Moslim, Petronas, Vikas Singh, AspenTech, aspenONE Global Conference, Boston, May 2010 PETRONAS Malaysia LNG Dynamic Simulation for LNG Plant Revamp 2013 Aspen Technology, Inc. All rights reserved |
41 Challenge Solution Results PETRONAS Malaysia LNG Dynamic Simulation for LNG Plant Revamp Challenge Aspen HYSYS Dynamics model to represent actual equipment, piping arrangements and controls A high fidelity emulation of CCC controller to reproduce the precise behavior of anti-surge control Torque and power characteristics of the gas turbines to reproduce precise conditions during start-up and shut down Over 45 Scenarios were simulated and analyzed in an iterative process using HYSYS Event Scheduler Ref: Siti Rafidah Moslim, Petronas, Vikas Singh, AspenTech, aspenONE Global Conference, Boston, May 2010 2013 Aspen Technology, Inc. All rights reserved |
42 Challenge Solution Results PETRONAS Malaysia LNG Dynamic Simulation for LNG Plant Revamp Challenge Better sizing of recycle valves and bypass valves based on all failure scenarios compared to steady state Relieving loads confirmed for various scenarios which form the basis for key relief valve sizing Start-up and shutdown procedures tested in advance of actual plant start-up
Safe Compressor Operating Points (outside surge line) Final Results (after implementing recommendations) Ref: Siti Rafidah Moslim, Petronas, Vikas Singh, AspenTech, aspenONE Global Conference, Boston, May 2010 2013 Aspen Technology, Inc. All rights reserved |
43 Challenge Solution Results Challenge Compressor operation and control critical to success of the overall gas processing project Customer determined that a dynamic simulation study was essential to verify the performance of the compressors and the associated control systems
JGC Ourhoud Algeria Gas Processing Facility Verification of Compressor Performance 2013 Aspen Technology, Inc. All rights reserved |
44 Challenge Solution Results JGC Ourhoud Algeria Gas Processing Facility Verification of Compressor Performance Challenge AspenTech Global Services commissioned to develop a Aspen HYSYS Dynamics model to represent actual equipment, piping arrangements and controls 5-stage compression train Detailed vendor (Nuovo Pignone) compressor curves implemented Production manifold & injection manifold modeled to match piping holdups Many scenarios were simulated and analyzed covering trips, feed changes, start-ups etc. The project was completed to a fixed budget and was executed within 12 weeks. This met JGC's design and construction schedule and enabled equipment changes to be ordered. 2013 Aspen Technology, Inc. All rights reserved |
45 Challenge Solution Results JGC Ourhoud Algeria Gas Processing Facility Verification of Compressor Performance Challenge The study revealed many aspects that were significant to the operation and control of the compressors, one example below: In the original control scheme the recycle from the Lift Gas Compressor (LGC) was taken downstream of the cooler. With a large pressure drop a large Joule Thomson effect was observed so that the feed to the Booster Compressor (BC) cooled and the heavy components dropped out in the suction drum. In order to avoid this it was recommended that the recycle be taken upstream of the cooler with a smaller valve on temperature control to prevent the suction temperature increasing too much. This modification was subsequently agreed, implemented and proved to work well.
2013 Aspen Technology, Inc. All rights reserved |
46 Global Services Expertise AspenTech Professional Services is organized around five regions and four global technology practices to deploy process and business solutions based on aspenONE products Service Areas Process Engineering/ Real-time Optimization Advanced Process Control Production Management & Execution Supply Chain Management
Regions Asia Pacific (APAC) Europe (EURA) Middle East Africa (MENA) North America (NORAM) Latin America (LATAM)
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47 AspenTech has 29 office locations in 20 countries and 142 Professional Services employees to effectively serve our customers on a global basis. Partner locations further expand our global delivery network. NALA 56 EMEA 48 APAC 38 142 Total * As of April 2013 AT office locations Key partner locations Service Delivery Centers 2013 Aspen Technology, Inc. All rights reserved |
48 Outline Overview of HYSYS V8 Compressor Overview Types Whats Important to Consider Surge Modeling Compressors in HYSYS Overview Demo Compressor Trip Case Studies Best Practices Customer Examples AspenTech Global Services & Capabilities Wrap-Up and Q&A 2013 Aspen Technology, Inc. All rights reserved |
49 aspenONE Engineering V8.0 The New HYSYS Solids Modeling in Aspen Plus Activated Economic Analysis Activated Energy Analysis Integrated Exchanger Design Plant Data View Easy To Adopt 2013 Aspen Technology, Inc. All rights reserved |
50 Online Training at Your Fingertips aspenONE Engineering 2013 Aspen Technology, Inc. All rights reserved |
51 New Online Training Courses for aspenONE Engineering V8 2013 Aspen Technology, Inc. All rights reserved |
52 Learn More 2013 Aspen Technology, Inc. All rights reserved |
53
OPTIMIZE 2013 Global Conference Join us in Boston for the industrys must-attend event!
OPTIMIZE 2013 6 8 May 2013 The Westin Waterfront Hotel Boston, MA USA
For more information, visit www.aspentech.com/agc 2013 Aspen Technology, Inc. All rights reserved |
54 Optimize 2013 Global Conference Foster Wheeler UK
Refinery wide modeling with Aspen HYSYS
Jord International
Optimization of a mixed refrigerant LNG process Kuwait National Petroleum Company
Refinery energy reduction using Aspen HYSYS May 6-8, 2013 See these and over 50 additional presentations and training sessions Inprocess
Reliability of Dynamic Simulation to Reproduce Plant Dynamics
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55 What Next? Get more information now Additional resources available at: http://www.aspentech.com/products/aspen-hysys.aspx http://www.aspentech.com/products/aspen-hysys-dynamics.aspx Videos also available at: www.youtube.com/user/aspentechnologyinc Contact info for todays presenters and hosts Glenn Dissinger glenn.dissinger@aspentech.com Martyn Blanchard martyn.blanchard@aspentech.com Luisa Herrmann luisa.herrmann@aspentech.com Ron Beck ron.beck@aspentech.com 2013 Aspen Technology, Inc. All rights reserved |