Getting Started With Aspen HYSYS Dynamics

2012 Aspen Technology, Inc.
All rights reserved

Getting Started with
Aspen HYSYS Dynamics
Solving safety and operability challenges
Dr. Glenn Dissinger,
Product Director, Aspen Technology
Hosted by:
Ron Beck,
Product Marketing, AspenTech
Optimizing Operations Webinar
Sept 5, 2012
2012 Aspen Technology, Inc. All rights reserved |

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Ongoing Series of Technical Webinars
Engineering Webinars for education and best practices

UPCOMING WEBINARS OF INTEREST:
Sept 5, 2012: Getting Started with Aspen HYSYS Dynamics
Sept 13, 2012 (Asia/Pacific time): Improved Heat Exchanger Design with
aspenONE EDR Integrated with Process Modeling (Tom Ralston)
Sept 20, 2012: Improving Olefins Plant Feedstock Flexibility and
Window of Operation Using Aspen Plus (Phil Edwards, SABIC UK)
Oct 24, 2012: Modeling Conversion of Carbon to Biomass in Algal
Systems (Dr. Eric Dunlop, Pan Pacific)
Dec 12, 2012: Solid Phase Modeling in Specialty Chemicals (Ajay
Lakshmanan)
OTHER TOPICS TO BE ANNOUNCED
A library of additional recent webinars on many engineering topics is
available on the AspenTech public website


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Common Models & Data
aspenONE Integration
Support
Manufacturing
& Supply
Chain

Conceptual
Engineering
Basic
Engineering
Detailed
Engineering
aspenONE engineering
Best-in-class engineering solutions in an integrated work flow
Aspen Simulation
Workbook & Aspen Online
Deployment
Aspen Petroleum
Downstream & HYSYS
Upstream
Aspen Equipment
Design & Rating
Aspen Basic
Engineering
Aspen Capital
Cost Estimator
(ACCE)

Aspen Plus
Dynamics, ACM &
Flare System &
Energy Analyzer
Aspen Plus
Aspen HYSYS
Aspen Process
Economic
Analyzer (APEA)
Detailed
Engineering

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Agenda
Introduction to Dynamic Simulation
What Is It?
Applications
Overview of HYSYS Dynamics
Demo Transitioning a Steady-State Model to Dynamics
Q&A

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Process Dynamics
Consider the simple bath tub example

Steady-state: F
i
= F
o

Dynamic: dV/dt = F
i
F
o

where V=V
init
@ t=0
V=H*A
F
o
= k * H
Dynamic simulation predicts how a process and its associated control
system will respond to various disturbances as a function of time
Usage has been increasing
Better tools
Safety and quality demands have increased
Today, steady-state design by itself is not enough!

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Applications of Dynamic Modeling & Simulation
Design / Analysis of Control Schemes
Design the process and control system simultaneously
Analyze and improve basic control strategies (e.g., fractionators,
compressor surge, location of sensors, etc.)
Pre-tune control loops
Evaluate, develop and test APC scenarios (DMCplus)
Operability Engineering Studies
Understand dynamic plant behavior, including upset propagation (e.g.,
slugging)
Operability studies of highly-integrated processes
Design / analysis of start-up, shutdown and process transition strategies
Hazard and Safety Studies
Design / analysis of pressure relief and flare systems
Safety studies
Design / analysis of emergency shutdown systems
Operator Training
DCS checkout
Graphics functionality/operability of the operator consoles

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Agenda
What Is It?
Applications and Success Stories
Q&A

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What Does HYSYS Dynamics Offer?
Seamless transition from Steady
State to Dynamic
Interactive environment
Rich choice between simple and
detailed modeling
A comprehensive library of
control and logical operations
Dynamics Assistant

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Steady State
Dynamic mode
Completely Integrated with HYSYS
Same program
Same GUI
Same thermodynamic models
All input data are shared
Steady state results can be used as initialization for
dynamic simulation

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Rich choice between simple and detailed
modeling options - Vessels
Simple Design Dynamics
A vessel with only the
volume specified
Detailed Plant Dynamics
A vessel with
Vessel elevation defined
Nozzle positions defined
Heat losses defined
Entrainment modeling
Level taps

or

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Rich choice between simple and detailed
modeling options - Valves
Simple Design Dynamics
A linear valve with instant action
Detailed Plant Dynamics
An equal percentage valve with
an actuator with linear rate
an actuator with a defined fail
mode
a holdup
an offset to simulate leaking
or

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Controllers
Boolean
Operations
Logical Operations
Comprehensive Library of Controller and
Logical Operations
Used to replicate control logic and strategies
used in the actual plant DCS system

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Dynamics Assistant
Can be VERY useful as a guide
to see what changes it
recommends

However, use the Make
Changes button with
caution as its advice may
NOT be what you want to do

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Agenda
What Is It?
Applications and Success Stories
Q&A

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Additional Data Required for a Dynamic Model
Dynamic
Model
Steady-State Model
Initial Model Input:
Thermodynamics
Components
Unit Operations
Flowsheet Construction
Dynamic Model
Additional Input:
Pressure-Flow Specs
Equipment Sizing
Controllers
Strip Charts

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Transitioning from Steady State to Dynamics
4 Steps are Needed
1. Pressure Flow Setup and Specifications
2. Equipment Sizing
3. Set up your Control Strategy
4. Set up your Strip Charts and Run the Model
2009 AspenTech. All Rights Reserved.
Step 1: Pressure Flow Setup and Specifications


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Solver Basics
Aspen HYSYS Dynamics Solver is different from the Steady
State Solver
Steady State Pressures and Flows are not related, but can
be set independently
Flow = 495 m3/s
Pres = 130 kPa
Flow = 55 m3/s
Pres = 120 kPa
Flow = 440 m3/s
Pres = 120 kPa
Flow = 440 m3/s
Pres = 375 kPa
Flow = 440 m3/s
Pres = 365 kPa
Flow = 440 m3/s
Pres = 375 kPa
No pressure drop across heat exchanger!

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Pressure Flow Solver in HYSYS Dynamics
Pressures and Flows are related, and can NOT be set
independently
Flow = 495 m3/s
Pres = 130 kPa
Flow = 55 m3/s
Pres = 120 kPa
Flow = 440 m3/s
Pres = 120 kPa
Flow = 440 m3/s
Pres = 375 kPa
Flow = 440 m3/s
Pres = 348 kPa
Flow = 440 m3/s
Pres = 360 kPa
There must be a pressure drop to get a flowrate!!

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Pressure-Flow Relationship Concepts
All unit operation models are categorized in one of the
following categories
Pressure Node Operations contain significant volume and
calculate a pressure based on the holdup of vapor in the unit
operation
Resistance Equation Operations calculate a pressure drop
based on a resistance equation

P/F specifications MUST be set on all boundary streams

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Guidelines for Transitioning to Dynamics
1. Add a resistance unit operation (e.g., valve, pump,
compressor) between all pressure nodes in the flowsheet
Internal flow rates will be calculated by the pressure gradients
throughout the flowsheet

2. One P/F specification should be made on each boundary
stream (feeds and products)
Make pressure specifications on boundary streams attached to
process equipment that use a resistance equation to calculate
flow rates (e.g., valves, pumps, compressor, heat exchangers
Recommendation Add valves to all boundary streams
(You will use them for flow controllers anyway once you add the control
strategy to the dynamic model!)


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Ensuring Pressure Gradient in Model
Guideline #1 Add valves between pressure nodes
Valve added between
two vessels

23
Guideline #2 Add valves on boundary streams

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Guideline #2 Set pressure specification on boundary streams

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Best Practice - PFD Display of Dynamic P/F Specifications
Available from drop-
down menu on PFD
Color Code
Green Pressure specified
Yellow Flow specified
Red Pressure and Flow specified
Blue None specified
Step 2: Equipment Sizing


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Size Matters in Dynamics!!
Consider the level control of a tank..
Noisy feed flow
What impacts the
stability of the
outlet flow?

28
Size Matters in Dynamics!!
Large tanks can mitigate disturbances

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Equipment sizing data can be entered on the
Rating or Dynamics tab
Step 3: Setting Up Your Control Strategy


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Basics of Control Theory
A control system is designed to maintain stable process
operations by compensating for disturbances
Key terms used by control engineers
Process Variable (PV): Process variable that you want to
maintain at a given operating point or set point
Manipulated Variable (MV): Process variable that is changed by
the controller
Disturbance Variable (DV): A process variable which upsets a
process and causes the control variables to move from the
desired set-points

Controls do what the process engineers can not

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Controller Library
PID Controller

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Basics of the PID Controller
The PID controller is the most used controller in the process
industries
The basic PID equation is:
OP(t) = K
c
E(t) + K
c
/
i
(E(t)dt + K
c
d
dE(t)/dt

P - Proportional I - Integral D - Derivative
where:
OP(t) = controller output value
E(t) = error between controller setpoint and process variable

and the tuning parameters are:
K
c
= controller gain
i

= controller integral reset
d
= controller derivative constant


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Key Input for the PID Controller Model
Controller Action
Controller Tuning
Parameters

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Controller Tuning - Recommendations
The values below are recommended starting points for
tuning control loops

System K
c
i
(minutes)
d
(minutes)
Flow 0.1 0.2 0
Level 2 10 0
Pressure 2 2 0
Temperature 1 20 0
Step 4: Running Your Model


37
Three Things To Consider Before Running
Your Model
1. Set up strip charts

2. Integration step sizes and speed
3. Event Scheduler

38
4 Steps are Needed
1. Pressure Flow Setup and Specifications
2. Equipment Sizing
3. Set up your Control Strategy
4. Set up your Strip Charts and Run the Model

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For more Aspen HYSYS Dynamics information

Aspen HYSYS Dynamics web page
http://www.aspentech.com/products/aspen-hysys-dynamics.aspx
White papers, case studies, tutorials, resources
Library of webinars-on-demand
www.aspentech.com > events > webinar-on-demand
Coming soon (will be sent to all webinar participants):
HYSYS Dynamics written getting-started-guide
HYSYS Dynamics computer-based-training (CBT) module
AspenTech Support site
Rich knowledge base of information, tips, technical support
Training videos, viewlets and CBTs
Technical bulletins
Aspen HYSYS LinkedIn group
2900 members; many discussions


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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

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Questions?

42
What Next?

Get more information now
Call your AspenTech account manager or
Call Aspen Telesales Direct:
USA: +1-855-882-7736
EUROPE & MIDDLE EAST: +44-1189-226400
ASIA/PACIFIC and INDIA: +65-6395-3900
Or email us at esales@aspentech.com
Contact info for todays presenter
Glenn.dissinger@aspentech.com

Getting Started With Aspen HYSYS Dynamics

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