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Note: For this case, you will discard the Cooler on Discharge side template
since the dew point temperature of the stream on the outlet side of the Cooler
is significantly lower than 43°C. This means that condensation cannot take
place, so there is no need of a downstream scrubber.
Notes:
The scrubbers will be sized from the following two equations. These
equations determine the minimum vessel diameter and a convenient
height. The computed diameter is the minimum to prevent the entraining
of liquid into the compressor from the vessel through the vapor line due to
an excessively high vapor velocity. This equation was originally developed
to set the percentage of flooding by vapor in distillation columns and
applies to systems at dew point conditions and far away from the critical
point [1], [2].
These formulas are only valid for the units given below and that their
conversion to the English system of measures is not straightforward [2].
Also, if the compressor suction stream or the Cooler outlet stream are too
far away from dew point conditions, considerably oversized scrubber
vessels are a possible result.
D 2.12 Q g0.5
H 1. 5 D
where
g : mass density of the vessel vapor outlet stream (kg/m3)
Q : mass density of the vessel vapor outlet stream (m3/s)
D : minimum vessel diameter (m)
H : vessel height (m)
The flowsheet is in steady state. Make sure that it is converged before
proceeding with the rest of this example.
Figure 7. Operating point trail for the Cv=720 USGPM at the anti-surge valve
Figure 7 now shows the impact of this larger Cv on the Discharge Valve
Failure scenario. Notice that the minimum compressor flow is now slightly
higher than the one in Figure 3. In conclusion, a larger Cv will avoid surge,
but you can only increase it to some maximum value before stonewall takes
place. This test case does not require the hot bypass valve to handle these
two scenarios.
Figure 9. Successful total power loss when using the previously found
overall settings
As you can see with Figure 10 (below), the loss of coolant does not represent
a serious inconvenience. The compressor suction stream temperature slightly
exceeds 70oC. For the still rotating shutdown compressor, the discharge
temperature is almost the same as the suction temperature.
Note: The flowsheet is in steady state. Make sure that it is converged before
proceeding with the rest of this example.
Running Scenarios
There are two sets of degrees of freedom to modify and a single criterion to
pass four scenarios.
The degrees of freedom are for:
the surge controller and anti-surge valve side
the hot-bypass valve size and overall discharge volume size
All scenarios have been set to convenient default values, so only minor
changes are involved. The single criterion for success or failure is based on
the trail of the compressor operating point in the compressor map that is
generated during each particular test scenario.
2 On the Dynamics ribbon tab, from the Select Scenario drop-down list,
select Discharge Valve Failure.
Note: You can select the Event Scheduler button on the Dynamics tab
of the ribbon to view further details regarding this scenario.
3 On the Dynamics ribbon tab, click the Run button. Make sure that the
Real Time option is cleared.
The test does not need to be run until completion of the 30 minute
setting. You can manually stop it after 5 minutes by selecting the Stop
button on the Dynamics ribbon tab.
See Figure 12 below to view the operating point trail on the compressor
map for the default settings of the surge controller parameters and the
anti-surge recycle valve.
Figure 14. Controlled shutdown test (left side) and total power loss (right
side). Both recycle valves are used at their default Cv values and simulate
surge and stone wall conditions.
Figure 15. Evolution of the compressor suction side temperature during the
total power loss scenario
For K-100, the Cooler on discharge side, no downstream scrubber
template seems to be a more reasonable one, since it only requires the anti-
surge recycle valve with moderate Cv and the operating point trails found
were acceptably close to either the surge or the stonewall limits. This
completes your study of the first compressor case.
Note: The flowsheet is in steady state. Make sure that it is converged before
proceeding with the rest of this example.
Running Scenarios
Figure 20. Default valve sizing and conditions for “Cooler on suction side”
template, compressor K-101
Figure 21. Discharge valve failure test for compressor K-101 in template
“Cooler on suction side”
References
[1] Douglas, James M. “Conceptual Design of Chemical Processes.” McGraw-
Hill, Inc., 1988.
[2] Luyben, William L. “Plantwide Dynamic Simulation in Chemical Process
and Control.” Marcel Dekker, 2002, Chapter 2.
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