05 - Dynamic Simulations For Safety and Reliability and Efficient Operations - Gautam

Dynamic Simulation for Safety, Reliability and
Efficient Operations
Dynamics and Compressor Surge Analysis
Feburary, 2016
Gautam Pradhan, Sr. Principal Business Consultant
Agenda
Steady State Vs. Dynamic Simulation
Why use Dynamic Simulation?
What is Aspen HYSYS Dynamics?
Dynamic Modeling of Compressors Challenges and Best Practices
- Data Analysis
- Steady State Model
- Dynamic Model with Control System, Configuring ASC
- Modelling Acceleration and Deceleration of Motor/Turbine Drives
- Result Analysis and Documentation
Activated Compressor Dynamics in Hysys V8.6 and Above
Dynamic Modeling of Expanders (Turbines)
Case Studies /Success Stories

2
2015 Aspen Technology, Inc. All rights reserved.
Steady State and Dynamic simulation

Dynamic
Steady State
Rating/Design
Support/Validation
Design/Rating/Optimization
Accumulation = 0
Accumulation <> / = 0
Linear Equations
Differential Equations
Flow Driven
Pressure Driven
Modular non- sequential
algorithm
Modular sequential
Algorithm
No Process Control
Process Control
Why Dynamic Simulation ?
Process plants are never truly at steady state

- Feed and environmental disturbances
- Heat Exchanger Fouling
- Catalyst Deactivation
- Equipment/Instrument Malfunctions
Transient behavior are best studied using Dynamic Simulation

-Transition between operating conditions
- Start-up, Normal/Emergency Shut-down Testing
Design/Operational Decision Support
Safety System Evaluation
Operator Training
Advanced Process Control

Dynamic modeling and simulation can address these issues:
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

Enabling design and verification of process control schemes
Building a fully representative dynamic model with high level details allows the control
and start-up scheme to be evaluated onshore rather than offshore.
Allows controller tuning ahead of start-up to give good control response.

A faster and safer start-up leads to early production and risk minimization.
Aspen HYSYS Dynamics

Aspen HYSYS
Dynamics is the Industry
Standard Dynamic
Modeling Software that
Combines Process
Engineering and Control
Engineering
Compressors Why Worry?

From both a design and controllability / operability point of view,
compressors provide unique issues and challenges
Design Issues
Expensive equipment
Often customized with long
lead times to replace
Operability Issues
Compressor trips are costly
Compressor surge is very
hazardous
Specialized anti-surge control
systems are common
Dynamic Modeling of Compressors - Challenges
Precise modeling required for design/operational decision support
ASC algorithm requires accurate thermodynamics properties along the surge line
Multiple performance curves ( IGV Opening, MW, Speed, )
ASC valve ( stroke time, delay, special valve characteristics)
Modeling start-up with different driver VS motor, fixed speed motor, turbine
Start-up from various SOP ( refrigeration compressors) and voltage
Acceleration and deceleration by Inertia and power balance
Dynamic Modelling: Compressor Surge Analysis Step
10
Performance Curves
Check The Compressor Performance Curves

Perform Extrapolation for Stone wall and
Surge area.
Plot the Surge Line by Joining Left Most points

( Min Flow, Max Head Points) at various
speeds.
Polynomial Surge Curve

Linear Surge Line
Stone Wall Curve
11
Performance Curve
For Fixed Speed Drive, performance

curve should be estimated for other
than Operating Speed Curves for
accurate modeling during coast down
and start-up.
If multiple speed curves are not

available, extrapolated curves should
be generated and entered to the
model
Extrapolated Performance Curve
12
Modeling Special Valve Characteristics

Special Valve Characteristics is modeled using Linear Interpolation
CV calculated and Exported to Valve Spec. at each time step

Opening as decided by Controller is imported to spread sheet at each time step
Interpolation Logic Statements

=IF(M27<=M17,O17,IF(M27<=M18,O18,IF(M27<=M19,O19,IF(M27<=M20,O20,IF(M27<=M21,O21,IF(M27<=M22,O22,IF(M27<=M23,O23,IF(M27<=M24,O24,IF(M27<=M25,O25)))))))))
=IF(M27<=M17,P17,IF(M27<=M18,P18,IF(M27<=M19,P19,IF(M27<=M20,P20,IF(M27<=M21,P21,IF(M27<=M22,P22,IF(M27<=M23,P23,IF(M27<=M24,P24,IF(M27<=M25,P25)))))))))
13
EQUIPMENT & PIPING DATA

HEAT EXCHANGERS
VESSELS
VESSEL
DIAMETER
VESSEL
HEIGHT
VESSEL
VOLUME
SHELL
VOLUME
OVER-ALL UA
SHELL SIDE
DESIGN FLOW &
PRESSURE DROP
TUBE SIDE DESIGN

FLOW & PRESSURE
DROP
CONTROL VALVE
AIR COOLERS
OVER-ALL UA
HOLD-UP
TUBE
VOLUME
DESIGN FLOW AND

PRESSURE DROP
PIPING ISOMETRICS
P&ID
No.
Line
No.
From
To
Associated
Pipe
Length
Nom.
Dia.
Inner
Dia.
45 deg
elbows
Long
radial
elbows
Short
radial
elbows
Soft
tees
Hard
tees
Ball
Valves
Check
valves
Isolation
valves
Calc
VOL
Delay time for sensor/transmitters/control valve should be taken into account for precise modeling
14
INERTIA OF DRIVER AND COMPRESSORS

TOTAL SYSTEM INERTIA OF THE DRIVER AND COMPRESSOR SYSTEM IS REQUIRED FOR
ACCURATE MODELING OF START-UP AND SHUT-DOWN and ESD OF COMPRESSORS
No.
Equipment
Motor
Low Speed Coupling (Incl. Hub)
3
4
Gear Shaft (Incl. Pinion Shaft)

Pinion Shaft
High Speed Coupling (Incl. Hub)
Compressor
Speed
GD2/4 (=J) at LS shaft
[rpm]
[kgm2]
Total
15
ASC Configuration
Surge control systems are designed to
Detect the imminent start of surging
Prevent the compressor from reaching this condition
Basic Strategy of Anti Surge Controller (ASC):

Open a recycle valve to provided increased throughput
A surge curve is used to detect imminent start of surging
Quick opening recycle valve controlled directly by ASC
Additional Possible Strategies:

Decrease speed, reducing surge flow limit
Reduce outlet pressure, reducing compressor head
Specialized surge controller technology

From compressor vendors
16
Other technology providers
ASC Configuration
Surge controller
attempts to maintain
a minimum flow rate
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
17
ASC Configuration - Other Technology Providers

Specialized surge controller algorithm can be emulated for use in Hysys.
From compressor vendors
Other technology providers
Information required for emulating third party surge controller algorithm

Details of the operation/features of the ASC, Details on Input signals/connections, methodology for surge
line characterization
Details on output signals/connections, Details on configuration/tuning parameters
Details on control algorithms (closed loop/open loop responses and transitions between the two)
Specific details on the application (if known/available), such as: Input data used, Input connections,
Algorithms employed
Configuration parameters (or how to calculate them),Output connection.
DLL can be created and registered as extension into HYSYS.

18
Modelling Acceleration/Deceleration of Motor/Turbine Drives

The rate of Acceleration/Deceleration is calculated from the total rotational inertia, power
consumption, and driver power and friction losses. The rate of Acceleration/Deceleration is
re-calculated at each time-step by a rigorous torque balance equation:
Where:
P
ILSS
Nmotor
Ncomp
19
= change in shaft power in each time-step

= inertia with respect to the low speed shaft
= motor speed
= compressor speed
Linear interpolation can be applied to use the motor speed vs torque curve at each time steps
=IF(M16<=M5,O5,IF(M16<=M6,O6,IF(M16<=M7,O7,IF(M16<=M8,O8,IF(M16<=M9,O9,IF(M16<=M10,O10,IF(M16<=M11,O11,IF(M16<=M12,O12,IF(M16<=M13,O13,IF(M16<=M14,O14))))))))))
=IF(M16<=M5,P5,IF(M16<=M6,P6,IF(M16<=M7,P7,IF(M16<=M8,P8,IF(M16<=M9,P9,IF(M16<=M10,P10,IF(M16<=M11,P11,IF(M16<=M12,P12,IF(M16<=M13,P13,IF(M16<=M14,P14))))))))))
20

Rated Torque = Rated Power*60*1000/(2**Motor Speed)
T = Rated Torque * ESD Trip * Speed Controller OP *Reduced Torque/100
Available Power = 2**N*T/ (60*1000)

Required Power = Power Consumed in Gas Compression + Power Losses
Power Losses = Power Loss Constant * Speed* Speed
Power consumed in gas compression is dynamically imported to spread sheet at each time step from
compressor performance data in HYSYS.
Power Imbalance = Available Power Required Power
Power Imbalance is used for calculating Acceleration or deceleration using the torque balance equation
21
Integrator Setting
Step Size should be reasonably set

to capture the Desired Operating
Locus 0.001 0.05 Sec Typical
Do not play with the Acceleration

factor, should be 1
Set Execution rate for P-F Solver,

Control and Logic Operations,
Composition and Flash calculation
to 1
In the Integrator Option, uncheck

Truncate large volume integration
error
Enable Static head contribution as

desired
22
Scenario Configurations Event Scheduler
Configure all Required Test

Scenario, ESD, Start-up, Etc.
using Event Scheduler
23
Result Analysis and Report

For Generating Report, Create a Strip Chart and add
all important variables:
- Compressor speed, Head, Flow
- Total Available Power, Torque
- Flow Through ASC, HGB
- Suction Temperature, Pressure, Flow
- Discharge Temperature, Pressure Flow
- Any Other Important Variables, Calculated Match

No. through HGB etc.
-
Drag and Drop variable from flow-sheet into strip
chart
24
Drag and Drop Variables

After the scenario runs, save
historical data as .CSV file for
analysis and report generation.
A Template can be created to
avoid repeated task for
multiple scenarios
25
26
Aspen HYSYS V8.6+ Activated Dynamics

Eliminate Compressor Damage by Compressor Surge Analysis
27
Activated Compressor Dynamics in Hysys V8.6+

Process Engineer
Steady
State
Simulation
Models
Controls Engineer
Dynamic
Simulation
Models
Dynamic analysis early in

the process improves
safety, operability & cost
effectiveness
Empower everyone to use dynamics

New users supply minimal inputs
Pre-made templates, scenarios & results forms
Experienced users can improve the template

28
Activated Compressor Surge Analysis

Dynamic model automatically built from steady state compressor model
Automatically generate results forms

29
Pre-defined
Emergency scenarios
Feedback
Activated Compressor Dynamics (1 of 2)
an innovative screening tool before full dynamic
compressor modeling. A good starting point to perform a
compressor study across a range of scenarios. The data are
presented in a well-organized manner, and pre-made results
displays are convenient.
Impressed with how quickly the flowsheet can be setup, and
likes the automation and how quickly you can obtain results
Liked the custom templates and the rewind functionality. The

recycle block is not reflective of a true dynamics case
Scenarios and input summary form useful. Valve and pipe
sizing should not be based on steady state flow. Offer
options to include hot bypass line and to start with surge
valve partially open
Customer Reference: Atkins (Ian Wyatt, Principal Engineer)
31
Modeling Expanders ( Turbines) in Hysys

Expander is an important piece of equipment in many process plants.
Expanders are often used in refrigeration units, LNG plants, gas plants, air
separation plants and ethylene plants.
Expanders are also often used as the driver for compressors or pumps. Examples
here are expanders running on steam or expanders that are part of a gas turbine.
Unlike Compressors, Getting Detailed Performance Curves for Expanders ( Flow Vs
Head & Efficiency at various speed is difficult as expander vendor do not provide
such curve.
For a compressor the feed actual volume flow is a good parameter to relate
compressor head and efficiency, however, for an expander, it is rather the discharge
actual volume flow that is the parameter of choice.
Most often, a single Mass Flow Vs Power Curve is provided by expander Vendor, but
only a point efficiency is generally provided rather than a curve.
32
Modeling Expanders ( Turbines) in Hysys

Recommended Modeling Approach:
Step 1:
Size a Control Valve so that at steady state with same pressure difference between inlet and outlet of
the turbine, gives same flow rate as the Turbine Design Flow .Inlet and outlet pressure of this control
valve is dynamically manipulated (at each time steps). This is done by first importing the inlet and
outlet pressure of the turbine to a spread sheet and then exporting these pressure to the inlet and
outlet of the control valve.
Step 2:
The flow rate [ACT_m3/h] through the Control Valve (sized in step 1 above) is imported to the
spread sheet and then exported to the capacity of turbine.
Step 3:
The Adiabatic Efficiency is calculated in spreadsheet using Mafi-Trench method as below:

E = 100*SQRT {(3.14 *D*N/60)/SQRT (H*1000)}
Where
E = Adiabatic Efficiency
D = Wheel Diameter of the Turbine
N = RPM of Turbine
H = Adiabatic Fluid Head of the turbine (imported from turbine in Hysys model)
33
Case Studies
PETRONAS Malaysia LNG
Dynamic Simulation for LNG Plant Revamp
JGC
Compressor Anti-Surge Valve design using HYSYS Dynamics simulation
Wintershall and InProcess
Assessing safer Blow-down option by Using Dynamic Process Simulation
Production Services Network
Perform operability analysis
34

Challenge
Solution
Results
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
35

Challenge
Solution
Results
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 antisurge 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
36

Challenge
Results
Solution
Better sizing of recycle valves and

bypass valves based on all failure
scenarios compared to steady state
Final Results
(after implementing recommendations)
Relieving loads confirmed for various

scenarios which form the basis for key
relief valve sizing
Safe Compressor
Start-up and shutdown procedures

tested in advance of actual plant start-up
Operating Points
(outside surge line)

37
Compressor Anti-Surge Valve design using HYSYS Dynamics

simulation
Business Challenges & Objectives
Better design for safety and reliability of compressor systems, especially:
Test Run-a Suction Blockage Comp2 out Temperature
100
Comp-2 out Temperature C
Anti Surge Valve Sizing

Anti Surge Valve Stroke Time
Anti Surge Controller parameters
80
85
60
40
40
20
0
0
100
Solution Overview
10
Time
15
20
Test Run-a Suction Blockage ASV Percentage open
ASV Percentage
open %
80
60
Aspen HYSYS Dynamics model with high level of detail

(compressor performance curves, isometrics, anti-surge valves,
and controllers)
57
40
20
0
10
Time
15
20
Test Run-a Suction Blockage Comp-2

7000
Results & Benefits
6000
Pressure controller set-points
5000
Head N-m/Kg
More reliable compressor anti-surge circuit design and

verification of design
4000
3000
2000
1000
Design conditions
0
0
5000
10000
15000
Flow m^3/h
Controllability
Ref: Mr. Kuroda (JGC Corporation), Aspen User Group Meeting, Japan, May 2006
38
20000
25000

Assessing safer Blow-down option by Using Dynamic Process Simulation
Challenge
Solution
Result
Plant revamp required a revision of

the blow-down strategy
Different simultaneous blow-down
scenarios evaluated
What measures are required to allow
a complete blow-down within 15
minutes following the API 521
directive of blowdown to 50% of
operating pressure or 6.9 barg within
15 minutes.
Ref: Michael Brodkorb Inprocess Group,
AspenTech Global Conference, Washington, D.C., May 2011
39

Safer Blow-down by Using Dynamic Process Simulation
Challenge
Solution
Result
Aspen Flare System Analyzer to model

the complete flare header system and
modelling of multiple Flare Tips to
predict correct pressure drop
Model the flare header in Aspen HYSYS
Dynamics for validation of pressure
drop and mass flows
Integrate the Aspen HYSYS Dynamics
models of the different process
sections with the flare header model
40

Safer Blow-down by Using Dynamic Process Simulation
Challenge
Result
Solution
Complete Dynamic Model gives a

max flare load of
75% (of total capacity)
Dynamic simulation can be used
for modelling the complete
process plant as well as the flare
headers and shows additional
capacity of the existing flare
system.
Low investment solution identified
reducing the investment for the
flare system upgrade significantly
(-70%)

41

Challenge
Solution
Results
Using dynamic simulation to model

emergency system response
Provide evaluation of alternate

process configurations or
equipment failures
Improve safety
Ref: David Francis, PSN

AspenTech User Conference, Houston, May 2009
42

Challenge
Results
Solution
Compressor modeling with Aspen

HYSYS Dynamics
Emergency Shutdown (ESD) and
Emergency Depressuring (EDP)
systems via Aspen HYSYS
Dynamics Cause & Effects

43

Challenge
Results
Solution
Increased safety margin for compressor

until confirmed protected against surge.
Eliminated need for Hot Gas Bypass
installation- Saving @ 2 Million capital
expenditure
Zone 10 Blowdown curves

160
120
140
100
120
Operator training tools revised based on

new understanding of ESD and EDP
systems
Pressure (barg)
90
80
100
70
80
60
50
60
40
40
30
20
20
10
0
0
0
12
16
20
24
28
Time (minutes)
Zone 10A
Zone 10B
Zone 10D
Zone 10C
Flare Load

44
32
Mass Flowrate (tonnes/hr)
Easy identification of trapped inventories
110
Conclusion
Numerous Dynamic Simulation Case Studies and Success Stories

Improved Operability, Safety, Reliability
Cost Saving both Capex and Opex
Proven Benefit
45
Thank You
AspenTech is ranked as a top
innovative growth company

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Dynamic Simulation for Safety, Reliability and

Gautam Pradhan, Sr. Principal Business Consultant

Case Studies /Success Stories

2015 Aspen Technology, Inc. All rights reserved.

Steady State and Dynamic simulation

2015 Aspen Technology, Inc. All rights reserved.

Why Dynamic Simulation ?

Process plants are never truly at steady state

Transient behavior are best studied using Dynamic Simulation

Design/Operational Decision Support

Safety System Evaluation

Advanced Process Control

2015 Aspen Technology, Inc. All rights reserved.

Why Dynamic Simulation ?

Design / Analysis of Control Schemes

Operability Engineering Studies

Hazard and Safety Studies

2015 Aspen Technology, Inc. All rights reserved.

Why Dynamic Simulation ?

Allows controller tuning ahead of start-up to give good control response.

2015 Aspen Technology, Inc. All rights reserved.

Aspen HYSYS Dynamics

2015 Aspen Technology, Inc. All rights reserved.

Compressors Why Worry?

2015 Aspen Technology, Inc. All rights reserved.

Dynamic Modeling of Compressors - Challenges

Precise modeling required for design/operational decision support

Multiple performance curves ( IGV Opening, MW, Speed, )

ASC valve ( stroke time, delay, special valve characteristics)

Start-up from various SOP ( refrigeration compressors) and voltage

Acceleration and deceleration by Inertia and power balance

2015 Aspen Technology, Inc. All rights reserved.

Dynamic Modelling: Compressor Surge Analysis Step

2015 Aspen Technology, Inc. All rights reserved.

Check The Compressor Performance Curves

Plot the Surge Line by Joining Left Most points

Polynomial Surge Curve

2015 Aspen Technology, Inc. All rights reserved.

For Fixed Speed Drive, performance

If multiple speed curves are not

Extrapolated Performance Curve

2015 Aspen Technology, Inc. All rights reserved.

Modeling Special Valve Characteristics

CV calculated and Exported to Valve Spec. at each time step

Interpolation Logic Statements

2015 Aspen Technology, Inc. All rights reserved.

EQUIPMENT & PIPING DATA

TUBE SIDE DESIGN

DESIGN FLOW AND

2015 Aspen Technology, Inc. All rights reserved.

INERTIA OF DRIVER AND COMPRESSORS

Low Speed Coupling (Incl. Hub)

Gear Shaft (Incl. Pinion Shaft)

High Speed Coupling (Incl. Hub)

GD2/4 (=J) at LS shaft

2015 Aspen Technology, Inc. All rights reserved.

Basic Strategy of Anti Surge Controller (ASC):

Additional Possible Strategies:

Specialized surge controller technology

Other technology providers

2015 Aspen Technology, Inc. All rights reserved.

Parameters for surge

2015 Aspen Technology, Inc. All rights reserved.

Available Power = 2**NT/ (601000)