Analyze and Troubleshoot Compressor Systems Easily with Activated Dynamics in Aspen HYSYS V8.6

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Dustin Kennedy
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6 September 29, 2014 Presenter Name, Presenter Title

Gulam Farooq, Senior Principle Business Consultant,

1 Analyze and Troubleshoot Compressor Systems Easily with Activated Dynamics in Aspen HYSYS V8.6 September 29, 2014 Presenter Name, Presenter Title Saif Sheikh, Business Consulting Director, AspenTech Gulam Farooq, Senior Principle Business Consultant, AspenTech September 29, Aspen Technology, Inc. All rights reserved

2 Ongoing Series of Technical Webinars Engineering Webinars for Education and Best Practices ON DEMAND WEBINARS OF INTEREST: Create World Class Design with Aspen One Engineering Ensure Safe Operations with Relief Sizing in Aspen Plus and Aspen Hysys Reduce Energy expenditure using Activated Energy Analysis Size Pressure Safety Valves and Design Flare Systems Stay Ahead in Process Design with Aspen One Exchange Upgrade Column Design Using Aspen Hysys Dynamics ADDITIONAL RESOURCES: Public Website: Aspen Technology, Inc. All rights reserved 2

aspenone Engineering 8.6 Highlights Activated Aspen HYSYS Dynamics V8.

dynamics in Aspen HYSYS allows quick compressor surge analysis PSV Aspen Design Plus & V8.

Estimating in ACCE Expand use of ACCE into detailed estimating E-Learning in Aspen Plus and

3 aspenone Engineering 8.6 Highlights Activated Aspen HYSYS Dynamics V8.6 in HYSYS ELIMINATE COMPRESSOR Compressor surge DAMAGE: analysis with one click Activated dynamics in Aspen HYSYS allows quick compressor surge analysis PSV Aspen Design Plus & V8.6 Rating in Aspen Plus SAFER PLANT OPERATIONS: Overpressure PSV protection design in and Aspen rating is Plus now in Aspen Plus! OVERPRESSURE PROTECTION: Rigorous fire event scenarios for PSV analysis Detailed Unit Rate Estimating in ACCE Expand use of ACCE into detailed estimating E-Learning in Aspen Plus and Aspen HYSYS V8.6 E-Learning resources are now curated in groups and are easily accessible from within Aspen Plus and Aspen HYSYS 2014 Aspen Technology, Inc. All rights reserved 3

4 Outline Business Challenge Compressor Overview Types Why worry? Surge Modeling Compressors in HYSYS Overview Activated Dynamics for Compressor Surge Analysis Activated Dynamics Overview Demo Wrap-Up and Q&A 2014 Aspen Technology, Inc. All rights reserved 4

5 Poll Question Level of experience with modeling of compressors: a. Experienced user of dynamic simulation for compressor modeling b. Some experience with dynamic simulation, but have not done much with compressors c. Steady-state modeling of compressors only d. Little to no experience modeling compressors 2014 Aspen Technology, Inc. All rights reserved 5

8 Compressors Three Typical Types Compressors are mechanical devices commonly used to increase the pressure of a gas and transport it through a pipeline Centrifugal Most common compressor used in industry Discharge Pressure (psia) Reciprocating Inlet Flow (acfm) Centrifugal 10 5 Axial Flow 10 6 Reciprocating Piston Used for very high pressures and low flow rates Axial Special compressor used for very high flow rates and low pressures Reference Compressor Handbook for the Hydrocarbon Industries, Gulf Publishing Co., Aspen Technology, Inc. All rights reserved 8

challenges Design Issues Expensive equipment Often customized with long lead times to replace Operability

9 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 Very fast dynamics Compressor trips are costly Compressor surge is very hazardous Specialized anti-surge control systems are common 2014 Aspen Technology, Inc. All rights reserved 9

10 What is Surge and Why is it Such a Problem? Surge is the point where a centrifugal compressor cannot add enough energy to overcome the system backpressure 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 2014 Aspen Technology, Inc. All rights reserved 10

Two Operating Modes Centrifugal & Reciprocating

12 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 2014 Aspen Technology, Inc. All rights reserved 12

Input for Multiple Head and Efficiency Curves The Enable

curves must use the same efficiency definition (Adiabatic

deactivated Remove any input value for efficiency on the

13 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 2014 Aspen Technology, Inc. All rights reserved 13

Input for Multiple Head and Efficiency Curves Able to Add Additional Curves for Other MW Gases Compressor performance impacted by significant shifts in gas molecular weight, particularly for low

14 Input for Multiple Head and Efficiency Curves Able to Add Additional Curves for Other MW Gases Compressor performance impacted by significant shifts in gas molecular weight, particularly for low pressure compressors Able to add performance curves for the different molecular weights, as well as Quasi- Dimensionless and Non- Dimensional curves 2014 Aspen Technology, Inc. All rights reserved 14

15 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 curve s 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 2014 Aspen Technology, Inc. All rights reserved 15

17 Cubic Compressor Curves Improve Operability Near Surge Region Non-Dimensional Curve input option to model compressor behavior near surge region Visualize compressor operation near the surge region 2014 Aspen Technology, Inc. All rights reserved 17

19 Aspen HYSYS V8.6 Activated Dynamics Eliminate Compressor Damage by Compressor Surge Analysis Activated Dynamics Compressor Surge Analysis Eliminate Compressor Damage Better Process Design Increase Compressor Life Reduce Maintenance Costs Improve Process Safety 2014 Aspen Technology, Inc. All rights reserved 19

20 Situation Today Experience and Expertise Required + Time-Consuming Process Manually create Dynamic flowsheets Manually Specify model for each scenario Manually create control scheme Manually Create events, strip charts, results 2014 Aspen Technology, Inc. All rights reserved 20

Simulation Models Dynamic Simulation Models Dynamic analysis early in the process improves safety, operability &

21 Aspen HYSYS V8.6 Activated Dynamics Improves Safety & Compressor Reliability Process Engineer Controls Engineer Steady State Simulation Models 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 2014 Aspen Technology, Inc. All rights reserved 21

22 Aspen HYSYS V8.6 Activated Dynamics Faster Transition Between Steady-State and Dynamic Model Automatically create dynamic flowsheets Automatically specify model for each scenario Access to multiple templates User can create templates Automatically create control scheme Automatically create events, strip charts, results 2014 Aspen Technology, Inc. All rights reserved 22

independent of parent flowsheet Subflowsheet generated with

23 Dynamic Subflowsheet Independent Dynamic Analysis, Within Steady-State Model Simplified dynamics ribbon Dynamic subflowsheet independent of parent flowsheet Subflowsheet generated with defaults for quick simulation 2014 Aspen Technology, Inc. All rights reserved 23

24 Templates Three Pre-built Templates for Compressor Configuration + Ability to Create Custom Templates Three pre-made templates Image updates depending on template selected Ability to create custom templates 2014 Aspen Technology, Inc. All rights reserved 24

25 Custom Templates Full Control: Build Templates Based on Your Design Preferences User can create templates using all HYSYS models Templates can be used to generate a dynamic subflowsheet 2014 Aspen Technology, Inc. All rights reserved 25

27 Aspen HYSYS V8.6 Activated Dynamics Reduce Time to Learn and Master Compressor Surge Analysis Easy to Learn Easier to Use Rapidly switch between Steady State & Dynamic Simulation with Activated Dynamics Faster Dynamic Modeling with Activated Dynamics Pre-made templates (for dynamics subflowsheets) Pre-built scenarios (Shutdown, Emergency Shutdown, Total Power Loss, and Discharge Valve Failure) Pre-configured strip charts Customizable templates (for faster dynamics modeling) Non-dimensional performance curves (for improved compressor modeling near surge region) Both Steady State and Experienced Dynamic Users benefit from Activated Dynamics in Aspen HYSYS V Aspen Technology, Inc. All rights reserved 27

29 Aspen HYSYS V8.6 Activated Dynamics Customer Testimonial The new Activated Compressor Surge Analysis feature is an innovative screening tool to perform a compressor study across a range of scenarios. The data is presented in a well-organized manner, and premade results displays are convenient. - Ian D. Wyatt Principal Engineer WS Atkins 2014 Aspen Technology, Inc. All rights reserved 30

32 4 6 May 2015 The Westin Boston Waterfront Boston, MA USA 3 full days of rich content to drive UPA Focused exclusively on optimizing process manufacturing OPTIMIZE 2013 featured 700+ attendees from over 40 countries 2014 Aspen Technology, Inc. All rights reserved 33

33 What Next? Get more information now Additional resources available at: Videos also available at: Contact info for today s presenters and hosts Saif Sheikh, Saifuddin.Sheikh@aspentech.com Gulam Farooq, Gulam.farooq@aspentech.com Thank you! 2014 Aspen Technology, Inc. All rights reserved 34

Generate Ethylene Vapor Pressure Curves with Aspen Plus V8.0

Generate Ethylene Vapor Pressure Curves with Aspen Plus V8.0 1. Lesson Objectives Learn how to use the Methods Assistant to select physical property methods Generate vapor pressure curves for Ethylene