Compressor Modeling Using Aspen HYSYS Dynamics

Compressor Modeling Using
Aspen HYSYS Dynamics

Glenn Dissinger, Director of Product Management
Martyn Blanchard, Global Practice Director
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April 23, 2013
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Compressor Modeling Using
Aspen HYSYS Dynamics
Glenn Dissinger, Director of Product Management
Martyn Blanchard, Global Practice Director

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.

Outline
 Overview of HYSYS V8
 Compressor Overview
– Types
– What’s 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

New Aspen HYSYS:
Easier to Use
Faster to Learn

Easier to Learn
Streamlined Workflow & Easier Access
New Aspen HYSYS
Multiple Views
Environments
Interactive Analysis

Workflow Oriented Ribbon -> Left to
Right
Navigation Pane to Easily

Browse Objects
Add Pure or Hypothetical

Components from the Same Form
Properties
Environment
Home
Ribbon
Units of Simulation Summary Analysis

Measure Options and Reports Tools
Solver
Simulation
Environment

Easy Navigation Pane
One Dockable
Status Model Palette
Icons

Stream Analysis Button in
Ribbon
One Click to Analyze

Case Study Button in Ribbon
Drag &inDrop
Results Variables
Table and Plots

Outline
– Types
– Surge
– Overview
– Demo
– Best Practices
 Wrap-Up and Q&A

Poll Question

Compressors – Three Typical Types
Compressors are mechanical devices commonly used to increase

the pressure of a gas and transport it through a pipeline
105 Centrifugal
• Most common compressor
104 used in industry
Reciprocating Piston
Discharge
103
• Used for very high pressures
Pressure Centrifugal and low flow rates
(psia)
102
Axial
Flow
Axial
• Special compressor used for
10
Reciprocating very high flow rates and low
pressures
1
1 10 10 10 10 10
2 3 4 5 6
0
Inlet Flow
(acfm)
Reference – Compressor Handbook for the
Hydrocarbon Industries, Gulf Publishing Co., 1979

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

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

Outline
– Types
– Surge
– Overview
– Demo
– Best Practices
 Wrap-Up and Q&A

Two Operating Modes – Centrifugal & Reciprocating
Operating
Mode

Theory - Efficiencies
• Isentropic Efficiency = ratio of isentropic

(ideal) power required for compression to Flow (ACFM) Polytropic Efficiency (%)
the actual power required Centrifugal 2000 69
5000 72
Efficiency(%) = (Power Requiredisentropic) / 10,000 73
(Power Requiredactual) x 100% 20,000 74
50,000 75
100,000 76
• Polytropic Efficiency = Work for a
mechanically reversible (polytropic) process
Pressure Ratio Polytropic Efficiency (%)
W =  V dP where Reciprocating 1.5 73
W = work 2.0 79
V = volume 3.0 83
dP = pressure difference 5.0 85
For a polytropic compression of a gas from P1 to P2

W = F1 (MW) (n/(n-1)) CF (P1/r1) (P2/P1)((n-1)/n) - 1]

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

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

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

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

Surge and Stonewall Curves

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 = MR2
EI = I IωI dω/dt
Ef = ffric I ω IωI
I = rotational inertia
EI = power to accelerate impeller
Ef = frictional work
ω = rotational speed
M = mass of impeller and rotating shaft
R = radius of gyration

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

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

Demonstration

Outline
– Types
– Surge
– Overview
– Demo
 Compressor Best Practice & Case Studies
– Best Practices
 Wrap-Up and Q&A

Centrifugal & Axial Compressors – What’s
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)

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
(don’t 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

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 isn’t 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)

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

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

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

PETRONAS – Malaysia LNG
Dynamic Simulation for LNG Plant Revamp
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

 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

• Better sizing of recycle valves Final Results

and bypass valves based on all (after implementing recommendations)
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 Safe Compressor
actual plant start-up Operating Points

(outside surge line)


JGC – Ourhoud Algeria Gas Processing Facility
Verification of Compressor Performance
 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

 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.

• 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.

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 Regions

 Process Engineering/  Asia Pacific (APAC)
Real-time Optimization  Europe (EURA)
 Advanced Process Control  Middle East Africa (MENA)
 Production Management  North America (NORAM)
& Execution
 Latin America (LATAM)
 Supply Chain Management

Service Delivery Centers
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.
EMEA APAC
NALA 48 38
56
142 Total
AT office locations * As of April 2013
Key partner locations

Outline
– Types
– Surge
– Overview
– Demo
– Best Practices
 Wrap-Up and Q&A


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Global Conference
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Reliability of Dynamic Simulation to Refinery wide modeling with Aspen

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Optimization of a mixed refrigerant Refinery energy reduction using Aspen
LNG process HYSYS
See these and over 50 additional presentations and training sessions

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 today’s 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

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Compressor Modeling Using

Aspen HYSYS Dynamics

Engineering Collaboration Webinar Series

© 2013 Aspen Technology, Inc. All rights reserved

OTHER RECENT WEBINARS:

© 2013 Aspen Technology, Inc. All rights reserved | 2

Common Models & Data

Basic Aspen Equipment Aspen Basic

The New Solids Activated Activated Integrated Plant Data Easy To

© 2013 Aspen Technology, Inc. All rights reserved | 4

The New Solids Activated Activated Integrated Plant Data Easy To

© 2013 Aspen Technology, Inc. All rights reserved | 5

© 2013 Aspen Technology, Inc. All rights reserved | 6

Aspen Technology may provide information regarding possible

© 2013 Aspen Technology, Inc. All rights reserved | 7

© 2013 Aspen Technology, Inc. All rights reserved | 8

© 2013 Aspen Technology, Inc. All rights reserved | 9

Streamlined Workflow & Easier Access

New Aspen HYSYS

© 2013 Aspen Technology, Inc. All rights reserved | 10

Navigation Pane to Easily

Add Pure or Hypothetical

Units of Simulation Summary Analysis

© 2013 Aspen Technology, Inc. All rights reserved | 12

© 2013 Aspen Technology, Inc. All rights reserved | 13

One Click to Analyze

© 2013 Aspen Technology, Inc. All rights reserved | 14

© 2013 Aspen Technology, Inc. All rights reserved | 15

© 2013 Aspen Technology, Inc. All rights reserved | 16

© 2013 Aspen Technology, Inc. All rights reserved | 17

Compressors are mechanical devices commonly used to increase

© 2013 Aspen Technology, Inc. All rights reserved | 18

From both a design and controllability / operability point of

© 2013 Aspen Technology, Inc. All rights reserved | 19

Surge is the point where a centrifugal compressor cannot add enough

© 2013 Aspen Technology, Inc. All rights reserved | 20

© 2013 Aspen Technology, Inc. All rights reserved | 21

© 2013 Aspen Technology, Inc. All rights reserved | 22

• Isentropic Efficiency = ratio of isentropic

For a polytropic compression of a gas from P1 to P2

© 2013 Aspen Technology, Inc. All rights reserved | 23

© 2013 Aspen Technology, Inc. All rights reserved | 24

The Enable Curves

One curve per speed

All curves must use

Individual curves may

Remove any input

© 2013 Aspen Technology, Inc. All rights reserved | 25

Compressor performance impacted by significant shifts in gas

Able to add performance

© 2013 Aspen Technology, Inc. All rights reserved | 26

 Surge Limit – Lower Flow

 Stonewall Limit – Upper Flow

© 2013 Aspen Technology, Inc. All rights reserved | 27

© 2013 Aspen Technology, Inc. All rights reserved | 28

Used to account for frictional energy

© 2013 Aspen Technology, Inc. All rights reserved | 29

 Surge controller takes

 Parameters for surge

© 2013 Aspen Technology, Inc. All rights reserved | 30

Used to model compressors

Notion of upstream and

© 2013 Aspen Technology, Inc. All rights reserved | 31