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1 Introduction 1
1 Introduction
Audience
This guide is intended for process and process systems engineers.
Related Documentation
Title Content
Aspen Flare System Analyzer Reference Manual for Using Aspen
Reference Manual Flare System Analyzer
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1 Introduction 3
2 Building and Running a
Model
Overview
This Getting Started tutorial shows the fundamental principles involved in
using Aspen Flare System Analyzer to design and rate a new flare system.
This guided tour will expose you to most of the major features of Aspen Flare
System Analyzer.
This tutorial assumes that you are familiar with the use of Microsoft Windows
and have some prior experience in the design of flare systems.
This example consists of the following main parts:
1 Building The Pipe Network - Pipes and nodes will be added using either
the Process Flowsheet or Pipe Manager.
2 Defining the Scenarios - Different scenarios will be set up to simulate
various process conditions.
3 Defining The Sources - Relieving sources will be added to each scenario.
4 Sizing the Network - Finally, the pipe network will be simulated and
results will be viewed both in textual and graphical form.
Data Requirements
Before you can start to build a computer model of the flare header system,
you must first define all the data that will determine your system.
When you are sizing a flare system, the initial pipe diameters may affect the
solution when there is a liquid phase and the liquid knockout drum is
modeled. You should initially size a network using vapor phase methods.
The following diagram shows the connectivity of the system that you will be
designing in this example.
Fig 2.1
The piping in the network diagram is detailed in the following table:
The flare tip is not a pipe segment, but rather a node that represents a zero
length piece of pipe with defined fittings loss coefficients. Since the internal
diameter is not specified, it will assume the same diameter as the upstream
pipe segment. Fittings loss coefficients for the flare tip exclude pipe
enlargement and junction losses for the connection to the upstream pipe
which will automatically be calculated.
In this example, you will consider three scenarios that represent one fire case
and two single blocked discharge cases. The following tables define the source
data for each scenario.
Fig 2.2
2 The current unit set is shown in the Units box. The default unit set is
Metric, which will be used for this example.
3 Confirm that the Edit Objects on Add check box is selected. This option
will open the object editor view each time a new object is added.
4 Click OK to close the Preferences Editor.
Note: Initially, all the check boxes in the Component types group are
selected. You can clear them by clicking Invert.
Note: Notice that now all the required components are shown in the
Selected components list, indicating that they have been installed in the
case.
The Component Manager will now appear as follows:
Fig 2.5
5 Click OK to close the Component Manager and accept the list of
components.
6 In the Navigation Pane, double-click Inputs on the Views pane, and then
select Components from the list. The Components data view will be
displayed:
Fig 2.6
Note: You do not need to include the .fnwx extension; Aspen Flare System
Analyzer will add it automatically.
Click Save to close the dialog box and save the file.
Note: Before proceeding any further, make sure that the Edit Objects on
Add check box on the General tab of the Preferences Editor is selected.
Fig 2.7
At this point the flowsheet should be blank, since we have not added a single
object yet.
The desired objects can be added by using either of the following methods:
Clicking the Palette on the Process Flowsheet tab will open the
Palette, which displays all the objects available in Aspen Flare System
Analyzer. You can add an object by dragging it onto the Process
Flowsheet.
Fig 2.8
Fig 2.9
By default the Flare Tip has been named as FlareTip1, which can be changed
to a more appropriate name as follows:
4 Click in the Name field on the Connections tab of the Flare Tip Editor.
5 Delete the default name and type Flare Tip as the new name.
Since this example is of smaller size, the Location field will be left blank.
This field is only useful for larger cases with multiple sections (areas)
within a same plant. Now you need to specify the pipe, which will be
simulated as a flare stack, and it is attached to the Flare Tip.
6 Select Stack from the list in the Upstream node field.
7 In the At field, select Downstream as the pipe end connected to the
Flare Tip.
In order to complete the input on the Flare Tip Editor, you need to
specify the Diameter and the Fitting Loss values on the Calculations
tab.
Note: The Fitting Loss Coefficient Basis should be set to Total Pressure
to indicate that the loss coefficient we are defining will calculate the pressure
loss in the Flare Tip including the velocity pressure loss.
8 On the Calculations tab, enter 876.3 as the diameter and 3 as the fitting
loss in the appropriate fields.
Fig 2.10
Now you have provided all the necessary information about the Flare Tip.
9 Click OK to close the view.
Notice that now two new objects have been added to the Process
Flowsheet. These may be drawn one on top of the other so you should
manually arrange them by clicking and dragging the object icons.
10 Open the Stack Object Editor by double-clicking the pipe icon on the
flowsheet and move to the Dimensions tab.
11 Specify the Length as 100 m and the Elevation Change as 100 m.
This will result in a vertical pipe measuring 100 m tall.
12 Select the Nominal Diameter as 36 inch and the Pipe Schedule as 40.
Note: Setting the tailpipe option to Yes will cause the pressure drop to be
calculated using the rated flows rather than the actual flow. For this pipe
which is a tail pipe to a control valve source, the rated flow and actual flow
will be the same so the setting of this option will have no effect.
Fig 2.21
You could also check the Process Flowsheet to ensure that the proper
connections have been made. A portion of the Process Flowsheet is displayed
below:
Note: The Mole Fractions are automatically estimated from the Molecular
Weight. Because HC is selected from the list, only hydrocarbon components
will be used to match the Molecular Weight.
9 Click OK to close the Control Valve Editor for Source 1. Click Add in
the Node Manager to add a new source. The node selection list will again
be displayed.
10 Select Relief Valve from the list, and then click Edit to open the Relief
Valve Editor.
11 Name the new source as Source 2 on the Connections tab.
12 Select Tail Pipe 2 in the Outlet field and set connection to be at
Upstream (of Tail Pipe 2).
Fig 2.37
13 On the Conditions tab, check that the relief valve set pressure or MAWP
is set to the default value of 10 bar which is correct for this source. Select
the Auto check box next to the Relieving Pressure field. This tells Aspen
Flare System Analyzer to calculate the relieving pressure from the MAWP
and the selected Contingency, which should be left as Operating in this
case. Check that the relieving pressure is calculated as 10.89 bar.
14 Still on the Conditions tab, check that the Allowable Backpressure is
set to 5.0 bar. Enter the required Mass Flow rate for this source of
100000 kg/ hr. Select the Auto check box next to the Rated flow field.
This tells Aspen Flare System Analyzer to calculate the rated flow for the
valve from the specified fluid conditions and properties, valve type and
orifice area.
15 Still on the Conditions tab, click the box next to the Orifice Area Per
Valve field to select orifice code api_T. Check that the orifice area is
Fig 2.38
17 Click OK to close the Relief Valve Editor.
The Node Manager will now appear as follows:
Fig 2.39
18 Close the Node Manager by clicking Close.
19 In the Navigation Pane area which is docked to the left of the Process
Flowsheet, select Inputs | Sources on the Views pane.
The Sources data sheet for the Default Scenario will be displayed:
Fig 2.40
You must now add the source data for the other two scenarios.
20 Select the Source 1 Only scenario from the Scenario Selector list in the
Run group on the Home tab of the Ribbon. Any open data views will now
display data for this scenario.
21 Make the following changes to the flowrates from the Sources data sheet
in the Source 1 Only scenario (all other information remains the same):
Source 1 - Mass Flow 100000 kg/hr, Mol. Wt. 20
Source 2 - Mass Flow 0 kg/hr, Mol. Wt. 25
Fig 2.42
Once the calculations are complete you can review the results.
4 Select Results | Messages from the Views tab on the Navigation Pane.
The Messages data view will be displayed.
Fig 2.43
The above view contains general information and warning messages
regarding the calculations.
5 Select Source 1 Only from the Scenario selector in the Run group on the
Home tab.
6 Select Results | Pressure/Flow Summary from the Navigation Pane.
The Pressure/Flow Summary will be displayed:
Fig 2.44
With the Pressure/Flow Summary sheet open, select each scenario in turn
using the Scenario Selector in the Run group.
Note: In the scenario Source 1 Only, the mach number problem on Tail
Pipe 1 is automatically highlighted.
7 At this point, save the model using either the Save icon on the Quick
Access Toolbar, or click the aspenONE Button at the upper left corner of
the application window then select Save from the Application Menu.
Overview
In this chapter of the Getting Started tutorial you will change the network
designed in Chapter 2 to model the tie-in of two new control valves into our
current system. The modified system will be simulated for two new scenarios,
one each for the new sources.
This tutorial assumes that you are familiar with the use of Microsoft Windows
and have some prior experience in the design of flare systems.
Note: This tutorial is a continuation of the one in the previous chapter and
requires that you complete that chapter before continuing with this one.
This example consists of the following main parts:
1 Building The Pipe Network - Pipes and nodes will be added using either
the Process Flowsheet or the Manager views.
2 Defining the Scenarios - Different scenarios will be set up to simulate
various process conditions.
3 Defining The Sources - Relieving sources will be added to each scenario.
4 Sizing the Network - Finally, the pipe network will be simulated and
results will be viewed both in textual and graphical form.
Note: When you are sizing a flare system, the initial pipe diameters may
affect the solution when there is a liquid phase and the liquid knockout drum
is modelled. You should initially size a network using vapour phase methods.
The following diagram shows the connectivity of the system which includes
the new sources you will be adding in this example.
Fig 3.1
The pipe segments in the network diagram are detailed in the following table.
Segment Length Nominal Schedule Fittings Elevation
Name (m) Diameter (inch) Loss Change (m)
Stack 100 36 40 0 100
Header 1 50 28 30 0 0
Header 2 50 28 30 0 0
Segment Length Nominal Schedule Fittings Elevation
Name (m) Diameter (inch) Loss Change (m)
Header 3 50 36 40 0 0
Tail Pipe 1 25 18 40 0 0
Tail Pipe 2 25 18 40 0 0
Tail Pipe 3 25 12 40 0 0
Tail Pipe 4 25 18 40 0 0
The new pipe segments Header 1, Header 2, Tail Pipe 3 and Tail Pipe 4 will be
added.
In this example, you will consider five scenarios that represent one fire case
and four single blocked discharge cases. The following tables define the
source data for each scenario.
The discharge flange size values are left undefined. In this case, they are
assumed to have the same diameter as the attached pipes.
Fig 3.2
4 Click the Look in field to select the appropriate disk drive and directory.
5 Next, select the file that you created in Chapter 2 from the list, and then
click Open.
Fig 3.3
2 Press DELETE. Click Toggle Connect/Arrange Mode again to switch
back to Arrange mode.
To add a Tee section after Header 3:
3 Open the Node Manager by clicking Nodes in the Build group on the
Home tab on the Ribbon.
Fig 3.4
4 Click Add and select Tee from the list that is displayed. Click Edit.
The Tee Editor will be displayed:
Note: Since this example is of smaller size, therefore the Location field will
be left blank. This field is only useful for larger case with multiple sections
(areas) within a same plant.
6 Move to the Calculations tab and verify that the Fitting Loss Method
setting is Miller.
7 Close the Tee Editor by clicking OK.
8 Click Close to close the Node Manager.
Now, you can add two pipe segments to the upstream and branch section
of Tee 3 using the Pipe Manager.
9 Open the Pipe Manager by clicking Pipes in the Build group.
Fig 3.6
10 Click Add to add a new pipe segment. Click Edit to open the Pipe Editor.
11 Change the default pipe name to Tail Pipe 4.
12 Specify Tee 3 as the Downstream node connection and select Branch
in the At field.
Fig 3.12
At this point you might want to rearrange the new items on the Process
Flowsheet. The Process Flowsheet should be similar as displayed below:
Fig 3.13
Fig 3.15
Fig 3.20
3 Change the default name to Source 3. Select Tail Pipe 3 in the Outlet
field and set connection to be at Upstream (of Tail Pipe 3).
4 Move to the Conditions tab and set the Mass Flow as 100000 kg/hr.
Fig 3.21
5 On the Composition tab, specify the Mol. Wt. to be 30.
Note: The composition will be calculated as soon as you tab away from the
Mol. Wt. field.
Note: The Mole Fractions are automatically estimated from the Molecular
Weight. Because HC is selected, only hydrocarbon components will be used to
match the Molecular Weight.
6 Click OK to close the Control Valve Editor for Source 3.
7 Repeat Step 2 to add a new source. Again select Control Valve and the
Control Valve Editor will be displayed.
8 Name the new source as Source 4.
9 Select Tail Pipe 4 in the Outlet field and set connection to be at
Upstream (of Tail Pipe 4).
Fig 3.23
10 Repeat 4-6 to add all the information required by the scenario. Specify
Mole Wt. to be 35 on the Composition tab.
11 Click OK to close the Control Valve Editor.
The Node Manager will now appear as follows:
Fig 3.25
14 You must now add the source data for the four scenarios.
15 Select the scenarios from the Scenario Selector in the Run group on the
Home tab. Any open data views will display data for the selected
scenario.
Make the following changes to the flowrates in all scenarios:
Scenarios Source 1 Source 2 Source 3 Source 4
(kg/hr) (kg/hr) (kg/hr) (kg/hr)
Source 1 Only 100000 0 0 0
Source 2 Only 0 100000 0 0
Scenarios Source 1 Source 2 Source 3 Source 4
(kg/hr) (kg/hr) (kg/hr) (kg/hr)
Source 3 Only 0 0 100000 0
Source 4 Only 0 0 0 100000
For each scenario, ensure that the sources which have a flowrate of 0 are
ignored (i.e. select the Ignore check box for the source).
Note: You can also add the single source scenarios by selecting the Add
Single Source Scenarios tool from Source Tools in Tools group on the
Home tab.
Fig 3.27
Once the calculations are complete you can review the results.
5 Select Results | Messages from the Views pane on the Navigation
Pane. The Messages sheet will be displayed.
Fig 3.28
The above view contains general information and warning messages
regarding the calculations. In this case the mach number exceeds the
design value of 0.5 for Tail Pipe 3, which was defined for each scenario.
It also shows both upstream and downstream pipe segment mach number
for each violation. It is due to smaller pipe segments causing very high
fluid velocities across the pipe segment.
At this point, it is a good idea to save your case before doing detail
design.
6 Click the aspenONE Button on the upper left corner of the application
window, and then select Save As from the Application Menu that is
displayed. Save the file as Getting Started 2 Rating.fnwx.
Design Calculations
1 We will now use Aspen Flare System Analyzer's design capabilities to
redesign the network to resolve the mach number problem we have
identified in the rating calculation we have just completed.
Fig 3.29
3 Select Results | Messages from the Views pane, and then select the
Sizing tab to see a list of changes that Aspen Flare System Analyzer has
made to the network.
4 Select Results | Pressure/Flow Summary.
The Pressure/Flow Summary data sheet will be displayed.
Fig 3.30
Notice that the upstream and downstream mach numbers are now within
the design specification for the given scenario. You can use the bottom
scroll bar to move across the columns.
We now have a flare system that is designed correctly for the Default
Scenario where all sources are relieving but we have not yet checked
that it is adequate for all of the scenarios. To do this we will do a Rating
calculation for all of the scenarios.
5 Open the Calculation Options Editor by clicking Options in the Run
group on the Home tab. Set the Calculation Mode to Rating on the
General tab. On the Scenarios tab, set the Calculate option to All
Scenarios. After closing the Calculation Options Editor, click the Run
icon to run the rating check.
6 When the calculations have finished, select Results | Messages from the
Views pane. Click the Problems tab where any violations of our system
design limits will be displayed. You will see that Aspen Flare System
Analyzer has detected a violation of the mach number limits for the tail
pipes in the single source scenarios.
Fig 3.31
The reason for this is that the lower back pressure in the system when
only a single source is relieving means that the gas density is reduced
resulting in higher velocities.
7 To fix this problem with our design we will re-run the Debottleneck
calculations for all the scenarios. Use the Calculation Mode selector on
the Ribbon to change the calculation mode to Debottleneck and then
click the Run icon.
8 When completed, review the Problems tab of the Messages view to
confirm that the flare system now meets all our design limits in all
scenarios. The Sizing tab will show which pipe sizes have been increased.
Note: We could have run the Debottleneck calculations for all scenarios
immediately after our first rating calculation and obtained the same results.
While this might have been faster, we have obtained a better understanding
of which scenarios have caused changes to pipe sizes by doing our
calculations in stages.
9 Select Results | Pressure/Flow Summary from the Views pane on the
Navigation Pane.
The Pressure/Flow Summary will be displayed.
Fig 3.33
Notice that the upstream and downstream mach numbers are now within
the design specification for the given scenario. You can use the bottom
scroll bar to move across the columns.
10 Click the aspenONE Button on the upper left corner of the application
window, and then select Save As from the Application Menu to save the
case as a new file.
11 Enter the new file name as Getting Started 2 Design.fnwx in the All
Files dialog box and click Save.