Plant Data in Aspen HYSYS Tutorial

Plant Data in Aspen HYSYS Tutorial

Overview & Background Information

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Example Case: Compressor Performance Monitoring

• Design curves from the

compressor vendor are
used to estimate the
polytropic efficiency
based on design
conditions.
• The compressor
performance varies with
the actual operating
conditions.

Estimate the polytropic efficiency of compression stages 1 and 2 using historical plant data.

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Compressor Performance Monitoring
Tag Name Description Units
• A calibration model is developed in HYSYS
P1001.PV Gas Feed (IN) P bar
using the Data Fit feature. T1002.PV K-101 Disch T C
– Plant measurements as shown on the right T1000.PV Gas Feed (IN) T C

– Tuned parameters W1000.PV K-101 Req Pw kW

– Head offsets F1000.PV Gas Feed (IN) F tonne/hr

T1003.PV EA-100 Gas Out P C

– Efficiency offsets
P1003.PV EA-100 Gas Out P bar

T1004.PV K-102 Disch T C

P1004.PV K-102 Disch P bar

W1001.PV K-102 Req Pw kW

T1007.PV EA-101 outlet temperature C

T1005.PV CW In T C

T1006.PV CW Out T C

F1001.PV CW Flow tonne/hr

F1002.PV Gas flow to EA-101 tonne/hr

T1008.PV Alternative measurement for T1002.PV C

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Data reconciliation model in Aspen HYSYS

• In order to run the data fit model with the plant data, the imported tag values from the data historian or
Excel workbook must be “pushed” to measured_1 fields in the Data Set.

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Tutorial summary
• 1: Import historical plant data
– 1a: import data from an Excel workbook
– 1b: Import data from a data historian

• 2: Condition imported plant data

– 2a: Deal with bad quality data
– 2b: Detect steady state for selected tags

• 3: Map model variables with plant measurements

– 1a: Select model variables
– 1b: Map tags to model variables

• 4: Execute the model against plant data

– 1a: Create a run sequence
– 1b: Add data sets to the sequence
– 1c: Run the model against selected data sets
– 1d: Analyze model results

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IMPORTANT: Before Starting the Tutorial

Before you begin, copy the Compressor folder from the

Samples directory to a writable directory.

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 1: Import historical plant data

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Three scenarios

• Plant operation personnel has identified that the plant data from 12/26/2016 6:00 AM to 12/26/2016
6:00 PM represents a typical operation scenario and should be used.

• Even though most plant measurements are available in the data historian, analyzer data for gas
compositions is only available offline.

• Additional useful historical data from 1-4 AM on 12/26 is not available in the data historian but is
available in an Excel workbook.

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To import the plant data

• Open the Aspen HYSYS case compressor.hsc.

• All required features to complete this tutorial can be found on the Plant Data ribbon tab in Aspen
HYSYS.

• Complete tasks 1 to 7 listed the following slides

• NOTE: To import plant measurements from the historian, the measurements have to already exist on
your historian. Alternatively, you can import data from Compressor_PlantData_Historian.xlsm from
the folder where compressor.hsc resides.

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Task 1: Search for the following plant measurements
in Aspen HYSYS
• The measurements on the right are relevant for Tag Name Description Units

the compressor monitoring model. These P1001.PV Gas Feed (IN) P bar

measurements should be available on the T1002.PV K-101 Disch T C

T1000.PV Gas Feed (IN) T C

historian for the given time interval for this step.
W1000.PV K-101 Req Pw kW
Hint: On the Plant Data ribbon tab, click Get
F1000.PV Gas Feed (IN) F tonne/hr
Plant Data | Import Tags from Historian.
T1003.PV EA-100 Gas Out P C
– Hint: You can use wildcard characters such, as * or P1003.PV EA-100 Gas Out P bar
?, in the search criteria; for example, *1?0?.PV. T1004.PV K-102 Disch T C

P1004.PV K-102 Disch P bar

• Alternatively, use the
W1001.PV K-102 Req Pw kW
Compressor_PlantData_Historian.xlsm file T1007.PV EA-101 outlet temperature C
available in the same folder as the example T1005.PV CW In T C
files. Follow instructions on next page for T1006.PV CW Out T C
importing from excel. F1001.PV CW Flow tonne/hr

F1002.PV Gas flow to EA-101 tonne/hr

T1008.PV Alternative measurement for T1002.PV C

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Task 1: Alternative to historian

• If a historian is not available or configured with the appropriate tags, click Get Plant Data | Import
from Excel to import these tags from the Excel file Compressor_PlantData_Historian.xlsm
(available in the compressor folder).

• If this alternative is used, you can skip tasks 2 and 3.

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Task 2: Examine plant measurements for the specified time windows

• For the given time windows between 12/26/2016 6 AM and 6 PM:

– Trend gas feed flow measurement (F1000.PV)
– Trend outlet gas temperature measurement from the 1st stage compressor (T1002.PV)
– Trend horsepower measurement from the 1st stage compressor (W1000.PV)

• Use the time range slider to view plant data for the specified time window.

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Task 3: Import the selected plant data into Aspen HYSYS

• Select the required tags in task 1 and import the data into Aspen HYSYS.
– After the import completes successfully, close the Import Tags from Historian dialog box.

• Check all measurement data imported for the specified time window.
– Hint: On the Plant Data ribbon tab, click View Raw Data to open the Tag Raw Data form.

• Import additional sets of plant data representing different operating scenarios (for example, between 6
PM on 12/26/2016 and 6 AM on 12/27/2016) for the same tags.

• Use the time range slider to narrow the time interval to display raw data from between 12:00 and 1:30
PM on 10/25/2016.

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Task 4: Import feed composition data from Excel workbook
• The gas feed composition shown below is not available in the data historian.

• Open Compressor_PlantData_Task4.xlsm in Excel. This file is available at the following location: AspenTech\Aspen HYSYS
V10.0\Samples\Plant Data\Compressor.
– You can create a blank Excel workbook from a template by clicking Tools | Get Plant Data Excel Template (Tag Name as Row Label) on the Plant Data
ribbon tab. In this tutorial, most component compositions are already specified in the worksheet to save time.

• Add three tags with the names and average values shown below for 6 AM to 6 PM on 12/26/2016.
– The propane composition should be calculated as formula = 1.0 - total compositions of the remaining components.

Tag Name Description Unit Value Lower Upper

A1000.PV Methane mole fraction fraction 0.7603 0 1

A1001.PV Ethane mole fraction fraction 0.0823 0 1

A1002.IV Propane mole fraction fraction Calculated 0 1

• Save the workbook.

• Import the data into Aspen HYSYS.

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Task 5: Import additional historical data from Excel workbook

• From the Compressor folder, open the Compressor_PlantData_Task5.xlsm workbook in Excel.

• The spreadsheet contains data sets DS1 and DS2, which represent EA-101 in operation and a EA-101
shutdown scenario respectively.

• Edit the Plant Data worksheet to validate the measurement tag for the following scenarios:
– T1000.PV has a missing value in DS1.
– Override the tag value with default value of 44 C for both DS1 and DS2.

• Save the workbook.

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Task 5: Import additional historical data from Excel workbook (Cont.)
• Data set DS2 represents a scenario in which intercooler EA-101 is shutdown for maintenance and EA-102 is used for
cooling
– However, the measurements from DS2 do not precisely indicate that EA-101 is down.

• We will need to find a way to equalize the inlet temperature to the outlet temperature of EA-101 without changing the
raw data.
– Create a tag EA101-STAT to represent EA-101 status with the Excel formula = IF([F1002.PV]>2.0,1,0). The status tag has a value of either
0 or 1.
– Create a formula tag T1007.IV in the Excel workbook with the Excel formula = IF([EA101-STAT]=1, [T1007.PV], [T1004.PV])
– Set the flow ratio in splitter block TEE-100 in similar way. That is, create a FLOW-RATIO tag in the Excel workbook with the Excel formula =
IF([EA101-STAT]=1,1,0).

• Double-check that the entry in the Source Device field is correct for each tag.
– Open the Import Tags from Historian dialog box and check the Data source name.

• Save the workbook.

• Import the workbook in Aspen HYSYS.

• On the Plant Data tab, click Manage Tags to open the Tag Manager to ensure all the data validation rules are
specified correctly.
– Hint: Select the Data validation checkbox on the Tag Manager form.

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Task 6: Examine the imported plant measurements in Aspen HYSYS

• Check that the raw values of the tags in Aspen HYSYS.

• Identify bad or missing tag values within the imported data.

• Check that the selected tags were created correctly in Aspen HYSYS using the Tag Manager.
– All tags added from the data historian should be DCS type.
– All tags created are Unitless type by default.
– Display the tag attributes with different combinations.

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Task 7: Map imported tag units with HYSYS units of measure

• Open the Tag Manager to examine the imported tags.

– Notice that all tags are Unitless.

• Assign tag Physical type and Unit in HYSYS to enable unit conversion between model variables and
plant tags.
– Hint: Use the Tags UOM form.
– Use Physical type Mass Flow and Unit tonne/h for flow measurement
– Use Physical type Power and Unit kW for power measurement
– Use Physical type Percent and Unit ppm or fract. for composition measurement
– Use Physical type Temperature and Unit C for temperature measurement
– Use Physical type Pressure and Unit bar for pressure measurement

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Congratulations! You have completed Step 1.
So far, you have accomplished the following tasks:

• Located the required measurement tags (DCS tag)

• Checked the values of key tags

• Selected operating windows based on the key tag values

• Added the selected measurement tags and data to the model

• Imported any additional required measurements from an Excel workbook if they were not available in
the data historian

• Examined the data

• Mapped tag units

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 2: Condition imported plant data

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Task 1: Specify data conditioning rules for the measurement tags

• Set the Average period of all plant measurements to 60 minutes.

– Hint: Open the Tag Manager and select the Averaging check box.

• Open the Tag Manager and select the Data validation check box.
– Note that the Lower limit and the Upper limit of the measurements should be populated already from the Excel
workbook for some tags. This was done in Task 4 of previous section.
– Select the corresponding clamp flags(Clamp at lower and Clamp at upper) for all measurements with specified
Lower limit and Upper limit that differ from the default values (-1e+20 and 1e+20, respectively).

• Specify an override tag for T1002.PV

– Use the alternative temperature measurement T1008.PV for the K-101 discharge line.

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Task 1: Specify steady state detection for measurement tags (contd.)

• Typically steady state detection (SSD) will only be performed for selected key measurements, such as feed flow.

• Enter the following SSD parameters for gas flow measurement F1000.PV
– Hint: Open the Tag Manager and select the Steady-state detection check box.
– Tolerance: 4 tonne/hr
– Trend Tolerance: 4 tonne/hr
– Timespan: 60 minutes

• On the Plant Data ribbon tab, click Condition Data to run Data Conditioning.
– A default name is given for the Data Condition Run. It is recommended to enter a meaningful Name and Description.

• Check the results of data conditioning run.

– Select a “good” data set which is At steady-state and Has good quality to run.
– Compare and understand the Raw value, Conditioned value and Average value of the tags in the detail form
 Hint: Click the link in the Details column.
 The Average value will be used in the model if the Average period of the tag is specified. Otherwise, the conditioned value will be used
in the model.
– Once a “good” data set is selected, you can rename it with more identifiable name.

• Identify at least five “good” data sets.

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 3: Map model variables to tags

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Data reconciliation model in Aspen HYSYS

• In order to run a data fit model with the plant data, the imported tag values from the data historian or
Excel workbook must be “pushed” to measured_1 fields in the Data Set.

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Data reconciliation model in Aspen HYSYS
• The efficiency offset and head offset for each stage are tuning parameters.

• The polytropic efficiencies for the stages are output variables.

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Task 1: Select and add model variables to mapping form
• On the Plant Data ribbon tab, click the Select & Map Variables button.

• From the Object to run drop-down list, select Data Recon – FlowSheetWide.

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Task 1: Select and add model variables to mapping form
(Cont’d)
• Add input variables
– Copy & paste the highlighted variables below to the plant data variables form

– Copy & paste the flow ratio variable for TEE-100 to the mapping Variables form.
– Copy & paste the mass flow variable for the GASIN stream to the Variables form.
– Optional: Copy & paste the gas molar compositions for the GASIN stream.
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Task 1: Select and add model variables to mapping form
(Cont’d)
• Add tuning parameters and output variables for result analysis.
– Copy & paste highlighted variables below to the plant data variables form.

– Copy & paste the polytropic efficiency of each stage to the mapping variable form.
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Task 2: Map the selected variables with tags
• Specify source tags for added model input variables

• You must map the model output variables to the tags only if you want to store model results in the data historian and thus make
them available to plant operators.
– You must create new output tags with the Local GUI type in Aspen HYSYS first before mapping.

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Task 2: Map the selected variables with tags (Contd.)

• Optional: Map the composition variables to the measurement tags.

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 4: Execute model against selected plant data

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Workflow to run model against plant data

1. Create a new run sequence

2. Select data sets to run sequence

3. Save variable snapshots (optional)

4. Execute model against selected data sets

5. Analyze the model results

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Task 1: Add run sequence and select data sets

• Create a new run sequence.

• Add the five data sets identified in task 2.

– Go to the Details grid of the run sequence.

• Run the model against all five data sets.

NOTE: At the end of a data fit run in HYSYS, a dialog box may appear, asking if you want to update the
start value of all optimization variables from their result value. If you do not want this dialog box to appear,
on the Solver Options tab of the Data-fit form, you can select the Default Responses check box.

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Task 2: Analyze results

• Select all five data sets

– Hint: On the Plant Data ribbon tab, click Analyze Results.

• Compare the plant data and results across five data sets.
– All variables should appear on the variables form.

• Trend the estimated polytropic efficiencies for both stages across five data sets.

• Plot the polytropic efficiency of the first stage vs. the following:
– Total gas flowrate
– Gas inlet temperature

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Task 3: Understand variable snapshots

• Open the Model Variable Snapshots form.

– Hint: On the Plant Data ribbon tab, click Manage Snapshots.
– Two snapshots are automatically generated Before and After the model run for each data set.
– If the model fails to converge, or if you are not satisfied with the results, you can restore the snapshot values in the
model.
– You can create snapshots at any point.

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Congratulations, you have finished the tutorial!