PETRONAS TECHNICAL STANDARDS

SEPARATOR MODELLING TECHNIQUES

PTS 20.22.10.39

OCTOBER 2011

2011 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic,
mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
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PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,of
PETRONAS OPUs/Divisions.

They are based on the experience acquired during the involvement with the design, construction, operation
and maintenance of processing units and facilities. Where appropriate they are based on, or reference is
made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied by PETRONAS'
OPUs in oil and gas production facilities, refineries, gas processing plants, chemical plants, marketing
facilities or any other such facility, and thereby to achieve maximum technical and economic benefit from
standardisation.

The information set forth in these publications is provided to users for their consideration and decision to
implement. This is of particular importance where PTS may not cover every requirement or diversity of
condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual operating
units to adapt the information set forth in PTS to their own environment and requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of work
and the attainment of the required design and engineering standards. In particular, for those requirements not
specifically covered, the Principal will expect them to follow those design and engineering practices which will
achieve the same level of integrity as reflected in the PTS. If in doubt, the Contractor or Manufacturer/Supplier
shall, without detracting from his own responsibility, consult the Principal or its technical advisor.

The right to use PTS rests with three categories of users:

1) PETRONAS and its affiliates.

2) Other parties who are authorised to use PTS subject to appropriate contractual
arrangements.
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred
to under 1) and 2) which requires that tenders for projects, materials supplied or - generally -
work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users,
PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by
any company or person whomsoever as a result of or in connection with the use, application or
implementation of any PTS, combination of PTS or any part thereof. The benefit of this disclaimer shall inure
in all respects to PETRONAS and/or any company affiliated to PETRONAS that may issue PTS or require the
use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements,
PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to any company or
person whomsoever and the PTS shall be used exclusively for the purpose they have been provided to the
user. They shall be returned after use, including any copies which shall only be made by users with the
express prior written consent of PETRONAS.

The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and
PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how users
implement this requirement.
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TABLE OF CONTENTS

1. INTRODUCTION ...............................................................................................................5
1.1 SCOPE ............................................................................................................................6
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ...............6
1.3 DEFINITIONS..................................................................................................................6
1.4 CROSS REFERENCES ..................................................................................................7
1.5 SYMBOLS AND ABBREVATIONS..................................................................................7
1.6 CHANGES FROM PREVIOUS EDITION ........................................................................7

2. EXCEPTIONS/AMMENDMENTS......................................................................................7

3. SEPARATOR IN MODELLING .........................................................................................8

4. TYPES OF SEPARATOR .................................................................................................8

4.1TWO PHASE SEPARATOR .............................................................................................8
4.2THREE PHASE SEPARATOR .........................................................................................9

5. MODELLING SEPARATORS ......................................................................................... 12

5.1 FLASHING METHODS ................................................................................................. 12
5.2 ENTRAINMENT IN SEPARATORS IN ICON (STEADY STATE MODELING) .............. 16

6. SEPARATOR IN DYNAMICS ......................................................................................... 18

6.1 TRANSITIONING SEPARATOR IN STEADY STATE TO DYNAMICS ......................... 18

7. PETRONAS BEST PRACTICES .................................................................................... 26

8. REFERENCES ................................................................................................................ 26
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LIST OF FIGURES

Figure 4.1.1: Schematic Diagram of 2 Phase Horizontal Separator .......................... 8

Figure 4.1.2: Schematic Diagram of 2 Phase Vertical Separator/Scrubber .............. 8
Figure 4.2.1: Schematic Diagram of 3 Phase Horizontal Separator .......................... 9
Figure 4.2.2: Schematic Diagram of 3 Phase Vertical Separator............................... 9
Figure 4.2.3: Schematic Diagram of MultiFeed Separator.. ……..…………………….7
Figure 4.2.4: 2-Phase MultiFeed Separator Face Plate..…………..……………………7
Figure 4.2.5: 3-Phase MultiFeed Separator Face Plate…………………………….……8

Figure 5.1.2.1: Schematic Diagram for Bubble Point Calculation ........................... 14

Figure 5.1.2.2: Schematic Diagram for Dew Point Calculation ................................ 15
Figure 5.2.1: Entrainment Functionality Tab: No Entrainment ................................ 16
Figure 5.2.2: Entrainment Functionality Tab: Feed Based ...................................... 16
Figure 5.2.3: Entrainment Functionality Tab: Feed Based ...................................... 17

Figure 6.1.1: Transitioning Separator in Steady State to Dynamics ....................... 18

Figure 6.1.2: Specifying Separator Sizing in Dynamics .......................................... 19
Figure 6.1.3: Separator in Steady State: Fixed Volume ........................................... 20
Figure 6.1.4: Separator in Steady State: Level at 50% ............................................. 21
Figure 6.1.5: Configuring a Separator in Dynamics ................................................. 22
Figure 6.1.6: Identifying DOF for a Separator ........................................................... 22
Figure 6.1.7: Adding a Liquid Product Valve and Level Controller ......................... 24
Figure 6.1.8: Adding a Pressure Controller .............................................................. 24
Figure 6.1.9: Adding a Feed Flow Controller ............................................................ 25
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1. INTRODUCTION

1.1 SCOPE

This PTS specifies requirements and gives recommendations for the preparation ofSteady-state
simulation model for separators. The party responsible for the process design and process
optimization work prepares these simulation models.

The requirements and recommendations in this PTS are independent of the tools withwhich the
simulation models are produced. However, it is advised that iCON (PETRONAS Process Simulation
Software) is used to generate the steady-state model to aid models accessibility. If other process
simulation software is used, it shall be endorsed by GTS Process Optimization Group and a copy of
the software shall be made available to PETRONAS.

For separator selection and design rules, please refer to PTS 31.22.05.11 for Gas/Liquid Separator
and PTS 31.22.05.12 for Liquid/Liquid and Gas/Liquid/Liquid Separator.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorized by PETRONAS, the distribution of this PTS is confined tocompanies
forming part of PETRONAS or managed by a Group company, and to
Contractors nominated by them.

This PTS is intended for use in oil refineries, gas plants, chemical plants, exploration and production
facilities and where applicable, supply/marketing installations. When PTSsare applied, a Management
of Change (MOC) process should be implemented. This is ofparticular importance when existing
facilities are to be modified.

If national and/or local regulations exist in which some of the requirements may be morestringent than
in this PTS, the Contractor shall determine by careful scrutiny which of therequirements are the more
stringent and which combination of requirements will beacceptable as regards to safety,
environmental, economic and legal aspects. In all casesthe Contractor shall inform the Principal of
any deviation from the requirements of this PTSwhich is considered to be necessary in order to
comply with national and/or localregulations. The Principal may then negotiate with the authorities
concerned with the objectof obtaining agreement to follow this PTS as closely as possible.

1.3 DEFINITIONS

The Contractor is the party that carries out all or part of the design, engineering,procurement,
construction, commissioning or management of a project or operation of afacility. The Principal may
undertake all or part of the duties of the Contractor.

The Manufacturer/Supplier is the party that manufactures or supplies equipment andservices to

perform the duties specified by the Contractor.

The Principal is the party that initiates the project and ultimately pays for its design andconstruction.
The Principal will generally specify the technical requirements. The Principalmay also include an
agent or consultant authorized to act for, and on behalf of, thePrincipal.

The word shall indicates a requirement.

The word should indicates a recommendation.
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1.4 CROSS REFERENCES

Where cross-references to other parts of this PTS are made, the referenced section
number is shown in brackets. Other documents referenced by this PTS are listed inSection 7.

1.5 SYMBOLS AND ABBREVATIONS

C Degree Celsius
T Temperature
P Pressure
kPa kilo pascal
kg/hr kilogram per hour
kgmole/hr kilogram mole per hour
SCMD Standard cubic meter per day

1.6CHANGES FROM PREVIOUS EDITION

The previous edition of this PTS was February 2009. Other than editorial editions, the following are
the main changes since that edition:

Old Section New Section Change

5.2 Deleted Back Flashed Calculation section due toseveral
inconsistency in the results –pending new robust approach
4 Added new section on Multifeed Separator
5.2 Added new Section 5.2: Entrainment in Separator (Steady
State Modeling)
6 Added new Section 6: Separator in Dynamics

2. EXCEPTIONS/AMMENDMENTS

Nil
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3. SEPARATOR IN MODELLING

Separation of oil and gas are the most critical of the field processing operation although it is still the
most common.

Separations are divided into 2 types which are scrubbers and separators.Scrubbers are designed to
handle relatively small quantities of liquid (gas scrubbing) and separators are used as the primary
liquid separations since it can handle larger liquid capacity.

The function of a separator is to provide removal of free gas from oil and/or water at a specific
temperature and pressure.There are also separators that are used to separate two immiscible liquid
phases using the density difference principle.

For modeling, there are several types of separators can be configured as described in section 4.

4. TYPES OF SEPARATOR

4.1 TWO PHASE SEPARATOR

A vessel that separates the mix phase fluids into gas and total liquid. A two-phase separator can be
horizontal, vertical or spherical. In the simulation software, only horizontal and vertical vessels are
available for modeling. It can be multiple feeds, with the liquid (oil, emulsion) leaves the vessel at the
bottom and the gas leaves the vessel at the top.

A two phase separator also consists of liquid-liquid separators. The function of this separator are to
separate two immiscible liquid phases.

Figure 4.1.1: Schematic Diagram of 2 Phase Horizontal Separator

Figure 4.1.2: Schematic Diagram of 2 Phase Vertical Separator/Scrubber

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4.2 THREE PHASE SEPARATOR

A vessel that separates the mixed phase fluids into gas and two types of liquids: light and heavy liquid
(mostly oil and water). A three-phase separator can be horizontal, vertical or spherical. For modeling,
only horizontal and vertical vessels are available. This type of separator is commonly called a free-
water knockoutseparator because its main use is to remove any free water that can cause problems
such as corrosion and formation of hydrates or tightemulsions, which are difficult to break.

Three phase separator can be multiple feeds, with the liquids (oil, water) leave the vessel at the
bottom through different valves, and the gas leaves the vessel at the top, passing through a mist
extractor to remove the small liquid droplets in the gas. The mist extractor could not be modeled in
the simulator, however, the effect could be demonstrated using the ‘Entrainment’ function as
described in Section 5.2.

Figure 4.2.1: Schematic Diagram of 3 Phase Horizontal Separator

 
Figure 4.2.2: Schematic Diagram of 3 Phase Vertical Separator
 
 
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Multifeed Separator

MultiFeed Separator represents a two or three phase separator which is capable of having multiple
feeds as well as a pressure drop and an energy duty. This allows the outlet temperature and pressure
to be specified. The number of liquid phases for a three phase MultiFeed Separator is two.

The energy duty is either specified directly or calculated based on the energy required in order to
meet the specified outlet temperature. The pressure drop between the inlet and outlet of the
separator can be either specified directly or calculated.

Figure 4.2.3: Schematic Diagram of MultiFeed Separator

Figure 4.2.4: 2-Phase MultiFeed Separator Face Plate

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Figure 4.2.5: 3-Phase MultiFeed Separator Face Plate

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5. MODELLING SEPARATORS

There are many type of separator modeling that can be done. The common one is flash calculation
methods where the inlet stream of the separator are specified and the outlet stream shall be
determine by the simulator. The other methods are by using back flash calculation method where
only the outlet stream specification are known in order to back calculate the inlet stream properties
that went into the separators.

In steady state modeling, the size of the separator can be assumed as infinity. Therefore, any
amount liquid or gas flow rates are applicable to used in the simulation.

5.1 FLASHING METHODS

The flashing method is performed to determine the product condition and phases. It is the standard
application by completely defined the feed stream(s).

The separator unit operation will only solve when the Degree-Of-Freedom is zero. Simulator will
determine the type of flash calculation needs to be performed based on the degree of freedom
concept. Once the composition of a stream and two property variables are known (vapor fraction,
temperature, pressure, enthalpy or entropy) of which one of the property variable must be either
temperature or pressure, the thermodynamic state of the stream is defined. When the simulator
recognizes that the stream is fully defined, it will perform a correct flash automatically.

Types of flash calculation are derived as below.

5.1.1 CONSTANT T-P FLASH CALCULATION METHOD

Isothermal or constant temperature flash calculation may be used to calculate the properties of any
single stage vapor-liquid, vapor-liquid-liquid, or liquid-liquid phase equilibrium. The independent
variables for this type of flash calculation are the temperature and pressure of the system and the
dependent variable are the vapor fraction, enthalpy and entropy.

If the mixture is a single phase at specified conditions, the property package calculates the isothermal
compressibility to determine if the fluid behaves as liquid or vapor. Fluids in the dense phase region
are assigned the properties of the phase that best represent their current state.
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Input parameter

Stream Material
page

Figure 5.1.1.1: Schematic diagram of T-P Flash Calculation

In the schematic diagram above,iCON steady state software were used for this example.By
specifying the temperature and pressure along with the composition, the simulator shall calculate the
vapor fraction.

5.1.2 CONSTANT VAPOR FRACTION

Vapor fraction and either temperature or pressure are the independent variables. This type of
calculation embodies all fixed quality points including bubble points and dew points.

Bubble point is the temperature at a specific pressure or pressure at any given temperature at which
the first stable vapor forms above a liquid. For a bubble point calculation for a stream of known
composition, the vapor fraction at the stream is set to 0.0 and defines the temperature or pressure at
which the bubble pointcalculation desired.

Dew point is the temperature at any given pressure or the pressure at any given temperature at which
liquid initially condense from a gas or vapor. It is specifically applied to the temperature at which
water vapor starts to condense from a gas mixture (water dew point) or which hydrocarbon starts to
condense (hydrocarbon dew point).For dew point, specify the vapor fraction to 1.0 and define the
temperature or pressure at which the dew point calculation is desired.
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Bubble point and dew point are special cases of quality point calculations. Temperature or pressure
can be calculated for any vapor quality between 0.0 and 1.0 by specifying the vapor fraction and the
corresponding independent variable. If error occurs when the simulator calculating the vapor fraction,
then it means that the specified vapor fraction does not exist under the given condition.

No flow since Input

VapFrac is 0.0

Figure 5.1.2.1: Schematic Diagram for Bubble Point Calculation

From the diagram above, by specifying the temperature and vapor fraction to 0.0 the bubble point
pressure of the stream shall be calculated. With a vapor fraction of 0.0, the stream is totally liquid.
Therefore, the flow rate at the outlet vapor stream from the separator is zero.
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No flow since Input

VapFrac is 1.0

Figure 5.1.2.2: Schematic Diagram for Dew Point Calculation

From the diagram above, by specifying the temperature and vapor fraction to 1.0 the dew point
pressure of the stream shall be calculated. With a vapor fraction of 1.0, the stream is totally gas or
vapor. Therefore, the flow rate at the outlet liquid stream from the separator is zero.

5.1.3 CONSTANT ENTHAPLY FLASH CALCULATIONS

Given the enthalpy and either temperature or pressure of a stream, the property package will
calculate the unknown dependent variables. Although the enthalpy of a stream cannot be specified
directly, it will often occur as the second property variable as a result of energy balances around unit
operations such as valves, heat exchanger and mixers.

If the simulator responds with an error message, this probably means that an internally set
temperature or pressure bound has been encountered. Since these bounds are set at quite large
values, there is generally some input that is directly or indirectly causing the problems such as an
impossible heat exchange.
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5.2 ENTRAINMENT IN SEPARATORS (STEADY STATE MODELING)

Two limiting phenomena in a vapor-liquid separator:

• Liquid carry-over in the gas stream
• Gas carry-under in the liquid stream

The onset of liquid carry-over is identified by the first trace of liquid in the gas stream, whilst the onset
of gas carry-under is identified by the first observable bubbles in the liquid underflow mark.
Vapour/liquid separation is one of the critical issues in facilities process design and operation.
Existence of liquid droplet in vapour product may cause problem to the consequence compression
system, as well as to the flaring system. The problem for flaring systems is that with the uncertainty of
design and operating conditions, liquid carryover droplets may be of such a size and composition that
they are incompletely combusted. This results in the emission of many undesirable compounds to
the atmosphere.

To configure the phenomena of carry-over for non-ideal separators in which the products arenot pure
phases, ‘Entrainment’ tab functionality shall be utilized steady state modeling in iCON. There are
three ‘Calculation Type’ to define such entrainment in iCON, namely ‘No Entrainment’, ‘Feed Based’
and ‘Product Based’.

1. No Entrainment
The separation is assumed to be ideal (no carry over).

Figure 5.2.1: Entrainment Functionality Tab: No Entrainment

2. Feed Based
This calculation type enables specification of the percent of the feed phase in equilibrium that goes
into the product. These variables are contained in the “Entrainment Percent” frame.

Figure 5.2.2: Entrainment Functionality Tab: Feed Based

The number of variables depends on the number of phases being used in the separator. Forexample,
a separator for 2 liquid phases with no solids will expose six variables labeled, “Vapourin Light
Liquid”, “Vapour in Heavy Liquid”, “Light Liquid in Vapour”, “Light Liquid in Heavy Liquid”, “Heavy
Liquid inVapour” and “Heavy Liquid in Light Liquid”.
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From the diagram above, “Vapour in Light Liquid” defines the percent of the vapour phase from the
equilibriumcalculation that goes into the light liquid product (Liq0 port). An empty specification
isassumed to be 0.0.

3. Product Based
This calculation type enables specification the amount of carry over in each product. These variables
are contained in the “Settings” and “Entrainment” frames.The basis can have any value from “Mole”,
“Mass” and “Actual Volume” and it is used todefine the basis of the entrainment
specification.Specification Type can be either Percent or Flow and it is used to define the type of
specification.

Figure 5.2.3: Entrainment Functionality Tab: Feed Based

The number of variables in the “Entrainment” frame depends on the number of phases beingused in
the separator. For example, a separator for 2 liquid phases with no solids will exposesix variables
labeled, “Vapour in Light Liquid”, “Vapour in Heavy Liquid”, “Light Liquid in Vapour”, “Light Liquid
inHeavy Liquid”, “Heavy Liquid in Vapour”, “Heavy Liquid in Light Liquid”.The image above uses a
specification type of flow in mass basis. In this case, “Vapour in LightLiquid” defines the mass flow of
vapour contained in the light liquid product (Liq0 port). Anempty specification is assumed to be 0.0.
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6. SEPARATOR IN DYNAMICS

In iCON, separator unit operation functionalities are enhanced, whereby the unit-op could be modeled
in dynamics simulation environment.Separators model pressure vessels in dynamics. The vessels
may be used to separate phases, or merely as buffer volumes.

The dynamic simulation engine has a number of important differences when compared tothe steady
state engine:
1. The steady state engine is solving for a single steady state point. The dynamic engine is
solving for a series of dynamic states. Each state is separated in time by the userselected
stepsize.
2. The steady state engine solves unit operations one at a time, and converges recyclestreams.
The dynamics engine solves pressures and flows using a network (simultaneous)solver, and
energy and composition balances on a per unit operation basis.Hence, all unit operations
which are not ignored must have a consistent set of pressure/flow specifications before the
integrator can run.

6.1 TRANSITIONING SEPARATOR IN STEADY STATE TO DYNAMICS

Figure 6.1.1: Transitioning Separator in Steady State to Dynamics

The process of changing a Steady State simulation into a Dynamic one shall comprises of these
elements:
• Add Unit Operation
• Size equipment
• Define pressure flow specifications
• Add controllers

Before a transition from Steady State to Dynamics occurs, the simulation flowsheet should be set up so
that a pressure drop exists across the plant. This pressure drop is necessary because the flow in iCON is
determined by the pressure drop throughout the plant. No pressure drop means no flow.
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6.1.1. Adding Unit Operations

Identify material streams which are connected to two unit operations with no pressure flow relation and
whose flow must be specified in Dynamic mode. A Separator in dynamics is a unit operation without a
pressure flow relation. Unit operations such as Valves, Heat Exchangers, or Pumps should be added
which define a pressure flow relation to these streams.

A separator is classified as a ‘Node’ in iCON, in which this equipment allows feed streams to be
separated. A separator may have volume associated to it, thus it requires users to specify the node
geometry when modeling the separator in dynamics. The examples to the associated node geometry are
separator’s length and diameter or separator’s volume.

6.1.2. Equipment Sizing

All unit operations in the simulation need to be sized using actual plant equipment or predefined sizing
techniques. Vessels should be sized to accommodate actual plant flowrates and pressures while
maintaining acceptable residence times. In iCON, if only the volume is specified, a default
(Length/Diameter) L/D of 2.0 will be assumed.

Appropriate vessel sizing is important for dynamic simulation analyses. The vessel hold-up will affect the
system’s transient response during dynamic analyses as the user moves from one operating regime to
the next. In addition, the vessel size affects the pressure calculations thatare associated with this unit
operation.

NOTES:
If the dimensions of the process equipment are not known, calculate the vessel size based on an
appropriate residence time:
- 10 minutes is typically a suitable residence time for liquid phase hold-ups
- 2 minutes is typically a suitable residence time for vapour phase hold-ups

Figure 6.1.2: Specifying Separator Sizing in Dynamics

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6.1.3. Defining pressure flow specifications: A Boundary Value

Pressure or flow specifications should be specified on all the boundary streams (feeds/product streams in
a Flowsheet), and all the internal pressures and flows would be solved simultaneously at each integration
step by the pressure-flow solver. The internal stream pressures and flowrates are calculated from the
pressure gradients in the flowsheet. The possible pressure or flow type specifications for a flowsheet
include:
• Pressure specification on a material stream
• Flow specification on a material stream
• Fixed pressure drop across equipment
• Pressure/Flow equation
• Resistance calculation (for valves)
• Conductance calculations (for process equipment)

Pressure Nodes
All unit operations (with hold-up) represent pressure nodes. Some other unit operations may contribute to
one or more nodes. For example:
• Heaters/Coolers with multiple zones
• Heat Exchanger – shell side/tube side
• Columns with multiple stages (trays)

Fundamental principle:Vessel equipment has a fixed geometry and thus a fixed volume.

Mathematically, this means that:

dV / dt=0

Therefore, for a fixed volume, a pressure node (vessel pressure) is calculated as a function of the vessel
temperature and the vessel holdup.

Figure 6.1.3: Separator in Steady State: Fixed Volume

In dynamic mode, the rate of change in vessel pressure is related to the rate of change of temperature
(enthalpy) and the rate of change of material hold-up (level):

.
dP / dt= fn(V, F, T)

where:
V = Fixed volume
F = Change in flow (hold-up)
T = Temperature (change in enthalpy)
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A volumetric flow balance around the vessel can be expressed as follows:

(Volume change due to pressure change)+
(Volume change due to flow changes)+
(Volume change due to temperature change) = 0.

The total volume change must always be zero.

Example
Consider the operation of a separator in dynamic mode that is initially at steady state with a level of 50%:

In Steady State,
Flow into separator = Flow out of separator, no accumulation

Figure 6.1.4: Separator in Steady State: Level at 50%

In Dynamics,
If the separator feed flow increases with the product flowrates (vapourand liquid) remaining unchanged,
the level (hold-up), temperature (enthalpy) and pressure of the vessel must all change from the steady
state condition.

Liquid Level Increases

Since:

Liquid Flow In – Liquid Flow Out = Accumulation (hold-up),

An increase in the feed liquid flowrate with a constant liquid productflowrate results in the liquid level
(hold-up) increasing.

Vessel Pressure Increases

The vessel pressure would increase for 2 reasons:
1. Vapour Flow In - Vapour Flow Out = Accumulation.

An increase in the feed vapourflowrate with a constant vapour productflowrate results in the vapour (hold-
up) increasing. Because vapour is a compressible fluid, the accumulation of vapour, occupying a
smallervolume, will cause the vessel pressure to rise.

2. The increase in liquid level also causes the vapour hold-up tooccupy a smaller volume within the
vessel, causing the vessel pressure to rise.

Pitfalls with Alternate Specifications

There are many cases where alternate specifications for a separator that will work satisfactorily. However
there are some specifications or combinations of specifications which will cause inconsistencies, and a
singular matrix – i.e. the pressure flow solver will not be able to solve even if the number of specs is
correct. Also, some specifications may work well at one operating point, but may cause inconsistencies at
a different operating point.
.
For example, it is possible to operate a separator with one or more flow specifications in the feed/product
streams. However, that the vessel pressure is a function of the inventory. If fixed feed rate is specified,
and the discharge valve shuts for any reason, the pressure will increase and eventually become
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physically unrealistic. Similarly, it is possible by means of fixed flowrates to empty the entire inventory out
of the separator which will result in the pressure attempting to be negative.

Degrees of Freedom Analysis (DOF)

For the concept of dynamic specifications, thesimultaneous solution of the pressure-flow (P/F)
relationships within the flowsheet requires the user to make a number of dynamic operating
specifications.
• P = Pressure
• F = Flow

Figure 6.1.5: Configuring a Separator in Dynamics

In this flowsheet, there are 7 variables in total that will define the system. These are:
1. Feed1 (pressure, flowrate= 2 variables)
2. Product1 (pressure, flowrate= 2 variables)
3. Product2 (pressure, flowrate= 2 variables)
4. V-100 (Pressure = 1 variable)

In addition, there are 4 equations that define the pressure-flow relationships in the flowsheet. These are:
1. VLV-100: Resistance to Flow equation FVLV-100 = Cv*(P1 - P2)^0.5
2. VLV-101: Resistance to Flow equation FVLV-101 = Cv*(P1 - P2)^0.5
3. VLV-102: Resistance to Flow equation FVLV-102 = Cv*(P1 - P2)^0.5
4. V-100: Pressure Node Relationship dP/dt = fn (V,F,T)

where:
P1 = upstream pressure (pressure of stream 1)
P2 = downstream pressure (pressure of stream 2)
Cv= the valve coefficient Cv,

With 7 variables and 4 equations, the DOF = 7-4 = 3. Therefore,3 pressure-flow P/F specifications need
to be made to define this system.

In this example, there are three Degrees of Freedom, requiring that three specifications be made to
define the system.

Figure 6.1.6: Identifying DOF for a Separator

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One possible solution

Specify:
1. Feed 1 Pressure
2. Stream 1 Pressure
3. VLV-100 Delta P
Although making these 3 specifications will satisfy the DOF analysis, the choice of specifications would
not make sense. PFeed 1, P1and deltaPVLV-100 are all related by the following equation:

PFeed 1 - P1 - deltaPVLV-100 = 0

Specifying the Flowsheet in this manner would lead to an inconsistentsolution. In fact the Flowsheet
would be under-specified because one of the specifications is redundant.

Another possible solution

Specify:
1. Feed1 Pressure
2. Product1 Pressure
3. Product2 Pressure

Consider the same Flowsheet with pressure specifications made on all the boundary streams. This
solution is consistent because the pressure in the vessel is calculated by the hold-up equation. (The
stream flowrates were calculated using the turbulent equation or the resistance to flow equation).

Guidelines to Remember:

1. One P/F specification should be made on eachboundary stream (feeds/products).

2. Make pressure specifications on boundary streamsattached to process equipment that use
resistance to flow / conductance relationships.
3. The equipment conductance orCv value combined with the pressure of the inlet and outlet
streams will be used to determine a flowrate through the equipment.
4. Internal flowrates will be calculated by pressuregradients (resistance to flow /
conductanceequations) throughout the flowsheet.

Summary of P/F Theory and Specifications:

1. The flow through the plant, or operation, is driven by the pressure gradient.
2. P/F theory defines the relationship between flow and pressure.
3. In order for the P/F solver to solve the flowsheet, there must be apressure gradient
established over the entire flowsheet.
4. The pressure gradient exists due to a specified pressure flowrelationship (or a specified
pressure drop) over all operations in the flowsheet.
5. The P/F solver works by finding P from F, according to the P/Ftheory, or by solving the
pressure node equation.
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6.1.4. Adding Controllers

Controllers can be added to the flowsheet using the same methods asfor other unit operations. The
‘Controller’button on the paletterepresents this unit operation. Once the Controller has been added tothe
flowsheet:
1. Make the necessary connections for the Process Variable Sourceand Output Target Object.
2. Select the Minimum and Maximum values for the ProcessVariable. These values should bracket
all possible PV values.
3. Size the valve – controller range. This is not necessary if a valvewas chosen as the Output Target
Object.
4. Select Controller Action, Reverse or Direct.
5. Input Controller Tuning Parameters.
6. If desired, choose the mode of the controller, Off, Manual, or Automatic.

Add a Liquid Product Valve and Level Controller

A liquid product valve is added at the liquid bottom stream and level controller is added to control the
liquid level in the separator.

Figure 6.1.7: Adding a Liquid Product Valve and Level Controller

Add a Pressure Controller

A pressure controller is added at the vapour stream to control the pressure inside the separator.

Figure 6.1.8: Adding a Pressure Controller

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Add a Feed Flow Controller

A feed flow controller is added at the feed inlet stream to manipulate the feed flow to the separator.

Figure 6.1.9: Adding a Feed Flow Controller

It should be noted that the actual configuration of the controllers surrounded a separator shall depends on
the actual control configurations in the Process Instrumentation and Piping (PID).
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7. PETRONAS BEST PRACTICES

1) Always specify the required properties such as temperature, pressure, mass flow and
composition at the material streams rather than separator spreadsheet to avoid confusion.
2) Make sure that the vapor fraction for vapor outlet stream always gives the value 1.0 and for liquid
outlet stream value 0.0 when doing dew point and bubble point calculation.
3) In dynamics, temperatures, pressures, flows and levels are typically regulated by control loops
rather than being specified as fixed values
4) Always use stripchartsas a powerful way of viewing dynamic simulations and the underlying
process behavior
5) To observe fast dynamics, the integral step size should be reduced. It could go down to 10 ms.
6) It is possible to run dynamics models with the same specifications to those used insteady state.
However, these specifications generally do not constitute “best practice” for dynamics models.
7) Controllers may also be used to control flows directly. It can work as a steady state
adjust/controller
8) A selector block in iCON could be used to implement ‘disturbance’ in dynamics modeling
9) iCON dynamics could be used for depressuring and blow down

8. REFERENCES

1) iCON manual
2) Hysys Reference, Version3.0
3) Elements of Field Processing, Campbell, WilliamC.Barron, May 1988.