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Dynamics
A Brief Tutorial (and supplement to training and online documentation)
Nicholas Brownrigg, Product Marketing, Aspen Technology, Inc.
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Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Setting up a Steady-State Compressor Model in Aspen HYSYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Preparing a Dynamic Model from a Steady-State Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adding and Plotting Compressor Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Modifying the Surge Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dynamic Modeling of Compressor Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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CVb
Introduction
Compressors, generally used to increase the pressure of a gas, are an integral part of many production processes in the oil
and gas, energy, and chemicals industries. They are highly specific to each process for which they are designed. As a
result, they are mostly custom manufactured, expensive, and difficult to replace.
Compressors operate with very fast dynamics. Even a slight disturbance to a processs steady-state could lead to a
compressor surge, which is the point at which a centrifugal compressor cannot add enough energy to overcome the
systems backpressure. A compressor surge can lead to the unit malfunctioning, including rapid flow reversals and
changes in axial thrust, high vibration, and damage to rotor seals and bearings, which could necessitate equipment
replacement. Additionally, a surge is dangerous for individuals working near the compressor and can lead to a process
becoming hazardous, especially if process gas is released to the surrounding atmosphere.
To combat compressor surge, specialized control systems are designed and implemented into processes. Control systems
are enacted to maintain fluid flow to the compressor, which keeps the unit from surging.
Predicting which process conditions will cause the compressor unit to surge, and designing the subsequent control
scheme is a challenging, involved task. Aspen HYSYS Dynamics allows users to view the dynamic response of
compressors to changes in a steady-state simulation, as well as explore control strategies to best minimize the impact of
process disturbances to ensure smooth compressor operation.
Aspen HYSYS Dynamics provides performance charts to help the user visualize the process changes and compressor
performance. Tables can be inserted to the dynamic simulation to aid in the exact quantification of the changes in the
process.
In this Jump Start guide, analyzing the dynamic surge response of a compressor using Aspen HYSYS Dynamics will be
explored.
While this Jump Start guide will walk the reader through the process of using Aspen HYSYS dynamics to model
compressor performance, AspenTech recommends that a range of other resources be called upon in conjunction with this
document to give the user a comprehensive view of how to use Aspen HYSYS. These may include:
AspenTech support website (support.aspentech.com) this website has a wealth of information on the use of
AspenTech products and provides answers to frequently asked questions
AspenTech courseware available in on-line and in-person versions
AspenTech business consultants
This document assumes that the user has Aspen HYSYS V8 or higher installed on his or her computer, and has completed
a functional process design.
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Having a converged, steady-state compressor model now enables continuation to dynamic simulation to view how the
compressor will respond under disturbance.
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Figure 3. Setup Window for Addition of Compressor Curves, Including Completed Curves
Input compressor operating data, which is usually obtained from compressor manufacturers. Compressor curves plot the
head of the compressor unit versus a volumetric fluid flow at a constant compressor operating rate. The efficiency of the
compressor for a volumetric fluid flow can also be defined. Figure 4 displays an example of data for the compressor in the
simulation, operating at 4900 rpm.
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After all compressor curve data has been entered and an operating speed for the compressor has been designated, return
to the setup window for the compressor curves, and click Plot Curves. A plot of the compressor curves for the
specified operating rates, as well as the current operating point for the steady-state compressor along the curves will be
displayed, shown in Figure 5. Additionally, a surge curve is displayed if the user enters the information. The surge curve
displays the boundaries past which the compressor would experience a surge in operation. Details on how to edit the
surge curve will be discussed in the following section.
Note that this plot is a view of head versus flow at various compressor speeds. To view compressor efficiency versus flow,
choose the efficiency option under the Plot Type grouping in the top right of the compressor plot window.
Clicking Surge Curve opens the following window in Figure 7. The compressor speed and/or the flow at which surge
occurs can be edited to either modify existing points or generate new points for the surge curve.
After ensuring that the compressor and surge curves are properly plotted, continue to the Inertia section of the Rating
tab to update parameters pertaining to the inertia of the compressor impeller and shaft, Figure 8.
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Finally, continue to the Dynamics tab to edit the surge controller. Click View Surge Controller, shown below in Figure 9.
This opens the surge controller window. Verify that the surge controller has the proper connections and objectives, and
then navigate to the Surge Control option under the Parameters tab. Here, the robustness of the surge controller can
be managed by varying the surge control parameters, as shown in Figure 10.
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The transfer function face plate will appear and display the current process value, as well as the current operating point,
shown in Figure 12.
Place both the transfer function face plate and the compressor curve plot on the simulation flowsheet for use in the
dynamic simulation.
Before running Aspen HYSYS Dynamics, note that the charts on the flowsheet for VLV-100, valve 23FE1015, the
compressor, and process stream 1 appear as follows:
VLV-100
23FE1015
Feed Pressure
1220
kPa
Molar Flow
1900
kgmole/h
Product Pressure
200.2
kPa
Pressure Drop
1.073
kPa
3.600e-012
kgmole/h
Feed Pressure
192.7
kPa
100.00
Molar Flow
Percentage Open
Compressor
Speed
6285
rpm
Power
3725
kW
26159.5
ACT_m3/h
Feed Pressure
183.6
kPa
Product Pressure
1220
kPa
1
Capacity
(act feed vol flow)
Temperature
35.00
Pressure
1220
kPa
Molar Flow
1900
kgmole/h
Figure 13. Key Parameters for VLV-100, Valve 23FE1015, Compressor 23KA001, and Stream 1
The flow through the surge control valve is essentially zero, indicating that there is no surge being experienced in the
compressor. This can be verified in the compressor curve plot. As a corollary, all 1900 kmol/hr of feed are flowing to the
compressor and exits through the splitter to stream 1. The compressor operates at the speed indicated on the compressor
curve plot.
To start the dynamic simulation of compressor behavior, click the Dynamics tab in the Aspen HYSYS ribbon, and then
click Run, shown in Figure 14 below.
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After clicking Run, the dynamic simulator begins collecting compressor flow, head, and efficiency performance data.
The transfer function block serves to provide the compressor a disturbance, which in turn, allows the user to see how the
compressor and its surge control loop will respond. To initiate the disturbance from the transfer function block, check the
Active box on the transfer function face plate, shown in Figure 15.
Figure 15. Transfer Function Face Plate with Active Option Checked to Stop Feed to Process
For the simulation set up, clicking the Active box completely stops the feed to the compressor. It can be observed on the
compressor curves plot that the compressor experiences surge when the feed is stopped, followed by the surge protection
control loop recycling fluid, which leaves the compressor back to the inlet in order to ensure continuous fluid flow through
the unit (Figure 16).
Figure 16. Compressor Curves Showing Surge Response and Control Response
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When the surge control loop is activated, the compressor operates at a higher rpm, has a higher head, and passes a
higher flow. This is evident when comparing the tables at steady-state in Figure 13 to the updated tables after initiating
the feed disturbance, as shown below in Figure 17.
VLV-100
23FE1015
Feed Pressure
1220
kPa
Molar Flow
2500
kgmole/h
Product Pressure
214.9
kPa
Pressure Drop
1.207
kPa
Molar Flow
2502
kgmole/h
Feed Pressure
206.4
kPa
Percentage Open
100.00
Compressor
Speed
6431
rpm
Power
4163
kW
27604.6
ACT_m3/h
Feed Pressure
195.8
kPa
Product Pressure
1220
kPa
1
Capacity
(act feed vol flow)
Temperature
35.00
Pressure
1220
kPa
0.0000
kgmole/h
Molar Flow
Product ceases to leave the process in stream 1 after the surge control loop begins, while the flow through the surge
control valve, VLV-100, jumps from zero to 2500 kmol/hr. This then makes its way back to the compressor through valve
25FE1015. An increase in compressor speed, capacity, and power can also be verified.
Unchecking the Active box on the transfer function face plate restores the feed stream to the compressor to 1900
kmol/hr. Accordingly, compressor performance will return to the original, steady-state operating point. Figure 18 shows
the compressor curves plot after returning the feed stream.
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The compressor gradually returns to the steady-state performance it began with. The following results table shows the
key process variables for the compressor at the operating point shown in Figure 18.
VLV-100
23FE1015
Feed Pressure
1220
kPa
Molar Flow
1900
kgmole/h
Product Pressure
200.4
kPa
Pressure Drop
1.072
kPa
3.600e-012
kgmole/h
Feed Pressure
192.8
kPa
100.00
Molar Flow
Percentage Open
Compressor
Speed
6283
rpm
Power
3724
kW
26147.8
ACT_m3/h
Feed Pressure
183.7
kPa
Product Pressure
1220
kPa
1
Capacity
(act feed vol flow)
Temperature
35.00
Pressure
1220
kPa
Molar Flow
1900
kgmole/h
Letting the process run with the feed stream renewed, shows that 1900 kmol/hr of fluid leaves the process in stream 1, as
previously observed in steady-state operation. The flow through the surge control valve returns to zero, while the
compressors speed, power, and capacity decrease to the steady-state values.
A view of the compressors efficiency curves throughout the dynamic disturbance modeling is shown in Figure 20.
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Conclusion
Controlling compressor surge is very significant for safe process operation and mitigating equipment malfunction and
subsequent replacement. Aspen HYSYS Dynamics helps engineers model the dynamic changes in performance expected
for a compressor experiencing a disturbance, as well as the response of a control loop connected to the compressor. Using
Aspen HYSYS Dynamics, many scenarios in which steady-state operation is interrupted can be considered and designed
for.
Both numerical and graphical dynamic models are generated in Aspen HYSYS Dynamics, which allows for in-depth
analysis to be performed on each completed simulation. In addition to stopping the feed to the compressor, as performed
in this guide, other compressor disturbances could be explored in Aspen HYSYS Dynamics. Control schemes and
parameters can also be modified, yielding more or less robust compressor control, depending on the users preference.
Aspen HYSYS Dynamics is a powerful tool that can be utilized to ensure safe and proper functioning of a processs
compressors.
Additional Resources
Public Website:
http://www.aspentech.com/products/aspen-hysys.aspx
http://www.aspentech.com/products/aspen-hysys-dynamics.aspx
Online Training:
http://www.aspentech.com/products/aspen-online-training
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About AspenTech
AspenTech is a leading supplier of software that optimizes process manufacturingfor energy, chemicals,
engineering and construction, and other industries that manufacture and produce products from a
chemical process. With integrated aspenONE solutions, process manufacturers can implement best
practices for optimizing their engineering, manufacturing, and supply chain operations. As a result,
AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become
more energy efficient. To see how the worlds leading process manufacturers rely on AspenTech to
achieve their operational excellence goals, visit www.aspentech.com.
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