07_dynamic_plant_simulation_t.pdf
TRANSCRIPT
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
1/29
1 D. Krenz / HDB / z3641.ppt
Linde Engineering
Dynamic Plant Simulation
Tehran, September 26th 2005
Dieter Krenz
Linde Engineering
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
2/29
2 D. Krenz / HDB / z3641.ppt
Linde EngineeringThe plant control system, plant tuning,operator training and the plant operatingpoint influences the overall plant result
HYCO plants have different topology
Several feeds, fuel gases, parallel trains etc. A control system shouldmeet the special plant topology
The operator knowledge is the key for a smooth plant operation
Training of the operator is a precondition for a good plant operation
A plant consists of many valves and controller
Tuning of these control loops have a great impact on the dynamicplant behavior
The plant operating point is responsible for the plant profit
Changing feed situations can lead to different best plant operatingpoints
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
3/29
3 D. Krenz / HDB / z3641.ppt
Linde EngineeringLinde applies simulation for training,control system design, tuning andoptimization
Simulation models are used for
Training
Control system design
Tuning of PID controller and plant units
Automatic plant start up
Best plant operation
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
4/29
4 D. Krenz / HDB / z3641.ppt
Linde EngineeringDynamic simulation reducescommissioning time andminimizes trail and error
Advantages
tests and demonstration of plant behavior already before plantstart-up
time consuming tests with the real plant can be done much
faster with a dynamic simulation model
reduced test activities with the real plant during commissioning
Overall Benefit
reduced commissioning time less trail and error
Best operation point
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
5/29
5 D. Krenz / HDB / z3641.ppt
Linde EngineeringLinde uses commercially availablesimulation as well ascustomized simulations in Excel
The purpose of the simulation defines the simulation tool
Excel for simulations of HYCO plants (reformer, shift reaction,simplified cold box, etc.)
Commercially available simulation packages such as HYSYSare used for studies
Lindes simulation tool OPTISIM when the accuracy of
property data is significant (Cold Box)
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
6/29
6 D. Krenz / HDB / z3641.ppt
Linde Engineering
Linde set up the simulation in orderto give the customer a easy to use tool
The simulation set up with EXCEL is flexible and user friendly
The simulation model is tailored to the actual plant and includesonly the major mass and energy balance. No special knowledge
necessary to use the simulation model
Easy to use simulation model with a comprehensive user interfacewhich can be modified in the look and feel
Both dynamic and steady state models are available
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
7/29
7 D. Krenz / HDB / z3641.ppt
Linde Engineering
Simulation set up in HYSYS
5m3
6m3
6m3
60m3
5m3
5m3
320m3
5m3
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
8/29
8 D. Krenz / HDB / z3641.ppt
Linde EngineeringA dynamic simulation showsthe expected plant behaviorbefore commissioning
Feed
H2/CO
in OXO
OXO
H2
to Shift
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
9/29
9 D. Krenz / HDB / z3641.ppt
Linde Engineering
Simulation set up in EXCEL (partly)
13797.2kg/h 38.0bar
13788 kg/h 1.0bar
4415.6kg/h
50.0% 4413 kg/h 1.30bar
76.3%
3.56mol% ch4
6803.4kg/h 15.8% 29.55mol% H2O
6800 kg/h 1.36mol% 1.30bar 44.16mol% h2
2.75mol% 1025.9cel 14.67mol% CO
7.92mol% CO2
0.15mol% N2 875 cel
40.0bar 67.2% 28.6bar 26.6bar 874.0cel
600 cel
0.94828 ch4 397 cel 100.0% 9.03MW
0 H2O 29 bar co2 ref 1.0bar 250 cel
0.0291 h2 7959 kg/h
0 CO
0.000485 CO2 2.0kg/h
0 C2H4 7959 kg/h 70000.0kg/h
0.009457 C2H6 70000 kg/h
0.0006 C3H6 51.8% 60.7% 81.3% 0.0% 0.0% 0.0%
0.003301 C3H8
0 C4H8
0.000641 i-C4H100.000621 n-C4H10 0.0% 1452.3kg/h 757.3kg/h 1090.6kg/h 0.0kg/h 0.0kg/h 0.0kg/h
0.000214 C5H12 1463 kg/h 758 kg/h 1072 kg/h 0 kg/h 0 kg/h 0 kg/h
0.0000388 C6H14
0.007864 N2 0.0kg/h
-21 kg/h
40.0bar
v
Feed
1
v
v
reformer
steam
co2imp
v ng v pg v tg v h2 v co v co2
v
air
co2rec
mp
tc
v pcbox
prereformer
v st. pref
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
10/29
10 D. Krenz / HDB / z3641.ppt
Linde Engineering
Well trained operator makeless errors in plant operation
Class room training is organized in the steps
Definition of the training goals
Explanation and demonstration of the process basics
Group work with the aid of a training simulator
discussion
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
11/29
11 D. Krenz / HDB / z3641.ppt
Linde Engineering
Example of Linde class room trainingwith dynamic simulation
1const30000.0kg/h flow in
periode100.0sec 30000.0kg/h
amplitude FIN2500.0kg/h 50.0% SP3
29500.79950.0%
2 KP PV3 FOUT2
360 TI 30000.2kg/h0 TD
44.7% OP3
0
10
20
30
40
50
60
0 100 200 300 400
time
PV3,SP3andOP3
PV3
OP3
SP3
drum MAN
AUTO
LC1
v
LC1
const
sinus
flow in
27000
27500
28000
28500
29000
29500
30000
30500
31000
0 100 200 300 400
time
FIN2andFOUT2
FIN2
FOUT2
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
12/29
12 D. Krenz / HDB / z3641.ppt
Linde EngineeringOur HYCO plant control systemsare successfully used indifferent plant topologies
The frequent operation of a plant load change is done totally automaticby Lindes control system
The control system calculates all setpoints (flows, O2, steam,
feed etc.) based on simplified or rigorus models
The operator has only to enter the target values for the products
If one plant unit trips the rest of the plant remains running
Changes of heating values are compensated for in a special heatvalue loop
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
13/29
13 D. Krenz / HDB / z3641.ppt
Linde Engineering
RemoteSP =
33000 kg/h
RemoteSP =
132000 kg/h
TC
Reformer
FC
FC
PC
FCFC
NG = 1500 kg/hFeed =
15000 kg/h
RemoteSP =
45000 kg/h
RemoteSP =
15000 kg/h
SP
Load
Steam
Feed
Min
Steam
FC
Air = 132000 kg/h
RemoteSP =
1500 kg/h
air /
purge
air /
gas
Reformer Load And Fuel Gas Control Training
820.5 celInternalSP =
45000 kg/h
InternalSP =
15000 kg/h
Internal SP =1500 kg/h
Internal SP =33000 kg/h
Internal SP =132000 kg/h
START
Simulation
STOP
Simulation
AUTO
AUTO
AUTO AUTOAUTO
MAN
AI O2 = 2.4 %
Excess
Air
Min
Air
Purge = 33000 kg/h
Steam =
45000 kg/h
InternalSP =
45000 kg/h
InternalSP =
15000 kg/h
InternalSP =1500 kg/h
InternalSP =33000 kg/h
InternalSP =132000 kg/h
InternalSP =820.5 cel
Load
controldetails
Air/temp
control
details 14 3 1.10000 75000
80 3 25000
Feedforward
8
+
TC-Out =
0 kg/h
Init OFFHOLD
Simulation
help on
Example of a reformer control systemfor demonstration of principle controlsystem features
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
14/29
14 D. Krenz / HDB / z3641.ppt
Linde Engineering
Control and simulationof a standard H2 plant
Reformer CO shift PSAH2 ProductFeed
Plant topology:
Control system:Based on the target value for the H2 product the setpoints for steam,
feed, temperatures, O2 etc are calculated via feedforward andfeedback
Simulation:
Based on a simplified energy and mass balance there are steady stateand dynamic simulation available
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
15/29
15 D. Krenz / HDB / z3641.ppt
Linde Engineering
Control and simulation of a HYCO Plant
Reformer MDEA Adsorber Cold Box
PSA
CO Product
H2 Product
Feed
Plant topology:
Control system:
Based on the target values for the products H2 and COthe setpoints for steam, feed, temperatures, O2 aswell as the flows and temperature setpoints in thecold box are calculated via feedforward andfeedback
Simulation:Based on a simplified energy and mass balancethere are steady state and dynamic simulationavailable
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
16/29
16 D. Krenz / HDB / z3641.ppt
Linde Engineering
Plant topology:
Control system:
Based on the target values for the products H2and OXO the setpoints for steam, feed,temperatures, O2 MDEA cycle flows,membrane pressure etc are calculated via
feedforward and feedback
Simulation:
Load changes have been simulated in HYSYS
POX CO-Shift MDEA Membrane
PSA Compressor
cooling
OXO Product
H2 Product
Feed
Control and simulation of aHYCO Plant with POX and membrane
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
17/29
17 D. Krenz / HDB / z3641.ppt
Linde Engineering
Plant topology:
Control system:
Based on the target values for the products H2 and CO the load is automaticallydistributed to CO shift and cold box. The setpoints for steam, feed,temperatures and O2 as well as the flow and temperature setpoints in the
cold box are calculated via feedforward and feedback.
Simulation:
Steady state simulation
Reformer CO-Shift PSA
MDEA
CO Product
H2 ProductFeed
Cold Box
Control and simulation of aHYCO Plant with POX and membrane
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
18/29
18 D. Krenz / HDB / z3641.ppt
Linde Engineering
ProductsPlant
FI
Controller
for correction
+Calculation
of
Setpoints
for the
Plant
Setpoint
Products
MeasurementSetpoint
Feedforward
Independent Plant
inputs such as
Reformer Load
CO2 Recycle etc
Calculation of independent plant inputs such as reformer load etc. basedon operator setpoint for the products
adjustment of all significant controller as a function of plant load byfeedforward
deviations between setpoints for products and actual measured productsare compensated by a controller
A General load control conceptis applied to all plant topologies
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
19/29
19 D. Krenz / HDB / z3641.ppt
Linde Engineering
setpoint
syngas temperature
Controller settings are responsiblefor the plant dynamic
step response isunstable
step response isexcellent
step response is tooslow
Reformer
TC
Fuel gas
control
TimeTime Time
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
20/29
20 D. Krenz / HDB / z3641.ppt
Linde Engineering
setpoint
syngastemperature
A dynamic simulation of thecontrol loop leads to anexcellent behavior in a short time
step response isexcellent
Reformer
TC
Fuel gascontrolTime
dynamic simulation based onmeasurements
Leads to the best overallresponse with minimum workin the real plant and minimum
trail and error
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
21/29
21 D. Krenz / HDB / z3641.ppt
Linde Engineering
Model Identification by setting V, TS, TOT and/or KI
Model EquationY_MOD = V*(1 - exp(-(t-TOT)/TS)) + KI*(t-TOT)
V TS TZ KI Delta_U Abtastzeit
20 1250 240 0 1000 50
0
5
10
15
20
-10 -1 450 950 1450 1950 2450
0
200
400
600
800
1000
1200
Y_MES
Y_MOD
Delta_U
Go To Control Hilfe Einblenden
A two step procedure with Lindestuning programm leads to bestcontroller settings in minimum time
PID-CONTROLLER TUNING
Setpoint DisIn DisOut
10 PID-Controller Periodend.1000 Plant Periodend.100
KP = 1 Amplitude200.0 Vertrkung 20 Amplitude0.0
TN = 800 Anstiegszeit 1250
SP TD = 0 PlantIN= Totzeit 240 PlantOut
PID_OUT+DisIN Integrations. 0
PID_OUT HIGH / LOW PV HIGH LOW SCALING PV=PlantOut+DisOUT
MH=50000.0 -ML=50000.0 PVH=1000.0 PVL=0.0
Sim.-zeit
3600.0 sec
Abtastzei t
1.0 sec
Zufallssignal
-ZinMin=0.1
ZinMax=0.1
Kin=0.0
ZouMin=0.0
ZouMax=0.0
Kou=0.0
0
2
4
6
8
10
12
14
0 494.2 988.5 1482.7 1976.9 2471.2 2965.4 3459.6
-500
0
500
1000
1500
PlantOut
SP
DisOut
PlantIn
DisIn
Input PlantInput Plant Model
Hilfe Einblenden
Model identification based onplant measuremnts
Dynamic simulation of theclosed loop
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
22/29
22 D. Krenz / HDB / z3641.ppt
Linde EngineeringDynamic Simulation is usedfor tuning of complex systemssuch as a steam system
PC-hh
SGTCOND
SGTEXTR:
cond
HP Header
MP Header
LP Header
HP-steamreformer.
HP-steamsyngas cooler.
MP-steam
co shift.
FC
Dilution steamreformer PC
PC-h
Auxilaryboiler
SGC
loadcontrol
FC
LP export
PC-h
TG
COND
TG
EXTR:
cond
PC
G
Power
PC-hh
PC-hh PC
FI
FI
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
23/29
23 D. Krenz / HDB / z3641.ppt
Linde Engineering
Simulation set up of asteam system simulation
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
24/29
24 D. Krenz / HDB / z3641.ppt
Linde Engineering
An automatic plant start up / shut-down with the aid of a sequence.
A sequence itself will perform valve and/or controller open/close/rampingin the same way as described in the operating manual and
is organized in steps such as purging, heating, feed in etc.
Before the next step will be executed the previous one must be finishedsuccessfully. This is checked by comparing actual with expected operatingconditions.
In case of an error (failed check) the sequence will hold. The operator will fixthe problem and resume the sequence.
The operator can hold and resume the sequence at any time.
Automatic Plant Start Up
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
25/29
25 D. Krenz / HDB / z3641.ppt
Linde Engineering
A PFD serves as visualization of all stepsvalve open/close is indicated by green/red
actions are yellow with a descriptiontransitions are blue with a description
Automatic Plant Start Up
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
26/29
26 D. Krenz / HDB / z3641.ppt
Linde EngineeringA plant model enables the plant operatorto change major plant variables andverify the best operating point
Independent plantinputs such as feed
composition
Plant Model
Observation of thepredicted products and
selection of theoperating point which
promises the best plantresult
Variation of plantvariables such as
steam/feed, reformeroutlet temperature etc.
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
27/29
27 D. Krenz / HDB / z3641.ppt
Linde Engineering
Example for a HYCO plant modelfor the operating point calculation
O2 0.00%
AC2104 O2-SP
1.22mol% 1.22mol% 0.00%
0.00% 0 kg/h
0 kg/h flue gas H2-Product
steam T2118 0 kg/h
FC2106 987 cel 0 Nm3/h
0 kg/h 0.00% F. 0.0kmol/h
D/C 28.6bar 0 kg/h
3.00kg/kg 855 cel 330 cel 0.00%
reformer 0.00% 0.00% shift 0.0kmol/h psa
co2=0.00mol% co2=0.00mol%580 cel co2=0.00mol% co2=0.00mol%
0.00% co2=0.00mol% co2=0.00mol% purge gas
feed co2=0.00mol% T co2=0.00mol% 0 kg/h
0.0kmol/h 855 cel dry ch4 0.000mol
FC2103 dry h2o 0.000mol
0 kg/h 0.00% h2 0.000mol0 kg/h 0.00% co 0.000mol
0.00% air co2 0.000mol
0 kg/h n2 0.000mol
Einsatzzusammensetzung 250 cel
0 ch4 0 49.22MJ/kg 9.73MJ /k g FC2115
0 H2O 0 Erdgas DWA Restg 0 kg/h
0 h2 0 0 kg/h
0 CO 0
0 CO2 0 0 kg/h 0 kg/h
0 C2H4 0 FC2119 FC24030 C2H6 0 0 kg/h 0 kg/h
0 C3H6 0 0.00% 0.00%
0 C3H8 0
0 C4H8 00 i-C4H10 0
0 n-C4H10 0
0 C5H12 0
0 C6H14 0
0 N2 0.0082
1.00 1.00
combustion
steam
D/C
Steam or D/C
feed
Production
feed / Producti
ON (to flar)
OFF (no flare
purge gas to flare
Man Auto
o2
Man Auto
temperatur
NSG
RUG
Einsatztyp
M1
M2
M3 HG1 HG2
Heizgastyp
HG3 HG4 HG5
wie Einsatz
aus HG-Typ
Heizgaswahl
Man Auto
ch2.sp
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
28/29
28 D. Krenz / HDB / z3641.ppt
Linde EngineeringLindes simulation models are easyto use and lead always to a improvedand smooth plant operation
Simulation models are tailored to your plant can run on normal PChardware and can be used immediately without any programmingwork
The operator can learn with simulation models the process behaviorwithout endangering the real plant. The Excel models are especiallygood because of their user interface (similar to the DCS) and the lowinvestment coasts
The plant tuning is done with simulation models in order to reduce
trail and error. This results in best plant operation under changingplant conditions.
-
7/29/2019 07_Dynamic_Plant_Simulation_T.pdf
29/29
29 D. Krenz / HDB / z3641.ppt
Linde Engineering
Thank you for your Attention.