aspen hysys presentation
TRANSCRIPT
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©2002 AspenTech. All Rights Reserved. 1
Process Modeling Using HYSYS
PTDF ENGINEERING TRAINING 30TH JULY, 2007
Customer Support/Training Department
• ISMAIL OLUTOSIN
• OGUNDIRAN OLUWASEUN
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©2002 AspenTech. All Rights Reserved. 2
Contact Information
Email: [email protected]
Internet: http://support.aspentech.com, www.weamandco.com
Technical Support Hotline: 084-235216, 084-235217, 084-797293, 08033532200, 08056366852
Email: [email protected], [email protected],[email protected]
Training
Customized Support Services
Before doing that :Ask for some help
to Support !!!
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Technical Support Internet Site
http://support.aspentech.com
Registered Customers can:
• Access current product documentation
• Search for tech tips, solutions and frequently asked questions
• Search for and download application examples
• Submit and track technical issues
• Search for and review known deficiencies and defects
• Report product defects
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A 100% Hands-on course - very little theory
Folders contain all information
From 9:00am to 4:00pm
Lunch-12:00-1pm
Coffee Break- 10mins 10am, 2.30pm
Course Organisation
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WHY USE SIMULATION MODELS?
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Lifecycle QuestionsWhat’s it worth?
How do we build it?How will it work?
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Time (seconds)
Measure Setpoint
How can we control it?
How do we run it?Why isn’t it working?
How much more can we do?
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S1S2
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Production Profile
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©2002 AspenTech. All Rights Reserved. 7
ENGINEERING DESIGN
Operability & SafetyOperability & Safety
AutomationAutomation
ProcessProcessDesignDesign
DetailedDetailedDesignDesign
OperationsOperations
ConceptualConceptualDesignDesign
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DEEP WATER EXPLORATIONOffshore
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©2002 AspenTech. All Rights Reserved. 9
Shell Bonga Subsea Flowline SystemOnline Dynamic Model for Wellbore, Flowline, and Topside Facilities
Business Problem:• Study of the coupled interaction
between production tubing, flow lines, risers, gas lift and topsides equipment in a continuous pressure-flow network.
Solution:• Hysys Dynamics for topside
models linked with Scandpower’s OLGA for transient flowline simulation.
Offshore
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©2002 AspenTech. All Rights Reserved. 10
Chevron De-Ethanizer Turbo Expander PlantCost-Effective Process Trainer
Business Problem:• Plant personnel require regular
process training
Solution:• HYSYS Dynamics simulation
model• Linked to Moore DCS
Implementation & Results:• Instilled process knowledge• Developed procedures for
abnormal operating scenarios• Troubleshooting of operations• Guaranteed operations
performance
Onshore
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©2002 AspenTech. All Rights Reserved. 11
Chevron Funiwa Transient Analysis. – Flow AssuranceIntegrate Transient Flowline with Facility Dynamic Model
Description:• Integrated flowline and facilities
dynamic models allow detection and remediation of severe slug flow in the riser.
Business Problem:• Flowline simulation alone will often
not properly predict slugging due to significant interactions with topsides.
Solution:• An Integrated Model using Hysys
Dynamics and Hysys Upstream Transient Flowline simulator properly modelled the behavior of this critical system.
Offshore
PIPELINE PROFILE
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-5000 0 5000 10000 15000 20000 25000 30000
HORIZONTAL DISTANCE (ft)
ELEV
ATI
ON
(ft)
Series1
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©2002 AspenTech. All Rights Reserved. 12
NAOC Ebocha Revamp Project Onshore
Business Problem:• Separator assessment study
and conversion of two phase separator to three phase
Solution:• Hysys.Process for steady state
modeling of the flow-station facility, combine with Hysys dynamics.
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©2002 AspenTech. All Rights Reserved. 13
Shell Oguta Flow station Debottlenecking
Business Problem:
• Commingling of gas from high pressure regime with gas from low pressure regime lead to some undesired condition
Solution:
• Hysys. Process, Hysys Dynamics and Aspen Flarenet were used to carry out the study.
Onshore
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Companies currently using our simulation software in Nigeria.
• SPDC
• CHEVRON
• ELF
• NAOC
• PAN OCEAN
• CAKASA
• AMAZON ENERGY
• DOVER ENGINEERING
• POINT ENGINEERING
• CHESTERMEAD
• FRONTIER OIL
• SUNLINK
• DELTAFRIK
• MOBIL
• AMAZON ENERGY
• NETCO
• CRESTVILLE
• WRPC
• PHRC
• NNPC R & D
• FODE
• SULDELLETRA
• UNILAG & ABU
• IPS
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Process Modelling using Hysys
COURSE AGENDA
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HYSYS Steady State Oil&Gas
Day 1
• Module 1 – Getting Started (Fluid Packages, Streams, Utilities)
• Module 2 – Propane Refrigeration Loop (Unit Operations)
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HYSYS Steady State Oil&Gas
Day 2
• Module 3 – Refrigerated Gas Plant (Heat Exchanger, Adjust)
• Module 4 – NGL Fractionation Train (Columns)
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HYSYS Steady State Oil&Gas
Day 3
• Module 5 – Oil Characterization (crude modeling)
• Module 6 – Gas Gathering (Pipe Segments)
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HYSYS Steady State Oil&Gas
Day 4
• Module 7 – Two Stage Compression (Recycles)
• Module 8 – Acid Gas Sweetening with DEA (Amines Package)
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HYSYS Steady State Oil&Gas
Day 5
• Module 9 – Natural Gas Dehydration with TEG
• Module 10 – Reporting in HYSYS (reports, EXCEL)
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Process Modeling using HYSYS
Getting Started
Propane Refrigeration Loop
Refrigerated Gas Plant
NGL Fractionation Train
Oil Characterization
Gas Gathering System
Two Stage Compression
Acid Gas Sweetening with DEA
Natural Gas Dehydration with TEG
Reporting in HYSYS
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©2002 AspenTech. All Rights Reserved. 22
HYSYS.Process = Steady State Simulator
• Windows based program
• Flowsheet and object oriented
• Event driven
• Modular operations, each operation is solved independently
• Non-sequential solving algorithm
HYSYS.Dynamic = Dynamic simulator
• HYSYS.Dynamic uses directly the models from HYSYS.Process
HYSYS Main Characteristics
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• Based on components
• Material Balance
• Component Balance
• Energy Balance
• Equilibrium information (Thermodynamic information is required) VLE / VLLE.
• Pressure drop is a data
• Accumulation = 0, we do not need any info regarding the sizing of the equipment
HYSYS Steady State Simulation
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• Basis Environment (container for all the thermo. info.)
• Select a fluid package(s)
• Oil Environment (focused on Oil modeling)
• Simulation Environment – PFD (process flow diagram)
• Main Flowsheet
-Sub-Flowsheet
-Column Environment (each column added in the PFD contains
a sub-flowsheet)
How HYSYS is structured
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Start Hysys & Create a new case
Basis Environment
Sub - Flow Sheet
Simulation Environment
How to know where I am ?
HYSYS Interface Main Structure
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Case File: filename.hsc
Simulation Basis Simulation Environment
- Fluid Packages (*.fpk) - Property Package - Component List - Parameters, etc
- Reactions, etc.
- PFD - Streams (w/ utilities) - Unit Ops - Sub-Flowsheets, etc
- Unit Op. Property Views
- Work Book
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Simulation Basis Manager
Thermodynamic Contents
• Hyprotech Database: components and BIPs
• Property Packages
• EOS• Activity Models• Others
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FPM: Hyprotech Database
Hyprotech thermodynamic engine
• Fluid package
List of components
Property Package
Set of thermo-physical
property calculations
Binary interactionfor
LV equilibrium
(1500)
(16000)
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Property Packages in HYSYS
Equations of State (EOS)
• PR, PRSV, SRK, MBWR, ZJ, KD, LKP
Activity Models
• Margules, van Laar, Wilson, NRTL, UNIQUAC
Others
• Chao-Seader
• Vapor pressure models
• ASME Steam
• Amines
• some empirical models
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EOS limitations
EOS reliable in predicting properties of most hydrocarbon based fluids over a large range of operating conditions
Their application has been limited to primarily non-polar or slightly polar components
Polar or non-ideal chemical systems have traditionally been handled using dual model approaches
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Selecting Property Package
Type of System Recommended Property PackageTEG Dehydration PRSour Water PR, Sour PRCryogenic Gas Processing PR, PRSVAir Separation PR, PRSVAtmospheric Crude Towers PR, PR Options, GSVacuum Towers PR, PR Options, GS<10mmHg, BK10, Esso KEthylene Towers Lee Kesler PlokerHigh H2 Systems PR, ZJ or GSReservoir Systems PR, PR OptionsSteam Systems Steam Package, CS or GSHydrate Inhibition PRChemical Systems Activity Models, PRSVHF Alkylation PRSV, NRTLTEG Dehydration with Aromatics PR
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HypoComponents
A hypothetical component can be used to model non-library components, defined mixtures, undefined mixtures, or solids
The minimum information required for defining a hypo is the Normal Boiling Pt or the Ideal Liq Density and Molecular Weight
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Flash calculation
A Flash calculation is the estimation of the thermodynamic properties of a process stream.
HYSYS can perform a Flash when:
1.- Composition is known.
2.- A couple of these variables is known: VF, T, P, H, S.
One of them must be T or P in order to estimate the rest.
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Flash Calculations
Temperature
PressureVaporFraction
Molar Enthalpy
• Dew point calculations• Bubble point calculations
TP
HS
VF
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Envelope Utility
Permits to show the different phase regions of a process streams. The Phase-Envelope can be plotted using several diagrams: P-H, P-T,…
This Envelope is calculated on a dry basis, you must be careful when applying the utility to mixtures containing H2O or any other component which can form a second liquid phase
The Envelope utility is restricted to the Peng-Robinson and SRK equations of state.
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Hydrate Formation Utility
• Incipient solid formation point for hydrates
• HYSYS can predict the incipient solid formation point for systems consisting of gas hydrates in equilibrium with a free-water phase, or for systems without a free-water phase
• If component water is not present HYSYS assume the stream to be saturated with water
• Calculation Models
• Assume free water• Asymmetric• Symmetric• Vapor only
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Hydrate Formation Utility
• Hydrate Formation Flag: displays the status of hydrate formation.
• Will Form• Will NOT Form
• Hydrate Type Formed: displays the types of Hydrate formed.
• If the temperature is higher than the formation temperature, then No Types is displayed in this field
• Equilibrium Phase
• Vapour Phase• Liquid Phase• Free Water Found• Assume Free Water
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Property Table Utility
This utility allows you to examine property trends over a range of conditions
We can use one or two independent variables and their respective range of interest
Next, you can select which dependent variables will be displayed
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Module 1 - Getting Started
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C7+, C7 and C8
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Flash Calculations
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Exploring the Simulation
With the Phase Envelope:Critical Point for GasWell 1. (-12.58 C, 11290 kPa)Cricondenbar for GasWell 1 12230 kPaDew Point Temperature for GasWell1 1 at 4000 kPa 97.13GasWell Temperature for 50% quality at 8000 kPa -32.33BubblePoint Temperature for GasWell3 at 6000 kPa -48
With the Workbook:Dew Point Temperature for GasWell1 1 at 4000 kPa 98.13GasWell Temperature for 50% quality at 8000 kPa -32.22BubblePoint Temperature for GasWell3 at 6000 kPa -48.06
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Property Table Utility
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Module 2 – Propane Refrigeration Loop
Objectives:
• Add and connect operations
• Use the graphical interface to manipulate flowsheets
• Understand forward-backward information propagation
• Convert simulation cases to templates
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Material and Energy Stream
Logical Operations
Sub-Flow Sheets and
Columns (= Special types of Sub-Flow Sheets)
Unit Operations
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Conversion to a Template
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Saving the Simulation as a Template
Representative of a plant process module or portion of a process module.
The stored template can be read from disk and efficiently installed as a complete sub-flowsheet
Some of the advantages of using templates are:
• Employs a different property package than the main case to which it is attached.
• Provides a convenient method for breaking large simulations into smaller ones.
• Is created once and can be installed in multiple cases.
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HYSYS key design aspect
Modular Operations are combined with a Non-Sequential solution algorithm.
• The information is processed as you supply it
• The results of any calculation are automatically propagated throughout the flowsheet, both forwards and backwards (they can calculate in either direction).
HYSYS solver is active
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Module 2 – Propane Refrigeration Loop
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Workshop
• In this module you will construct, run, analyze and manipulate a Propane Refrigeration Loop simulation.
• You will convert the completed simulation to a template, making it available to connect to other simulations.
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Propane Refrigeration Loop
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Fix Vf, T, %mol.
Fix Vf, T
Calc P
Fix P, Q Calc P, T, Vf
Calc P
Fix PCalc P
Calc P Calc Q
Calc T
Calc Q
Forward–backward information propagation
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Exploring the Simulation: Exercice 1
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Process Modeling using HYSYS
Getting Started
Propane Refrigeration Loop
Refrigerated Gas Plant
NGL Fractionation Train
Oil Characterization
Gas Gathering System
Two Stage Compression
Acid Gas Sweetening with DEA
Natural Gas Dehydration with TEG
Reporting in HYSYS
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Module 3 – Refrigerated Gas Plant
Objectives:
• Install and converge heat exchangers
• Understand logical operations: Balance and Adjust
• Linking templates
• Use the Case Study
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Modelling Heat Exchangers
Cooler / Heater: single-sided unit operations where only one process stream passes through the operation.
Shell and Tube heat exchanger: a two-sided unit operation that permits two process streams to exchange heat.
LNG exchanger: allows for multiple (more than two) process streams.
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HXModels
Shell & Tube heat exchangers
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orBalanceErrQhhmQhhm lossouthotinhothotleakincoldoutcoldcold )()( ,,,,
lossouthotinhothotleakincoldoutcoldcoldt QhhmQhhmFLMTDUAQ )()()( ,,,,
Heat Exchanger calculations
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Heat Exchanger specifications
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• Temperature, Pressure and mass flow
• Pressure Drops
• UA
• Delta T
• LMTD
• Duty
Heat Exchanger specifications
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Adding the Balance• Mole
• An overall balance is performed where only the molar flow of each component is conserved.
• Outlet streams will have the same molar flow rate and composition as the inlet stream, but will contain no vapour fraction, temperature, or pressure values.
• Mass.
• An overall balance is performed where only the mass flow is conserved. The outlet stream will contain no composition,
• Heat.
• An overall balance is performed where only the heat flow is conserved.
• Mole and Heat.
• An overall balance is performed where the heat and molar flow is conserved.
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Logical operation: Adjust
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Select the sub-flowsheet Icon
Select the template *.tpl (Propane loop for example)
Link the main flowsheet
variables to the sub-flow
sheet variables
Linking Sub-flowsheets
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Remove heavy ends of a gas stream in order to meet a Dew Point Specification = f (TLTS)
KEY PARAMETER:KEY PARAMETER:TemperatureTemperature
Workshop: refrigerated gas plant
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Workshop
Simplified version of a refrigerated gas plant.
• The purpose is to find the LTS (Low Temperature Separator) temperature at which the hydrocarbon dewpoint target is met
• The Sales Gas hydrocarbon dewpoint should not exceed -15°C at 6000 kPa
• The incoming gas is cooled in two stages
• 1. by exchange with product Sales Gas in a gas-gas exchanger (Gas-Gas)
• 2. In a propane chiller (Chiller), represented here by a Cooler operation
• A Balance operation will be used to evaluate the hydrocarbon dewpoint of the Product Stream at 6000 kPa
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Challenge
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Process Modeling using HYSYS
Getting Started
Propane Refrigeration Loop
Refrigerated Gas Plant
NGL Fractionation Train
Oil Characterization
Gas Gathering System
Two Stage Compression
Acid Gas Sweetening with DEA
Natural Gas Dehydration with TEG
Reporting in HYSYS
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Module 4 – NGL Fractionation Train
Objectives:
• Add columns using Input Experts
• Use pre-built column templates
• Add specifications to columns
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Input Experts
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• Solver for distillation columns. Iterative procedure to solve the following equations:
• Heat and material balances around the column• Equilibrium equations on each tray • Summation equations
• Require: feeds completely defined, pressure profile and a number of specifications (depending on the column configuration)
Background
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# Columns Specifications=
# Side Heat Exchanger + # Side draws +# Side Strippers + # Pumparounds
Absorber = 0 SpecRefluxed Absorber = 1 SpecReboiled Absorber = 1 SpecDistillation Column = 3 Specs
Column Specifications
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Column Subflowsheets
Sub-flowsheets
• Contain equipment and streams
• Exchange information with the parent flowsheet through the connected streams
Columns Subflowsheets
• From the main environment, the column appears as a single, multifeed multiproduct operation
• You can enter the column subflowsheet by clicking the Column Environment icon on the Column property view
• You can return to the parent environment by clicking either:
• the Parent Environment button on the Column runner view• the Enter Parent Simulation Environment icon in the tool bar.
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Process Modeling using HYSYS
Getting Started
Propane Refrigeration Loop
Refrigerated Gas Plant
NGL Fractionation Train
Oil Characterization
Gas Gathering System
Two Stage Compression
Acid Gas Sweetening with DEA
Natural Gas Dehydration with TEG
Reporting in HYSYS
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Oil Characterization using C7Plus
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Module 6 – Gas Gathering
Objectives:
• Use of the Pipe Segment in HYSYS to model pipelines
• Use the Mixer
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• Pipe Segment takes into account the topography (elevation level)
• Includes three calculation modes:
- Pressure drop- Length- Flow
• Depending on what information is specified, the mode will automatically be assigned.
Pipe Segment
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Correlations Sizing
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Pipe Flow Correlations• The table summarizes the characteristics of each model.
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Pipe Segment: Rating
100 m
150 m
125 m
6 m
-0.5 m -1 m
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Rating Tab
• Append a Segment
• Select the fitting/Pipe cell
• Specify the length and the elevation change
• Press the View Segment to select
• The Schedule (Nominal and inner diameter)• Pipe Material• Roughness• Pipe Wall Conductivity
• Pipe• Swage• Elbow• Bend• 180 Degree Close return• Tee Branch Blanked• Tee as elbow
• Coupling union• Gate valve• Diaphragm Valve• Globe Valve• Angle Valve• Blowoff Valve
• Plug Cock• Butterfly Valve• Ball Valve• Check Valve• Foot Valve• Water meter
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Heat transfer models
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Pipe Sizing: Heat Transfer Page
• Heat loss
• Overall HTC
• Global• By segment
• Estimate HTC
• Global• By segment
- Pipe wall- Inner HTC- Insulation- Outer HTC
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Workshop
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Process Modeling using HYSYS
Getting Started
Propane Refrigeration Loop
Refrigeration Gas Plant
NGL Fractionation Train
Oil Characterization
Gas Gathering System
Two Stage Compression
Acid Gas Sweetening with DEA
Natural Gas Dehydration with TEG
Reporting in HYSYS
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Module 7 – Two Stage Compression
Objectives:
• Use the RECYCLE operation in HYSYS
• Choose suitable RECYCLE locations
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·
·
R Assumed Calculated
•Required when mixing downstream material
stream(s) with upstream material stream(s), and
when there is mass I/O across the flowsheet
•Recycle operation - a mathematical unit
operation
Recycle – Logical operation
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• HYSYS uses the conditions of the assumed stream (outlet) and solves the flowsheet up to the calculated stream (inlet).
• HYSYS then compares the values of the calculated stream to those in the assumed stream.
• Based on the difference, HYSYS modifies the values in the calculated stream and passes the modified values to the assumed stream.
• The calculation process repeats until the values in the calculated stream match those in the assumed stream within the specified tolerance.
Recycle
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• Nestedyou have single Recycle or multiple recycles not connected
• Simultaneousyour flowsheet has multiple interconnected recycles.
The smaller the tolerance value, the tighter the tolerance !!!
Recycle Parameters
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The first choice is often in the actual recycling stream. OK for only one Recycle.
Three basic rules:
• Placed it AFTER Mixers and BEFORE separating operations (Separators, Columns, and Tees).
• Never place a Recycle operation in a position that will conflict with an Adjust operation.
• Place it in stable streams (never the output of a column).
Recycle location
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• Feed gas enters the compressor station at 35°C and1725 kPa
• The gas is to be delivered at 6900 kPa
• Compression is done in two Stages
• Each stage consists of KO drum, compressor and cooler.
• Liquids from each separator are recycled back to previous stage
Workshop
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Your PC takes tooYour PC takes toolong to convergelong to converge
Challenge
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Challenge
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Process Modeling using HYSYS
Getting Started
Propane Refrigeration Loop
Refrigeration Gas Plant
NGL Fractionation Train
Oil Characterization
Gas Gathering System
Two Stage Compression
Acid Gas Sweetening with DEA
Natural Gas Dehydration with TEG
Reporting in HYSYS
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Module 8 – Acid Gas Sweetening with DEA
Objectives:
• Simulate a Distillation Column and an Absorber using the Amines Property Package
• Use of the SET operation
• Use of the Spreadsheet
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Amines Prop. Package
The Amines package contains the thermodynamic models developed by D.B. Robinson & Associates for their proprietary amine plant simulator, AMSIM.
The equilibrium acid gas solubility and kinetic parameters for the aqueous-amine solutions in contact with H2S and CO2 have been incorporated into this property package.
The Amines package incorporates a specialized stage efficiency model to permit simulations of columns on a real tray basis.
The stage efficiency model calculates H2S and CO2 component stage efficiencies based on the tray dimensions.
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Recommended Lean Amine Strengthin Water
Amine % wt.
MEA 15 – 20
DEA 25 – 35
TEA, MDEA 35 – 50
DGA 45 – 65
Suggested values
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Damping Factor
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Logical operation
Set the value of a specific Process Variable (PV) in relation to the same PV in another object, such as P of two streams.
You can set them to equal values or inequality with offset.
In this case, we want to set P of DEA to recycle 35 KPa lower than that in Gas to Contactor.
Set operation
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Spreadsheet
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Workshop
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Regenerator Operation
Constant component efficiencies for H2S and CO2
Modified HYSYS Input-Output
Damping factor (0.25-0.50)
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Challenge
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Process Modeling using HYSYS
Getting Started
Propane Refrigeration Loop
Refrigeration Gas Plant
NGL Fractionation Train
Oil Characterization
Gas Gathering System
Two Stage Compression
Acid Gas Sweetening with DEA
Natural Gas Dehydration with TEG
Reporting in HYSYS
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Module 9 – Natural Gas Dehydration with TEG
Objectives:
• Model a typical TEG dehydration unit
• Determine the water dew-point for a gas
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TEG Prop. Package
The PR equation of state applies a functionality to some specific component-component interaction parameters.
Key components receiving special treatment include He, H2, N2, CO2, H2S, H2O, CH3OH, EG and TEG.
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• Removal of water from reservoir fluids
• Water can cause Solid Hydrates & Corrosion (w/ H2S/CO2)
• Dehydration with Glycol, Silica Gel or Molecular Sieves
Workshop
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Challenge
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Process Modeling using HYSYS
Getting Started
Propane Refrigeration Loop
Refrigeration Gas Plant
NGL Fractionation Train
Oil Characterization
Gas Gathering System
Two Stage Compression
Acid Gas Sweetening with DEA
Natural Gas Dehydration with TEG
Reporting in HYSYS
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Module 10 – Reporting in HYSYS
Objectives:
• Show different way to extract the information of HYSYS
• Excel Macro