Aspen HYSYS Presentation

©2002 AspenTech. All Rights Reserved. 1

Process Modeling Using HYSYS

PTDF ENGINEERING TRAINING 30TH JULY, 2007

Customer Support/Training Department

• ISMAIL OLUTOSIN

• OGUNDIRAN OLUWASEUN


Contact Information

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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


WHY USE SIMULATION MODELS?


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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Production Profile


ENGINEERING DESIGN

Operability & SafetyOperability & Safety

AutomationAutomation

ProcessProcessDesignDesign

DetailedDetailedDesignDesign

OperationsOperations

ConceptualConceptualDesignDesign


DEEP WATER EXPLORATIONOffshore


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


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


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

-60

-40

-20

0

20

40

60

-5000 0 5000 10000 15000 20000 25000 30000

HORIZONTAL DISTANCE (ft)

ELEV

ATI

ON

(ft)

Series1


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.


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


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


Process Modelling using Hysys

COURSE AGENDA


HYSYS Steady State Oil&Gas

Day 1

• Module 1 – Getting Started (Fluid Packages, Streams, Utilities)

• Module 2 – Propane Refrigeration Loop (Unit Operations)



Day 2

• Module 3 – Refrigerated Gas Plant (Heat Exchanger, Adjust)

• Module 4 – NGL Fractionation Train (Columns)



Day 3

• Module 5 – Oil Characterization (crude modeling)

• Module 6 – Gas Gathering (Pipe Segments)



Day 4

• Module 7 – Two Stage Compression (Recycles)

• Module 8 – Acid Gas Sweetening with DEA (Amines Package)



Day 5

• Module 9 – Natural Gas Dehydration with TEG

• Module 10 – Reporting in HYSYS (reports, EXCEL)


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


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


• 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


• 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


Start Hysys & Create a new case

Basis Environment

Sub - Flow Sheet

Simulation Environment

How to know where I am ?

HYSYS Interface Main Structure


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


Simulation Basis Manager

Thermodynamic Contents

• Hyprotech Database: components and BIPs

• Property Packages

• EOS• Activity Models• Others


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)


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


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


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


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


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.


Flash Calculations

Temperature

PressureVaporFraction

Molar Enthalpy

• Dew point calculations• Bubble point calculations

TP

HS

VF


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.


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


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


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


Module 1 - Getting Started


C7+, C7 and C8


Flash Calculations


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


Property Table Utility


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


Material and Energy Stream

Logical Operations

Sub-Flow Sheets and

Columns (= Special types of Sub-Flow Sheets)

Unit Operations


Conversion to a Template


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.


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


Module 2 – Propane Refrigeration Loop


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.




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



Exploring the Simulation: Exercice 1




Getting Started









Reporting in HYSYS


Module 3 – Refrigerated Gas Plant

Objectives:

• Install and converge heat exchangers

• Understand logical operations: Balance and Adjust

• Linking templates

• Use the Case Study


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.


HXModels

Shell & Tube heat exchangers


orBalanceErrQhhmQhhm lossouthotinhothotleakincoldoutcoldcold )()( ,,,,

lossouthotinhothotleakincoldoutcoldcoldt QhhmQhhmFLMTDUAQ )()()( ,,,,

Heat Exchanger calculations


Heat Exchanger specifications


• Temperature, Pressure and mass flow

• Pressure Drops

• UA

• Delta T

• LMTD

• Duty

Heat Exchanger specifications


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.


Logical operation: Adjust


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


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


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


Challenge



Getting Started









Reporting in HYSYS


Module 4 – NGL Fractionation Train

Objectives:

• Add columns using Input Experts

• Use pre-built column templates

• Add specifications to columns


Input Experts


• 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


# Columns Specifications=

# Side Heat Exchanger + # Side draws +# Side Strippers + # Pumparounds

Absorber = 0 SpecRefluxed Absorber = 1 SpecReboiled Absorber = 1 SpecDistillation Column = 3 Specs

Column Specifications


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.



Getting Started









Reporting in HYSYS


Oil Characterization using C7Plus


Module 6 – Gas Gathering

Objectives:

• Use of the Pipe Segment in HYSYS to model pipelines

• Use the Mixer


• 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


Correlations Sizing


Pipe Flow Correlations• The table summarizes the characteristics of each model.


Pipe Segment: Rating

100 m

150 m

125 m

6 m

-0.5 m -1 m


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


Heat transfer models


Pipe Sizing: Heat Transfer Page

• Heat loss

• Overall HTC

• Global• By segment

• Estimate HTC

• Global• By segment

- Pipe wall- Inner HTC- Insulation- Outer HTC


Workshop



Getting Started


Refrigeration Gas Plant







Reporting in HYSYS


Module 7 – Two Stage Compression

Objectives:

• Use the RECYCLE operation in HYSYS

• Choose suitable RECYCLE locations


·

·

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


• 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


• 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


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


• 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






Your PC takes tooYour PC takes toolong to convergelong to converge

Challenge


Challenge



Getting Started









Reporting in HYSYS


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


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.


Recommended Lean Amine Strengthin Water

Amine % wt.

MEA 15 – 20

DEA 25 – 35

TEA, MDEA 35 – 50

DGA 45 – 65

Suggested values


Damping Factor


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


Spreadsheet


Workshop


Regenerator Operation

Constant component efficiencies for H2S and CO2

Modified HYSYS Input-Output

Damping factor (0.25-0.50)


Challenge



Getting Started









Reporting in HYSYS


Module 9 – Natural Gas Dehydration with TEG

Objectives:

• Model a typical TEG dehydration unit

• Determine the water dew-point for a gas


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.


• Removal of water from reservoir fluids

• Water can cause Solid Hydrates & Corrosion (w/ H2S/CO2)

• Dehydration with Glycol, Silica Gel or Molecular Sieves

Workshop


Challenge



Getting Started









Reporting in HYSYS


Module 10 – Reporting in HYSYS

Objectives:

• Show different way to extract the information of HYSYS

• Excel Macro

Documents

Aspen HYSYS Presentation