Hy Sys Sizing User Guide

SIZING
User Guide
Copyright
November 2004
Copyright 1981-2004 by Aspen Technology, Inc. All rights reserved.
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iii
Table of Contents
1 Introducing Sizing................................................ 1-1
1.1 Introduction .................................................... 1-2
1.2 The Capabilities of Sizing .................................. 1-3
2 Interface .............................................................. 2-1
2.1 Interface Basics ............................................... 2-2
3 Sizing Basics ........................................................ 3-1
3.1 Introduction .................................................... 3-2
3.2 Importing Unit Operations ................................. 3-2
3.3 Menu Bar Options............................................. 3-6
3.4 Exporting Data ...............................................3-14
4 Basis Phase .......................................................... 4-1
4.1 Introduction .................................................... 4-2
4.2 General Project Page ........................................ 4-2
4.3 Global Selection Page ....................................... 4-6
4.4 Global Sizing/Design Page ................................. 4-8
5 Selection Phase .................................................... 5-1
5.1 Introduction .................................................... 5-2
5.2 Equipment Categories....................................... 5-3
6 Sizing Phase......................................................... 6-1
6.1 Introduction .................................................... 6-3
6.2 Sizing and Displaying Individual Item Data .......... 6-4
6.3 Vessels Category.............................................. 6-6
6.4 Heat Transfer Category....................................6-11
6.5 Rotating Equipment Category ...........................6-16
6.6 Tower Category ..............................................6-20
6.7 Reactor Category ............................................6-25
6.8 Solids Handling Category .................................6-28
iv
7 Theory.................................................................. 7-1
7.1 Selection......................................................... 7-2
7.2 Sizing............................................................. 7-5
7.3 References .....................................................7-24
Index.................................................................... I-1
Introducing Sizing 1-1
1-1
1 Introducing Sizing
1.1 Introduction................................................................................... 2
1.2 The Capabilities of Sizing............................................................... 3
1.2.1 The Sizing Difference................................................................ 4
1-2 Introduction
1-2
1.1 Introduction
Sizing is a revolutionary integrated process evaluation system
that unifies process simulation, equipment selection, sizing,
design, and detailed capital evaluation operations into one
application. This allows for open interaction between process
and project engineers during the design phase of a project.
Applying Sizing gives your company the competitive advantage
that you need and it allows you to do the following:
Reduce overhead by reducing your proposal costs.
Bid on more projects and win more projects (if you must
lose, lose with minimal time and effort).
Increase accuracy by focusing your people on profitable
projects.
Faced with your design conclusions, you need answers to
decide on funding, staffing, and choosing one project
over another.
Evaluate client requests, prepare proposals, and lump-
sum bids that were once both time consuming and
resource demanding.
Increase client base by providing your clients with
alternatives that were once too expensive to create.
Reduce your process design time and promote the best
design forward in the lifecycle based on economics.
With Sizing, you have an easy-to-use application with a variety
of interfaces. Sizing has a built-in, fully functional, interactive
relationship with HYSYS. You can readily select the entire
flowsheet or a single operation for sizing, designing, and
evaluating. Built on the solid foundation of AEA Technologys
PICASSO framework, Sizing combines AEAs solid process
understanding and knowledge base, and the Icarus
Corporations design and costing knowledge base into one
application.
The PICASSO framework is a technology developed by AEA
Technology that provides the infrastructure for building
component based applications. It allows the assembly of an
arbitrary collection of parts, which individually focus on highly
specific problems, into one integrated application.
Introducing Sizing 1-3
1-3
Hence, Sizing is a collection of modules assembled by the
PICASSO framework that combines the strengths of various
focused applications for the sizing, selection, and other rule
based utilities with the mechanical design and costing modules
from Icarus into one consolidated application.
1.2 The Capabilities of
Sizing
The following list highlights some of the capabilities of Sizing:
Two-way integration with HYSYS.
Automatic equipment selection options that recommend
equipment types based on process conditions and
heuristics.
Rigorously size equipment based on process simulator
derived data using industry accepted methods.
Update HYSYS with accurate equipment capacity
information for simulating in rating or dynamics mode.
Uses ICARUS Kbase to implement a wide variety of
mechanical design standards (ASME, BS5500, JIS, API,
and DIN) to conform to the engineering and construction
best practices.
Uses Kbase to simulates vendor methods for cost of
process equipment that conforms to design standards
and manufacturing costs based on self-contained and
updated multi-national cost bases (UK, Japan, US).
Uses Kbase to develop installation bulks independent of
process equipment cost, by implementing design
methods for civil, steel, insulation, electrical, piping, and
instrumentation through built-in P&Ids, stored
isometrics, control system network schematics,
foundation design, and volumetric models.
General project (plants bulk and process equipment)
capital cost reporting and engineering, procurement,
construction cost modeling, and scheduling.
1-4 The Capabilities of Sizing
1-4
1.2.1 The Sizing Difference
Unlike traditional cost evaluation systems, Sizing extracts
greater value by unifying process simulation, equipment
selection and sizing, and detailed capital evaluation operations
into one integrated application. This allows your project and
process engineers to openly interact during the design phase of
the project.
By using Sizing, you can empower your asset teams to quickly
evaluate process ideas and conceptual designs by automatically
extending your process simulation models into process
equipment and design estimates for rating and/or dynamic
simulation. All this allows you to make solid capital
investment decisions.
Make the Right Decision at the Right Time.
Interface 2-1
2-1
2 Interface
2.1 Interface Basics............................................................................. 2
2.1.1 Windows Functionality .............................................................. 2
2.1.2 Desktop.................................................................................. 3
2.1.3 Interface Terminology ............................................................... 5
2.1.4 Primary Interface Elements ....................................................... 8
2.1.5 The Property View.................................................................. 11
2.1.6 Manoeuvring Through the Interface .......................................... 13
2.1.7 Supplying Input ..................................................................... 15
2.1.8 Editing Input ......................................................................... 19
2.1.9 Closing Views ........................................................................ 19
2-2 Interface Basics
2-2
2.1 Interface Basics
The following chapter deals with the interface basics required to
use Sizing and they are listed below:
Windows functionality
Desktop and tool bar
Common terminology
Primary interface elements
2.1.1 Windows Functionality
Sizing has the same basic features as in other Windows 95/98 or
NT 4.0 based programs.
Minimize, Maximize/Restore, and Close icons located
in the upper right corner of most views.
Object icon located in the upper left corner of most
views, which contains the normal Windows 3.x menu.
Most of the different views found in Sizing are resizable to some
degree. The following list provides a brief description of the
resizable views:
When Minimize, Maximize/Restore, and Close icons
are available, the view can be resized vertically and
horizontally.
When Minimize and Close icons are available, the view
can only be resized vertically.
When the Close icon or Close and Pin icons are
available, the view cannot be resized.
Interface 2-3
2-3
2.1.2 Desktop
The figure below shows the basic components of the Sizing
Desktop:
Desktop Features
The main features of the Desktop are described in the following
table:
Figure 2.1
Object Definition
Title Bar Indicates the Sizing file currently loaded.
Menu Bar Provides access to common Flowsheet commands through
a drop-down menu system.
Menu Bar Tool Bar
Title Bar Environment/Mode Label
Object Status Status Bar Trace Window Scroll Bar
2-4
Some additional things about the Sizing Desktop as follows:
When the mouse pointer is placed over a icon/button, its
descriptive name pops up below the pointer and a flyby
function is displayed in the status bar.
The Desktop itself has both a vertical and horizontal
scroll bar. These are automatically created when
necessary.
Tool Bar
The icons on the tool bar provide immediate access to the most
common commands, which are also available as menu items.
Refer to the following table to see how the icons are displayed
and for a brief description:
Tool Bar Contains various icons which invoke a specific command
when clicked.
Environment
/Mode Label
Indicates the environment and mode in which you are
currently working.
Status Bar When the mouse pointer is placed over an icon in the tool
bar, the Object Palette, or a Property View, a brief
description of its function is displayed in the Status Bar.
The Status Bar also displays solver status information.
Scroll Bar Scrolls vertically (in the above case) through the Trace
Window.
Object
Status
Window/
Trace
Window
The Object Status Window (left pane) shows current status
messages for Flowsheet objects while the Trace Window
(right pane) displays Solver information. The windows can
be resized vertically or horizontally by clicking and dragging
the windows frames located between or above them.
Name Icon Description
New Case Create a new case.
Open Case Locate and open an existing case.
Save Case Save the active case.
Run All Phases Runs all the phases on the Project Input
Data property view.
Object Definition
For more details on the
Object Status Window
or Trace Window, refer
to Section 1.3 -
Object Status
Window/Trace
Window in the HYSYS
User Guide.
Interface 2-5
2-5
2.1.3 Interface Terminology
The following terminology is used to describe the various Sizing
interface elements:
Run to Next
Phase
Runs one phase at a time on the Project
Input Data property view.
Reset All Phases Resets all the phases to their default values.
PFD Open the PFD for the current Flowsheet.
Home View/
Enter Sizing/
Economix
Enters the Sizing environment (if you are not
currently in it). If you are already in the Sizing
environment, this button opens the Project
Input Data property view.
Leave
Environment
Exits the Sizing environment and takes you
into the HYSYS Simulation Environment.
Term Definition
View Any graphical representation found on the Desktop, for
example, a property view for an operation.
Button Invokes a command when clicked.
Pin Is usually found in place of the Minimize and
Maximizes/Restore icons in the upper right hand
corner of the property view. This Pin converts a Modal
Property View to a Non-Modal Property View.
Tabs Provides a logical grouping of information in the form
of pages.
Pages Provides access to detailed information regarding the
selected object.
Drop-Down List A list of available options for a given input cell.
Scroll Bar Provides access to information which cannot be
displayed in the current size of a menu or view.
Scroll Button Part of the Scroll Bar, allowing you to slide the list up
or down, or left or right.
Input Cell or
Field
Location in a view for supplying or viewing information,
e.g. temperatures, pressure, etc. In many cases, it has
a drop-down list associated with it.
Object Status Each property view shows the status of the associated
object with a coloured background (red for a missing
parameter, yellow for a warning message and green
for OK).
Name Icon Description
Pin icon
2-6
Objects
The term object is used throughout the document to refer to an
individual stream or operation. Within Sizing, information
associated with an object can be displayed in a variety of ways
(Workbook, PFD, Property View, etc.).
Through the object oriented design, the information displayed
by each interface element is tied to the same underlying object.
The result being that if a parameter changes in the Flowsheet, it
is automatically updated in every location. You can also access
the Object Inspect menu to display commands (i.e., printing,
direct access to a property view, etc.) tied to an object (for
example an icon in a PFD).
Icon Invokes a command when clicked, similar to the
button.
Close Icon Either closes the view (double-clicking), or produces a
drop-down menu of common Windows commands.
Radio Button Always found in groups of at least two; only one can be
active at a time.
Checkbox Items or settings which are On or Off. Clicking the
checkbox turns the function On. Clicking it again turns
it Off.
Minimize/
Maximize
Either iconize the current view (minimize), or expand
the view to its full size.
Active
Highlighted
Location
The current active location is always indicated by
highlighting.
Group Organizational border within a page that groups
related functions together. Each group has its own
active location.
Matrix A group of cells through which you can manoeuvre
with the mouse or keyboard arrow keys.
Term Definition
Close icon
Minimize icon
Maximize icon
Right-click on an object to
access the Object Inspect
menu.
Interface 2-7
2-7
Selecting Items
Selecting refers to either picking a specific item from a list, or
invoking a button command. There are four methods used for
selecting objects and functions in Sizing.
Active View/Active Location
Although several views can be displayed on the Desktop at any
time, only one view is active or has focus. When a view is active,
the title bar is highlighted. Within the view only one location can
be active, but depending on the location of focus, the form of
highlighting differs (i.e., cell, field, button, etc.).
Method Description
Selecting a cell Using the mouse, move the cursor to the location and
click to select.
Clicking a button Click on the button, or move the focus location (using
the TAB key or SHIFT TAB combination) and press
ENTER.
Selecting from a
drop-down menu
or list
Move the focus location into the drop-down, and use
the mouse pointer or keyboard arrows to highlight the
selection, then press ENTER to select.
Multiple list
selections
Click and drag the cursor over the items you want to
select (provided they are all sequential in the list).
Release the mouse button after you have selected the
desired items. Alternatively, you can highlight
sequential items by selecting the first item in the list,
holding down the SHIFT key and selecting the last
item in the list. If the items are not sequential, select
the first item with the left mouse button and then
select additional items with the mouse while holding
down the CTRL key.
The Project Input Data
view has focus as
indicated by the title bar
being highlighted.
2-8
Refer to the following figure:
2.1.4 Primary Interface
Elements
Although information can be supplied and accessed in a variety
of ways, the following primary interface elements for interacting
with Sizing are available:
Figure 2.2
Highlighted tab Highlighted location
Element Description
PFD A graphical environment for building your Flowsheet and examining process
connectivity. Process information can be displayed for each individual stream
or operation as needed.
Basis Input Data
Property View
Contains multiple tabs where you can supply the necessary information to
perform the rating and economic calculations for the project.
Reports Output Data
Property View
Contains multiple tabs and pages that display the results of the calculations
that were carried out based on the information contained on the Basis Input
Data Property view.
Interface 2-9
2-9
PFD View
Refer to the following figure to see how the PFD view is
displayed:
Throughout the Sizing interface, user specified values are
displayed in blue and calculated values are shown in black.
Figure 2.3
Object Inspect the
PFD by right-
clicking on an
empty area of the
PFD to display the
Object Inspect
menu as seen in
the figure.
Double-click any icon on
the PFD to display the
objects property view.
2-10
Project Input Data Property View
Refer to the following figure to see how the Project Input Data
Property View is displayed:
Reports Output Data Property View
This view contains multiple tabs and pages that display the
results of the calculations that were carried out based on the
information contained on the Basis Input Data Property view.
Figure 2.4
The status bar shows the current
status of the economic calculations.
The tabs provide a logical grouping of
information in the form of pages or radio
buttons
The pages
list different
views that
are available
on the
current tab.
Interface 2-11
2-11
2.1.5 The Property View
A property view contains multiple tabs placed within a single
border. These are used extensively in Sizing to allow access to
all information associated with an item in a single view.
A common structure was adopted for the property views. After
you become familiar with the format and usage of one property
view, each additional one you encounter behaves and is
structured in a similar manner.
Accessing Pages using the Tabs
Moving between tabs can be done in the following ways:
Select the desired tab with the mouse.
Use the Hot Key combination CTRL SHIFT N, which
cycles you through the tabs (CTRL SHIFT P cycles
backwards).
Place the mouse pointer to the direct left or right of the
tabs (remaining inside the border of the property view).
The cursor changes to a tab switch cursor which points
in the direction in which the tabs are cycled. Click to
cycle through the tabs.
Several time saving features have been built into the Property
View:
Sizing always remembers which tab you were last on,
returning to that tab automatically the next time you
open that view. Each property view remembers its
settings independently; for example, two different
streams could automatically open to different tabs.
There are various ways of moving from one tab to the
next including selecting the desired tab or by using the
Hot Key combination.
Supplying or specifying input is accomplished in a variety of
manners. Some definitions and terminology are presented in
order to adequately explain the functionality and capabilities of
Sizing.
The mouse pointer does
not change if the first or
last page tab is active
and the pointer is
placed to either the left
or right of the tabs.
2-12
Tabs
Each property view is made up of several tabs, which are
displayed at the bottom of the view. These tabs provide a logical
grouping for the object information. When a tab is active it
seems to be on top of the other tabs indicating it is the current
tab. To see how an active tab is displayed, refer to the Active
View/Active Location section.
Pages
In general, each tab provides access to more than one page or
view. The section on the left side of the property view has the
same name as the current tab. Within this section is a list of
available pages, with the current page being highlighted.
The information contained on a specific page may be accessed
by simply selecting the page from the list. This page index is
always present for the specific tab and its appearance is not
dependent upon the selection of the page.
Fields or Cells
This is a location in a view for supplying or viewing information,
e.g., stream names, temperatures, etc. Fields are single input
field (Input Stream field on a unit operation). Cells are
contained within a group as part of a matrix or table. An
example of matrix cells are those found in the Worksheet tab of
every unit operation views.
In many cases, cells and fields have an associated drop-down
list, indicated by a down arrow next to or within the field or cell.
This produces a list of available options associated with that
field. Another common feature in both field and cell in a matrix,
is the drop-down list that appears beside the field or cell. The
drop-down list provides you with a list of units associated to the
field or cell variable.
Down Arrow icons
Interface 2-13
2-13
2.1.6 Manoeuvring Through
the Interface
Sizing uses Windows conventions for interaction between the
user and the application. These are described in the following
section.
Hot Keys ALT Key
Most labels, including the items on the menu bar, input cell
identifiers, and Button labels, have a single letter underlined.
This letter works in conjunction with the ALT key as a Hot Key
combination, the result of which varies depending on the label
type.
For menu bar Items (Edit for example), pressing ALT E
opens the drop-down menu under Edit.
For Input Cell Identifiers (Name, for example), pressing
ALT N moves the active location directly to that input
cell.
For Buttons (Close, for example), pressing ALT C
invokes the button command.
Keep in mind that any keyboard input applies to the active view.
For example, if an input cell identifier on the active view has the
letter F underlined, you cannot directly open the File Menu by
ALT F, as your input is being applied to the active view.
The ALT key by itself automatically advances the active location
to the first item in the menu bar (File). The keyboard arrows
move left and right through the row, and the down arrow opens
the active menu item. If a drop-down menu has underlined
letters, you can invoke the command by using that letter only.
For example, with the File menu open, you can Save a case by
pressing the s key.
Moving Through a View
When moving through a view using the keyboard functions,
each input cell and button is accessed sequentially. You can
HYSYS uses a number of
Hot Keys for performing
commands.
The mouse can be used
to move the active
location to any cell by
moving the pointer over
the cell and click.
2-14
move the active location using the TAB (forward) and SHIFT
TAB (reverse) keys. If the active location is on a cell in a matrix,
the TAB key does not advance you to the next cell in that
matrix, but to the next active location in the view. This location
may be a button or another group.
Sizing indicates the active location of the cursor in a view in one
of two ways:
In the case of an input cell, the active location is
indicated by a thicker border around the cell.
In the case of a button, the perimeter of the button is
highlighted and the label is surrounded by a dashed box.
Figure 2.5
Shows input
cell as the
Active Location
If this radio button was the active location, pressing TAB would
advance to the General Equipment Sizing and Design group,
while SHIFT TAB would move back to the Restore Default Basis
button at the bottom of the view.
When Run All Phases button is the active location, pressing TAB would advance the
highlight to Save New Basis button, while SHIFT TAB would reverse the highlight to
the Run Phase button.
Interface 2-15
2-15
2.1.7 Supplying Input
Text Input
In Sizing, input is required on the Basis Input Data property
view. When the required input is textual there are instances
where you are required to either supply the input from the
keyboard (e.g. company name) by simply selecting the field or
cell, entering the text and pressing ENTER.
Input is selected from the drop-down list when the input is
related to the ICARUS database to ensure that the naming
conventions and spelling are correct (relative to ICARUS). To
supply input for this type of cell, do one of the following:
Click in the input cell and then click on the Drop-down
List icon within the cell. A drop-down list displays all the
available inputs that you can select by clicking on the
appropriate input with the mouse.
Click in the input cell and then press the SPACEBAR to
open the drop-down list. Manoeuvre through the list of
inputs using the up and down arrow keys and then press
ENTER to select the input.
Numerical Input
If the input is numerical, the approach is slightly different. The
field and input cell displays the same, however, when a value is
entered into the field or cell, a new field containing a Drop-
down List icon and a unit is displayed beside the field.
Drop-down list icon
Drop-down list icon
2-16
The drop-down list displays the current default unit for the input
cell property. When you have supplied the number and have
pressed ENTER, Sizing assumes that the default unit was
correct.
If you are supplying the number with a different unit than the
default, there are two methods available for identifying it.
Figure 2.6
A drop-down list is displayed when supplying a
number with different units than the default.
Method Action
Keyboard Input a space after the number and then begin typing in
the unit. The unit becomes highlighted in the drop-down
list.
Mouse After supplying the numerical value, but before pressing
ENTER, open the drop-down list and locate the desired unit
While Sizing is matching
your input to the list of
units, you can stop
entering text and use any
of the other methods for
locating the unit (such as
selecting it with the
mouse or using the up
and down arrows).
Interface 2-17
2-17
When you begin entering the units, the drop-down list displays:
Drop-Down Lists and Scroll Bars
Drop-down lists are used extensively in Sizing to provide an
efficient means of locating existing streams, operations, or
units. These menus can be accessed either using the mouse or
by using the keyboard. After a drop-down list is opened,
manoeuvre through the list using the mouse or keyboard.
A drop-down list for a Text input cell, can be opened at any time
by clicking the applicable drop-down list icon. This not only
opens the menu, but moves the active location to that input cell.
You can also open the drop-down list for the current active cell
by pressing the keyboard down arrow.
Figure 2.7
Display the units associated to the
field or cell in the drop-down list
after supplying a numerical value
by selecting the down arrow.
As you supply more of the unit, the highlight moves
through the list covering the unit that most closely
matches the input. Pressing ENTER accepts both the
number and the unit. The value is recalculated using
the default unit and is transferred to the Active
Location.
The F2 key opens the
drop-down list.
2-18
If the stream is being attached for the first time, the highlight in
the drop-down list displays at the top of the list. If the input cell
already has a stream in it, the highlight is on that stream.
For a numerical input cell, the drop-down list is located next to
the input cell or field and contains the list of units. This
automatically opens as soon as you stop supplying numerical
input (signified by a SPACE) and begin entering the unit.
Alternatively, the drop-down list can be opened at any time
(which terminates the number entry) by selecting the drop-
down list icon.
After a drop-down list is opened, you can manoeuvre through it
in the following ways:
The most convenient method is using type-matching.
After a drop-down list is open, keyboard input is
interpreted to find the first menu item which best
matches your input. As you continue to supply input, the
matching continues. Pressing ENTER terminates the
string and accepts the highlighted item.You can also use
the keyboard arrow keys to move to any item.
If the menu contains six items or less, it displays without
a scroll bar. In this case, you can use the mouse to
directly select the desired item, or use the up and down
keyboard arrows to mark the item and then select it with
the ENTER key.
The PAGE UP and PAGE DOWN keys move the menu by
one page, and the HOME and END keys take you to the
first and last item. The desired item is selected by
highlighting it and pressing ENTER.
The Scroll Bar/Scroll Button provides similar
functionality. Selecting the Up and Down Scroll Arrows
advance the menu by one item. The scroll button can be
selected with the primary mouse button and dragged up
and down to quickly scroll the menu.
Selecting the space between the scroll button and the
scroll arrow advances the menu up or down one page.
The desired item can then be selected with the primary
mouse button.
Interface 2-19
2-19
2.1.8 Editing Input
You can edit your input in the following ways:
When the input cell is active, any information you supply
over-rides the previous input.
Use the drop-down list to replace the previous input.
Make an insertion point using the mouse or press F2 and
use the arrow keys.
When editing numerical input, if you simply type in a new
value and press ENTER, Sizing accepts the input and
assumes it is in the default units.
2.1.9 Closing Views
To close a view, use any of the methods described below:
Double-click on the Object icon in the upper left corner
of the view.
Click once on the Object icon to open the drop-down
menu. the Close function in this drop-down menu has the
C underlined. Press the C to close the view.
CTRL F4 closes the active view.
Click on the Close icon in the upper right hand corner of
the view.
2-20
Sizing Basics 3-1
3-1
3 Sizing Basics
3.1 Introduction................................................................................... 2
3.2 Importing Unit Operations............................................................. 2
3.2.1 Selecting Single Unit Operation .................................................. 3
3.2.2 Selecting Multiple Unit Operations .............................................. 4
3.2.3 Selecting Single, Multiple, or All Unit Operations........................... 5
3.3 Menu Bar Options........................................................................... 6
3.3.1 File......................................................................................... 7
3.3.2 Edit ...................................................................................... 10
3.3.3 Simulation............................................................................. 10
3.3.4 Tools .................................................................................... 11
3.3.5 Window ................................................................................ 11
3.3.6 Help ..................................................................................... 13
3.4 Exporting Data............................................................................. 14
3-2 Introduction
3-2
3.1 Introduction
Sizing provides an easy-to-use environment with a variety of
interfaces including a fully interactive relationship with HYSYS
that can readily select either the entire flowsheet or individual
pieces of process equipment to be sized, designed, or evaluated.
3.2 Importing Unit
Operations
Sizing has the ability to import simulation data from HYSYS, but
requires that the unit operation be completely solved before it
can be imported into Sizing. Unsolved unit operations are not
evaluated and no reports are generated.
Chapter Description
Sizing Basics This chapter provides an introduction to Sizings capabilities
and features.
Basis Phase The Basis Phase chapter covers the first tab of Project Input
Data view. Here, you provide the global settings for
selection and design parameters. In addition, general
project information (location, owner, etc.) is provided on
this tab.
Selection
Phase
This chapter allows you to get familiar with the Selection
Phase tab of the Project Input Data view.
Sizing Phase The Sizing Phase chapter gives an explanation of the all the
parameters required by the equipment sizing routines in
Sizing.
Design
Phase
All the Design information is discussed in this chapter.
Report This chapter allows you to get familiar with the extensive
reports that Sizing generates for a project.
Theory The Theory chapters elaborates on the selection criterion as
well as the sizing equation for each unit operation.
Sizing Basics 3-3
3-3
3.2.1 Selecting Single Unit
Operation
On the HYSYS.Process PFD, you can select a single unit
operation through the Object Inspection menu. The method
for selecting a unit operation is as follows:
1. Right-click on a unit operation icon and the Object
Inspection menu opens, as shown in the figure below.
Figure 3.1
3-4 Importing Unit Operations
3-4
2. From the Object Inspection menu, select the Select For
Sizing option and HYSYS outlines the icon in light grey to
show it is selected. Refer to the following figure to see how
the objects are displayed when they are selected for sizing.
3. To deselect an object icon, right-click on the icon and select
Remove Selection For Sizing from the Object
Inspection menu.
3.2.2 Selecting Multiple Unit
Operations
You can select multiple unit operations for sizing on the PFD
using the following method:
1. Do one of the following to select multiple objects:
Click and drag the mouse over the unit operations you
want to select (provided they are all sequential on the
PFD).
Highlight unit operations by selecting the first unit
operation that you want to select, holding down the
SHIFT key and selecting the last unit operation. Release
the SHIFT key.
2. Right-click on a highlighted unit operation icon. The Object
Inspection menu opens.
3. From the Object Inspection menu, select the Select For
Sizing option and HYSYS outlines the icons in light grey to
show they are selected.
4. To deselect all previously selected unit operations, highlight
them all and right-click to display the Object Inspection
menu. Then click the Remove Selection For Sizing option.
Figure 3.2
You may see a different
colour depending upon
your windows settings
You may see a different
colour depending upon
your windows settings
Sizing Basics 3-5
3-5
3.2.3 Selecting Single,
Multiple, or All Unit
Operations
If no unit operation is selected on the PFD, you can select them
once in the Sizing Environment. To enter the environment, click
the Enter Sizing and Economix Environment icon on the tool
bar and the No Unit Operations Selected view is displayed.
Clicking No takes you to the Select HYSYS Objects for Sizing
view, as seen in the figure below.
Here, you may select or remove unit operations as desired, then
click the Continue button to enter the Sizing Environment
Figure 3.3
Enter Sizing and Economix
Environment icon
3-6 Menu Bar Options
3-6
3.3 Menu Bar Options
In Sizing, you can access most of the tasks using the hot keys or
buttons associated with them. This provides quick access to the
capabilities of the program. Each of these functions can also be
accessed through the menu bar. The list of commands or
function groups, which is displayed at the top of the HYSYS
Desktop, operates as a drop-down menu system. By selecting
one of the options in the menu bar, a menu of associated
commands or options is opened.
In addition to the functions already described, the menu bar
also provides access to a number of functions that can only be
accessed through this route. Included in the functions that can
only be accessed via the menu bar are setting the Session
Preferences (units, default naming schemes, etc.) and accessing
the Script Manager.
In this section, a description of each of the options that are
available through the menu bar is provided. In cases where the
options are described elsewhere in greater detail, only a quick
review is provided. Others, such as Session Preferences and
Scripting are described completely.
You can access the menu bar options in three ways:
Select the desired menu bar item using the primary
mouse button, which automatically opens the associated
menu.
Use the Alt key in combination with the underlined letter
in the menu bar title. For example, Alt T opens the Tools
menu.
Use the Alt key by itself to move the active location to
the File option in the menu bar. Once the menu bar
becomes the Active location in HYSYS, you can
manoeuvre through it using the keyboard. The up and
down arrows move through the menu associated with a
specific item, while the left and right arrows move you to
the next menu bar item, automatically opening the
associated menu.
If you want to switch focus from the menu bar without making a
selection, press the ESC key or the ALT key.
Session Preferences
can be accessed through
the Tools menu bar item
only.
Sizing Basics 3-7
3-7
3.3.1 File
The menu options can be grouped into Five main categories:
Starting a Simulation
Saving a Simulation
Closing a Simulation
Printing
Exiting the Program
Starting a Simulation
The New and Open options under File in the menu bar allow
you to create a new case or open an existing case.
Selecting New creates a new, blank case in HYSYS.
Selecting Open allows you to open an existing case and
read its information into HYSYS.
Saving a Simulation
HYSYS has three different save commands and they are
described in the following table:
Command Description
Save Saves the case using the current file name and location.
Save As With this saving option, you need to enter a name and
location to which you want to save the file. The Save
Simulation Case As view appears when you select the
Save As command. You are able to choose the File Path
and a File Name for the case. HYSYS automatically
attaches the appropriate file extension,.hsc.
Save All Use this option to save all currently opened HYSYS cases.
You are asked to select which cases should be saved. Select
multiple cases with the CTRL key and the primary mouse
button. Once the cases have been highlighted, click the
Save button to save the case(s) as shown in the view, or
the Save As button to save with a new name and/or
location.
File menu options
A menu item with an
arrow head pointing to the
side has further options on
a submenu.
3-8
The following figure shows how the Save As view is displayed:
Closing a Simulation
Two of the options under File in the menu bar involve closing
your simulation:
Figure 3.4
Figure 3.5
Command Description
Close Case Closes the active case. Before closing the case, you are
asked if the case should be saved.
Close All Allows you to close more than one case at a time. The
name of each opened file is displayed. You select which
case(s) you want to close.
Sizing Basics 3-9
3-9
Printing
The printing section contains the following options:
Exiting the Program
You can exit from the current Session of Sizing by selecting the
Exit option from the File drop-down menu.
Figure 3.6
Command Description
Print Allows you to print Specsheets for streams and operations.
Print
Window
Snapshot
Prints a bitmap snapshot of what currently appears in the
active Sizing view.
Printer Setup Allows you to select the default printer, print orientation,
paper size, etc. It is similar to the Printer Setup commands
in other Windows applications.
3-10
3.3.2 Edit
The functions listed under Edit in the menu bar are described as
follows:
3.3.3 Simulation
The functions listed under Simulation in the menu bar are
described as follows:
Command Description
Cut Removes the selected cell(s) from the current view. You
can then use the Paste function to place the removed
cell(s) in another location or in another application.
Copy Copies the selected cell(s) to the Clipboard. You can then
use the Paste function to place the copied cell(s) in another
location or in another application.
Copy Special Copies the selected values/objects and their corresponding
labels to the clipboard.
Paste Allows you to place copied or cut selections in the location
of your choice.
Command Description
Run All Allows you to run all phases and generate a report.
Run Phase Run only the current phase.
Reset Resets the data back to the Basis Phase tab on the Basis
Input Data view.
Basis
Environment
This option takes you back to the Basis Environment.
Edit menu options
Simulation menu options
Sizing Basics 3-11
3-11
3.3.4 Tools
The options under Tools are:
3.3.5 Window
This menu contains general Windows application functions. The
options are:
The last section in this menu lists all open views on the Desktop.
The active view is indicated with a checkmark.
Command Description
PFDs Opens the PFD for any Flowsheet.
Reports Opens the Report Manager.
Load Workspace Opens the Load Workspace dialog, which displays all
cases that are currently open
Script Manager Provides access to the Script Manager.
Macro Language
Editor
Accesses the HYSYS Macro Language Editor view.
Case Security HYSYS allows you to lock a case to a password or a
password and security lock devise such as a Green or
White security key.
Echo ID Scans your computer and displays all of the available
locking codes. The Lock code column either displays
the lock code for the associated hardware device or
"Not Found" if no lock code is available.
Preferences Accesses the Session Preferences. The Session
Preferences view can be accessed only through the
Tools menu.
Command Description
Arrange Desktop Cascades all windows which are currently open and not
iconized. Face plates are placed in rows or column
according to the specifications on the Simulation page
of the Session Preferences view.
Arrange Icons Arranges icons horizontally at the bottom of the
Desktop.
Close Closes the active view.
Close All Closes all views.
Save Workspace Saves the current view layout for future use.
Load Workspace Loads another HYSYS case which is currently open.
This function allows you to toggle between cases.
Tool menu options
Window menu options
3-12
Save Workspace
You can save different Workspace arrangements within a HYSYS
case. The Workspace is a specific organization of views for the
current case. For example, you could create an arrangement of
views which has the PFD, Workbook, Controllers, Strip Charts,
etc. You can name each arrangement individually, then re-
access the arrangement at any time.
This has no effect on the calculation status. It is simply the way
the views are arranged. After changes are made to the Desktop
arrangement, you can then reload a saved arrangement to re-
access the window layout.
Load Workspace
The Load Workspace view displays all cases that are currently
open.
Figure 3.7
Figure 3.8
Sizing Basics 3-13
3-13
The Workspaces contained within each case appear in the
Available Workspaces group. When loading a Workspace,
select the case that contains the Workspace, select an
Available Workspace and click the Load button.
3.3.6 Help
The following options are available under the Help menu:
Figure 3.9
Command Description
HYSYS Help Topics Displays HELP contents.
Help on Extending HYSYS Help topics for OLE functionality.
Help on the Current Form Accesses the help topic for the active window.
Bug Reports Accesses HYSYS bug reporting option.
About HYSYS Provides information about HYSYS.
3-14 Exporting Data
3-14
3.4 Exporting Data
Before or after Sizing has completed its calculations and
generated the Project Reports Output view, you can transfer
the data back to HYSYS. Sizing only updates the unit
operation(s) that you have specified.
On the Economix Data Transfer Panel view confirm the unit
operation you would like to transfer data for. You can select/
unselect the unit operation or equipment category by clicking in
the checkbox in front of them. The table beside the equipment
list shows the old HYSYS as well as the newly calculated Sizing
sizing data.
Click the Accept and Transfer All button to transfer the results
for all the unit operations. Another option is to select specific
unit operations, and click the Accept and Transfer Current
Selections to transfer only the selected unit operations data. If
you do not want to transfer Sizing generated data into HYSYS,
click the Exit Without Transferring button.
Figure 3.10
Basis Phase 4-1
4-1
4 Basis Phase
4.1 Introduction................................................................................... 2
4.2 General Project Page ..................................................................... 2
4.2.1 Minimum Basis Radio Button...................................................... 3
4.2.2 Project Basis Radio Button......................................................... 4
4.2.3 Title Block Radio Button ............................................................ 5
4.3 Global Selection Page..................................................................... 6
4.4 Global Sizing/Design Page............................................................. 8
4.4.1 General Radio Button................................................................ 8
4.4.2 Vessels Radio Button ................................................................ 9
4.4.3 Heat Transfer Radio Button...................................................... 11
4.4.4 Rotating Equipment Radio Button ............................................. 14
4.4.5 Towers Radio Button............................................................... 15
4.4.6 Reactors Radio Button............................................................. 17
4-2 Introduction
4-2
4.1 Introduction
The Basis Phase tab is the first tab of the Project Input Data
view in the Sizing environment. This tab allows you to define
default global settings for the current case. There are three
pages available on this tab: General Project, Global Selection,
and Global Sizing/Design.
There are four buttons on this tab that appear regardless of
which page you have selected. These buttons are described
below:
4.2 General Project Page
The General Project page can be used to define the various
parameters that are applicable for the entire project. Items like
project location, start date, project name and customer
information can be defined on this page. The views on this page
can be accessed by selecting the appropriate radio button in the
Categories group. Each radio button in this group is detailed in
the sections below.
Button Function
Save New Basis Clicking this button saves the current basis to a *.xml
file. This allows you to retrieve the basis for use in any
Sizing project.
Set Preferred
Basis
This button allows you to reset the current basis to a
set of preferred Basis defaults.
Load Saved Basis Clicking this button allows you to retrieve a basis that
has been saved previously. The current basis is
overwritten with information from the saved file.
Restore Default
Basis
Clicking this button overwrites the current basis with
the information in the Basis.def file in the applications
root directory. All current basis information is lost and
reset to the original software Basis defaults! Use this
feature with caution.
Basis Phase 4-3
4-3
4.2.1 Minimum Basis Radio
Button
Select the Minimum Basis radio button to display the
following:
Figure 4.1
Field Description
Continent Adjusts the various location dependent cost fields
based on the actual geographical location of the
project site. The system calculates values such as
freight (domestic and ocean), taxes/duties,
contractor fee, wage rates and workforce
productivities.
Country Base Specifies the country base location establishing
the basis of the estimates, e.g., style and cost
basis for engineering design, materials, and
construction.
Project Installation
Type
Determines the configuration of the projects
scale, adjusting direct, indirect and bulk costs to
suit the size of the project. There are five choices
available from the drop-down list: Grass roots/
Clear field, Plant addition-adjacent to existing
plant, Plant additions-inside existing plant, Plant
addition-suppressed infrastructure, and Plant
modification/Revamp.
Contingency Percent This field has the value of the contingency
percentage calculated by the standard basis
expert based on user specification of project
information. This allows the user to modify the
value estimated by Sizing. This value represents:
Construction Contingency
Material Contingency
Engineering Contingency
As a minimum you need
to address these setting
to get proper and
realistic output results.
4-4 General Project Page
4-4
4.2.2 Project Basis Radio
Button
Select the Project Basis radio button to display the following:
USD per GBP (applies
to UK country base
only)
This field defines the currency exchange ratio for
USD:GBP and only applies when dealing with the
United Kingdom (UK) country base.
USD per kJPY
(applies to JP
country base only)
This field defines the currency exchange ratio for
USD:kJPY and only applies when dealing with the
Japan (JP) country base.
Figure 4.2
Field Description
Process
Description
Drives the design allowances for all the equipment
whose material is system-generated. User entered
costs are not affected. A new and unproven process
has a higher design allowance compared with a proven
process. This is applied against all non-quoted
equipment.
Process
Complexity
Used to adjust contingency. Highly complex implies
high temperature/pressure and a lot of process control
(e.g., batch), whereas simple implies a simple process
design and control.
Process Control You can provide either digital, analog or distributed
control system for the project and the process control
strategy is fixed with this choice.
Estimated Start
Year/Month/Day
of Basic
Engineering
These three fields show the year, month, and day that
the basic engineering begins. Refer to ICARUS
Reference, Engineering, for a definition of engineering
functions.
Soil Condition
Around Site
Select the nature of the soil most prevalent at the
construction site. This impacts the development of all
foundations, the amount of pillings developed, any
excavation and trenching work items, and the
construction rental required.
Field Description
USD = United States
Dollar
GBP = Great Britain
Pound
KJPY = 1000 Japanese
Yen
Basis Phase 4-5
4-5
4.2.3 Title Block Radio Button
Select the Title Block radio button to display the following.
Pressure Vessel
Design Code
Specifies the design code used for pressure vessels
design for the different country base settings.
Vessel Diameter
Specification
Specifies the vessel diameter in the component
specification form as inside diameter (ID) or outside
diameter (OD).
P and I Design
Level
Specifies the level of instrumentation provided for the
equipment. The P and I may be standard
instrumentation (STD) or highly instrumented (Full).
Refer to the Icarus Piping and Instrumentation
Drawing for instrumentation on specific equipment.
Transfer Stream
Data to Design
and Cost Engine
Allows for the mapping of stream data to the Icarus
design and costing engine.
Figure 4.3
Field Description
Customer or
Owner Name
Specifies the name of the customer or owner for whom
this project is being built. The system prints this name
in reports exactly as entered.
Project Name Enter the name of this particular project. The system
prints this name in reports exactly as entered.
Job Number Specifies the job number for this project. The system
prints this number in reports exactly as entered.
Prepared By Specifies the name of the user. The system prints this
title in reports exactly as entered.
Country Enter the country name. The system prints this name
in reports exactly as entered.
Province or State Enter the province/state in this field. The system prints
this name in reports exactly as entered.
Legal Land
Description
Enter the legal land description of the project site. The
system prints this name in reports exactly as entered.
Run Date Enter the project run date. The system prints this
name in reports exactly as entered.
Field Description
4-6 Global Selection Page
4-6
4.3 Global Selection Page
This page allows you to define the default selection settings for
each equipment type. You have the option of either automatic
equipment type and orientation selection or you can set the
equipment type and orientation globally. Also, for heat transfer
equipment, you can globally specify the equipment type for
exchanger. You can select the orientation for the reflux
accumulator as well.
Equipment components belonging to similar categories are listed
along with the equipment type and can be access by selecting
the appropriate radio button in the Equipment Categories group.
Equipment Type
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Separators X X X X
3 Phase Separators X X X X
Tanks X X
Tray Sections X
Coolers X
Heaters X
Heat Exchangers X X
Air Coolers X
Partial Condensers X X X X X
Total Condensers X X X X
3 Phase Condensers X X X X X
Reboilers X
3 Phase Reboilers X
Compressors X X
Expanders X
Pumps X
Plug Flow Reactors X X
Basis Phase 4-7
4-7
In the table above, an X signifies if the text in the top row is
applicable to the equipment type listed on the left. If it is, then it
identifies if an equipment component can be auto selected or if
it must be manually selected. For example, the equipment type
Separator allows the automatic selection of equipment type and
the automatic selection of orientation. Where as, the Rotary
Vacuum Filter, does not allow for automatic equipment type
selection, nor does it have an orientation, but it is a valid
equipment type.
Continuously
Stirred Tank
Reactors
X X
General Reactors X
Baghouse Filter X
Cyclone X X
Hydrocyclone X
Rotary Vacuum
Filter
X
Equipment Type
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4-8 Global Sizing/Design Page
4-8
4.4 Global Sizing/Design
Page
This page allows you to define some of the default sizing and
design settings for each equipment type. Equipment types are
organized into six radio buttons listed in the Equipment
Categories group. Depending upon the equipment category
selected, relevant sizing and design information is displayed.
The six different equipment categories are as follows:
General
Vessels
Heat Transfer
Rotating Equipment
Towers
Reactors
4.4.1 General Radio Button
When the General radio button is selected, general equipment
design characteristics becomes visible. The following fields are
displayed in the General Equipment Sizing and Design group:
Design Pressure - Multiplier
Design Pressure - Adder
Design Vacuum - Multiplier
Design Temperature - Adder
Only Apply Design Temperature Adder if Operating
Above
Figure 4.4
Basis Phase 4-9
4-9
4.4.2 Vessels Radio Button
When the Vessels radio button is selected both vessel type and
vessel sizing and design characteristics become visible. The
vessel type may be either a Separator or a Storage Tank.
Separator Radio Button
If the Separator radio button is selected, the Separator Sizing
and Design group are further broken down by General,
Vertical and Horizontal radio buttons which each defining
different sizing and design characteristics outlined as shown in
the following table.
Figure 4.5
4-10
Separator Sizing and
Design View
Design Variables Design Characteristics
General radio button Process Design Auto select vertical sep. if feed vapour mass fraction
exceeds
Minimum liquid holdup time
Minimum liquid surge time
Mist eliminator
Vapour-Liquid
Separation
Separation factor method (with mist eliminator)
Separation factor method (without mist eliminator)
Default separation factor (default method only)
Droplet diameter (Theoretical method only)
Separation factor multiplier (applies to all methods)
Vapour velocity design multiplier
Liquid-Liquid
Separation
Height of light liquid
Height of heavy liquid
Droplet diameter
Maximum terminal settling/rising velocity
Vertical radio button Process Design Solution set selection criteria
Minimum height to diameter ratio
Maximum height to diameter ratio
Minimum holdup height
Minimum surge height
Mist eliminator thickness
Diameter allowance for mist eliminator
Height above mist eliminator
Minimum disengagement height (with mist eliminator)
Minimum disengagement height (without mist
eliminator)
Vapour-Liquid
Separation
Inlet diverter
Minimum height of inlet nozzle above HLL
Separation factor multiplier (GPSA and York
methods without mist eliminator only)
Liquid-Liquid
Separation
Baffle plate
Height of liquid above baffle plate (if Baffle plate is
present)
Minimum downcomer width
Minimum height of inlet nozzle above NLL
Horizontal radio
button
Process Design Solution set selection criteria
Minimum length to diameter ratio
Maximum length to diameter ratio
Minimum vapour space height (with mist eliminator)
Minimum vapour space height (without mist
eliminator)
Vapour-Liquid
Separation
Separation factor multiplier (GPSA and York
methods only)
Basis Phase 4-11
4-11
Storage Tank Radio Button
If the Storage Tank radio button is selected, the following
sizing and design characteristics for the Storage Tank vessel
type are displayed:
Holding Time
Maximum Capacity per Vessel
Percent Spare Capacity Per Tank
Vertical Vessels - Height to Diameter Ratio
Horizontal Vessels - Length to Diameter Ratio
4.4.3 Heat Transfer Radio
Button
When the Heat Transfer radio button is selected, the heat
transfer equipment types and their sizing and design
characteristics become visible. The choices for heat transfer
equipment type are as follows:
Shell and Tube Exchanger
Aerial Cooler
Process Furnace
These options are described in the following sections.
Figure 4.6
Process Furnace
Shell and Tube Exchanger Aerial Cooler
4-12
Shell and Tube Exchanger Radio
Button
If the Shell and Tube Exchanger radio button is selected, the
Shell and Tube Exchanger group are further broken down by
Process, Geometry, and TEMA Types radio buttons which
each define different sizing and design characteristics outlined
as follows:
Shell and Tube
Exchanger Sizing and
Design View
Process Utility Fluids Cooler
Heater
Condenser
Reboiler
Minimum approach for automatic
selection of utility fluid
Hot Side Stream Cooler
Heater
Heat Exchanger
Condenser
Maximum Pressure Drop Hot side
Cold side
Fouling Factors Hot side
Cold side
Geometry Exchanger Maximum number of shells in series (E,
I, J shells)
Maximum number of shells in series (D,
F, G, H, M shells)
Maximum number of shells in series (K,
X shells)
Maximum number of shells in parallel (all
shell types)
Maximum shell inside diameter
Counter-current in first tube pass
Bundle Tube outside diameter
Tube wall thickness
Tube pitch factor (pitch = outside
diameter x factor)
Tube layout angle
Maximum tube length
Minimum tube length
Max. number of tube passes (vertical
thermosiphon reboilers)
Max. number of tube passes (all other
types)
Minimum number of tubeside passes
Baffle type
Basis Phase 4-13
4-13
Aerial Cooler Radio Button
If the Aerial Cooler radio button is selected, the Aerial Cooler
Sizing and Design group displays Process and Geometry
radio buttons, which each define different sizing and design
characteristics shown below:
TEMA Type Floating Heat Exchanger Front end head type
Shell type
Rear end head type
Fixed Tube Heat
Exchanger
U-tube exchanger
Kettle-type Reboiler
U-tube Kettle-type
Reboiler
Thermosiphon Reboiler-
Horizontal Floating Head
Horizontal Fixed Tube
Sheet
Horizontal U-tube
Vertical Fixed Tube Sheet
Shell and Tube
Exchanger Sizing and
Design View
Aerial Cooler Sizing
and Design View
Design Characteristics
Process Air Inlet Temperature
Fouling Factor
Maximum Pressure Drop
Geometry Tube Outside Diameter
Tube Wall Thickness
Tube Pitch Factor (pitch = outside diameter x factor)
Minimum Tube Length
Maximum Tube Length
Minimum Number of Tube Passes
Maximum Number of Tube Passes
Number of Tube Rows Calculation Method
Fin Height
Fin Width
Number of Fins per inch (per 25mm)
Minimum Bay Length to Width Ratio
Exchanger Length to Width Ratio
Minimum Number of Fans Per Bay
Maximum Fan Diameter
4-14
Process Furnace Radio Button
If the Process Furnace button is selected, the sizing and
design characteristic for Thermal Efficiency Percent are
displayed.
4.4.4 Rotating Equipment
Radio Button
When the Rotating Equipment radio button is selected, the
rotating equipment types and their sizing and design
characteristics become visible.
The choices for rotating equipment type are as follows:
Pump
Compressor
Expander
The following table lists the design characteristics available for
each rotating equipment type:
Figure 4.7
Rotating Equipment
Type
Pump Number of Spares
Capacity Overdesign Factor
Head Overdesign Factor
Reflux Pump Head
Expander Pump Compressor
Basis Phase 4-15
4-15
4.4.5 Towers Radio Button
When the Towers radio button is selected the tower types and
their sizing and design characteristics become visible. The
choices for tower type are General, Trayed and Packed.
General Radio Button
If the General radio button is selected, the following general
column sizing and design characteristics are displayed:
Stages with vapour in feed - sizing based on
Area tolerance
Bottom sump height
Vapour disengagement height
Towers sized with multiple sections - designed as
Compressor Air and Gas Compressors:
Capacity Overdesign Factor
Head Overdesign Factor
Gas Compressors Only:
Centrifugal - driver type
Reciprocating - driver type
Expander Capacity Overdesign Factor
Figure 4.8
Rotating Equipment
Type
Packed
General Trayed
4-16
Trayed Radio Button
If the Trayed radio button is selected, the Trayed Tower Sizing
and Design group are further broken down by General, Sieve,
Valve and Bubble Cap radio buttons which each define
different sizing and design characteristics outlined as follows:
Trayed Tower Sizing
and Design View
General radio button Tower Data:
Tray type
Overall tray efficiency (percent)
Diameter factor
Tray Data:
Tray spacing
System foaming factor
Downcomer / Weir Data:
Downcomer type
Downcomer clearance
Maximum downcomer backup (percent)
Weir height
Maximum weir loading
Sieve radio button Tray thickness
Maximum pressure drop per tray (height of
liquid)
Maximum tray flooding (percent)
Hole diameter
Hole spacing (Hole spacing = Hole diameter x
factor)
Valve radio button Tray thickness
liquid)
Design manual
Orifice type
Valve density
Valve thickness
Hole area (percent of active area)
Bubble Cap radio
button
Tray thickness
liquid)
Cap slot height
Basis Phase 4-17
4-17
Packed Radio Button
If the Packed radio button is selected, the following packed
tower sizing and design characteristics are displayed:
Packing type
Pressure drop correlation
Maximum flooding (percent)
Maximum pressure drop per unit length
4.4.6 Reactors Radio Button
When the Reactors radio button is selected the following
reactor sizing and design characteristics become visible.
Vertical Vessel - Height to Diameter Ratio
Horizontal Vessels - Length to Diameter Ratio
Packing Type for Packed Reactors:
Figure 4.9
4-18
Selection Phase 5-1
5-1
5 Selection Phase
5.1 Introduction................................................................................... 2
5.2 Equipment Categories.................................................................... 3
5.2.1 Vessels Category...................................................................... 4
5.2.2 Heat Transfer Category ............................................................. 6
5.2.3 Rotating Equipment Category..................................................... 9
5.2.4 Tower Category...................................................................... 12
5.2.5 Reactors Category.................................................................. 12
5.2.6 Solids Handling Category......................................................... 14
5-2 Introduction
5-2
5.1 Introduction
The Selection Phase tab allows you to do detailed equipment
selection and specification for each unit operation being
simulated in Sizing. When you access the Selection Phase tab, a
number of groups become visible, as outlined in the figure
below.
There are three groups available on this tab:
Equipment Categories. This shows the various
equipment categories available in Sizing. You can display
the equipment associated with each category, in the
Category Items group, by selecting the appropriate radio
button.
Category Items. This lists the various equipment which
belong to the currently selected equipment category.
Detailed Equipment Selection. This displays detailed
equipment information related to the currently selected
equipment item highlighted in the Category Items group.
Figure 5.1
The Equipment
Categories group
filters the
equipment items
by category
name.
Equipment items
are displayed in
the Category
Items group.
The equipment items imported into Sizing
are listed in the Category Items group
based on the radio button selected in the
Equipment Categories group.
The Detailed Equipment Selection group allows
you to specify specific selection parameter
defaults for each equipment category item
based on its unit operation type.
Selection Phase 5-3
5-3
5.2 Equipment Categories
All the available equipment imported into Sizing can be
displayed in the Category Items view. Equipment items are
organized by category according to the radio button selected.
The filtering of equipment into groups is particularly convenient
when a large case is imported into Sizing. The six different
equipment categories available along with their associated unit
operation types are listed below:
The All Equipment category lists all the equipment items which
were imported to Sizing and is more convenient for small cases
imported into Sizing.
Initially, the various imported equipment items are detailed
according to default settings specified in the Global Selection
page of the Basis Phase tab.
Equipment Categories Unit Operation Type
Vessels Separator
3 Phase Separator
Tank
Heat Transfer Coolers
Heaters
Heat Exchangers
Air Coolers
Partial Condensers
Total Condensers
3 Phase Condensers
Reboilers
3 Phase Reboilers
Rotating Equipment Compressors
Expanders
Pumps
Towers Tray Sections
Reactors Plug Flow Reactors
Continuously-Stirred-Tank Reactors
Conversion Reactors
Equilibrium Reactors
Gibbs Reactors
Solid Handling Baghouse Filter
Cyclone
Hydrocyclone
5-4 Equipment Categories
5-4
Each unit operation may contain several unique specification
fields. For the Equipment Type field, located in the Detailed
Equipment Selection group, a drop-down list is available. The
drop-down list is located within the edit bar and are enabled
once the appropriate field is selected. Using these drop-down
lists, each equipment item can be further specified based on
equipment type.
5.2.1 Vessels Category
The Vessels category includes all the vessel types. The following
unit operation types are included in this category:
Separator
3 Phase Separator
Tank
The Detailed Equipment Selection group automatically lists
selection information specific to each unit operation type, when
it is selected in the Category Items group.
Separator Selection
The following table describes the various fields listed in the
Detailed Equipment Selection group for a Separator unit
operation type.
Field Description
Unit Operation
Type
Displays the unit operation type.
Equipment Type Displays the equipment type for the unit operation.
The following equipment types are available for
separators:
Standard Process Vessel
Jacketed Process Vessel
Multi-walled Process Vessel
Vapour Mass
Fraction of Feed
Displays the vapour mass fraction of the feed stream
to the equipment.
Vessel
Orientation
Displays the equipment orientation (horizontal or
vertical).
Selection Phase 5-5
5-5
3 Phase Separator Selection
Detailed Equipment Selection group for a 3 Phase Separator
unit operation type.
Tank Selection
Detailed Equipment Selection group for a Tank unit operation
type.
Field Description
Unit Operation
Type
The following equipment types are available for 3
phase separators:
Jacketed Process Vessel
Vapour Mass
Fraction of Feed
Displays the vapour mass fraction of the feed stream
to the equipment.
Vessel
Orientation
Displays the equipment orientation (horizontal or
vertical).
Field Description
Unit Operation
Type
The following equipment types are available for tanks:
Flat-Bottom Storage Tank With Optional Roof
Vertical Standard Process Vessel
Vertical Jacketed Process Vessel
Vertical Multi-walled Process Vessel
Horizontal Standard Process Vessel
Horizontal Jacketed Process Vessel
Horizontal Multi-walled Process Vessel
Low Pressure Gas Storage Vessel
Sphere
Spheroid
Cryogenic Storage Tank
Cone Bottom Storage Bin
Live Bottom Storage Bin
5-6
5.2.2 Heat Transfer Category
The Heat Transfer category includes all the heat transfer related
types. The following unit operation types are included in this
category:
Cooler
Heaters
Heat Exchangers
Air Coolers
Partial Condensers
Total Condensers
3 Phase Condensers
Reboilers
3 Phase Reboilers
Cooler Selection
Detailed Equipment Selection group for a Cooler unit operation
type.
Field Description
Unit Operation
Type
The following equipment types are available for cooler:
Floating Head Shell and Tube Heat Exchanger
Fixed Tube Sheet Shell and Tube Heat Exchanger
U-tube shell and Tube Heat Exchanger
Selection Phase 5-7
5-7
Heater Selection
Detailed Equipment Selection group for a Heater unit operation
type.
Heat Exchanger Selection
Detailed Equipment Selection group for a Heat Exchanger unit
operation type.
Field Description
Unit Operation
Type
heaters:
A-frame Type Process Furnace
Box-type Cylindrical Process Frame
Vertical Cylindrical Process Furnace
Field Description
Unit Operation
Type
The following equipment types are available for heat
exchangers:
5-8
Air Cooler Selection
Detailed Equipment Selection group for an Air Cooler unit
operation type.
Partial/Total/3 Phase Condenser
Selection
Detailed Equipment Selection group for Partial, Total and 3
Phase Condenser unit operation types.
Field Description
Unit Operation
Type
The following equipment types are available for air
coolers:
Air Cooler
Free Standing
Rack-Mounted
Field Description
Unit Operation
Type
Equipment Type
- Exchanger
Displays the equipment type for the unit operation.
The following equipment types are available for the
exchanger section:
Air Cooler, Free Standing or Rack-Mounted
Equipment Type
- Reflux Pump
Refer to Section 5.2.3 - Rotating Equipment
Category.
Equipment Type
- Reflux
Accumulator
Refer to Section 5.2.1 - Vessels Category.
Selection Phase 5-9
5-9
Reboiler/3 Phase Reboiler Selection
Detailed Equipment Selection group for a Reboiler unit
operation type.
5.2.3 Rotating Equipment
Category
The Rotating Equipment category includes all the rotating
equipment types. The following unit operation types are
included in this category:
Compressors
Expanders
Pumps
Field Description
Unit Operation
Type
Equipment Type Specifies the equipment type for the unit operation.
reboilers:
U-tube Kettle-type Reboiler
Kettle-type Reboiler with Floating Head
Thermosiphon-type Reboiler (Horizontal Shell
with Floating Head)
with fixed Tube Sheet)
with U-tube)
Thermosiphon-type Reboiler (Vertical Shell with
Fixed Tube Sheet)
5-10
Compressor Selection
Detailed Equipment Selection group for a Compressor unit
operation type.
Field Description
Unit Operation
Type
Inlet Pressure Displays inlet pressure
Inlet
Temperature
Displays inlet temperature
Exit Pressure Displays exit pressure
Exit Temperature Displays exit temperature
Estimated Actual
Volume Capacity
at Inlet
Conditions
Displays volume capacity estimate
Estimated Driver
Power
Displays estimated driver power.
compressors:
Gas Compressor - Centrifugal Horizontal
Gas Compressor - Centrifugal Integral Gear
Gas Compressor - Reciprocating
Gas Compressor - Reciprocating with Integral Gas
Engine
Air Compressor - Centrifugal with Motor
Air Compressor - Centrifugal with Turbine
Air Compressor - Reciprocating with Gas Engine
Air Compressor - Reciprocating with Motor
Air Compressor - Single Reciprocating One Stage
Air Compressor - Single Reciprocating Two-Stage
Selection Phase 5-11
5-11
Expander Selection
Detailed Equipment Selection group for an Expander unit
operation type.
Pump Selection
Detailed Equipment Selection group for a Pump unit operation
type.
Field Description
Unit Operation
Type
expanders:
Gas Turbine with Combustion Chamber
Steam Turbine Driver, Condensing Type
Steam Turbine Drive, Non-condensing Type
Field Description
Unit Operation
Type
Equipment Type Displays the equipment type for the unit operation. The following equipment
types are available for pumps:
Canned Rotor Gear Pump
Standard External Gear Rotary
Pump
Mechanical Seal Gear Pump
Diaphragm Pump - TFE Type
Reciprocating Simplex Pump -
Steam Driver
Reciprocating Duplex Pump -
Steam Driver
Triplex Plunger Pump - Motor
Driver
Reciprocating Positive
Displacement Plunger Pump
Rotary (Sliding Vanes) Pump
Slurry Pump
Canned Motor Pump
Centrifugal Single or Multi-stage
Pump
General Service Pump
General Service In-line Pump
Vertical Sump Pump - Turbine
Impeller
Low Consistency Stock Pump
Standard ANSI Magnetic Drive
Pump
Standard ANSI Single-Stage
Pump
Plastic ANSI Single-Stage Pump
API 610 Pump
API 610 In-line Pump
Axial Flow Vertical Pump
5-12
5.2.4 Tower Category
The Tower category includes all the tower types available.
Currently, the only unit operation type available in this category
is the Trayed Section type.
Detailed Equipment Selection group for the Tray Section unit
operation type.
5.2.5 Reactors Category
The Reactors category includes all the reactor types available.
The following types of reactors are included in this category:
Plug Flow Reactors
Continuously-Stirred-Tank Reactors
Gibbs Reactors
Conversion Reactors
Field Description
Unit Operation
Type
columns:
Standard Tower - Packed
Standard Tower - Trayed
Tray Type
(trayed column
only)
Displays the tray type for the column. The following
tray types are available for trayed columns:
Sieve Trays
Valve Trays
Bubble Cap Trays
Tower sized with
multiple sections
- designed as
Displays the diameter type for the column. The
following column types are available for both trayed
and packed columns:
Single - Diameter
Double - Diameter
5-13
Plug Flow Reactor Selection
Detailed Equipment Selection group for a Plug Flow Reactor
unit operation type.
Continuously Stirred Tank Reactor
(CSTR) Selection
Detailed Equipment Selection group for a Continuously-
Stirred-Tank Reactor unit operation type.
Field Description
Unit Operation
Type
The following equipment types are available for plug
flow reactors:
Standard Tower - Packed Single Diameter
Field Description
Unit Operation
Type
The following equipment types are available for a
CSTRs:
Agitated Tank - Enclosed, Jacketed
Agitated Tank - Enclosed
Agitated Tank - Open Top
5-14
Gibbs, Conversion, and Equilibrium
Reactor Selection
Detailed Equipment Selection group for Gibbs, Conversion,
and Equilibrium Reactor unit operation types.
5.2.6 Solids Handling Category
The Solids Handling category includes all the solids handling
related types. The following unit operation types are included in
this category:
Baghouse Filter
Cyclone
Hydrocyclone
Rotary Vacuum Filter
Simple Solid Separator
Field Description
Unit Operation
Type
general reactors:
Standard Tower - Packed Single Diameter
Sphere
Spheroid
Box-type Process Furnace
Box-type Reformer without Catalyst
Pyrolysis Unit
5-15
Baghouse Filter Selection
Detailed Equipment Selection group for a Baghouse Filter unit
operation type.
Cyclone Selection
Detailed Equipment Selection group for a Cyclone unit
operation type.
Field Description
Unit Operation
Type
baghouse filters:
Baghouse with Motor Shakers
Baghouse with Injected Pulsed Air
Field Description
Unit Operation
Type
Equipment Type Specify the equipment type for the unit operation.
cyclones:
Cyclone Dust Collector
Multiple-Cyclone Dust Collector
5-16
Hydrocyclone Selection
Detailed Equipment Selection group for a Hydrocyclone unit
operation type.
Rotary Vacuum Filter Selection
Detailed Equipment Selection group for a Rotary Vacuum
Filter unit operation type.
Field Description
Unit Operation
Type
The following equipment type is available for
hydrocyclones:
Water-only Cyclone - Mineral Separator
Field Description
Unit Operation
Type
The following equipment types are available for rotary
vacuum filters:
Rotary Drum Filter
Rotary Disk Filter
5-17
Simple Solid Separator Selection
Detailed Equipment Selection group for a Simple Solid
Separator unit operation type.
Field Description
Unit Operation
Type
The following equipment types are available for simple
solid separators:
Cyclone Dust Collector
Multiple-cyclone Dust Collector
5-18
Sizing Phase 6-1
6-1
6 Sizing Phase
6.1 Introduction................................................................................... 3
6.2 Sizing and Displaying Individual Item Data ................................... 4
6.3 Vessels Category............................................................................ 6
6.3.1 Separator Sizing ...................................................................... 7
6.3.2 3 Phase Separator Sizing........................................................... 8
6.3.3 Tank Sizing............................................................................ 10
6.4 Heat Transfer Category................................................................ 11
6.4.1 Cooler/Heater/Heat Exchanger/Condenser Sizing........................ 12
6.4.2 Reboiler/3 Phase Reboiler Sizing............................................... 15
6.5 Rotating Equipment Category ...................................................... 16
6.5.1 Pump Sizing .......................................................................... 18
6.5.2 Compressor Sizing.................................................................. 18
6.5.3 Expander Sizing ..................................................................... 19
6.6 Tower Category............................................................................ 20
6.6.1 Packed Tower Sizing ............................................................... 21
6.6.2 Trayed Tower Sizing................................................................ 23
6.7 Reactor Category ......................................................................... 25
6.7.1 Plug Flow Reactor Sizing ......................................................... 26
6.7.2 Continuously-Stirred-Tank Reactor Sizing................................... 27
6.7.3 Gibbs, Conversion and Equilibrium Reactor Sizing ....................... 27
6.8 Solids Handling Category ............................................................. 28
6.8.1 Baghouse Filter Sizing............................................................. 28
6.8.2 Cyclone Sizing ....................................................................... 29
6.8.3 Hydrocyclone Sizing................................................................ 29
6-2 Sizing Phase
6-2
6.8.4 Rotary Vacuum Filter Sizing......................................................29
Sizing Phase 6-3
6-3
6.1 Introduction
The Sizing Phase tab allows you to do a detail equipment sizing
for all the equipment items being simulated in Sizing. When you
access the Sizing Phase tab view, a number of groups become
visible, as displayed below:
There are three groups available on this tab:
Equipment Categories. This shows the various
equipment categories available in Sizing. You can display
the equipment associated with each category, in the
Category Items group, by selecting the appropriate radio
button.
Category Items. This lists all the equipment in the
category selected in Equipment Categories group.
Sizing Input Details. This automatically lists sizing
information specific to each unit operation type. You can
specify different sizing parameters for the equipment
item selected in the Category Items group.
Figure 6.1
6-4 Sizing and Displaying Individual Item Data
6-4
Equipment items are filtered by category according to the radio
button selected in the Equipment Categories group. The six
different equipment categories available in Sizing along with
their associated unit operation types are listed below:
6.2 Sizing and Displaying
Individual Item Data
On the Sizing Phase tab, you can size individual unit operations
and view the sized data as well. To size a unit operation, do as
follows:
1. Select the unit operation in the Category Item list.
2. Click the Size Selected Item button.
Equipment Categories Category Items
Vessels Separators
3 Phase Separators
Tanks
Heat Transfer Coolers
Heaters
Heat Exchangers
Air Coolers
Partial Condensers
Total Condensers
3 Phase Condensers
Reboilers
3 Phase Reboilers
Rotating Equipment Compressors
Expanders
Pumps
Towers Trayed Sections
Reactors Plug Flow Reactors
Continuously Stirred Tank Reactors
Gibbs Reactors
Conversion Reactors
Solid Handling Baghouse Filter
Cyclone
Hydrocyclone
If you sized a unit
operation once using
the Size Selected
Item button, it is not
sized again when the
Size All Items or Run
Phase buttons are
clicked.
Sizing Phase 6-5
6-5
You also have the option to size all unit operations at the same
time. To size all unit operations, do as follows:
1. Click the Size All Items button.
You have the option to view the sized data for the unit operation
after sizing is complete. The procedure to view the sizing output
is as follows:
1. Select the unit operation already sized from the Category
Item group.
2. Click the Item Sizing Output button.
The Item Sizing Output view is displayed as follows:
The above view displays the calculated sizing data for the
selected unit operation.
Figure 6.2
You may view the sizing output data of any sized item. You
may then return to the input view of any item, modify the
input values and then resize the item again until the results
are satisfactory. Once the Run Phase button is clicked, the
values are committed to the Design Phase and the size input
may not longer be modified.
6-6 Vessels Category
6-6
6.3 Vessels Category
This category is used to size all vessel related unit operations,
which are preselected on the Selection Phase tab. The various
unit operations along with their available equipment types
included in this category are outlined in the following table.
Equipment sizing is determined based upon unit operation type
(i.e. Separator, Tank etc.). An overview of the sizing information
available for each unit operation type is outlined in the following
sections.
Category Items Equipment Type
Separator Standard Process Vessel
Jacketed Process vessel
3 Phase
Separator
Jacketed Process vessel
Tank Flat-Bottom Storage Tank With Optional Roof
Low Pressure Gas Storage Vessel
Sphere
Spheroid
Cryogenic Storage tank
Cone Bottom Storage Bin
Live Bottom Storage Bin
Sizing Phase 6-7
6-7
6.3.1 Separator Sizing
When an equipment item belongs to the Separator unit
operation type, it is sized according to a number of parameters
available in the Separator Sizing Input Details group. The sizing
parameters available depend on the equipment orientation.
Sizing details are organized by radio buttons. The General radio
button is always available while either the Horizontal or
Vertical radio button is available depending on the orientation.
The following fields are available when the General radio button
is selected:
Solution set selection criteria
Minimum liquid holdup time
Minimum liquid surge time
Mist eliminator
Separation factor multiplier (with mist eliminator)
Separation factor multiplier (without mist eliminator)
Default separation factor (Default method only)
Vapour velocity design multiplier
The following fields are available when the Horizontal radio
button is selected:
Minimum vapour space height (without mist eliminator)
Separation factor multiplier (GPSA and York methods
only)
The following fields are available when the Vertical radio button
is selected:
6-8
eliminator)
Inlet diverter
without mist eliminator only)
6.3.2 3 Phase Separator Sizing
When an equipment belongs to the 3 Phase Separator unit
available in the 3 Phase Separator Sizing Input Details group.
The sizing parameters available depend on equipment
orientation.
Sizing details are organized by radio buttons. The General and
3 Phase radio buttons are always available while the
Horizontal, Vertical and 3 Phase Vertical radio buttons
become available depending on the vessel orientation.
The following sizing parameter fields are available when the
General radio button is selected:
Solution set selection criteria
Minimum holdup time
Minimum surge time
Mist eliminator
Separation factor method (with mist eliminator)
Separation factor method (without mist eliminator)
Default separation factor (Default method only)
Vapour velocity design factor
Horizontal radio button (Horizontal Vessel only) is selected:
Minimum vapour space height (without mist eliminator)
Sizing Phase 6-9
6-9
only)
Vertical radio button (Vertical Vessel only) is selected:
eliminator)
Inlet diverter
without mist eliminator only)
If the 3 Phase radio button (both Horizontal and Vertical
Vessels) is selected you can specify the following sizing
parameters:
Height of light liquid
Height of heavy liquid
Droplet diameter
Maximum terminal setting/rising velocity
If the 3 Phase Vertical radio button (Vertical Vessels only) is
selected you can specify the following sizing parameters:
Baffle plate
Height of liquid above baffle plate
Minimum downcomer width
Minimum height of inlet nozzle above NLL
6-10
6.3.3 Tank Sizing
When an equipment item belongs to the Tank unit operation
type, it is sized according to a number of parameters available
in the Tank Sizing Input Details group. The sizing parameters
available depend on the equipment orientation.
The Input Details group allows you to specify the following sizing
parameters for the tank:
Total actual volume flow
Holding time
Maximum capacity per storage vessel
Percent spare capacity per storage vessel
Height/Length to diameter ratio*
* Not required for spheres
Figure 6.3
Sizing Phase 6-11
6-11
6.4 Heat Transfer
Category
This category is used to size all heat transfer related unit
operations, which are preselected on the Selection Phase tab.
The various unit operations along with their available equipment
types included in this category are outlined in the following
table.
Figure 6.4
Cooler Floating Head Shell and Tube Heat Exchanger
Heater Floating Head Shell and Tube Heat Exchanger
Box-type Process Frame
Heat Exchanger Floating Head Shell and Tube Heat Exchanger
6-12 Heat Transfer Category
6-12
(i.e. Cooler, Heater, Reboiler). An overview of the sizing
information available for each unit operation type is outlined in
the following sections.
6.4.1 Cooler/Heater/Heat
Exchanger/Condenser
Sizing
When an equipment item belongs to either the Cooler, Heater,
Heat Exchanger, Air Cooler, or Condenser (partial, total, three
phase) unit operation type, it is sized according to a number of
parameters available in the Sizing Input Details group. The
various sizing parameters available depend upon the equipment
type used. Sizing parameters differ depending upon whether or
not the equipment type is of Process Furnace, Shell and Tube
Exchanger or Air Cooler type as outlined in the following
sections.
Air Cooler Air Cooler, Free Standing or Rack-Mounted
Partial
Condenser /
Total Condenser
/ 3 Phase
Condenser
Reboiler / 3
Phase Reboiler
U-tube Kettle-type Reboiler
Kettle-type Reboiler with Floating Head
with Floating Head)
with Fixed Tube Sheet)
with U-tube)
Thermosiphon-type Reboiler (Vertical Shell with
Fixed Tube Sheet)
Sizing Phase 6-13
6-13
Process Furnace
If the equipment is of Process Furnace type (i.e., A-frame type,
Box-type cylindrical), then the only sizing parameters available
in the Process Furnace Input Details are:
Absorbed duty
Furnace thermal efficiency
Shell and Tube Exchangers
If the equipment is of Shell and Tube type (i.e. U-tube shell and
tube, Fixed tube sheet shell and tube) then an extensive set of
sizing parameters become available.
Sizing details for Shell and Tube type heat transfer equipment
are organized into three radio buttons. The first two deal with
Exchanger and Bundle geometry respectively and the final
button deals with Process details.
Exchanger radio button
If the Exchanger radio button is selected, you can specify the
following sizing parameters:
Front end head type
Shell type
Rear end head type
Maximum number of shells in series (E,I, J shell only)
Maximum number of shells in series (D,F,G,H,M shell
only)
Maximum number of shells in series (K,X shell only)
Maximum number of shells in parallel
Maximum shell inside diameter
Hot stream side
Counter-current in first tube pass
6-14 Heat Transfer Category
6-14
Bundle radio button
If the Bundle radio button is selected, you can specify the
Tube outside diameter
Tube wall thickness
Tube pitch
Tube layout angle
Maximum tube length
Minimum tube length
Maximum number of tubeside passes
Minimum number of tubeside passes
Baffle type (ignored for D, K and X shells)
Process radio button
If the Process radio button is selected, you can specify the
Maximum hot side pressure drop
Maximum cold side pressure drop
Hot side fouling factor
Cold side fouling factor
Air Cooler
If the equipment is an Air Cooler type (Free standing or Rack-
mounted), then the sizing parameters available in the Cooler
Input Details group are as follows:
Service Type (determines Overall Heat Transfer
Coefficient)
Overall Heat Transfer Coefficient (Default service type
only)
Air Inlet Temperature
Fouling Factor
Maximum Pressure Drop
Tube Outside Diameter
Tube Wall Thickness
Tube Pitch Factor (pitch = outside diameter x factor)
Number of Tube Passes
Sizing Phase 6-15
6-15
Number of Tube Rows Calculation Method
Fin Height
Fin Width
Number of Fins per Inch (per 25 mm)
Exchanger Length to Width Ratio
Minimum Number of Fans Per Bay
6.4.2 Reboiler/3 Phase
Reboiler Sizing
When an equipment item belongs to the Reboiler or 3 Phase
Reboiler unit operation type, it is sized as a Shell and Tube
Exchanger, previously outlined in the Section - Shell and
Tube Exchangers. The Exchanger, Bundle and Process radio
buttons are available as before along with an additional Utility
Fluid radio button detailed below.
Utility Fluid radio button
If the Utility Fluid radio button is selected, you can specify the
Utility Fluid
Minimum approach for automatic selection of utility fluid
(degC)
6-16 Rotating Equipment Category
6-16
6.5 Rotating Equipment
Category
This category is used to size all rotating equipment related unit
Figure 6.5
Sizing Phase 6-17
6-17
types included in this category are described in the following
table:
Equipment sizing is based on unit operation type (Pump,
Compressor, etc.) and information for each is described in the
following sections.
Pump Standard ANSI Single Stage Pump
Plastic ANSI Single Stage Pump
API 610 Pump
API 610 In-line Pump
Axial Flow Vertical Pump
Canned Motor Pump
Centrifugal Single or Multi-stage Pump
General Service Pump
General Service In-line Pump
Vertical Sump Pump - Turbine Impeller
Low consistency Stock Pump
Standard ANSI Magnetic Drive Pump
Canned Rotor Gear Pump
Standard External Gear Rotary Pump
Mechanical Seal Gear Pump
Diaphragm Pump - TFE Type
Reciprocating Simplex Pump - Steam Driver
Reciprocating Duplex Pump - Steam Driver
Triplex Plunger Pump - Motor Driver
Reciprocating Positive Displacement Plunger
Pump
Rotary (Sliding Vanes) Pump
Slurry Pump
Compressor Gas Compressor - Centrifugal Horizontal
Gas Compressor - Centrifugal Integral Gear
Gas Compressor - Reciprocating
Gas Compressor - Reciprocating with Integral Gas
Engine
Air Compressor - Centrifugal with Motor
Air Compressor - Centrifugal with Turbine
Air Compressor - Reciprocating with Gas Engine
Air Compressor - Reciprocating with Motor
Air Compressor - Single Reciprocating One-Stage
Air Compressor - Single Reciprocating Two-Stage
Expander Gas Turbine with Combustion Chamber
Steam Turbine Driver, Condensing Type
Steam Turbine Driver, Non-Condensing Type
6-18 Rotating Equipment Category
6-18
6.5.1 Pump Sizing
When an equipment item belongs to the Pump unit operation
in the Pump Sizing Input Details group.
The Sizing Input Details group allows you to specify the
following pump sizing parameters:
Liquid specific gravity
Operating capacity
Operating head
Operating hydraulic power
Mechanical efficiency
Capacity overdesign factor
Head overdesign factor
6.5.2 Compressor Sizing
When an equipment item belongs to the Compressor unit
available in the Compressor Sizing Input Details group.
Operating capacity
Operating adiabatic head
Operating polytropic head
Adiabatic efficiency
Polytropic efficiency
Operating gas power
Head overdesign factor
Sizing Phase 6-19
6-19
6.5.3 Expander Sizing
When an equipment item belongs to the Expander unit
available in the Expander Sizing Input Details group.
Operating capacity
Operating mass enthalpy changes
Operating power output
6-20 Tower Category
6-20
6.6 Tower Category
This category is used to size the Tower section of a Column (the
Reboilers and Condensers are sized under the Heat Transfer
category). Towers can be either trayed or packed.
Equipment sizing is determined based on tower type (Trayed or
Packed).
An overview of the sizing information available for each type is
outlined in the following sections.
Category Item Equipment Type
Trayed Section Standard Tower - Packed
Standard Tower - Trayed
Figure 6.6
Sizing Phase 6-21
6-21
6.6.1 Packed Tower Sizing
If the equipment is a Standard Tower - Packed type, then an
extensive set of sizing parameters become available.
Sizing details for Packed Tower are organized by radio buttons.
The General radio button details general sizing information and
the Packed radio button details packing specific sizing
information.
is selected:
Stages with Vapour in Feed - Sizing Based On
Area tolerance
Bottom sump height
Packed Radio Button
The following fields are available when the Packed radio button
is selected:
Packing type
Pressure drop correlation
Maximum allowable flooding (percent)
Maximum allowable pressure drop
Packing Types
From the drop-down list, the packing type for a Packed column
may be chosen. The following packing types are available in
different sizes for packed columns:
Ballast Rings (Metal/Plastic)
Ballast Plus Rings (Metal)
Ballast Saddles (Plastic)
6-22 Tower Category
6-22
Berl Saddles (Ceramic)
Cascade MiniRing (Metal/Plastic/Ceramic)
Chempak (Metal)
Flexipac (Metal Structured)
Flexirings (Metal)
Gempak (Metal Structured)
Glitsch Grid (Metal Structured) Structured
Goodloe (Metal Structured) Structured
Heli-Pak (Wire Coil Packing)
Hy-Pak Rings (Metal)
Hypertil (Metal Structured) Structured
Intalox Saddles (Ceramic)
Jaeger Max Pack SS C2
Jaeger Tri Packs (Plastic)
Jaeger VSP SS
Koch-Sulzer (BX) (Metal Structured) Structured
Lessing Experimental (Metal) 1-1/2 inch
Leva Packing (Plastic) No. 2
Maspak (Plastic)
Montz A-2 (Metal Structured) Structured
Neo-Kloss (Metal Structured) Structured
Norton Intalox Metal Tower Packing
Nutter Rings (Metal)
Pall Rings (Metal/Plastic)
Protruded (Metal)
Raschig Rings 1/32 inch wall (CSteel)
Raschig Rings 1/16 inch wall (CSteel)
Raschig Rings (Ceramic/Carbon)
Super Intalox Saddles (Plastic/Ceramic)
Tellerettes (Plastic)
Cross-Partition Rings (Ceramic)
Sizing Phase 6-23
6-23
6.6.2 Trayed Tower Sizing
If the equipment is a Standard Tower - Trayed type, then an
extensive set of sizing parameters become available.
Sizing details for Trayed Columns are organized by radio
buttons. The General and Trayed radio buttons are always
available while the Sieve Tray, Valve Tray, or Bubble Cap
Tray radio buttons are available depending on the tray type
selected in the Selection Phase tab.
is selected:
Stages with Vapour in Feed - Sizing Based On
Area tolerance
Bottom sump height
Tower sized with multiple sections - designed as
Trayed Radio Button
The following fields are available when the Trayed radio button
is selected (fields are organized into categories):
Overall tray efficiency (percent)
Diameter factor
Tray spacing
Tray thickness
Maximum pressure drop per tray (height of liquid)
Downcomer type
Downcomer clearance
Maximum downcomer backup (percent)
Weir height
Maximum weir loading
For more information
regarding tray types,
refer to Section 5.2.4 -
Tower Category.
6-24 Tower Category
6-24
Sieve Tray Radio Button
The following fields are available when the Sieve Tray radio
button is selected:
Hole diameter
Hole spacing factor
Valve Tray Radio Button
The following fields are available when the Valve Tray radio
button is selected:
Design manual
Orifice type
Valve density
Valve thickness
Bubble Cap Tray Radio Button
The following fields are available when the Bubble Cap Tray
radio button is selected:
Cap slot height
Sizing Phase 6-25
6-25
6.7 Reactor Category
This category is used to size all reactor related unit operations,
which are preselected on the Selection Phase tab.
table:
Figure 6.7
Plug Flow Reactor Standard Tower - Packed Single Diameter
6-26 Reactor Category
6-26
(PFR, CSTR, Gibbs, Equilibrium, and Conversion Reactors). An
overview of the sizing information available for each unit
operation type is outlined in the following sections.
6.7.1 Plug Flow Reactor Sizing
When the equipment item belongs to the Plug Flow Reactor unit
operations type, it is sized according to a number of parameters
available in the Sizing Input Details group. Sizing parameters
differ depending on whether or not the reactor is a packed type
or a tank type.
Packed Plug Flow Reactor
If the reactor is Packed Plug Flow reactor, the following sizing
parameters available in the Sizing Input Details group are:
Tube diameter
Tube length
Number of tubes
Void Fraction
Continuously-
Stirred-Tank Reactor
Gibbs Reactor
Equilibrium Reactor
Conversion Reactor
Standard Tower - Packed Single-Diameter
Sphere
Spheroid
Box-type Process Frame
Box-type Reformer without Catalyst
Pyrolysis Unit
Sizing Phase 6-27
6-27
Tank Plug Flow Reactor
If the reactor is Tank type Plug Flow reactor (Vertical/Horizontal
Standard Process Vessel, Vertical/Horizontal Jacketed Process
Vessel, etc.) the following sizing parameters available in the
Sizing Input Details group are:
Minimum Reactor capacity
Height/Length to diameter ratio
6.7.2 Continuously-Stirred-
Tank Reactor Sizing
When the equipment item belongs to the CSTR Reactor unit
available in the Continuously-Stirred-Tank Reactor Sizing Input
Details group.
following sizing parameters for CSTR reactors:
Height to diameter ratio
6.7.3 Gibbs, Conversion and
Equilibrium Reactor Sizing
When the equipment item belongs to the General Reactor unit
available in the Gibbs, Equilibrium or Conversion Reactor Sizing
Input Details group.
following sizing parameters for general reactors:
Height/Length to diameter ratio
6-28 Solids Handling Category
6-28
6.8 Solids Handling
Category
This category is used to size all solids handling related unit
table.
Equipment sizing is determined based upon unit operation type.
An overview of the sizing information available for each unit
operation type is outlined in the following sections.
6.8.1 Baghouse Filter Sizing
When an equipment item belongs to the Baghouse Filter unit
available in the Baghouse Filter Sizing Input Details group.
following sizing parameters for baghouse filters:
Bag diameter
Surface area per bag
Number of bags per baghouse
Surface area per baghouse
Number of Baghouses
Baghouse Filter Baghouse with Motor Shakers
Baghouse with Injected Pulsed Air
Cyclone Cyclone Dust Collector
Hydrocyclone Water Cyclone Dust Collector
Rotary Vacuum Filter Rotary Drum Filter
Rotary Disk Filter
Rotary Vacuum Filter Cyclone Dust Collector
Simple Solid Separator Cyclone Dust Collector
Sizing Phase 6-29
6-29
Total surface area
6.8.2 Cyclone Sizing
When an equipment item belongs to the Cyclone unit operation
in the Cyclone Sizing Input Details group.
following sizing parameters for cyclones:
Cyclone diameter
Number of cyclones
6.8.3 Hydrocyclone Sizing
When an equipment item belongs to the Hydrocyclone unit
available in the Hydrocyclone Sizing Input Details group.
following sizing parameters for Hydrocyclone:
Hydrocyclone diameter
Number of Hydrocyclones
6.8.4 Rotary Vacuum Filter
Sizing
When an equipment item belongs to the Rotary Vacuum Filter
unit operation type, it is sized according to a number of
parameters available in the Rotary Vacuum Filter Sizing Input
Details group.
following sizing parameters for rotary vacuum filters:
Filter diameter
Filter length
6-30 Solids Handling Category
6-30
Theory 7-1
7-1
7 Theory
7.1 Selection........................................................................................ 2
7.1.1 Automatic Selection Methods ..................................................... 2
7.2 Sizing............................................................................................. 5
7.2.1 Sizing Results Used in Design................................................... 21
7.3 References................................................................................... 24
7-2 Selection
7-2
7.1 Selection
The purpose of this document is to outline the Equipment
Selection and Sizing procedures used in Sizing.
Sizing Selection refers to the process of creating one or more
pieces of physical process equipment from a given HYSYS unit
operation. Many unit operations have an automatic selection
option, where Sizing selects a piece or pieces of equipment
based on process conditions and some pre-defined rules. All unit
operations have a "manual" selection option, where the user can
specify the equipment type to be used for a given unit
operation. When the Selection Phase is run, the selection
method (either automatic or manual) is applied to unit
operations in the case. The user can then edit the selected
equipment type for each unit operation on the Selection Phase
tab.
7.1.1 Automatic Selection
Methods
The following section gives details of the automatic selection
rules.
Separator, 3-Phase Separator
If an energy stream is attached to the separator, a jacketed
process vessel is selected. Otherwise, a standard process vessel
is selected. There is also an option for automatic selection of
separator orientation. If the vapour mass loading (i.e. the mass
fraction of vapour in the combined feed stream) is greater than
the maximum allowed for a horizontal separator, the orientation
is vertical; otherwise it is horizontal. You can set the maximum
vapour loading in the Separator Sizing and Design Basis.
Theory 7-3
7-3
Tank
The following table describes the selection logic for storage
tanks.
In the case of Liquid as the stored product type, the Selection
proceeds from top to bottom; i.e. a condition takes precedence
over another condition which appears below it in the table. For
example, if a liquid storage vessel has a design temperature of -
100
o
F, it is selected as a Cryogenic Storage Tank regardless of
Design Pressure and Design Vacuum.
Partial Condenser, 3-Phase
Condenser
The same selection logic as with separators applies to the
orientation of the reflux accumulator drum for these
condensers. The total condenser is not included, because the
reflux drum feed is always 100% liquid.
Compressor
Each compressor equipment type has allowable operating
ranges for actual volume capacity, required driver power, inlet
and outlet temperature, and inlet and outlet pressure. Each of
the equipment types is given a rating based on the operating
conditions of the compressor unit operation. A given operating
Storage Type Additional Conditions Selected Tank Type
Solid -- Cone-bottom Storage Bin
Gas Design Vacuum < 0 psig or
Design Pressure > 2.5 psig
Sphere
All Other Conditions Low-pressure Gas Storage
Vessel
Liquid Design Temp < -50
o
F Cryogenic Storage Tank
Design Vacuum < 0 psig or
Design Pressure > 2.5 psig
Horizontal Standard Process
Vessel
Design Pressure <= 15 psig Flat-bottom Storage Tank
All other conditions Horizontal Standard Process
Vessel
7-4 Selection
7-4
variable is given the highest rating if it falls in the midpoint of
the allowable range. If the operating variable falls outside the
allowable range, the variable is given a zero rating. The
composite rating of the compressor is the product of the
individual variable ratings. The compressor with the highest
composite rating is then selected. You can specify to use this
methodology on the set of gas compressors only, air
compressors only, or both.
Plug Flow Reactor
If packing exists (i.e. Void Fraction < 1.0), a Single-diameter
Packed Tower is selected. If there is no packing, a Vertical
Standard Process Vessel is selected. If there is no packing and
an energy stream is attached, a Vertical Jacketed Process Vessel
is selected.
CSTR
If there is an energy stream, an Agitated Tank - Enclosed &
Jacketed is used. If the CSTR is operating within 1 psi of
atmospheric pressure, and Agitated Tank - Open Top is used.
Otherwise, an Agitated Tank - Enclosed is used.
Cyclone
If the Number of Parallel Cyclones is 1, or if the inlet actual
volume flow is less than 900 ft3/min, a single Cyclone Dust
Collector is selected. Otherwise, a Multiple-Cyclone Dust
Collector is used.
Heater
If the outlet temperature is less than the temperature of the
hottest available utility fluid (taking into account the minimum
approach temperature), a floating-head shell and tube
exchanger is selected. Otherwise, an A-frame Type Process
furnace is selected.
Theory 7-5
7-5
7.2 Sizing
General (applies to all Equipment
Types)
For all unit operations, Design Pressure, Design Vacuum, and
Design Temperature are calculated. Sizing determines the
minimum and maximum operating pressure and temperature by
checking all streams attached to the unit operation. The Design
calculations are as follows:
If the unit operation is not operating under pressure (i.e.
vacuum conditions), the Design Pressure is 0 psig. If the unit
operation is a Tank, and it is operating below 15 psig, Design
Pressure
1
is used only.
If the minimum operating pressure is below atmospheric (i.e. <
0 psig), vacuum design is required:
The minimum allowable Design Vacuum is -14.7 psig.
(7.1)
(7.2)
(7.3)
(7.4)
Design Pressure
1
Maximum Operating Pressure (gauge)
Design Pressure Multiplier
=
Design Pressure
2
Maximum Operating Pressure
Design Pressure Adder
+ =
Design Pressure MAX (Design Pressure
1
Design Pressure
2
) , =
Design Vaccum Minimum Operating Pressure(gauge)
Design Vaccum Multiplier
=
7-6 Sizing
7-6
Design Temperature is calculated simply by applying the adder
to the operating temperature:
If the unit operation is operating below the Design Temperature
Cold Point, the adder is not applied and Design Temperature =
Operating Temperature.
Separator, 3-Phase Separator
(Equipment Type: Process Vessel)
The Sizing routines are based on the publications of Svrcek &
Monnery
1,2
. These sizing methods apply to separators and 3-
phase separators selected as Standard, Jacketed or Multi-Walled
Process Vessels.
Depending on the sizing input specifications, multiple solution
sets may be generated for a given separator. Sizing selects a
solution set based on the selection criteria (minimum weight,
minimum diameter, or minimum height/length). If desired, the
user can change the selected solution set. The selected solution
set dimensions are committed to the Design Phase.
Tank (Equipment Type: all possible
Tank selections)
Tanks are sized based on the following equations:
(7.5)
(7.6)
(7.7)
(7.8)
Design Temperature Minimum Operating Temperature
Design Temperature Adder
+ =
Total Storage Capacity Inlet Volume Flow Holding Time =
Spare Capacity Factor 1 1 Percent Spare Capacity Per Tank 100 ( ) ( ) =
Total Capacity (min) Total Storage Capacity Spare Capacity Factor =
Theory 7-7
7-7
If the Total Capacity exceeds the Maximum Capacity per Tank,
multiple tanks are created by rounding up Equation (7.9) to
the nearest whole number, i.e.,
The required tank dimensions are then calculated based on the
Tank Capacity (min.) and L/D or H/D ratio:
where:
Factor = 4 for cylinder, 6 for sphere or spheroid
Ratio = L/D or H/D ratio
The dimensions are always rounded up to the nearest 6", so the
tank capacity is then re-calculated:
(7.9)
(7.10)
(7.11)
(7.12)
(7.13)
(7.14)
(7.15)
(7.16)
Number of Tanks Total Capacity Max Capacity per Tank =
Tank Capacity (min) Total capacity(min) Number of Tanks =
Vessel Diameter Factor Tank Capacity (min) Ratio ( ) ( )
1 3
=
Tank Capacity (actual) Factor Diameter
2
Length or Height ( ) =
Total Capacity (actual) Tank Capacity (actual) Number of Tanks =
Tank Storage Capacity Total Storage Capacity Number of Tanks =
Total Spare Capacity Total Capacity (actual) Total Storage Capacity =
Tank Spare Capacity Total Spare Capacity Number of Tanks =
7-8 Sizing
7-8
Tray Section (Equipment Type:
Standard Tower, Trayed or Packed)
Tray sizing in Sizing is similar to the auto-section feature in the
HYSYS tray sizing utility. The actual tower equipment design
type (single-diameter or double diameter) depends on the user
selection (in the Selection Phase) and the number of sections
calculated by sizing.
For example, if tray sizing calculated 3 sections with diameters
of 4ft, 6ft and 8ft, and you have selected a single-diameter
design, the tower is 8 ft diameter. If you select a double-
diameter design, it has a bottom section diameter of 8ft and a
top section diameter of 6ft. The double-diameter towers can be
used only if sizing calculates more than one section.
Air Cooler (Equipment Type: Aerial
Cooler)
The HYSYS Cooler, Air Cooler, and all Condensers can be
selected as an Aerial Cooler equipment type. Aerial cooler sizing
is based generally on the method outlined in the Gas Processors
Suppliers Association Engineering Data Book, Revised Tenth
Edition, 1994, Volume I, Section 10. It is an iterative procedure
involving the convergence of a number of parameters, including
the overall heat transfer coefficient and the pressure drop
specification.
User-Selected Tower
Design Type
Number of Sections
(calculated by Sizing)
Actual Design Type)
Single-Diameter 1 or more Single-Diameter
Double-Diameter 1 Single-Diameter
Double-Diameter 2 or more Double-Diameter
Theory 7-9
7-9
Tube Geometry Calculations
The bare tube area, fin area and total extended area per unit of
tube length are calculated based on the tube and fin
dimensions. The number of tubes per unit of row width is
calculated based on the tube pitch. The extended area per unit
of row area is then calculated:
Number of Tube Rows
An initial estimate is made for the overall heat exchanger
coefficient. The number of tube rows is then calculated
according to the Selected method:
Hudson Products Corp. Method:
Therma Technology Inc. Method
(7.17)
(7.18)
(7.19)
(7.20)
If Delta Temp is: OR if Overall Coefficient is: Number Of Rows
<= 20 -- 3
>20 and <=100 -- 4
>100 and <= 200 < 2.8 5
>200 and <= 300 < 1.87 6
>300 < 1.4 8
Extended Area per Unit of Row Area Number of Tubes per Unit of Row Width
Total Extended Area per Unit of Tube Length
=
Delta Temp Process Inlet Temp Air Inlet Temp =
Number of Rows 4.9 8.15 Delta Temp Overall Coefficient 21.43 ( ) [ ]
0.359

(rounded up to the nearest integer)
+ =
Delta Temp Process Inlet Temp Process Outlet Temp =
7-10 Sizing
7-10
In Equations (7.18) through (7.20), all temperatures are in F
and Overall Coefficient is in Btu/h-ft2-F.
Air Temperature Rise
The estimated air temperature rise is calculated as follows:
Mean Temperature Difference
The Log-Mean-Temperature-Difference is calculated as follows:
Initially, the number of tube passes is set to the specified
maximum. The corrected LMTD (CMTD) is then calculated
based on the LMTD and the number of tube passes.
Total Extended Area
The total extended area required is calculated as follows:
(7.21)
(7.22)
(7.23)
(7.24)
(7.25)
(7.26)
AirTempRise OverallCoefficient 1 + ( ) 10 [ ]
ProcessInletTemp ProcessOutletTemp + ( ) 2 AirInletTemp [ ]
=
AirOutletTemp AirInletTemp AirTempRise + =
DeltaT1 ProcessOutletTemp AirInletTemp =
DeltaT2 ProcessInletTemp AirOutletTemp =
LMTD DeltaT2 DeltaT1 ( ) ln DeltaT2 DeltaT1 ( ) ( ) =
Total Extended Area Cooling Duty CMTD Overall Coefficient ( ) =
Theory 7-11
7-11
The total extended area per unit of bay area is calculated:
Bay Dimensions and Number of Bays
The Length per Bay, Width per Bay and Number of Bays is
calculated using the specifications for Minimum Bay Length to
Width Ratio and Maximum Tube Length.
Tubeside Pressure Drop
The tubeside pressure drop is calculated using the Beggs & Brill
correlation. Both single-phase and two-phase pressure drop is
supported. If the calculated pressure drop exceeds the
maximum allowable, the number of tube passes is reduced by
one until the pressure drop specification is satisfied.
Tubeside Heat Transfer Coefficient
The tubeside heat transfer coefficient calculation depends on
whether the aerial cooler is operating in condensing or single-
phase service.
Single-Phase Cooling Service
(7.27)
(7.28)
Total Extended Area per Unit of Bay Area Extended Area per Unit of Row Area

Number of Rows
=
TubesideCoefficient 0.023 NRe
0.8
NPr
0.333
FluidThermCond TubeID =
7-12 Sizing
7-12
Condensing Service
For condensing service, the condensing coefficient is calculated
according to the method of Boyko and Kruzhilin (from Process
Heat Transfer by Hewitt, Shires and Bott, CRC Press, 1994, pp.
682-683):
The overall tubeside coefficient is the average of the inlet and
outlet condensing coefficients:
Air Properties, Flow and Heat Transfer
Coefficient
The average air properties (mass density, thermal conductivity,
heat capacity and viscosity) are calculated using the inlet and
outlet air temperature. The required mass flow of air per bay is
calculated as follows:
The air velocity is then calculated based on the air properties
and mass flow, as well as the exchanger and tube geometry.
The air Reynolds and Prandtl numbers are calculated, and finally
the air heat transfer coefficient is estimated.
(7.29)
(7.30)
(7.31)
LiquidCoeff 0.021 LiquidThermCond TubeID NRe
0.8
NPr
0.43
=
InletCondensingCoeff LiquidCoeff 1.0 InletVapMassFrac LiqDensity VapDensity + [ ]
0.5
=
OutletCondensingCoeff LiquidCoeff 1.0 OutletVapMassFrac LiqDensity VapDensity + [ ]
0.5
=
(7.32)
TubesideCoefficient InletCondensingCoeff OutletCondensingCoeff + ( ) 2 =
(7.33)
MassFlowAirPerBay CoolingDuty AirHeatCapacity AirTempRise NumberOfBays ( ) =
Theory 7-13
7-13
Overall Heat Transfer Coefficient
The overall coefficient is calculated according to the following
equation:
where:
Fan Calculations
The fan diameter is calculated according to the following
equation:
Initially the Number of Fans per Bay is set to the minimum
specified. If the calculated fan diameter exceeds the maximum
allowable fan diameter, the Number of Fans per Bay is
incremented by one and the fan diameter is re-calculated.
The power per fan is then calculated using the air properties, air
flow, exchanger geometry and fan diameter.
Cooler, Heater, Heat Exchanger,
Reboiler, Condenser (Equipment
Type: Shell & Tube Exchanger)
Sizing shell and tube exchanger sizing is based on AEA
Technologys Shell and Tube exchanger design program
HTFS.TASC. For each exchanger, the TASC calculation engine,
which is embedded into Sizing, runs in Design mode. A TASC
(7.34) OverallCoeff 1 1 TubesideCoeff AreaRatio FoulingFactor AreaRatio 1 AirCoeff + + [ ] =
(7.35)
(7.36)
AreaRatio Extended Area per Tube Bare Tube Area per Tube =
FanDiameter 0.4 FaceAreaPerBay NumberOfFansPerBay 4 ( )
0.5
(rounded up to the nearest 1 inch)
=
7-14 Sizing
7-14
input file produced by Sizing is located in the <HYSYS Install
Path>\Scripts \HeatExchangers directory and is called
Hestdes.TAI. The data contained in this input file is always for
the exchanger which was most recently sized by Sizing. The file
can be opened using a full version of TASC in order to perform a
more detailed thermal design. Refer to the TASC documentation
for further information. The HYSYS Heat Exchanger, Cooler,
Heater, Condenser (all types) and Reboiler (all types) can be
mapped to a Shell and Tube Exchanger equipment type.
Heater, General Reactor (Equipment
Type: Furnace)
A very simple sizing calculation is performed for Furnaces:
The HYSYS Heater and the General Reactors (Gibbs,
Equilibrium, Conversion) can be selected as a Furnace
equipment type. For the General Reactors, the Absorber Duty
comes from an attached energy stream (if present).
Compressor (Equipment Type: Air or
Gas Compressor)
The following equations are used for sizing:
(7.37)
(7.38)
(7.39)
(7.40)

(7.41)
Fired Duty Absorbed Duty (From HYSYS) Percent Thermal Efficiency 100.0 ( ) =
Design Mass Capacity Inlet Mass Flow Capacity Overdesign Factor =
Design Adiabatic Head Adiabatic Head Head Overdesign Factor =
Design Polytropic Head Polytropic Head Head Overdesign Factor =
Gas Power Design Mass capacity Design Polytropic Head Percent
Polytropic Efficiency 33000 lb-ft/min-hp 100
(
)

=
Theory 7-15
7-15
The Scheels equation
3
(from page 13-29 of GPSA data book)
estimates the Mechanical Losses as,
Expander (Equipment Type: all
Turbines)
The following equations are used for sizing:
(7.42)
(7.43)
(7.44)
(7.45)
(7.46)
(7.47)
Mechanical Losses Gas Power
0.4
=
Design Power Gas Power Mechanical Losses + =
Driver Power Design Power rounded up to next
larger available driver size
=
Design Mass Capacity Inlet Mass Flow Capacity Overdesign Factor =
Design Power DesignMass Capacity Mass Enthalpy In Mass Enthalpy Out ( ) =
Driver Power Produced Design Power rounded to the next
smaller drive size
=
7-16 Sizing
7-16
Pump (Equipment Type: all Pumps)
Currently, frictional losses in suction and discharge piping are
not taken into account in head calculations.
Plug Flow Reactor (Equipment Type:
Packed Tower)
A HYSYS PFR may be selected as a standard Packed Tower. The
Packed Tower has the same cross-sectional area as the multiple
tubes, i.e.:
The Vessel inside Diameter is then rounded up to the nearest 6",
and the Total Area is calculated as shown below.
(7.48)
(7.49)
(7.50)
(7.51)
(7.52)
(7.53)
(7.54)
(7.55)
(7.56)
Design Volume Capacity Inlet Actual Volume Flow Capacity
Overdesign Factor
=
Design Head Operating Head Head Overdesign Factor =
Hydraulic Power Design Volume Capacity Design Head
Specific Gravity 3960 USgal-ft/min-hp
=
Design Power Hydraulic Power Percent Pump Efficiency 100 ( ) =
Drive Power Design Power rounded up to next larger
available drive size
=
Total Area (min) 4 Tube Diameter ( )
2
Number of Tubes =
Vessel Inside Diameter 4 Total Area (min) =
Total Area (actual) 4 Vessel Inside Diameter
2
=
Vessel Height Tube Length (rounded up to the nearest 6 ) =
Theory 7-17
7-17
Packing Height is then rounded to the nearest 6. The Vessel
Height, is at least 1ft greater than the Packing Height, e.g.
Plug Flow Reactor (Equipment Type:
Process Vessel)
The user must supply a reactor volume in the HYSYS case.
Sizing does not default the reactor volume or space time, etc.,
because of the multitude of reaction types and kinetics
available. The user-supplied reactor volume is then used to
calculate the reactor dimensions:
where:
Factor = 4 for cylinder, 6 for sphere or spheroid
Ratio = L/D or H/D ratio
(7.57)
(7.58)
Vessel Height from
Equation (7.56) (ft)
Packing Height (ft)
Calculated Vessel
Height (ft)
20 15 20
20 19.5 20.5
(7.59)
(7.60)
(7.61)
(7.62)
(7.63)
Packing Volume (min) Total Area (actual) Vessel Height
1 Void Fraction ( )

=
Packing Height Packing Volume (min) Total Area (actual) =
Packing Volume (actual) Packing Height Total Area (actual) =
Vessel Volume Vessel Height Total Area (actual) =
Void Volume Vessel Volume Packing Volume =
Vessel Diameter Factor Reactor Capacity (min) Ratio ( )
3
=
Vessel Length or Height Vessel Diameter Ratio =
7-18 Sizing
7-18
Now the dimensions are rounded up to the nearest 6". So, the
actual reactor capacity is calculated:
If there is liquid flow in the reactor,
And if the reactor is vertical,
CSTR (Equipment Type: Agitated
Tank)
The same methodology as with the PFR as a Process Vessel
(described above) applies to the CSTR. The Agitated Tanks have
Vertical orientation.
General Reactor (Equipment Type:
Agitated Tank, Process Vessel,
Packed Tower, Sphere, Spheroid)
General reactor includes Gibbs, Equilibrium and Conversion type
reactors. The same methodology as with the PFR as a Process
Vessel (described above) applies to the General Reactor when
selected as a vessel.
(7.64)
(7.65)
(7.66)
(7.67)
Reactor Capacity (actual) Factor Diameter
2
Length or Height ( )
=
Liquid Holdup Volume Liquid Level Fraction Reactor
capacity (min)
=
Liquid Holdup Percent Liquid Holdup Volume Reactor Capacity (actual) 100 =
Liquid Holdup Depth Liquid Holdup Percent Vessel Height 100 =
Theory 7-19
7-19
General Reactor (Equipment Type:
Process Furnace, Box-type Reformer
without Catalyst, Pyrolysis Unit)
General reactor includes Gibbs, Equilibrium and Conversion type
reactors. The same methodology, as with the Heater as a
Process Furnace, applies to the General Reactor when selected
as a Furnace or Furnace Reactor.
Baghouse Filter (Equipment Type:
Baghouse)
Baghouse filters are sized in HYSYS because the process
calculations (i.e. outlet stream conditions and composition)
depends on the performance/size of the baghouse. Therefore,
Sizing uses the HYSYS values for Bag Diameter, Area per Bag,
Number of Bags Per Cell, Area per Cell, Number of Cells and
Total Cell Area. One additional sizing calculation performed by
Sizing is:
Sizing also calculates the solid, gas and total Actual Volume
Flow and Mass Flow on a per Baghouse (i.e. per Cell) and
Overall basis.
Cyclone (Equipment Type: Cyclone
Dust Collector)
Like the Baghouse, Cyclones are sized in Sizing using the HYSYS
values for Cyclone Body Diameter and Number of Cyclones in
Parallel. Sizing calculates the solid, gas and total Actual Volume
Flow and Mass Flow on a per Cyclone and Overall basis.
(7.68) Total Number of Bags Number of Bags Per Cell Number of Cells =
7-20 Sizing
7-20
Hydrocyclone (Equipment Type:
Water-only Cyclone - Mineral
Separation)
The methodology used for the Cyclone also applies to the
Hydrocyclone. Sizing calculates the solid, liquid and total Actual
Volume Flow and Mass Flow on a per Hydrocyclone and Overall
basis.
Rotary Vacuum Filter (Equipment
Type: Rotary Drum or Disk Filter)
Sizing uses the HYSYS values for Filter Radius to calculate the
Filter Diameter (Filter Radius * 2, rounded up to the nearest 6")
and Filter Width (rounded up to the nearest 6"). The following
additional calculations are also done by Sizing:
Sizing also calculates the solid, liquid and total Actual Volume
Flow and Mass Flow on a per Filter and Overall basis.
(7.69)
(7.70)
Filter Surface Area Filter Diameter Filter Length (Width) =
Solids Handling Rate Total Solid Mass Flow Filter Surface Area =
Theory 7-21
7-21
7.2.1 Sizing Results Used in
Design
The following table lists the sizing output results that are
committed to the Design Phase for use as input when Run
Phase button is clicked (to move from the Sizing Phase to the
Design Phase).
Unit Operation Equipment Type Sizing Output Used in Design
All operations All equipment types Design pressure (if
applicable)
Design temperature (if
applicable)
Design vacuum (if
applicable)
Operating temperature (if
applicable)
Separator,
3-Phase
Separator
Process Vessel Vessel Diameter
Vertical Process
Vessel
Vessel Capacity
Vessel Height
Fluid Volume Percent
Demister Thickness
Horizontal Process
Vessel
Vessel Length
Tank All Tanks Number of Tanks
Vessel Diameter
Vessel Capacity
Vertical Tank Vessel Height
Horizontal Tank Vessel Length
Process Vessel Set Application Type to
STORAGE
7-22 Sizing
7-22
Tray Section Single-Diameter
Tower (Trayed or
Packed)
Vessel Diameter
Vessel Height
Single-Diameter
Tower (Trayed)
Tray Type
Tray Thickness
Tray Spacing
Number of Trays
Single-Diameter
Tower (Packed)
Number of Packed Sections
(= Number of Stages)
Total Packing Height
Double-Diameter
Tower (Trayed or
Packed)
Bottom Section Diameter
Bottom Section Height
Top Section Diameter
Top Section Height
Double-Diameter
Tower (Trayed)
Bottom Section Number of
Trays
Top Section Number of
Trays
Double-Diameter
Tower (Packed)
Bottom Packing Height
Top Packing Height
Aerial cooler Aerial cooler Bare Tube Area
Tube Thickness
Tube Length
Bay Width
Number of Bays
Fin Pitch
Tube Fin Height
Number of Tube Rows
Tube Pitch
Number of Fans per Bay
Power per Fan
Heater Process Furnace Fired Duty
Standard Gas Flow (if
applicable)
Actual Liquid Volume Flow
(if applicable)
Process Type
Theory 7-23
7-23
Cooler,
Heater,
Heat
Exchanger,
Condensers,
Reboilers
Shell and Tube Heat
Exchanger
Surface Area
Number of Shells
Tube Pressure
Tube Temperature
Number of Tube Passes
Shell Pressure
Shell Temperature
Number of Tubes per Shell
Extended Tube Length
Tube Thickness
Tube Pitch
Shell Diameter
TEMA Classification
Compressor All Compressors Actual Volume Capacity
Driver Size
Expander All Turbines Power Output
Pump All Pumps Actual Volume Capacity
Head
Driver Size
Efficiency
CSTR Agitated Tank Vessel Diameter
Vessel Height
Vessel Capacity
Fluid Depth
PFR Single-Diameter
Tower (Packed)
Vessel Diameter
Vessel Height
(0 if Void Fraction = 1, 1 if
Void Fraction < 1, > 0)
PFR,
General Reactor
Vertical Process
Vessel (Standard,
Jacketed, Multi-
walled)
Vessel Diameter
Vessel Height
Vessel Capacity
Fluid Depth
Horizontal Process
Vessel (Standard,
Jacketed, Multi-
walled)
Vessel Diameter
Vessel Height
Vessel Capacity
7-24 References
7-24
7.3 References
1
Svrcek, W. Y., Monnery, W. D., Design Two-Phase Separators Within
the Right Limits" from Chemical Engineering Progress, 53-60,
October, 1993.
2
Svrcek, W. Y., Monnery, W. D., "Successfully Specify Three-Phase
Separators" from Chemical Engineering Progress, 29-40,
September, 1994.
3
Engineering Data Book, Gas Processors Suppliers Association,
Volume 1, 10th Edition, 1994
General Reactor Single-Diameter
Tower (Packed)
Vessel Diameter
Vessel Height
(Vessel Height - 1ft)
(1)
Sphere, Spheroid Vessel Diameter
Vessel Capacity
Vessel Height (Spheroid
only)
Process Furnace,
Box-type Reformer
without Catalyst,
Pyrolysis Unit
Fired Duty
Standard Gas Flow (if
applicable)
Actual Liquid Volume Flow
(if applicable)
Process Type
Baghouse Filter All Baghouse Filters Number of Units
Total Actual Volume Flow
Surface Area
Cyclone Cyclone Dust
Collector
Diameter
Number of Units
Total Actual Volume Flow
per Unit
Rotary Vacuum
Filter
Rotary Drum Filter,
Rotary Disk Filter
Surface Area
Solids Mass Flow Rate
Solids Handling Rate
Hydrocyclone Water-only Cyclone
- Mineral Separation
Diameter
Number of Cyclones per
Manifold
Total Mass Flow
I-1
Index
A
Automatic Selection Methods
3-Phase Condenser 7-3
3-Phase Separator 7-2
Compressor 7-3
CSTR 7-4
Cyclone 7-4
Partial Condenser 7-3
Plug Flow Reactor 7-4
Separator 7-2
Tank 7-3
B
Basic Input Data 2-10
Basis Phase Tab 4-1
Selection Phase Tab 5-1
Sizing Phase Tab 6-1
Basis Phase 4-1
General Project Page 4-2
Global Design Page 4-8
Global Selection Page 4-6
Button Bar 2-4
C
Closing Views 2-19
Compressor
Composite Rating 7-4
Mechanical Losses 7-15
D
Design Phase
Imported Sizing Results 7-21
Drop Down Lists 2-17
E
Editing Input 2-19
Equipment Sizing
3-Phase Separator 7-6
Air Cooler 7-8
Baghouse Filter 7-19
Compressor 7-14
Condenser 7-13
Cooler 7-9
CSTR 7-18
Cyclone 7-19
Expander 7-15
General Equipment Sizing 7-5
General Reactor 7-14, 7-18
Heat Exchanger 7-13
Heater 7-137-14
Hydrocyclone 7-20
Plug Flow Reactor 7-167-17
Pump 7-16
Rotary Vacuum Filter 7-20
Separator 7-6
Tank 7-6
Tray Section 7-8
Exporting Data 3-14
F
File Menu
starting a simulation 3-7
G
General Project Page
Minimum Basis Button 4-3
Project Basis Button 4-4
See also Basis Phase
Title Block Radio Button 4-5
Global Design Page
General Radio Button 4-8
Heat Transfer Button 4-11
Reactors Button 4-17
Rotating Equipment Button 4-14
Towers Button 4-15
Vessels Button 4-9
Global Selection Page
H
Help Options 3-13
Hot Keys 2-13
I
Importing Unit Operations 3-2
M
Menu Bar
access 3-6
edit 3-10
saving a simulation 3-7
starting a simulation 3-7
Menu Bar Options 3-5
Edit 3-10
File 3-7
I-2 Index
I-2
Help 3-13
Sizing 3-10
Tools 3-11
Window 3-11
P
PICASSO 1-2
Printing 3-9
Property Pages and Tabs 2-11
Property View
pages 2-12
tabs 2-12
Property Views
cells 2-12
highlight location 2-12
S
Saving
save as 3-7
Saving a Case
save all 3-7
Saving a Simulation 3-7
Scroll Bars 2-17
Selecting Items 2-7
Selecting Multiple Unit Operations 3-4
Selecting Single Unit Operations 3-3
Selection Phase 5-1
Equipment Categories 5-3
Heat Transfer 5-6
Reactors 5-12
Rotating Equipment 5-9
Solids Handling 5-14
Tower 5-12
Vessels 5-4
Sizing
Capabilities 1-3
Sizing Basics 3-1
Sizing Interface 2-1
Active View/Location 2-11
Basics 2-2
Interface Elements 2-8
Manoeuvring Through 2-13
PFD View 2-9
Property Pages 2-12
Property Tabs 2-12
Selecting Items 2-13
Terminology 2-5
Sizing Phase 6-1
Heat Transfer Category 6-11
3 Phase Reboiler Sizing 6-15
Condenser Sizing 6-12
Cooler Sizing 6-12
Heat Exchanger Sizing 6-12
Heater Sizing 6-12
Reboiler Sizing 6-15
Reactor Category 6-25
CSTR Sizing 6-27
General Reactor Sizing 6-27
Plug Flow Reactor Sizing 6-26
Rotating Equipment Category 6-16
Compressor Sizing 6-18
Pump Sizing 6-18
Sizing and Displaying Individual Items 6-4
Solids Handling Category 6-28
Baghouse Filter Sizing 6-28
Cyclone Sizing 6-29
Hydrocyclone Sizing 6-29
Rotary Vacuum Filter Sizing 6-29
Tower Category 6-20
Packed Tower Sizing 6-21
Trayed Tower Sizing 6-23
Vessels Category 6-6
3 Phase Separator Sizing 6-8
Separator Sizing 6-7
Tank Sizing 6-10
Starting a Simulation 3-7
using the menu bar 3-7
Supplying Input 2-15
T
TASC 7-13
The Property View 2-11
W
Workspace
Loading 3-12
Saving 3-12

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