DYNAMIC SIMULATION COURSE 2013

Beta
DYNAMICS
QUICK GUIDE
2013
By:
Eng. Ahmed Deyab Fares
eng.a.deab@gmail.com adeyab@adeyab.com

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com

DYNAMIC SIMULATION COURSE 2013

NGL FEED (St. State Case)

A stream of NGL at 15oC, 380 kPa and with a Std Ideal Liq Vol Flow of
200 m3/hr and the following composition:
Component
Ethane
Propane
i-Butane
n-Butane

Mole Fraction
0.01
0.43
0.07
0.12

Component
i-Pentane
n-Pentane
n-Hexane

Mole Fraction
0.05
0.04
0.28

Is fed to a Valve (pressure drop =70 kPa) and then sent to a Separator.
The Liquid product from the separator is then fed to a Pump (delta P =
1900 kPa) with adiabatic efficiency of 75% and then flashed down
through a Valve (P=70 kPa). The valve outlet is then sent to the tube
side of a Shell and Tube Heat Exchanger, where it exchanged heat with
a shell inlet stream named (Shell In), the shell out stream named (Shellout) have the following information:
Temperature
155 oC

Pressure
1100 kPa

Std Ideal Liq Vol Flow

55 m3/hr

Component

Mole Fraction

Component

Mole Fraction

Ethane
Propane
i-butane
n-butane

0
0
0
0.03

i-pentane
n-pentane
n-hexane

0.11
0.11
0.75

The P for both shell & tube sides=70 kPa, and UA = 8000 kJ/C-h. The
tube side outlet is then sent to a heater in order to meet the column feed
temperature (50oC) the P inside the heater is 70 kPa.
Calculate:
- The pressure of the Column Feed Stream
- The molar flowrate of the Column Feed Stream

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com

DYNAMIC SIMULATION COURSE 2013

Transitioning From St. State to Dynamics

1) Equipment Sizing
Vessel

Heater

Heat Exchanger
Shell

Volume

85 m

33 m

9m

Tube

33 m3

2) Enable pressure flow equations not

pressure drop
Valves
F= Fn(Cv, P1, P2)
Heat Transfer Equipment
F= KP
Rotary Equipment
Characteristic Curve (Q vs H & Q vs Efficiency)
Vessels
dp/dt=Fn (V, F, T)

3) Enable stream pressure specifications on

ALL BOUNDRY STREAMS

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com

DYNAMIC SIMULATION COURSE 2013

Adding PID controllers in Aspen HYSYS

PID Controllers
Process Variable - the "measured" variable. This is usually the variable that
you want to control, i.e. pressure, temperature, liquid level, etc.
Output Target Object - the "adjusted" variable. This is what the
controller can change in order to control the process variable. This is most
often a valve.
Action - the action of the controller can be chosen as Reverse or Direct. The
OP of a Direct action controller will rise as the PV rises above the SP.
Likewise; the OP will fall if the PV falls below the SP. Conversely, the OP of a
Reverse action controller will fall if the PV rises above the SP, and rise if the
PV falls below the SP.
Mode - the mode of the controller can be chosen as: Off, Man. (manual),
Auto (automatic), or Tune. In Manual mode, the user can set the OP; in
Automatic mode, the user can set the SP.
SP - the setpoint of the controller. This is the "goal" value. The controller
will always strive to have the process variable meet this value.
PV - an abbreviation for the Process Variable.
OP - an abbreviation for the Output Variable.
Kc - the controller gain.
Ti - the integral time of the controller.
Td - the derivative time of the controller.
PV Minimum - should be set to the minimum value that the PV could reach
during the simulation.
PV Maximum - should be set to the maximum value that the PV could
reach during the simulation. It is used with PV minimum to determine the
"span" of the controller.

Note that not every variable must be set for each controller. The value for each cell
will depend on the controllers situation.

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com

DYNAMIC SIMULATION COURSE 2013

NGL Controllers
Separator
Feed Controller

Separator
Pressure Controller

Connections
Controller Name

NGL-FC

Flare-PC

Process Variable Source

To Sep, Mass Flow

Separator, Vessel Pressure

Output Target Object

Parameters
Action

VLV-100

VLV-102

Reverse

Direct

PV Minimum

0 kg/h

135 kPa

PV Maximum

250 000 kg/h

415 kPa

Mode

Auto

Auto

SP

1.169 e+5 kg/h

310 kPa

Kc
TI

0.1
0.2 minutes

2.0
2.0 Minutes

Separator
Level Controller

Column Feed
Temperature Controller

Connections
Controller Name

Separator-LC

Heater-TC

Process Variable Source

Separator, Liquid Percent Level

ColFeed, Temperature

Output Target Object

Parameters
Action

VLV-101

Heater-Q (0 2.0e7 kJ/hr)

Direct

Reverse

PV Minimum

0%

15C

PV Maximum

100%

80C

Mode

Auto

Auto

SP

50%

50C

Kc
TI

2.0
10 Minutes

5
20 Minutes

Add a strip chart to monitor the change of the vessel pressure

with time around the Set Point (SP)
By: Eng. Ahmed Deyab Fares
Mobile: 002-01227549943 - Email: adeyab@adeyab.com

DYNAMIC SIMULATION COURSE 2013

Depropanizer
The heated stream from the NGL Feed steady state case is fed to the 12th
tray of a depropanizer (distillation column) which consists of 24 stages, a
full reflux condenser and Kettle reboiler. The pressures inside the
condenser and reboiler are 1925 and 2070 kPa respectively. Column
reflux ratio is 2.
The second specification for the distillation column is a 0.95 mole
fraction of both ethane and propane comes out of the condenser stage.
You may need to install valves to the 2 column products

Column Sizing:

Volume

Condenser

Reboiler

10 m3

20 m3

For the Tray Section, specify the following values on the Tray Sections
page of the Rating tab.
Type of trays
Tray Spacing
Diameter
Weir Height
Flow Paths
Foaming Factor
Tray Volume [m3]

Rating (dynamics) DP
Stage 12 Pressure

Valve tray
600 mm
3.7 m
60 mm
2
0.85
..

..
..

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com

DYNAMIC SIMULATION COURSE 2013

Depropanizer Column Controllers

Condenser
Condenser
Pressure Controller Level Controller
Connections
Cond-LC

Controller Name

Cond-PC

Process Variable Source

Condenser, Vessel
Pressure

Condenser, Liquid Percent

Level

VLV-103

Reflux Stream (0 3000)

PV Minimum

Direct
1725 kPa

Direct
0%

PV Maximum

2070 kPa

100%

Mode

Auto

Auto

SP

1925 kPa

50%

Kc
TI

2.0
2.0 Minutes

2.0
10 Minutes

Output Target Object

Parameters
Action

Reboiler
Level Controller

Tray 23
Temperature Controller

Connections
Controller Name

Reb-LC

Tray 23-TC

Process Variable Source

Reboiler, Liquid Percent Level

Main TS, Stage Temp., Stage

23

Output Target Object

Parameters
Action

VLV-104

Q Reb (0 1.0e8 kJ/hr)

Direct

Reverse

PV Minimum

0%

100C

PV Maximum

100%

200C

Mode

Auto

Auto

SP

50%

140C

Kc
TI

2.0
10 Minutes

5
20 Minutes

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com

DYNAMIC SIMULATION COURSE 2013

Exercise:
Change the Output Variable for the Condenser-LC to Cond-Q, from
Reflux. Make sure that you choose reasonable values for the maximum
and minimum cooling duty. Change the molar flow specification for the
Reflux stream to 1620 kgmole/h (3560 lbmole/hr).

Does this control strategy provide better control over the DePropanizer?

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com

DYNAMIC SIMULATION COURSE 2013

Tank Filling
Feed stream consists of 0.8 H2O, 0.04 O2, and 0.16 N2 (Mole fractions) @
25C and 3 bar-g, and a flow rate of 4000 Kg/hr, enters a Tank
(Volume= 3 m3, Liquid Volume Percent 0%)
Fluid pkg: Peng Robinson
Feed and both products stream Valves spec:
Pressure drop for all valves = 100 kPa
CV (Conductance):

VLV-100
70

VLV-101
50

VLV-102
50

- Control the tank liquid percent level and the feed mass flow

Controllers:

SP
Kc
Ti (Minutes)
PV Min
PV Max

LIC

FIC

50%
0.5
5
0%
100%

4000 kg/hr
0.5
1
0 Kg/hr
9000 Kg/hr

- Run the integrator for 180 min. with acceleration of 0.5

- Create a strip chart to monitor the filling of the tank with the
controller setpoint.
By: Eng. Ahmed Deyab Fares
Mobile: 002-01227549943 - Email: adeyab@adeyab.com

DYNAMIC SIMULATION COURSE 2013

Refrigerated Gas Plant

A feed stream is fed to a valve (delta P= 70 kPa) before entering an inlet separator,
which removes the free liquids (both water and other more dense liquids). Overhead
gas from the inlet Separator is fed to the tube side of a shell & tube heat exchanger,
the tube side outlet (-10 oC) is then sent to a Chiller where it is cooled to -20oC,
which will be modeled simply as a Cooler (Pressure Drop=35 kPa). The cold stream is
then separated in a low-temperature separator (LTS). Overhead gas from the LTS is
fed to the shell side of the shell & tube heat exchanger where it is heated with the
inlet separator vapor to meet Sales Gas Specifications.
Feed Stream:
Pressure
6200 kPa

Temperature
0C
Composit ion:
Component
N2
H2S
CO2
Methane
Ethane
Propane

Mole%
0.0066
0.0003
0.0003
0.7576
0.1709
0.0413

Component
i-Butane
n-Butane
i-Pentane
n-Pentane
n-Hexane
H2O

Molar Flow Rate

1440 kgmole/h
Mole%
0.0068
0.0101
0.0028
0.0027
0.0006
0.0000

Use Peng Robinson (PR) Equation of State

Shell & Tube Heat Exchanger Parameters:

Build a steady state case and convert it to dynamics (make the necessary
changes).
Enter a vessel volume of 2 m3 (70 ft3) for both separators
Set up the following PID controllers.
1- Control the level of the inlet separator with the following parameters:

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com 10

DYNAMIC SIMULATION COURSE 2013

2- Control the pressure of the LTS (Low Temp Separator) by
manipulating the valve on the Sales Gas stream (Shell Side outlet
stream) with the following parameters:

Run the case in the dynamics mode

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com 11

DYNAMIC SIMULATION COURSE 2013

Control Loop Exercise

1- For the following heat exchanger, draw a feedback control loop
It is desired to control the Exit stream temperature, T2, at a certain set point, SP.

2- For the following heat exchanger, draw a feedback control loop.

It is desired to control the liquid level inside the tank, H, at certain set
point, SP.

3- For the following column, draw a feedback control loop

It is desired to control column's bottom temperature, T, at certain set
point, SP.

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com 12

DYNAMIC SIMULATION COURSE 2013

Expanding the overhead system

1- Add a Splitter (TEE)
2- Add the Relief Valve (Orifice Area = 1300 mm2)

3- Add the Air Cooler (delta P =70 kPa)

4- Add the Accumulator

5- Add the Vapour Product Valve (delta P =70 kPa)

6- Add the Pump (Pump Speed = 85 rpm)

Curve Speed = 60 rpm
Flow (USGPM)
0
100
200
300
400
500
600
700
800

Head (ft)
275
260
235
190
150
140
100
70
40

% Efficiency
0
42
60
66
70
75
69
65
60

7- Add a Reflux Valve (delta P =70 kPa)

By: Eng. Ahmed Deyab Fares
Mobile: 002-01227549943 - Email: adeyab@adeyab.com 13

DYNAMIC SIMULATION COURSE 2013

Controllers:
- Accumulator Pressure Controller

- Accumulator Level Controller

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com 14

DYNAMIC SIMULATION COURSE 2013

By: Eng. Ahmed Deyab Fares

Mobile: 002-01227549943 - Email: adeyab@adeyab.com 15