Pressure Flow Theory

Pressure Flow Theory

@2005 AspenTech -AII Rights reserved.

EB1017.04.05
Document1

Pressure Flow Theory

Workshop
The Pressure Flow Theory module introduces you to the 1U1derlying concepts
necessary for developing your own dynamic simulations with Aspen HYSYS
Dynamics. Sorne ofthe things you will leam :from this module are:

The underlying assumptions of dynamic simulation with Aspen HYSYS

How to analyze your Flowsheet to make appropriate pressme flow

specifications

Which pressure-flow specifications make sense

How to troubleshoot the process Flowsheet for inconsistent pressure-flow

specifications

Learning Objectives
Once you have completed this section, you wil11U1derstand:

The basic concepts of dynamic simulation in Aspen HYSYS

Dynamic pressure flow specifications

Process Flowsheets

Preuure Flow Thaory

Theoretical Foundations
The Pressure-Flow Solver: A Boundary Value Problem
In tams of pressmes and flows, perhaps tb.e simplest way to view tbe pressure tlow
solver in Aspen HYSYS Dynamics is to consider tb.e Flowsheet as a Boundary Value
Problem.

lf you were to make pressure or tlow specifications on all tb.e boundary streams
(feedslproduct s1reams in a Flowsheet), tb.m all tb.e intemal pressures and flows
would be solved Sllllultaneously at eacb. integra1ion step by tbe pressure-flow solver.
The intema1 stteam pressures and flow rates are calculated ftom tb.e pressure
grad.ients in tb.e Flowsheet. Flow rates are detennined ftom:
Since pressure gradients
are lhe dving fon::e for
flow In Allpen HYSYS, care
should be taken to ensure
that the preesure prollle of
the flowsheet has been
propaty speclfted.

1. Changes in vapour pressure nodes (vessels with hold-ups) witb.in tb.e Flowsheet
system.

2.

Resistance across valves

3.

Conductance through equipment (coolers, heaters, heat exchangers)

Pressure Nodes
All unit operatims (witb. hold-up) represent pressure nodes. Some unit operations
may con.tribute to one or more nodes. For example:

Heaters/Coolers witb. multiple zones

Heat Exchanger- shell side/tube side

Columns witb.multiple stages (ttays)

Pruaure Flow Thaory

Fundamental Principie
Vessel equipment has a fixed geometty and thus a fixed volume. Ma1hema1ically,
this means that:
Thia concept i8
fundamental to perforrring
dynamic simulation
analyses with Aspen
HYSYS.

dV

dt

-O

(1)

Therefure, fura fixed volume, a pressure node (vessel pressure) is calculated as a

fimctian ofthe vessel temperature and the vessel hold up.
In dynamic mode, the rate of cbange in vessel pressure is related to the rate of
change oftemperature (enthalpy) and the rate of change of material hold-up Qevel):

dP

dt = fn(V, F, T)

(2)

where: Y= Fixed volume

F = Clumge in tlow (hold-up)

T= Temperature (dlange in en1halpy)

A volumetric flow balance around the vessel can be expressed as follows:
(3)

where: AY.= Volume change dueto pressure cbange

ll.VF = Volume change du.e to flow clumges

ll.Vr= Volume cbange du.e to temperature diange
The total volume change must always be zero.

Pressure Flow Theory

Example
Consider the operation of a separator in dynamic mode that is initially at steady state
with a level of 60%:
Figura 1

------Assume fixed flow

Flowin
Fixed geometry
60%

------Assume fixed flow

Remember:

In Steady State,
Flow into separator = Flow out of separator,
no accumulation.
But in Dynamics, if the separator feed flow increases with the
product flow rates (vapour and liquid) remaining oochanged, the
level (hold up), temperature (enthalpy) and pressure of the vessel
must all change from the steady state condition.

Liquid Level lncreases

Since
Liquid Flow In - Liquid Flow Out = Accumulation (hold-up),
an increase in the feed liquid Flowrate with a constant liquid product Flowrate results
in the liquid level (hold-up) increasing.

Pressure Flow Theory

Vessel Pressure lncreases

The vessel pressure would increase for two reasons.

l.

Vapour Flow In - Vapour Flow Out= Accumulation.

An increase in the feed vapour Flowrate with a constant vapour product Flowrate
results in the vapour (hold up) increasing. Because vapour is a compressible fluid,
the accumulation ofvapour, occupying a smaller volume, will cause the vessel
pressure to rise.
2.

The increase in liquid level also causes the vapour hold-up to occupy a smaller
volume within the vessel, causing the vessel pressure to rise.

Distributed and Lumped Models

Most chemical engineering systems have thermal and component gradients in three
dimensions (x, y, z) as well as in time. This is known as a distributed system. Thus,
in the formulation of chemical engineering problem equations, we obtain a set of
partial differential equations in the x, y, z and t domains.
Ifthe x, y, and z gradients are ignored, the system is lumped and all the physical
properties are considered to be equal in space. In such, an analysis in which only the
time gradients are considered, the chemical engineering system equations are
represented by a set of ordinary differential equations (ODE's). This method saves
calculation time and provides a solution that is reasonably close to the distributed
model solution.
Aspen HYSYS uses lumped models for all unit operations. For instan.ce, in the
development ofthe equations describing the separator, it is assumed that there are no
thermal, pressure or concentration gradients present In other words, the temperature,
pressure, and component gradients are the same throughout the entire separator.
Aspen HYSYS does take into account the static pressures in the fluid and vapour
phases. This can result in a dP/dz effect in a vessel. However, Aspen HYSYS does
not solve any partial differential equations.

Pressure Flow Theory

Pressure-Flow Relationship for Valves

In any Flowsheet, the valve unit operation describes the resistance to flow between

two material streams by the Turbulent Flow equation:

(4)

where: P 1 = upstream pressure (pressure of stream 1)

P2 = downstream pressure (pressure of stream 2)

C., = the valve coefficient, Aspen HYSYS will calculate this value on
request

Pressure-Flow Relationship for Other Operations

More generally, flow rates in Aspen HYSYS Dynamics are related to delta P. Ali
process equipment relates the flow between its feed and product streams with flow
equations that are similar to the turbulent flow equation. Toe form ofthese equations
is:

F = k J pAP

(5)

where: k = Conductance, which is a constant representing the reciprocal of

resistance to flow

p = Stream bulk density

AP = Pressure gradient across the operation
Specifying Cv or k values, rather than a fixed delta P, across valves and process
equipment provides for a more realistic simulation. By specifying these variables, the
pressure drop through valves and process equipment can change with changes in
flow, as would happen in an actual plant. This allows the Dynamic simulator to more
accurately model the actual operating conditions of the plant

Pruaure Flow Thaory

Pressure/Flow Networks
In Aspen HYSYS Dynamics the pressure/flow network is described in terms of
nodes, resistance and canductance. Flow takes place in stteams from one node tD
anotber. Thus there are two basic sets ofequaticms 1hat define the pressure/flow
network:
The reelatance to flow
lhrough valves and lhe
conductance lhrough
process equipment
determlnee atream flow
rales between nodes.

1.

Equations tbat define 1he material balance at 1he nodes

2.

Equations tbat define 1he flow- condw:tance and resistance tD flow

The simplest case is tbat ofincompressible tlow with no accumulation at 1he nodes.
In this situation, the tlow equations are a fimction ofthe pressure gradient ancl
equipm.ent parameters su.ch as 1he pipe diameter and rougbness. The material balance
at the nodes is simply that the accmnulation is zero.
In a more comprehensive dynamic simulatim the pressure tlow equations are more
complex. They account for:

Multi-phase tlow with 1he potential for slippage between pbases

The rate ofchange of pressure at the nodes as a fimction of1he equipment

geom.etry, hold-op and mthalpy of the pbases

Flow rates 1hat are determined not mly bypressure gradient but also by
weir heigb.ts (columns) and density differences

Simultaneous Solution Approach to Pressure Flow Balances

Since pressures at nodes are a fimction of the flow rates in.to and out of the nodes ancl
the flow rates through equipment are fimctions of the opstream ancl downstream
pressures, the relatimships between pressure and Flowrate equations in Aspen
HYSYS Dyna.mics are significantly coupled. To find a solution to 1he pressure-flow
relationships in Aspen HYSYS Dynamics, a simultaneous solution of the Flowsheet
is performed. Solving for 1he tlows ancl pressures requires the simultaneous solutim
ofa set of linear ancl nm-Jinear equations..

Pressure Flow Theory

Figura 2

Pl, P2, P3 etc. represent Pressme Nodes (Vessels with hold up)

Fl, F2, F3 etc. represent streams with flow rates

Moreover, in order to epitomize computational effort, Aspen HYSYS Dynamics

partitions the equations describing any unit operation into three classes:

Pressme/flow relationships

Energy relationships

Compositional relationships

These groups of equations can then be integrated/solved with different frequencies.

Typically, the pressme flow relationships will have the smallest step size and the
composition relationships the largest.
The grouping of the equations also permits a different solution strategy to be applied
to each group. In particular, it is possible to solve the pressme/flow relationships
simultaneously across the entire Flowsheet while the other equations (composition,
enthalpy) are solved on a module-by-module basis.

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Pruaure Flow Thaory

lfyou suspect tbat 1he P/F solver is failing because ofthe interaction wi1h the VLE
correlation, then you can do one ofth.e following:

Reduce tbe integration step size-1bis can be accessed ftom 1he mmu bar:
SimulatiGD - lntegrator- Generd.

Change tbe ftequmcy ofintegration steps pee step size (composition and
cmthalpy). This can be accessed ftom the menu bar: Simulation lntegrator- ExeeutiGD.

Figure 3

~ l IB)

lntegrator

Calculalion Execution Rales~ - - - - - - - -

lnlegralion Conbo

ro A1.1lomatic

E.xecution rates as per integrator time step:

(" Manyal

Pressure Flow Solver

Control and Logical Ops

lnlegration Tim
Unils
Cur,entTime
Acceleralion
End Time
Real time
Dis la lnlerval.
Real lime factor

lnlegration Step
Units
Ste Size
Minimum
Maximum

General

Continue

10

l~J 51~

lntegr<1.tor

Executii:m

minutes

6 07.3917

Tf
<oo-Sto'T

Ener C.alculations
Composilion and Flash Calculations
Use these defaull periods for ali operalions

_J

000000
20.38

seconds

r_
Optii:ms

!!esel

- floooo
~

000-=--General

Heat loss
Display

!...Conlinue..j

Execution

Oplions
B,eset

Heat loss
DisJ>lay

Preuure FlowThaory

11

Degrees of Freedom Analysis

In Module 2 we in1roduced 1he cancept of dynamic specificaticms. The simultaneous
solution of 1he pressure-flow rela1ionships wi1hin the Flowsheet requires the user to
make a number of dynamic operating specificaticms.

P = Pressure

F=Flow

In 1bis Flowsheet, 1here are 7 variables in total that will define the system. These are:
Figure 4

Vapo1..1r

-....---~ ~

Feed
1

~~-=+--~--..~

VLV-100

VLV-101

Product
1

V-100
Separator

Liquid

VLV-102

Product

l. Feedl (pressure, flowrate- 2 variables)

2.

Productl (pressure, flowrate- 2 variables)

3. Product2 (pressure, flowrate- 2 variables) and

4. V-100 (Pressure - 1 variable)

In addition, there are 4 equations that define the pressure-fl.ow relationships in the
Flowsheet. 1hese are:
l.

VLV-100: Resistance to Flow equation FVLv-100 = fn(Cv, Pi, P2)

2.

VLV-101: Resistance to Flow equation FVLv-101 = fn(Cv,P1, P2)

3.

VLV-102: Resistance to Flow equation FVLv-102 = fn(Cv, Pi, P2)

4. V-100: Pressure Node Relationsbip dP/dt = fn(V,F,T)

With 7 variables and 4 equatians, the OOF = 7-4 = 3. Therefore, 3 P/F specifications
need to be made te define 1his system.

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Pressure Flow Theory

Understanding the Placement of P/F Specifications

Why do some P/F specifications work while others don't?
Aspen HYSYS Dynamics is equipped with a Dynamics Assistant that analyzes the
Flowsheet to identify problems. (We will discuss this simulation aid later in this
module). However, with a greater understanding ofthe role ofthe P/F solver and the
P/F calculations you will be better able to:

Specify the process Flowsheet correctly

Troubleshoot the process Flowsheet to identify P/F problems

Use the power of Aspen HYSYS Dynamics to its full capabilities

Making Consistent Pressure or Flow Specifications

As mentioned earlier, Aspen HYSYS Dynamics users can select from a variety of
pressure-flow specification combinations to solve the process Flowsheet. These
include:

Pressure specifications on material streams

Flow specifications on material streams

Fixed pressure drop specifications across equipment

Pressure/Flow calculations for valves -resistance to flow (Cv)

Conductance calculations (k) for process equipment

In the previous example, we had three Degrees ofFreedom, requiring that three
specifications be made to define the system.

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Preuure Flow Thaory

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One Posslble Solutlon

Specify:
Figure 5

...

Vapour

--....---,..

Feed

VLV-100

VLV-101

Product
1

P, F?

V-100
Separator

P?

P,F?

Liquid

VLV-102

Product
2

P.F?

Feed 1 Pressure

Stream 1 Pressure

VLV-100 DeltaP

A11hough making 1hese 1hree specifications will satisfy the DOF analysis, the choice
of specifications would not make sen.se. P,ee41, P1 and Pvi.v-100 are ali related by the
following equation:
PFeedl -P -APYLY-100

(6)

Specifying the Flowsheet in this manner would lead toan inconsistent solution. In
filct, 1he Flowsheet would be unda--specified because one of1he specifications is

redundan.t

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Pruaure Flow Thaory

Anothar Posslble Solutlon

Specify:
Figure 6

Vapour

_..,..,.._~ ~
Feed
1

~~...+
.....~ - - .1

VLV-100

Feedl Pressure

Productl Pressure

Product2 Pressure

Product

V-100
Separator

Liquid

VLV-101

VLV-102

Product

Consider the same Flowsheet with pressure specifications made on all the boundary
streams. This solutlon is consistmt because the pressure in the vessel is calculated by
1he hold-up equation. (The stream fl.ow rates were calculated using the turbulent
equation or 1he resistance to fl.ow equation).
Guidelinea to Remember:

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One P/F apecificalion ahould be made on each boundary atream

(feeda/producta)

Maka preuure speclflcallons on boundary streams attached to process

equlpment that UN reslstance to ftowlconductance 19latlonshlps.

Aapen HYSYS Dynamica will uae the equipmant conductanca or Cv valua

combinad with the preaaure of tha inlet and outlet atreama to detannina a
Flowrate through the equlpment.

lntemal ftow ratea will be calculatacl by prauura gradianta (reaiatanca to

ftowlconductance equations) throughout the Flowaheet.

Pressure Flow Theory

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Summary of P/F Theory and Specifications:

1.

The flow tbrough the plant, or operation, is driven by the pressure gradient.

2.

P/F theory defines the relationship between flow and pressw-e.

3.

The Aspen HYSYS P/F solver solves a set oflinear and non-linear equations
simultaneously to determine the P/F relationship.

4.

In order for the P/F solver to solve the Flowsheet, there must be a pressure
gradient established over the entire Flowsheet.

5.

The pressure gradient exists dueto a specified pressure flow relationship (ora
speci:fied pressure drop) over all operations in the Flowsheet.

6.

The P/F solver works by finding P from F, according to the P/F theory, or by
solving the pressure node equation.

7.

Following any flow path tbrough the Flowsheet, the user should be able to see
the pressure gradient, or expect to see a pressure gradient established along the
path. If the pressure gradient cannot be seen, an additional pressure specification
may be needed.

8.

If the user follows a flow path to the boundary of the Flowsheet, they should see
that at such a location, a pressure gradient does not exist, nor can it be
established. This means that a pressure (or flow) specification is always needed
on boundary streams.

Other Possible Solutions

Ifwe modeled the same unit operation without using valves on all product streams,
then we could not make P specifications on all boundary streams. Remember the
lumped parameter model - the model assumes there are no pressure gradients inside
the unit operation. Thus, if a pressure specification is made on the vapour product
stream it is best not to make pressure specifications on the other unit operation
streams. This can lead to an inconsistent solution because once one stream pressure
is known they all become known, resulting in no pressure gradients in the unit
operation.

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1&

Pruaure Flow Thaory

Figure 7

Vapour
Product

Feed
1

Separator

Liquid
Product

It is possible to have flow specifications on all unit operation streems as lcmg as the
vessel pressure is controlled.
Figure 8

,--------w Vapour

Product

Feed
1

Separator

Sep PC

..__ _ _ _ __ .. Liquid
Product

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Pressure Flow Theory

17

Exercise
Modifying the Flowsheet in dynamics
Load the saved case FHT_Dynl.hsc.
Modify the Flowsheet such that there is a Cooler downstream of the Sep Vap 1
stream.
1.

Add a Cooler and move the P/F specifications.

2.

Calculate the resistance to flow for the Cooler. Like the Valve, the flow through
the Cooler is calculated as a fimction of delta P.

Using the conductance equation provides a more realistic simulation. Toe pressure
drop across the Cooler can change with increases or decreases in flow. Ifthe Cooler
pressure drop were fixed, then it would not vary. Because we specify the resistance
to flow as the dynamic specification, then we can make a pressure specification as
the boundary specification. Toe flow rates are calculated by the resistance equation.
Save your case as Exercise.hsc.

Save your case!

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Pressure Flow Theory