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Computational Methods
Integrate Compressor
Performance Maps
into Process Simulation
Grant Stephenson
Honeywell Process Solutions
30,000
Design Operation
20,000
15,000
10,000
3,760 rpm
3,850 rpm
3,950 rpm
4,000 rpm
5,000
0
Design Operation
25,000
5,000
10,000
15,000
20,000
25,000
Power, hp
Polytropic Head, ft
25,000
20,000
15,000
10,000
3,760 rpm
3,850 rpm
3,950 rpm
4,000 rpm
5,000
0
30,000
5,000
Derime Operation
20,000
20,000
25,000
30,000
700
15,000
10,000
3,760 rpm
3,850 rpm
3,960 rpm
4,000 rpm
5,000
0
15,000
Derime Operation
800
5,000
10,000
15,000
20,000
Power, hp
Polytropic Head, ft
25,000
10,000
600
500
400
300
3,760 rpm
3,850 rpm
3,960 rpm
4,000 rpm
200
100
0
25,000
5,000
10,000
15,000
20,000
25,000
p Figure 1. These performance maps represent design (top) and derime (bottom) operation of a high-pressure, mixed-refrigerant compressor.
30,000
20,000
15,000
10,000
Design
Derime
5,000
0
25,000
Power, hp
Polytropic Head, ft
25,000
5,000
10,000
15,000
20,000
25,000
30,000
20,000
15,000
10,000
Design
Derime
5,000
0
5,000
10,000
15,000
20,000
25,000
30,000
p Figure 2. Superimposing performance maps reveals that the power vs. suction flowrate relationships for design and derime operation are very different.
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0.7
0.7
0.6
0.6
0.5
0.5
Reduced Power
Computational Methods
0.4
0.3
0.2
Design
Derime
0.1
0
0.4
0.3
0.2
Design
Derime
0.1
0
0.1
0.2
0.3
0.4
0.5
0.6
0.1
0.2
0.3
0.4
0.5
0.6
p Figure 3. A reduced performance map aggregates a series of performance curves into a single curve in the reduced coordinate system.
(1)
(2)
(3)
(4)
(5a)
(5b)
(5c)
0.7
Design
Derime
Fitted
0.6
0.6
Reduced Power
0.7
0.5
0.4
0.3
0.2
0.5
0.4
0.3
Design
Derime
Fitted
0.2
0.1
0.1
0
0
0.2
0.4
0.6
0.8
0.2
0.4
0.6
0.8
p Figure 4. The surge, normal, and stonewall operation segments of the aggregate performance curves can be represented by different functions.
(6)
(7)
Functional representation of
the reduced performance map
Based on a visual inspection of Figure 3, a quadratic
function appears to be a good choice for representing the
aggregate performance curves for both polytropic head,
f4(Qr), and power, f5(Qr). However, experience has proven
Polytropic Head
Power
Surge
Exponential
Quadratic
Normal
Power
Power
Stonewall
Quadratic
Quadratic
otherwise. A quadratic function is not a suitable representation of the aggregate power curve, which is not symmetric
about the perpendicular line through its apex. In addition, a
quadratic function fitted to the data typically will not extrapolate through the origin a necessary physical constraint. A
quadratic function is also not a suitable representation of the
aggregate curve of polytropic head at low values of reduced
volumetric suction flow, where it becomes nearly linear.
The next likely choice of functional form would be a
higher-order polynomial. However, high-order polynomials
can wobble, even within the range of the data being fitted,
and they may not extrapolate well both significant disadvantages for process simulation.
Experience has shown that a very good fit is obtained
when the aggregate performance curves are divided into
three segments representing the surge, normal, and stonewall regions of the performance curves and the segments
are represented by the functions listed in Table 1.
The functions parameters and the segments end points
are determined by fitting the curves to the reduced data.
This yields smooth, piecewise-fitted curves, as shown in
Figure 4. The functions fit the curve segments well, and they
extrapolate well for both low and high reduced volumetric
suction flows. Although flowrates below the reduced surge
flow are not physically meaningful, reasonable extrapolation to low flows is required to ensure robust solution of the
compressor unit-operation model. Reasonable extrapolation
in the stonewall region facilitates robust solution up to the
stonewall flow.
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CEP June 2011 www.aiche.org/cep
45
Computational Methods
14
VLV-100
K-100
Surge
Controller
VLV-103
3
E-100
PIC-100
V-100
MIX-101
V-101
12
VLV-101
Q-101
MIX-100
K-100
15
TEE-100 11
10
4
17
13
RCY-1
K-100
Speed
16
Q-100
LIC-100
8
VLV-102
p Figure 5. This compressor loop flowsheet was created by a process simulator that rigorously models compressors over their entire operating range.
3.5e+004
2,800 rpm
3,200 rpm
3,400 rpm
2,800 rpm
Operating Point
3.0e+004
Head, m
2.5e+004
2.0e+004
1.5e+004
1.0e+004
5.0e+004
0.00
5,000
10,000
15,000
20,000
25,000
46
1.800e+004
3,360 (rpm)
1.500e+004
1.200e+004
1.328e+004 (m3)
9,000
2.152e+004 (m)
6,000
2,995
3,000
3,005
Minutes
Literature Cited
1. Stephenson, G., et al., Profit More from Process Simulation,
Chem. Processing, 72 (8), pp. 2326 (Aug. 2009).
2. Willetts, I., and A. Nair, Using High-Fidelity Dynamic Simulation to Model Compressor Systems, Chem. Eng. Progress,
106 (4), pp. 4448 (Apr. 2010).
3. Batson, B. W., Invariant Coordinate Systems for Compressor
Control, presented at the International Gas Turbine and Aeroengine Congress and Exhibition, Birmingham, U.K. (June 1996).
Grant Stephenson is an Engineering Fellow with Honeywells Automation Control Solutions business, where he serves as the global
process simulation architect for Honeywell Process Solutions. He
has worked in the field of process simulation for more than 35 years,
with particular interest in dynamic simulation, equation-oriented
modeling and simultaneous solution of flowsheet models, and the
application of modeling and optimization to plant operations. He
is the originator of the dynamic simulation engine of the Shadow
Plant simulator and is a pioneer of the hybrid solution architecture
and its application to large-scale dynamic simulation. Before joining
Honeywell, he held positions with DuPont Canada, Atomic Energy
of Canada, the Univ. of Western Ontario (in the engineering facultys
Systems Analysis Control and Design Activity, SACDA, group), and
SACDA Inc. He holds an MSc degree in applied mathematics from the
Univ. of Western Ontario.
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