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Jump Start: Activated Exchanger Design & Rating in

Aspen HYSYS
A Brief Tutorial (and supplement to training and online documentation)
Lauren Sittler, Product Management, Aspen Technology, Inc.

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Jump Start: Activated Exchanger Design & Rating in Aspen HYSYS

Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
New Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview of the User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Starting Activated EDR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
The EDR Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
The Model Status Pie Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
The Operational Risk Pie Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Flowsheet Highlights and Flyovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Model Status Flowsheet Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operational Risk Flowsheet Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
The Activated EDR Summary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Summary Table Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Converting Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Converting a Simple Model to Rigorous EDR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Converting a Rigorous EDR Model to Simple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Jump Start: Activated Exchanger Design & Rating in Aspen HYSYS

Introduction
Activated Exchanger Design & Rating (EDR) is a new Activated Analysis tool available within AspenTechs V8.4
simulators, Aspen Plus and Aspen HYSYS. Like Activated Energy Analysis and Activated Economic Evaluation, Activated
EDR helps process engineers quickly evaluate feasible design alternatives and immediately assess the impact on
flowsheet capital and operating expenditures.

Activated EDR provides an easy way to convert simple heat exchanger models to rigorous models, and provides quick
access to rigorous model details. The EDR dashboard uses visual indicators to convey information about heat exchangers
model status and shows all operational risks, if any, that have been detected in rigorous heat exchanger models.

New Capabilities
Convert simple heat exchanger models into rigorous designs in one click to obtain a fully rigorous, cost-optimized
geometry that accurately models thermal and hydraulic performance
Easily track and change the model-type for all heat exchanger equipment in the simulation
Instantly view operational risks, such as vibration and erosion, right from the flowsheet

Overview of the User Interface


Starting Activated EDR
EDR Activation is turned on and off from the Activated Analysis panel. Open the Analysis Panel by clicking on the
Activated Analysis button on the Home ribbon (Figure 1).

Figure 1. Opening the Activated Analysis panel

Click the heat exchanger icon to turn it on and click the close button to turn it off (Figure 2). Opening and closing the EDR
dashboard does not affect the EDR models in your flowsheet; it will not automatically convert a simple model to rigorous
and vice versa. It will simply reveal more information about the heat exchanger models in your simulation and provide
access to EDR controls.

Figure 2. The Activated EDR icon

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Jump Start: Activated Exchanger Design & Rating in Aspen HYSYS

The EDR Dashboard


The dashboard is the first component displayed when you activate EDR (Figure 3). It contains two pie charts: Model
Status and Operational Risk.

Color Model Status Color Operation Risk Level

Grey Simple heat exchanger Grey Simple heat exchanger

Blue Rigorous exchanger Green Rigorous exchanger, no warnings

Yellow Rigorous exchanger, operation warnings detected


Rigorous exchanger,
Red
calculation error Red Rigorous exchanger, serious risks detected

Figure 3: The EDR dashboard

The Model Status Pie Chart


The Model Status Pie Chart shows relatively how many exchanger models in the flowsheet are rigorous EDR and how
many are simple. Rigorous EDR models provide much greater accuracy in modeling the actual operation of heat exchanger
equipment in a process as compared to simple models. The percentage of grey in this chart represents an opportunity to
improve the fidelity of the process model.

Simple models provide a very limited amount of sizing data that is only accurate within a small range of operating points.
Rigorous models provide full heat exchanger geometry, and model heat transfer and hydraulic performance as process
conditions change.

The Operational Risk Pie Chart


The Operational Risk Pie Chart shows the proportion of exchangers in the flowsheet that contain identified risks. Only
rigorous models can predict when an operation risk is present, therefore no operation risk status is given for simple
models. For rigorous models, the yellow section of the pie chart indicates a warning was detected by EDR.

All of the operation risk warnings that are identified by EDR have been classified into categories for Activation. The yellow
categories for each model type are shown below, as well as a sample of the red risks for Shell&Tube exchangers. Red risks
are reserved for the most serious risk types and are extremely rare.

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Jump Start: Activated Exchanger Design & Rating in Aspen HYSYS

Yellow Operational Warning Categories Identified by Activation

Shell&Tube, AirCooled, PlateFin FiredHeater


Pressure Pressure
Temperature Temperature
Vibration Vibration
Erosion: RhoV2 Erosion: RhoV2
Heat Transfer Heat Transfer
Pressure Drop Pressure Drop
Flow Flow
Other (all other risks in EDR that Combustion
do not fall into the above Other
categories)

Red Risks Identified by Activation for Shell&Tube Exchangers


Choking will occur in one of the nozzles.
This exchanger cannot operate within the specified flow. The calculated nozzle pressure drop exceeds the absolute
pressure.
This exchanger cannot operate with the specified flow. The calculated total nozzle pressure drop exceeds the inlet
pressure.
The total calculated bundle pressure drop exceeds the bundle inlet pressure. The bundle outlet pressure has been reset,
artificially.
The large nozzle pressure loss, at the specified temperature and vapor fraction, suggests the flow will be choked. All or
part of the pressure drop may be scaled to permit the calculation to proceed. The difference between inlet and outlet
pressure will then be inconsistent with the calculated pressure loss.

Flowsheet Highlights and Flyovers


Flowsheet components can be turned on by clicking on the dashboard panels. Clicking on the Model Status panel will turn
on Model Status highlights and flyovers and clicking on the Operational Risk panel will turn on Operational Risk highlights
and flyovers (Figure 4).

Figure 4: Turning on flowsheet components

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Jump Start: Activated Exchanger Design & Rating in Aspen HYSYS

Model Status Flowsheet Components


Model Status highlights circle rigorous exchangers in blue (Figure 5) and simple exchangers in grey (Figure 6). Hover over
a blue highlight to see a setting plan for the EDR design, as well as key geometry and heat transfer information. Hover over
a grey highlight to see information about the simple model and convert the model to rigorous.

Figure 5. Rigorous Model Status flyover

Figure 6. Simple Model Status flyover

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Jump Start: Activated Exchanger Design & Rating in Aspen HYSYS

Operational Risk Flowsheet Components


Click on the Operational Risk panel of the dashboard to reveal which exchangers contain operational risks detected by
EDR. Hover over the highlight to show which kinds of warnings are present for that exchanger (Figure 7). Click on the
circle at the flyovers heading to reveal a 2nd level flyover that shows the exact warning found by EDR (Figure 8).

Figure 7. Operational Risk highlights and flyovers

Figure 8. Operation warnings

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Jump Start: Activated Exchanger Design & Rating in Aspen HYSYS

The Activated EDR Summary Table


The Summary table is an organized list of all heat exchangers in your flowsheet. From this table you can access rigorous
exchanger forms, convert models from simple to rigorous and rigorous back to simple, and view operation warnings for all
models in your flowsheet (Figure 9).

All of the columns in this table can be sorted ascending or descending. The last three columns can also be filtered. This
allows you the flexibility to look at all models in a particular flowsheet, sort by model status, look at only heat exchangers
that contain risks, and etc.

Figure 9. The Activated EDR Summary table

Summary Table Organization

Column 1: Displays the title of the unit operation block for that exchanger. If the model is rigorous, this
Exchanger Name title will be a link to open the unit operation form and display the EDR model details.

Column 2:
Shows the location of the exchanger if its located in a subflowsheet or hierarchy block.
Subflowsheet:

Column 3: Contains a toggle button that shows the EDR model type or Convert for simple models.
Model Status Click on this button to convert the exchanger from simple to rigorous or vice versa.

For rigorous models, an indicator shows the exchangers operational risk status. Click the
Column 4:
indicator to view the operation warnings for this heat exchanger. Click on the column
Operation Risk Status
heading to view a summary of all risks.

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Jump Start: Activated Exchanger Design & Rating in Aspen HYSYS

Converting Models
The chart below in Figure 10 shows the possible conversions between simple unit operations and the corresponding
rigorous EDR models in Aspen HYSYS.

Rigorous Model Types Supported in Aspen HYSYS:

HYSYS Unit Operation Corresponding Rigorous EDR Model

Heat Exchanger Shell&Tube Thermal

Air Cooler AirCooled

LNG Exchanger PlateFin

FiredHeater FiredHeater

Figure 10. Simple to Rigorous Model conversions

Converting a Simple Model to Rigorous EDR


Convert forms for simple models can be accessed from either the Activated EDR Summary Table or the Model Status
Flowsheet Flyovers, shown below in Figure 11.

Figure 11. Accessing Convert forms

Click on the Convert button from either of these locations to begin model conversion. The form shown below in Figure 12
will open.

Convert forms in HYSYS


Heat Exchanger and Air Cooler unit operations allow for autosizing, interactive sizing, and file import to convert to a
rigorous Shell&Tube or AirCooled, respectively.

On the Convert form, complete the following steps in Figure 12:

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1. Choose a sizing
method from the radio
buttons in the top box.

2. If sizing with a template,


choose the EDR template
from the browser. If
importing a file, select the 3. Click the Convert
EDR file to import from the button to continue.
browser.

Figure 12: Steps to complete Model Conversion

Special Conversions for PlateFin and FiredHeater Models


To convert these models to rigorous, an EDR file must be imported; rigorous sizing is not supported in simulation. To
import, click on the Convert button then follow the on-screen instructions to import the EDR file and complete
specification in HYSYS.

Converting a Rigorous EDR Model to Simple


You can access the form to convert rigorous models back to simple from the Activated Summary Table. Click on a button
in the 3rd column for an EDR model type (Figure 13).

Figure 13. Exchanger Summary Table

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Jump Start: Activated Exchanger Design & Rating in Aspen HYSYS

When you click on this button, instructions for the particular model will appear. Read the steps that will be used to achieve
the conversion.

Then click on the Convert button (Figure 14) to go to the forms where those steps can be completed.

Figure 14. Convert to Simple Dialogue

Figure 15. Convert to simple end-point

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Additional Resources
Public Website:
www.aspentech.com/products/activation

Aspen Online Training:


www.aspentech.com/products/aspen-online-training

On Demand Short Presentations:


www.brainshark.com/aspentech1/activated-edr

Aspen YouTube Channel:


www.youtube.com/user/aspentechnologyinc

Jump Start Tutorial Series:


Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.4

About AspenTech
AspenTech is a leading supplier of software that optimizes process manufacturingfor energy, chemicals,
engineering and construction, and other industries that manufacture and produce products from a
chemical process. With integrated aspenONE solutions, process manufacturers can implement best
practices for optimizing their engineering, manufacturing, and supply chain operations. As a result,
AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become
more energy efficient. To see how the worlds leading process manufacturers rely on AspenTech to
achieve their operational excellence goals, visit www.aspentech.com.
Worldwide Headquarters
Aspen Technology, Inc.
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Bedford, MA 01730
United States
phone: +17812216400
fax: +17812216410
info@aspentech.com

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phone: +12815841000
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phone: +97317503000

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