Introduction to Dynamics

-1-

Introduction to Dynamics

Page 1 of 16

Introduction to Dynamics

-2-

Work-Shop
This module provides an introduction to the basic concepts of dynamic modelling in HYSYS/UniSim with reference to the key differences between steady state modelling and dynamics. Some of the things you will learn from this module are: What is dynamic modelling? What can dynamic modelling achieve? Why is it best to not start with a steady state model? Selection and positioning of pressure-flow specifications

Learning Objectives
Once you have completed this module, you will understand: The basic concepts of dynamic simulation in HYSYS/UniSim Dynamic pressure flow specifications Building of simple dynamic models.

Prerequisites
This module, and the course as a whole, requires the following abilities: Familiarity with the building and use of HYSYS Steady State models, including: o Building PFD flowsheets o Definition of fluid packages and components o Navigation of and familiarity with the HYSYS environment

Page 2 of 16

Introduction to Dynamics

-3-

Introduction to Dynamics
Capabilities of Dynamic Modelling
Steady state modelling is a standard tool for process engineering design. Although it is a powerful tool for development of heat and mass balances and sizing of key equipment within known constraints, steady state models will not tell you how the process is controlled or how it behaves over time. In addition, as process equipment will function differently depending on the conditions and flows it is experiencing, steady state models will not be able to readily inform the engineer how a transition from one particular state to another will be made. Dynamic models can accurately simulate processes such as start-up, shutdown, starting/stopping equipment, equipment failure, transient conditions such as varying throughput, and pressure variations. Dynamic models will, in effect, behave as realistically to the real process as possible if good quality data is used. Dynamic simulations can be interacted with during a run, and be told whether to run as fast as possible, or to progress in real time. Process plant dynamics are principally governed by their control schemes, therefore process control modelling and control valve dynamics provide an important part of dynamic simulation. A second major factor in dynamics is the modelling of volume, which will determine rates of pressure build-up and decrease, as well as the behaviour of liquid levels and loading. These together with the performance over time of rotating equipment such as pumps, compressors (including their anti-surge characteristics) and expanders provide some of the most important factors in dynamic modelling which are not required in steady state simulations.

Page 3 of 16

Introduction to Dynamics

-4-

Theoretical Foundations
The Pressure-Flow Solver: A Simple Example
Consider the operation of a separator in dynamic mode that is initially at steady state with a level of 60%.

Remember:

In Steady State, Flow into separator = Flow out of separator i.e. no accumulation

But in Dynamics, if the separator feed flow increases with the product flow rates (vapour and liquid) remaining unchanged, the level (hold-up), temperature, and pressure of the vessel must all change from the steady state condition.

Liquid Level Increases

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.

Page 4 of 16

Introduction to Dynamics

-5-

Vessel Pressure Increases

The vessel pressure would increase for two reasons: 1. Vapour flow in Vapour flow out = Accumulation An increase in the feed vapour flow rate with a constant vapour product flowrate results in the vapour (hold-up) increasing. Because vapour is a compressible fluid, the accumulation of the vapour, 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.

Pressure-Flow Relationships
More generally, flow rates in HYSYS/UniSim Dynamics are related to delta P. All process equipment relates the flow between its feed and product streams with flow equations that are similar to the turbulent flow equation. The form of these equations is F = k P where: k = conductance to flow = stream bulk density P = pressure gradient across the operation (5)

Specifying Cv or k values, rather than a fixed pressure drop, 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 flow, as would happen in an actual plant. This allows the Dynamic simulator to more accurately model the actual plant operating conditions.

Page 5 of 16

Introduction to Dynamics

-6-

Pressure-Flow Networks
In HYSYS/UniSim Dynamics the pressure / flow network is described in terms of nodes, resistance and conductance. Flow takes place in streams from one node to another. Thus there are two basic sets of equations that define the pressure/flow network: 1. Equations that define the material balance at the nodes 2. Equations that define the flow conductance and resistance to flow The simplest case is that of incompressible flow with no accumulation at the nodes. In this situation, the flow equations are a function of the pressure gradient and equipment parameters such as pipe diameter and roughness. The material balance at the nodes is simply that the accumulation is zero. In a more comprehensive dynamic simulation, the pressure flow equations are more complex. They account for: Multi-phase flow with the potential for slippage between phases The rate of change of pressure at the nodes as a function of the equipment geometry, hold-up, and enthalpy of the phases Flow rates that are determined not only by pressure gradient, but also by weir heights (columns) and density differences.

Simultaneous Solution Approach to Pressure Flow Balances

Since pressures at nodes are a function of the flow rates in and out of the nodes, and the flow rates through equipment are functions of the upstream and downstream pressures, the relationships between pressure and flowrate equations in HYSYS/UniSim Dynamics are significantly coupled. To find a solution to the pressure-flow relationships in HYSYS/UniSim Dynamics a simultaneous solution of the flowsheet is performed. Solving for the flows and pressures requires the simultaneous solution of a set of non-linear equations.

Page 6 of 16

Introduction to Dynamics

-7-

P1, P2, P3, .etc. represent Pressure Nodes (Vessels with hold-up F1, F2, F3, .etc. represent streams with flow rates

Moreover, in order to optimize computational effort, HYSYS/UniSim Dynamics partitions the equations describing any unit operation into three classes: Pressure/flow relationships Energy relationships Compositional relationships

These groups of equations can then be integrated/solved with different frequencies. Typically, the pressure flow relationships will have the smallest step size and the compositional 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 pressure/flow relationships simultaneously across the entire flowsheet while the other equations (composition, enthalpy) are solved on a module-by-module basis. If you suspect the P/F solver is failing because of the interaction with the VLA correlation, then you can do one of the following: Reduce the integration step size this can be accessed from the menu bar: Simulation -> Integrator -> General Change the frequency of integration steps per step size (composition and enthalpy). This can be accessed from the menu bar: Simulation -> Integrator -> Execution

Page 7 of 16

Introduction to Dynamics

-8-

Page 8 of 16

Introduction to Dynamics

-9-

Degrees of Freedom Analysis

In order for a flowsheet to solve, we need to introduce the concept of dynamic specifications. The simultaneous solution of the pressure-flow relationships within the flowsheet requires the user to make a number of dynamic operating specifications. P = Pressure F = Flow

In this flowsheet there are 7 variables in total that will define the system. These are Feed 1 o One variable for pressure o One variable for flowrate Product1 o One variable for pressure o One variable for flowrate Product 2 o One variable for pressure o One variable for flowrate V-100 o One variable for pressure

In addition, four equations define the pressure-flow relationships in the flowsheet: VLV-100: resistance to flow equation Fvlv-100 = fn(Cv, P1, P2) VLV-101: resistance to flow equation Fvlv-101 = fn(Cv, P1, P2) VLV-102: resistance to flow equation Fvlv-102 = fn(Cv, P1, P2) V-100: Pressure node relationship dP/dt = fn (V,F,T)

Page 9 of 16

Introduction to Dynamics

- 10 -

With 7 variables and 4 equations, the DOF = 7 4 = 3. Therefore, 3 PF specifications need to be made to define this system. Starting the integrator without any specifications gives the following error which confirms this number:

Understanding the Placement of P/F Specifications

Why do some P/F specifications work while others dont? HYSYS/UniSim Dynamics is equipped with Dynamics Assistant that analyzes the flowsheet to identify problems. However, with a greater understanding of the role of the 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

Making Consistent Pressure or Flow Specifications

As mentioned earlier, 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 of freedom requiring that three specifications be made to define the system.

Page 10 of 16

Introduction to Dynamics

- 11 -

Page 11 of 16

Introduction to Dynamics

- 12 -

One Possible Solution

Specify: Feed 1 Pressure Stream 1 Pressure VLV-100 Delta P

Although making these three specifications will satisfy the DOF analysis, the choice of specifications would not make sense. Pfeed1, P1 and Pvlv-100 are all related by the following equation: Pfeed1 P1 Pvlv-100 = 0 (6)

Specifying the flowsheet in this manner would lead to an inconsistent solution. In fact, the flowsheet would be under-specified because one of the specifications is redundant.

Page 12 of 16

Introduction to Dynamics

- 13 -

Another Possible Solution

Specify: Feed 1 Pressure Product 1 Pressure Product 2 Pressure

Consider the same flowsheet with pressure specifications made on all the boundary streams. The solution is consistent because the pressure in the vessel is calculated by the hold-up equation. (The stream flow rates were calculated using the turbulent equation or the resistance to flow equation) Guidelines to remember One P/F specification should be made on each boundary stream (feeds/products) Make pressure specifications on boundary streams attached to process equipment that use resistant to flow/conductance relationships HYSYS/UniSim will use the equipment conductance or Cv value combined with the pressure of the inlet and outlet streams to determine a flowrate through the equipment. Internal flowrates will be calculated by pressure gradients (resistance to flow/conductance equations) throughout the flowsheet.

Page 13 of 16

Introduction to Dynamics

- 14 -

Summary of P/F Theory and Specifications:

The flow through the plant, or operation, is driven by the pressure gradient. P/F theory defines the relationship between flow and pressure The HYSYS/UniSim P/F solver solves a set of linear and non-linear equations simultaneously to determine the P/F relationship In order for the P/F solver to solve the flowsheet, there must be a pressure gradient established over the entire flowsheet The pressure gradient exists due to a specified pressure/flow relationship (or a specified pressure drop) over all the operations in the flowsheet The P/F solver works by finding P from F, according to the P/F theory, or by solving the pressure node equation. Following any flow path through 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. Immediately upstream of a pressure boundary there will be no pressure gradient, e.g. if the outlet of a valve is connected to a boundary stream, the valve outlet pressure will be the same as the boundary stream.

Page 14 of 16

Introduction to Dynamics

- 15 -

Other Possible Solutions

If we modelled 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.

It is possible to have flow specifications on all unit operation streams as long as the vessel pressure is controlled.

Page 15 of 16

Introduction to Dynamics

- 16 -

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. If the 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 (ODEs). This method saves calculation time and provides a solution that is reasonably close to the distributed model solution. HYSYS/UniSim uses lumped models for all unit operations. For instance, in the development of the 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. HYSYS/UniSim 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, HYSYS/UniSim does not solve any partial differential equations.

Page 16 of 16