Jump Start: Activated Exchanger Design & Rating in Aspen HYSYS® V8.4 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 AspenTech’s 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
Rigorous exchanger, calculation error
Yellow
Rigorous exchanger, operation warnings detected
Red
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
• Combustion
• Erosion: RhoV2
• Heat Transfer
• Heat Transfer
• Pressure Drop
• Pressure Drop
• Flow
• Flow • Other (all other risks in EDR that do not fall into the above 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 flyover’s 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 it’s 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 exchanger’s 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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Jump Start: Activated Exchanger Design & Rating in Aspen HYSYS ®
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 EDR file to import from the browser.
3. Click the Convert button to continue.
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: www.aspentech.com/Activated_EDR_Plus_V84.pdf
About AspenTech AspenTech is a leading supplier of software that optimizes process manufacturing—for 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 world’s leading process manufacturers rely on AspenTech to achieve their operational excellence goals, visit www.aspentech.com.
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