MODELLING CASCADED SPLIT RANGE (CASC-SRC) CONTROLLERS IN ASPEN HYSYS DYNAMICSVijay Sarathy
This document demonstrates modeling a cascaded split range controller (CASC-SRC) in Aspen HYSYS Dynamics to control an LNG pump and vaporizer control valve. The CASC-SRC uses a high pressure pump speed controller and vaporizer flow controller, both operating in reverse action. An SRC is added with the flow controller as the first input and pump controller as the second. Low and high range values for each controller are calculated and assigned in the SRC configuration. With the CASC-SRC in auto mode, HYSYS stabilizes at operating points matching the original set points of 2950 rpm pump speed and 7500 kmol/h flow.
Vessel Liquid Level On/Off Control in Aspen HYSYS DynamicsVijay Sarathy
The document describes how to implement an on/off control system for liquid level in a process vessel using Aspen HYSYS Dynamics. Digital points and a boolean latch operator are used to activate and deactivate the drain valve as the liquid level reaches high and low points. When the liquid level reaches 1800mm, the drain valve opens to drain liquid from the vessel. The valve closes once the level falls to 450mm, allowing the vessel to refill. Figures S.1 through S.9 show the setup and configuration of the digital points, latch operator, and drain valve to achieve this on/off level control behavior.
Basic Tutorial on Aspen HYSYS Dynamics - Process control (Tutorial 3)Hamed Hoorijani
This document provides instructions for simulating a dynamic process using Aspen HYSIS software. The process involves cooling methane feed in a two-phase separator and controlling the separator temperature and pressure. It describes:
1) Defining the feed stream and adding process equipment like the separator and cooler to the flowsheet.
2) Adding transfer functions to model temperature distribution and dead time.
3) Adding controllers to regulate separator conditions and cooler duty.
4) Creating a strip chart to monitor key temperatures over time.
5) Simulating the process dynamically and observing the changes in temperatures.
It also provides steps for simulating the process using a cascade control loop configuration and adjusting controller and transfer
Tutorial on Aspen Hysys Dynamics - Separator level controllerHamed Hoorijani
This is my first tutorial on Aspen HYSYS - Dynamic mode. It shows how to use dynamic mode to control the liquid level of a separator in aspen Hysys.
you can find the tutorial video on my youtube channel as well.
video of this tutorial on youtube: https://youtu.be/zFETFlE68Gk
Basic Tutorial on Aspen HYSYS Dynamics - Process ControlHamed Hoorijani
This document provides a tutorial for simulating a gas process system in steady state and dynamic mode using Aspen HYSIS. It includes process specifications, operating conditions, equipment details, and controller settings. The tutorial instructs the user to: 1) build the steady state process model and solve it; 2) add PID controllers to control liquid level and pressure; and 3) use the Dynamic Assistant to simulate the dynamic behavior of the system over time.
Line Sizing presentation on Types and governing Equations.Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Pipeline Sizing. This is an introduction to understand more about their:-
-The basic idea.
-Simplified method for calculations.
-Equations.
-Data Tables.
-Worked Examples.
-Excel Sheets for Calculation.
-Links to other topics which may be interesting.
You can find also more at:
http://hassanelbanhawi.com/staticequipment/linesizing/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Impact of No. of Pipe Segments on the flow rate calculated by Pipe Model (Pag...Waqas Manzoor
A dynamic simulation was performed in Aspen HYSYS to calculate the maximum flow rate of natural gas through a 6-inch SCH 80 pipeline 12 km in length. The simulation showed that the pipeline could transport up to 4.01 MMSCFD of gas at a downstream pressure of 100 psig. However, the actual maximum flow rate would be lower due to pipe roughness and aging effects. It was determined that the pipeline would be unable to meet forecasted demand of 5-6 MMSCFD in 2015. A steady-state simulation could not calculate flow rates after specifying the total pressure drop across the pipeline.
MODELLING CASCADED SPLIT RANGE (CASC-SRC) CONTROLLERS IN ASPEN HYSYS DYNAMICSVijay Sarathy
This document demonstrates modeling a cascaded split range controller (CASC-SRC) in Aspen HYSYS Dynamics to control an LNG pump and vaporizer control valve. The CASC-SRC uses a high pressure pump speed controller and vaporizer flow controller, both operating in reverse action. An SRC is added with the flow controller as the first input and pump controller as the second. Low and high range values for each controller are calculated and assigned in the SRC configuration. With the CASC-SRC in auto mode, HYSYS stabilizes at operating points matching the original set points of 2950 rpm pump speed and 7500 kmol/h flow.
Vessel Liquid Level On/Off Control in Aspen HYSYS DynamicsVijay Sarathy
The document describes how to implement an on/off control system for liquid level in a process vessel using Aspen HYSYS Dynamics. Digital points and a boolean latch operator are used to activate and deactivate the drain valve as the liquid level reaches high and low points. When the liquid level reaches 1800mm, the drain valve opens to drain liquid from the vessel. The valve closes once the level falls to 450mm, allowing the vessel to refill. Figures S.1 through S.9 show the setup and configuration of the digital points, latch operator, and drain valve to achieve this on/off level control behavior.
Basic Tutorial on Aspen HYSYS Dynamics - Process control (Tutorial 3)Hamed Hoorijani
This document provides instructions for simulating a dynamic process using Aspen HYSIS software. The process involves cooling methane feed in a two-phase separator and controlling the separator temperature and pressure. It describes:
1) Defining the feed stream and adding process equipment like the separator and cooler to the flowsheet.
2) Adding transfer functions to model temperature distribution and dead time.
3) Adding controllers to regulate separator conditions and cooler duty.
4) Creating a strip chart to monitor key temperatures over time.
5) Simulating the process dynamically and observing the changes in temperatures.
It also provides steps for simulating the process using a cascade control loop configuration and adjusting controller and transfer
Tutorial on Aspen Hysys Dynamics - Separator level controllerHamed Hoorijani
This is my first tutorial on Aspen HYSYS - Dynamic mode. It shows how to use dynamic mode to control the liquid level of a separator in aspen Hysys.
you can find the tutorial video on my youtube channel as well.
video of this tutorial on youtube: https://youtu.be/zFETFlE68Gk
Basic Tutorial on Aspen HYSYS Dynamics - Process ControlHamed Hoorijani
This document provides a tutorial for simulating a gas process system in steady state and dynamic mode using Aspen HYSIS. It includes process specifications, operating conditions, equipment details, and controller settings. The tutorial instructs the user to: 1) build the steady state process model and solve it; 2) add PID controllers to control liquid level and pressure; and 3) use the Dynamic Assistant to simulate the dynamic behavior of the system over time.
Line Sizing presentation on Types and governing Equations.Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Pipeline Sizing. This is an introduction to understand more about their:-
-The basic idea.
-Simplified method for calculations.
-Equations.
-Data Tables.
-Worked Examples.
-Excel Sheets for Calculation.
-Links to other topics which may be interesting.
You can find also more at:
http://hassanelbanhawi.com/staticequipment/linesizing/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Impact of No. of Pipe Segments on the flow rate calculated by Pipe Model (Pag...Waqas Manzoor
A dynamic simulation was performed in Aspen HYSYS to calculate the maximum flow rate of natural gas through a 6-inch SCH 80 pipeline 12 km in length. The simulation showed that the pipeline could transport up to 4.01 MMSCFD of gas at a downstream pressure of 100 psig. However, the actual maximum flow rate would be lower due to pipe roughness and aging effects. It was determined that the pipeline would be unable to meet forecasted demand of 5-6 MMSCFD in 2015. A steady-state simulation could not calculate flow rates after specifying the total pressure drop across the pipeline.
VARIOUS METHODS OF CENTRIFUGAL COMPRESSOR SURGE CONTROLVijay Sarathy
This document discusses four methods of surge control for centrifugal compressors: 1) controlling surge with a simple minimum flow cold bypass between the discharge and suction sides; 2) controlling surge by altering compressor speed to meet discharge pressure requirements; 3) controlling surge by altering inlet guide vanes or compressor speed to reset cold bypass flow; 4) controlling surge by correlating differential pressure across the compressor to reset minimum cold bypass flow.
This tutorial introduces how to model a gas absorption process in HYSYS using a packed column where CO2 is absorbed from a gas stream into propylene carbonate. The key steps are: 1) defining the components, streams, and packed column, 2) specifying stream compositions and flow rates, 3) running the simulation, 4) changing from trays to packed section, 5) obtaining the column diameter, height, and exit gas CO2 concentration. Increasing the solvent flow rate decreases the exit CO2 concentration without significantly changing column size.
1. The document discusses procedures for calculating pressure safety valve (PSV) sizes for various scenarios that could lead to overpressure. It covers scenarios like closed outlets, external fires, control valve failures, hydraulic expansion, heat exchanger tube ruptures, and power or cooling failures.
2. Calculation methods include enthalpy balances for fractionating columns and the use of relief equations specified in codes like API 521. Worst cases are chosen from all possible scenarios to determine the required PSV size.
3. Key scenarios discussed in detail include closed outlets on vessels, external fires, failures of automatic controls, hydraulic expansion, heat exchanger tube ruptures, total and partial power failures, reflux losses,
Accumulation and Over-pressure: difference between accumulation and overpressureVarun Patel
Accumulation is pressure above the maximum allowable working pressure that vessel experience during high pressure event. Hence, when we say ‘accumulation’, its mean we are talking about the vessel or equipment.
On the other hand, Overpressure is pressure above the set pressure of the pressure safety valve that PSV experience during high pressure event. Hence, when we say ‘accumulation’, its mean we are talking about the pressure relief valve.
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
Natural gas condensates can form liquid slugs in transmission lines. This presentation describes alternative modelling strategies to determine slug volumes
This presentation covers process safety considerations and when a dynamic simulation is required. We also provide a modelling approach and a case study on Coker Bottoms Steam Generator, which includes information on device selection and device sizing.
Juan Pablo Hernández presented information on control valve sizing for compressible fluids. Control valves are used to meet process conditions and product quality specifications. Three methods for sizing control valves were compared: hand made calculations, Fisher software, and Aspen Hysys simulation. All three methods produced similar results for the example case of sizing a control valve for superheated steam. However, the Fisher software was identified as the preferred method due to providing reliable sizing in less time compared to hand calculations.
Surge Control for Parallel Centrifugal Compressor OperationsVijay Sarathy
1. The document discusses different methods for controlling parallel gas compressors to prevent surge during varying load conditions.
2. The base load method operates one compressor at maximum flow while the other swings based on demand, but is inefficient and requires frequent intervention.
3. The suction side speed control and equal flow balance methods aim to control both compressors independently using a master pressure controller and additional elements, but have disadvantages related to complexity and control dynamics.
4. The equidistant to surge line method coordinates anti-surge and load sharing controllers to keep the operating points of both compressors equally distanced from the surge line to handle varying loads while preventing surge.
This document discusses overpressure scenarios and required relief rates for process equipment. It identifies key data needed for the analysis such as P&IDs and equipment specifications. Common overpressure scenarios are described such as fires, control valve failures, thermal expansion, and utility failures. Industry guidelines for analyzing these scenarios are presented. Methods for determining applicable scenarios, calculating relief rates, and addressing special cases like gas blowby are outlined. The document stresses being conservative in initial analysis and reviewing all relevant guidelines.
This document provides guidelines for selecting, sizing, and specifying relief devices such as pressure relief valves and rupture disks. It discusses general criteria for relief device selection, mechanical design considerations, and specific selection criteria for different services. It also covers relief device calculations, requisitioning, specifications, identification, protection, packaging, and documentation. The guidelines are based on standards from ASME, API, and ISO, and are intended to help achieve maximum technical and economic benefit from standardization when designing oil, gas, chemical, and other processing facilities.
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS Gerard B. Hawkins
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
CONTENTS
1 INTRODUCTION
1.1 Purpose
1.2 Scope of this Guide
1.3 Use of the Guide
2 ENVIRONMENTAL ISSUES
2.1 Principal Concerns
2.2 Mechanisms for Ozone Formation
2.3 Photochemical Ozone Creation Potential
2.4 Health and Environmental Effects
2.5 Air Quality Standards for Ground Level Concentrations of Ozone, Targets for Reduction of VOC Discharges and Statutory Discharge Limits
3 VENTS REDUCTION PHILOSOPHY
3.1 Reduction at Source
3.2 End-of-pipe Treatment
4 METHODOLOGY FOR COLLECTION & ASSESSMENT OF PROCESS FLOW DATA
4.1 General
4.2 Identification of Vent Sources
4.3 Characterization of Vents
4.4 Quantification of Process Vent Flows
4.5 Component Flammability Data Collection
4.6 Identification of Operating Scenarios
4.7 Quantification of Flammability Characteristics for Combined Vents
4.8 Identification, Quantification and Assessment of Possibility of Air Ingress Routes
4.9 Tabulation of Data
4.10 Hazard Study and Risk Assessment
4.11 Note on Aqueous / Organic Wastes
4.12 Complexity of Systems
4.13 Summary
5 SAFE DESIGN OF VENT COLLECTION HEADER SYSTEMS
5.1 General
5.2 Process Design of Vent Headers
5.3 Liquid in Vent Headers
5.4 Materials of Construction
5.5 Static Electricity Hazard
5.6 Diversion Systems
5.7 Snuffing Systems
6 SAFE DESIGN OF THERMAL OXIDISERS
6.1 Introduction
6.2 Design Basis
6.3 Types of High Temperature Thermal Oxidizer
6.4 Refractories
6.5 Flue Gas Treatment
6.6 Control and Safety Systems
6.7 Project Program
6.8 Commissioning
6.9 Operational and Maintenance Management
APPENDICES
A GLOSSARY
B FLAMMABILITY
C EXAMPLE PROFORMA
D REFERENCES
DOCUMENTS REFERRED TO IN THIS PROCESS GUIDE
TABLE
1 PHOTOCHEMICAL OZONE CREATION POTENTIAL REFERENCED
TO ETHYLENE AS UNITY
FIGURES
1 SCHEMATIC OF TYPICAL VENT COLLECTION AND THERMAL OXIDIZER SYSTEM
2 TYPICAL KNOCK-OUT POT WITH LUTED DRAIN
3 SCHEMATIC OF DIVERSION SYSTEM
4 CONVENTIONAL VERTICAL THERMAL OXIDIZER
5 CONVENTIONAL OXIDIZER WITH INTEGRAL WATER SPARGER
6 THERMAL OXIDIZER WITH STAGED AIR INJECTION
7 DOWN-FIRED UNIT WITH WATER BATH QUENCH
8 FLAMELESS THERMAL OXIDATION UNIT
9 THERMAL OXIDIZER WITH REGENERATIVE HEAT RECOVERY
10 TYPICAL PROJECT PROGRAM
11 TYPICAL FLAMMABILITY DIAGRAM
12 EFFECT OF DILUTION WITH AIR
13 EFFECT OF DILUTION WITH AIR ON 100 Rm³ OF FLAMMABLE GAS
The document provides an overview of a module on flare system design and calculation. It discusses gas flaring definitions, components of a flare system, types of flares, environmental impacts, and considerations for flare system design and sizing calculations. Key aspects covered include gas flaring principles, when flaring occurs, composition of flared gases, reducing flaring through recovery systems, and sizing the flare header to minimize backpressure while limiting gas velocity.
Energy saving in urea plant by modification in heat exchanger and processPrem Baboo
Energy is the prime mover of economic growth and is vital to the sustenance of a modern economy. Improvement in energy
efficiency reduces cost of production & results in environmental benefits, e.g. mitigation of global warming by way of less emission of
Green house gases in the atmosphere. Over the years several energy conservation measures have been taken towards reduction in
specific energy consumption and improvement in energy efficiency. The efforts’ resulted in reduction in specific energy consumption
from 6.27G. Cal/tone of Urea to 5.421 G.Cal/tone of Urea in 2015-16 as shown in the Graph No 1 & 2 with energy & down time.
Further a major modification of all plants is under way. Most of the schemes have been implemented in 2012 and the further
modifications expected to result again reduction of energy consumption for ammonia and Urea plants. This paper described some of
the modification in urea plants implemented recently in May/June 2016.
Based on the information provided, a hydrocarbon system and petroleum refining process type have been selected. The recommended property package is NRTL.
Does this help summarize the recommended package? Let me know if you need any clarification or have additional questions!
A QUICK ESTIMATION METHOD TO DETERMINE HOT RECYCLE REQUIREMENTS FOR CENTRIFUG...Vijay Sarathy
Turbomachinery Engineers often conduct studies to determine if a hot gas bypass is required for a given centrifugal compressor system. This would mean building a process model and simulating it for Emergency Shutdown conditions (ESD) & Normal Shutdown conditions (NSD) to check if the compressor operating point crosses the surge limit line (SLL). A quick estimation method that uses dimensionless number called the inertia number can be used to check prior to the study, if a Hot gas bypass (a.k.a. Hot Recycle) is required in addition to an Anti-surge line (ASV or a.k.a Cold Recycle).
Aspen HYSYS is a process simulator that allows users to design and simulate chemical processes. It uses fundamental engineering relationships for mass and energy balances and thermodynamic models like equations of state to predict process behavior. Aspen HYSYS can help optimize existing plants and design new chemical plants by allowing users to evaluate many design cases and process conditions. It has built-in property packages and thermodynamic models that provide accurate property predictions for a wide range of components and conditions.
Exploring LPG Cylinders for Medical Oxygen - A Preliminary StudyVijay Sarathy
This document studies using LPG cylinders to supply medical oxygen in emergencies. It analyzes how long oxygen can be supplied from an LPG cylinder at flow rates of 0.5 and 2 liters per minute. The study finds the cylinder can supply oxygen at 0.5 liters/min for about 3 hours and at 2 liters/min for about 45 minutes before the pressure drops to 1 atmosphere. Governing equations for transient blowdown of the cylinder are derived in the appendices.
Heating Value Estimation for Natural Gas ApplicationsVijay Sarathy
For natural gas custody transfer applications, the gross calorific or gross heating value is necessary for both the buyer and seller to estimate the sales price of natural gas. In case of fuel suppliers, heat content is expressed in terms of Higher Heating value (HHV) to estimate fuel charges in kWh. Whereas Lower Heating Value (LHV) is employed to estimate fuel requirements since the total energy input for a specific power output is already fixed. To understand how fuel heating values are affected, LHV and HHV is explained as,
VARIOUS METHODS OF CENTRIFUGAL COMPRESSOR SURGE CONTROLVijay Sarathy
This document discusses four methods of surge control for centrifugal compressors: 1) controlling surge with a simple minimum flow cold bypass between the discharge and suction sides; 2) controlling surge by altering compressor speed to meet discharge pressure requirements; 3) controlling surge by altering inlet guide vanes or compressor speed to reset cold bypass flow; 4) controlling surge by correlating differential pressure across the compressor to reset minimum cold bypass flow.
This tutorial introduces how to model a gas absorption process in HYSYS using a packed column where CO2 is absorbed from a gas stream into propylene carbonate. The key steps are: 1) defining the components, streams, and packed column, 2) specifying stream compositions and flow rates, 3) running the simulation, 4) changing from trays to packed section, 5) obtaining the column diameter, height, and exit gas CO2 concentration. Increasing the solvent flow rate decreases the exit CO2 concentration without significantly changing column size.
1. The document discusses procedures for calculating pressure safety valve (PSV) sizes for various scenarios that could lead to overpressure. It covers scenarios like closed outlets, external fires, control valve failures, hydraulic expansion, heat exchanger tube ruptures, and power or cooling failures.
2. Calculation methods include enthalpy balances for fractionating columns and the use of relief equations specified in codes like API 521. Worst cases are chosen from all possible scenarios to determine the required PSV size.
3. Key scenarios discussed in detail include closed outlets on vessels, external fires, failures of automatic controls, hydraulic expansion, heat exchanger tube ruptures, total and partial power failures, reflux losses,
Accumulation and Over-pressure: difference between accumulation and overpressureVarun Patel
Accumulation is pressure above the maximum allowable working pressure that vessel experience during high pressure event. Hence, when we say ‘accumulation’, its mean we are talking about the vessel or equipment.
On the other hand, Overpressure is pressure above the set pressure of the pressure safety valve that PSV experience during high pressure event. Hence, when we say ‘accumulation’, its mean we are talking about the pressure relief valve.
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
Natural gas condensates can form liquid slugs in transmission lines. This presentation describes alternative modelling strategies to determine slug volumes
This presentation covers process safety considerations and when a dynamic simulation is required. We also provide a modelling approach and a case study on Coker Bottoms Steam Generator, which includes information on device selection and device sizing.
Juan Pablo Hernández presented information on control valve sizing for compressible fluids. Control valves are used to meet process conditions and product quality specifications. Three methods for sizing control valves were compared: hand made calculations, Fisher software, and Aspen Hysys simulation. All three methods produced similar results for the example case of sizing a control valve for superheated steam. However, the Fisher software was identified as the preferred method due to providing reliable sizing in less time compared to hand calculations.
Surge Control for Parallel Centrifugal Compressor OperationsVijay Sarathy
1. The document discusses different methods for controlling parallel gas compressors to prevent surge during varying load conditions.
2. The base load method operates one compressor at maximum flow while the other swings based on demand, but is inefficient and requires frequent intervention.
3. The suction side speed control and equal flow balance methods aim to control both compressors independently using a master pressure controller and additional elements, but have disadvantages related to complexity and control dynamics.
4. The equidistant to surge line method coordinates anti-surge and load sharing controllers to keep the operating points of both compressors equally distanced from the surge line to handle varying loads while preventing surge.
This document discusses overpressure scenarios and required relief rates for process equipment. It identifies key data needed for the analysis such as P&IDs and equipment specifications. Common overpressure scenarios are described such as fires, control valve failures, thermal expansion, and utility failures. Industry guidelines for analyzing these scenarios are presented. Methods for determining applicable scenarios, calculating relief rates, and addressing special cases like gas blowby are outlined. The document stresses being conservative in initial analysis and reviewing all relevant guidelines.
This document provides guidelines for selecting, sizing, and specifying relief devices such as pressure relief valves and rupture disks. It discusses general criteria for relief device selection, mechanical design considerations, and specific selection criteria for different services. It also covers relief device calculations, requisitioning, specifications, identification, protection, packaging, and documentation. The guidelines are based on standards from ASME, API, and ISO, and are intended to help achieve maximum technical and economic benefit from standardization when designing oil, gas, chemical, and other processing facilities.
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS Gerard B. Hawkins
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
CONTENTS
1 INTRODUCTION
1.1 Purpose
1.2 Scope of this Guide
1.3 Use of the Guide
2 ENVIRONMENTAL ISSUES
2.1 Principal Concerns
2.2 Mechanisms for Ozone Formation
2.3 Photochemical Ozone Creation Potential
2.4 Health and Environmental Effects
2.5 Air Quality Standards for Ground Level Concentrations of Ozone, Targets for Reduction of VOC Discharges and Statutory Discharge Limits
3 VENTS REDUCTION PHILOSOPHY
3.1 Reduction at Source
3.2 End-of-pipe Treatment
4 METHODOLOGY FOR COLLECTION & ASSESSMENT OF PROCESS FLOW DATA
4.1 General
4.2 Identification of Vent Sources
4.3 Characterization of Vents
4.4 Quantification of Process Vent Flows
4.5 Component Flammability Data Collection
4.6 Identification of Operating Scenarios
4.7 Quantification of Flammability Characteristics for Combined Vents
4.8 Identification, Quantification and Assessment of Possibility of Air Ingress Routes
4.9 Tabulation of Data
4.10 Hazard Study and Risk Assessment
4.11 Note on Aqueous / Organic Wastes
4.12 Complexity of Systems
4.13 Summary
5 SAFE DESIGN OF VENT COLLECTION HEADER SYSTEMS
5.1 General
5.2 Process Design of Vent Headers
5.3 Liquid in Vent Headers
5.4 Materials of Construction
5.5 Static Electricity Hazard
5.6 Diversion Systems
5.7 Snuffing Systems
6 SAFE DESIGN OF THERMAL OXIDISERS
6.1 Introduction
6.2 Design Basis
6.3 Types of High Temperature Thermal Oxidizer
6.4 Refractories
6.5 Flue Gas Treatment
6.6 Control and Safety Systems
6.7 Project Program
6.8 Commissioning
6.9 Operational and Maintenance Management
APPENDICES
A GLOSSARY
B FLAMMABILITY
C EXAMPLE PROFORMA
D REFERENCES
DOCUMENTS REFERRED TO IN THIS PROCESS GUIDE
TABLE
1 PHOTOCHEMICAL OZONE CREATION POTENTIAL REFERENCED
TO ETHYLENE AS UNITY
FIGURES
1 SCHEMATIC OF TYPICAL VENT COLLECTION AND THERMAL OXIDIZER SYSTEM
2 TYPICAL KNOCK-OUT POT WITH LUTED DRAIN
3 SCHEMATIC OF DIVERSION SYSTEM
4 CONVENTIONAL VERTICAL THERMAL OXIDIZER
5 CONVENTIONAL OXIDIZER WITH INTEGRAL WATER SPARGER
6 THERMAL OXIDIZER WITH STAGED AIR INJECTION
7 DOWN-FIRED UNIT WITH WATER BATH QUENCH
8 FLAMELESS THERMAL OXIDATION UNIT
9 THERMAL OXIDIZER WITH REGENERATIVE HEAT RECOVERY
10 TYPICAL PROJECT PROGRAM
11 TYPICAL FLAMMABILITY DIAGRAM
12 EFFECT OF DILUTION WITH AIR
13 EFFECT OF DILUTION WITH AIR ON 100 Rm³ OF FLAMMABLE GAS
The document provides an overview of a module on flare system design and calculation. It discusses gas flaring definitions, components of a flare system, types of flares, environmental impacts, and considerations for flare system design and sizing calculations. Key aspects covered include gas flaring principles, when flaring occurs, composition of flared gases, reducing flaring through recovery systems, and sizing the flare header to minimize backpressure while limiting gas velocity.
Energy saving in urea plant by modification in heat exchanger and processPrem Baboo
Energy is the prime mover of economic growth and is vital to the sustenance of a modern economy. Improvement in energy
efficiency reduces cost of production & results in environmental benefits, e.g. mitigation of global warming by way of less emission of
Green house gases in the atmosphere. Over the years several energy conservation measures have been taken towards reduction in
specific energy consumption and improvement in energy efficiency. The efforts’ resulted in reduction in specific energy consumption
from 6.27G. Cal/tone of Urea to 5.421 G.Cal/tone of Urea in 2015-16 as shown in the Graph No 1 & 2 with energy & down time.
Further a major modification of all plants is under way. Most of the schemes have been implemented in 2012 and the further
modifications expected to result again reduction of energy consumption for ammonia and Urea plants. This paper described some of
the modification in urea plants implemented recently in May/June 2016.
Based on the information provided, a hydrocarbon system and petroleum refining process type have been selected. The recommended property package is NRTL.
Does this help summarize the recommended package? Let me know if you need any clarification or have additional questions!
A QUICK ESTIMATION METHOD TO DETERMINE HOT RECYCLE REQUIREMENTS FOR CENTRIFUG...Vijay Sarathy
Turbomachinery Engineers often conduct studies to determine if a hot gas bypass is required for a given centrifugal compressor system. This would mean building a process model and simulating it for Emergency Shutdown conditions (ESD) & Normal Shutdown conditions (NSD) to check if the compressor operating point crosses the surge limit line (SLL). A quick estimation method that uses dimensionless number called the inertia number can be used to check prior to the study, if a Hot gas bypass (a.k.a. Hot Recycle) is required in addition to an Anti-surge line (ASV or a.k.a Cold Recycle).
Aspen HYSYS is a process simulator that allows users to design and simulate chemical processes. It uses fundamental engineering relationships for mass and energy balances and thermodynamic models like equations of state to predict process behavior. Aspen HYSYS can help optimize existing plants and design new chemical plants by allowing users to evaluate many design cases and process conditions. It has built-in property packages and thermodynamic models that provide accurate property predictions for a wide range of components and conditions.
Exploring LPG Cylinders for Medical Oxygen - A Preliminary StudyVijay Sarathy
This document studies using LPG cylinders to supply medical oxygen in emergencies. It analyzes how long oxygen can be supplied from an LPG cylinder at flow rates of 0.5 and 2 liters per minute. The study finds the cylinder can supply oxygen at 0.5 liters/min for about 3 hours and at 2 liters/min for about 45 minutes before the pressure drops to 1 atmosphere. Governing equations for transient blowdown of the cylinder are derived in the appendices.
Heating Value Estimation for Natural Gas ApplicationsVijay Sarathy
For natural gas custody transfer applications, the gross calorific or gross heating value is necessary for both the buyer and seller to estimate the sales price of natural gas. In case of fuel suppliers, heat content is expressed in terms of Higher Heating value (HHV) to estimate fuel charges in kWh. Whereas Lower Heating Value (LHV) is employed to estimate fuel requirements since the total energy input for a specific power output is already fixed. To understand how fuel heating values are affected, LHV and HHV is explained as,
Empirical Approach to Hydrate Formation in Natural Gas PipelinesVijay Sarathy
This document describes a methodology for estimating natural gas hydrate formation in pipelines. It presents an empirical approach using equations to model the pipeline temperature profile based on factors like operating pressure, temperature, heat transfer rate, and Joule-Thomson cooling effect. The methodology is applied to a case study of a 20km pipeline carrying natural gas. The results show the pipeline exit temperature remains above the hydrate formation temperature calculated along the pipeline length using established correlations, avoiding hydrate plug formation. In practice, heating the inlet gas or adding hydrate inhibitors can further increase this difference to improve safety.
Evaporation Pond Process Design in Oil & Gas IndustryVijay Sarathy
In the upstream oil & gas industry, produced water is a by-product of well production. Hydrocarbon wells initially produce less water but in late field life, the water content increases. Produced water can contain oil carryover and a host of salts with TDS ranging anywhere from 2,000 mg/L to 40,000 mg/L for which evaporation ponds are used to concentrate by evaporating the associated water.
The energy requirement consists of pumping concentrate to the pond and in some cases aeration is provided to enhance the rate of evaporation. The ponds are lined with synthetic liner material to prevent seepage of water into the soil. In case of any corrosive compounds in the water, the number of layers is increased. Landscape and topography play a role in setting up evaporation ponds and it is necessary to have a flat terrain to avoid any overflow of the contents.
Evaporation ponds must also ensure that the amount of water entering is minimized and avoid any flooding. As part of waste disposal, the ponds maybe designed to accumulate sludge over the life time of the operating wells or can be periodically removed. The below figure depicts an evaporation pond.
The following article focuses on estimating the rate of evaporation, water surface temperature and rate of heat transfer to the water in an evaporation pond.
Key Thermo-Physical Properties of Light Crude OilsVijay Sarathy
1) The document discusses methods for estimating key thermo-physical properties of light crude oils, such as latent heat of vaporization, using correlations based on distillation data and critical properties.
2) It provides examples of the Katz-Firoozabadi and Riazi-Daubert correlations that can be used to calculate properties like molecular weight, specific gravity, critical pressure and temperature.
3) The document works through a case study to estimate the latent heat of vaporization of a light crude oil at 325°K using distillation data, volume average boiling point, and the provided property correlations.
Cooling Towers in Process Industries are part of Utilities design. As the name suggests their primary purpose is to provide cooling requirements to industrial hot water from unit operations & unit processes. Examples include chillers and air conditioners. The principle of operation is to circulate hot water through a tower and allow heat dissipation to the ambient. Cooling towers can operate by natural draft or forced draft methods wherein fans are used to increase heat transfer.
Design Considerations for Antisurge Valve SizingVijay Sarathy
This document provides guidelines for sizing an anti-surge valve for a centrifugal compressor. It begins with definitions of surge and how it can damage compressors. It then outlines the methodology for sizing an anti-surge valve, which involves calculating the valve coefficient based on parameters like mass flow rate, pressure ratio, piping geometry, and gas properties. The document provides a case study applying this methodology to size a 4" anti-surge valve for a gas compressor system operating between 11.61 and 30.13 bara.
Gas Compression Stages – Process Design & OptimizationVijay Sarathy
The following tutorial demonstrates how to estimate the required number of compression stages and optimize the individual pressure ratio in a multistage centrifugal compression system.
Gas Condensate Separation Stages – Design & OptimizationVijay Sarathy
The life cycle of an oil & gas venture begins at the wellhead where subsurface engineers work their way through surveying, drilling, laying production tubing and well completions. Once a well is completed, gathering lines from each well is laid to gather hydrocarbons and transported via a main trunk line to a gas oil separation unit (GOSP) to be processed further to enhance their product value for sales. Gas condensate wells consist of natural gas which is rich in heavier hydrocarbons that are recovered as liquids in separators in field facilities or gas-oil separation plants (GOSP).
The following tutorial is aimed at demonstrating how to optimize and provide the required number of separation stages to process a gas condensate mixture and separate them into their respective vapour phase and liquid phase – termed as “Stage Separation”. Stage separation consists of laying a series of separators which operate at consecutive lower pressures to strip out vapours from the well liquids & resulting in a stabilized liquid. Prior to any hydrocarbon processing in a gas processing plant or a refinery, it is imperative to maximize the liquid recovery as well as provide a stabilized liquid hydrocarbon.
ECONOMIC INSULATION FOR INDUSTRIAL PIPINGVijay Sarathy
Thermal Insulation for Industrial Piping is a common method to reduce energy costs in production facilities while meeting process requirements. Insulation represents a capital expenditure & follows the law of diminishing returns. Hence the thermal effectiveness of insulation needs to be justified by an economic limit, beyond which insulation ceases to effectuate energy recovery. To determine the effectiveness of an applied insulation, the insulation cost is compared with the associated energy losses & by choosing the thickness that gives the lowest total cost, termed as ‘Economic Thickness’.
The following tutorial provides guidance to estimate the economic thickness for natural gas piping in winter conditions as an example case study.
Flash Steam and Steam Condensates in Return LinesVijay Sarathy
In power plants, boiler feed water is subjected to heat thereby producing steam which acts as a motive force for a steam turbine. The steam upon doing work loses energy to form condensate and is recycled/returned back to reduce the required make up boiler feed water (BFW).
Recycling steam condensate poses its own challenges. Flash Steam is defined as steam generated from steam condensate due to a drop in pressure. When high pressure and temperature condensate passes through process elements such as steam traps or pressure reducing valves to lose pressure, the condensate flashes to form steam. Greater the drop in pressure, greater is the flash steam generated. This results in a two phase flow in the condensate return lines.
Piping systems associated with production, transporting oil & gas, water/gas injection into reservoirs, experience wear & tear with time & operations. There would be metal loss due to erosion, erosion-corrosion and cavitation to name a few. The presence of corrosion defects provides a means for localized fractures to propagate causing pipe ruptures & leakages. This also reduces the pipe/pipeline maximum allowable operating pressure [MAOP].
The following document covers methods by DNV standards to quantitatively estimate the erosion rate for ductile pipes and bends due to the presence of sand. It is to be noted that corrosion can occur in many other scenarios such as pipe dimensioning, flow rate limitations, pipe performance such as pressure drop, vibrations, noise, insulation, hydrate formation and removal, severe slug flow, terrain slugging and also upheaval buckling. However these aspects are not covered in this document.
Based on the erosional rates of pipes and bends, the Maximum Safe Pressure/Revised MAOP is evaluated based on a Level 1 Assessment procedure for the remaining strength of the pipeline. The Level 1 procedures taken up in this tutorial are RSTRENG 085dL method, DNVGL RP F-101 (Part-B) and PETROBRAS’s PB Equation.
Natural Gas Pipeline Transmission Cost & EconomicsVijay Sarathy
In any pipeline project, an economic analysis has to be performed to ensure the project is a viable investment. The major capital components of a pipeline system consists of the pipeline, Booster station, ancillary machinery such as mainline valve stations, meter stations, pressure regulation stations, SCADA & Telecommunications. The project costs would additionally consist of environmental costs & permits, Right of Way (ROW) acquisitions, Engineering & Construction management to name a few.
The following tutorial is aimed at conducting a pipeline economic analysis using the method of Weight Average Capital Cost (WACC) to estimate gas tariffs, project worth in terms of Net Present Value (NPV), Internal Rate of Return (IRR), Profit to Investment Ratio (PIR) and payback period. The cost of equity is estimated using the Capital Asset Pricing Model (CAPM).
Predicting Performance Curves of Centrifugal Pumps in the Absence of OEM DataVijay Sarathy
Chemical and Mechanical Engineers in the oil & gas industry often carry out the task of conducting technical studies to evaluate piping and pipeline systems during events such as pump trips and block valve failures that can lead to pipes cracking at the welded joints, pump impellers rotating in the reverse direction and damaged pipe supports due to excessive vibrations to name a few. Although much literature is available to mitigate such disturbances, a key set of data to conduct transient studies are pump performance curves, a plot between pump head and flow.
The present paper is aimed at applying engineering research in industrial applications for practicing engineers. It provides a methodology called from available literature from past researchers, allowing engineers to predict performance curves for a Volute Casing End Suction Single Stage Radial Pump. In the current undertaking, the pump in question is not specific to any one industry but the principles are the same for a Volute Casing End suction radial pump.
Load Sharing for Parallel Operation of Gas CompressorsVijay Sarathy
The art of load sharing between centrifugal compressors consists of maintaining equal throughput through multiple parallel compressors. These compressors consist of a common suction and discharge header. Programmable logic controllers (PLCs) can be incorporated with load sharing functions or can be incorporated as standalone controllers also. Control signals from shared process parameters such as suction header pressure or discharge header pressure can be then fed to individual controllers such as compressor speed controllers (SC) or anti-surge controllers (UIC) to ensure the overall load is distributed efficiently between the compressors.
The following article covers load sharing schemes for parallel centrifugal compressor operation.
Basic Unit Conversions for Turbomachinery Calculations Vijay Sarathy
Turbomachinery equipment like centrifugal pumps & compressors have their performance stated as a function of Actual volumetric flow rate [Q] & Head [m/bar]. The following tutorial describes how pump/compressor head can be expressed in energy terms as ‘kJ/kg’. Turbomachinery head expressed in kJ/kg describes, how many kJ of energy is required to compress 1 kg of gas for a given pressure ratio. The advantage of using energy terms to estimate absorbed power is that it is based on the amount of ‘mass’ compressed which is independent of pressure and temperature of a fluid.
Single Phase Liquid Vessel Sizing for HYSYS DynamicsVijay Sarathy
Process Facilities often have intermediate storage facilities that store liquids prior to transporting to downstream equipment. The period of storage is short, i.e., of the order of minutes to hours & is defined as Holdup time. The Holdup time can also be explained as the reserve volume required to ensure safe & controlled operation of downstream equipment.
The intermediate vessel also acts as a buffer vessel to accommodate any surge/spikes in flow rates, and is termed as surge time.
Vessel Volume is an input data required in Process Dynamic Simulation and the following exercise covers estimation of volume required for single phase liquid flow into an intermediate vertical/horizontal/flat bottomed process vessel
Key Process Considerations for Pipeline Design BasisVijay Sarathy
Prior to venturing into an oil & gas pipeline project, the project team would require a design basis, based on which the project is to proceed. Oil & Gas Pipeline design begins with a route survey including engineering & environmental assessments. The following document provides a few key considerations for process engineers to keep in mind, the factors that matter when preparing a pipeline design basis from a process standpoint.
Chemical Process Calculations – Short TutorialVijay Sarathy
Often engineers are tasked with communicating equipment specifications with suppliers, where process data needs to be exchanged for engineering quotations & orders. Any dearth of data would need to be computed for which process related queries are sometimes sent back to the process engineer’s desk for the requested data.
The following tutorial is a refresher for non-process engineers such as project engineers, Piping, Instrumentation, Static & Rotating Equipment engineers to conduct basic process calculations related to estimation of mass %, volume %, mass flow, actual & standard volumetric flow, gas density, parts per million (ppm) by weight & by volume.
Process Design for Natural Gas TransmissionVijay Sarathy
This document provides an overview of the process design methodology for natural gas transmission from a gas plant to a city power station via a pipeline and booster compressor station. Key details include:
- Natural gas composition and properties, pipeline lengths and specifications
- Three part design methodology for the upstream pipeline, booster compressor, and downstream pipeline
- Property estimation methods including Kay's rule, Sutton correlations, and Dranchuk-Abou-Kassem equation of state
- Accounting for non-hydrocarbon gases like CO2 and H2S using Wichert & Aziz correlations
The design process involves estimating pipeline parameters, mixture properties, pressure drops, temperatures and flows to safely transmit the natural gas while
A high-Speed Communication System is based on the Design of a Bi-NoC Router, ...DharmaBanothu
The Network on Chip (NoC) has emerged as an effective
solution for intercommunication infrastructure within System on
Chip (SoC) designs, overcoming the limitations of traditional
methods that face significant bottlenecks. However, the complexity
of NoC design presents numerous challenges related to
performance metrics such as scalability, latency, power
consumption, and signal integrity. This project addresses the
issues within the router's memory unit and proposes an enhanced
memory structure. To achieve efficient data transfer, FIFO buffers
are implemented in distributed RAM and virtual channels for
FPGA-based NoC. The project introduces advanced FIFO-based
memory units within the NoC router, assessing their performance
in a Bi-directional NoC (Bi-NoC) configuration. The primary
objective is to reduce the router's workload while enhancing the
FIFO internal structure. To further improve data transfer speed,
a Bi-NoC with a self-configurable intercommunication channel is
suggested. Simulation and synthesis results demonstrate
guaranteed throughput, predictable latency, and equitable
network access, showing significant improvement over previous
designs
Applications of artificial Intelligence in Mechanical Engineering.pdfAtif Razi
Historically, mechanical engineering has relied heavily on human expertise and empirical methods to solve complex problems. With the introduction of computer-aided design (CAD) and finite element analysis (FEA), the field took its first steps towards digitization. These tools allowed engineers to simulate and analyze mechanical systems with greater accuracy and efficiency. However, the sheer volume of data generated by modern engineering systems and the increasing complexity of these systems have necessitated more advanced analytical tools, paving the way for AI.
AI offers the capability to process vast amounts of data, identify patterns, and make predictions with a level of speed and accuracy unattainable by traditional methods. This has profound implications for mechanical engineering, enabling more efficient design processes, predictive maintenance strategies, and optimized manufacturing operations. AI-driven tools can learn from historical data, adapt to new information, and continuously improve their performance, making them invaluable in tackling the multifaceted challenges of modern mechanical engineering.
Accident detection system project report.pdfKamal Acharya
The Rapid growth of technology and infrastructure has made our lives easier. The
advent of technology has also increased the traffic hazards and the road accidents take place
frequently which causes huge loss of life and property because of the poor emergency facilities.
Many lives could have been saved if emergency service could get accident information and
reach in time. Our project will provide an optimum solution to this draw back. A piezo electric
sensor can be used as a crash or rollover detector of the vehicle during and after a crash. With
signals from a piezo electric sensor, a severe accident can be recognized. According to this
project when a vehicle meets with an accident immediately piezo electric sensor will detect the
signal or if a car rolls over. Then with the help of GSM module and GPS module, the location
will be sent to the emergency contact. Then after conforming the location necessary action will
be taken. If the person meets with a small accident or if there is no serious threat to anyone’s
life, then the alert message can be terminated by the driver by a switch provided in order to
avoid wasting the valuable time of the medical rescue team.
Blood finder application project report (1).pdfKamal Acharya
Blood Finder is an emergency time app where a user can search for the blood banks as
well as the registered blood donors around Mumbai. This application also provide an
opportunity for the user of this application to become a registered donor for this user have
to enroll for the donor request from the application itself. If the admin wish to make user
a registered donor, with some of the formalities with the organization it can be done.
Specialization of this application is that the user will not have to register on sign-in for
searching the blood banks and blood donors it can be just done by installing the
application to the mobile.
The purpose of making this application is to save the user’s time for searching blood of
needed blood group during the time of the emergency.
This is an android application developed in Java and XML with the connectivity of
SQLite database. This application will provide most of basic functionality required for an
emergency time application. All the details of Blood banks and Blood donors are stored
in the database i.e. SQLite.
This application allowed the user to get all the information regarding blood banks and
blood donors such as Name, Number, Address, Blood Group, rather than searching it on
the different websites and wasting the precious time. This application is effective and
user friendly.
Prediction of Electrical Energy Efficiency Using Information on Consumer's Ac...PriyankaKilaniya
Energy efficiency has been important since the latter part of the last century. The main object of this survey is to determine the energy efficiency knowledge among consumers. Two separate districts in Bangladesh are selected to conduct the survey on households and showrooms about the energy and seller also. The survey uses the data to find some regression equations from which it is easy to predict energy efficiency knowledge. The data is analyzed and calculated based on five important criteria. The initial target was to find some factors that help predict a person's energy efficiency knowledge. From the survey, it is found that the energy efficiency awareness among the people of our country is very low. Relationships between household energy use behaviors are estimated using a unique dataset of about 40 households and 20 showrooms in Bangladesh's Chapainawabganj and Bagerhat districts. Knowledge of energy consumption and energy efficiency technology options is found to be associated with household use of energy conservation practices. Household characteristics also influence household energy use behavior. Younger household cohorts are more likely to adopt energy-efficient technologies and energy conservation practices and place primary importance on energy saving for environmental reasons. Education also influences attitudes toward energy conservation in Bangladesh. Low-education households indicate they primarily save electricity for the environment while high-education households indicate they are motivated by environmental concerns.
1. RATIO CONTROLLER USAGE IN ASPEN HYSYS DYNAMICS
The use of a Ratio controller in Aspen HYSYS Dynamics can be demonstrated using a Mixing Operation. Two
streams of water, ‘Stream 1’ at 3 bar(a) & 25
0
C and ‘Stream 2’ at 3 bar(a) & 50
0
C need to be mixed with a
mass ratio of 0.85 (85%), i.e., ‘Stream 1’ mass flow is 85% of ‘Stream 2’. A HYSYS model can be built using a
ratio controller which can be used to regulate the flow of ‘Stream 1’ (VLV-100) such that at all points in time,
‘Stream 1’ Mass flow is 85% of ‘Stream 2’.
Figure 1. HYSYS Dynamics Model Setup
Figure 2. Ratio Controller Setup – Page 1
Figure 3. HYSYS Model Setup – Page 2 Figure 4. Ratio Controller Setup – Page 3
VLV-100 opening is corrected by the Ratio
controller (RATO-100) to 42.31% (OP value) to
maintain Stream 1 : Stream 2 mass ratio at 0.85