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 Hysys Training Course- Brief Details

Course – Dynamic Simulation, Column & Compressor focus

Participant Background – Process Engineering
Pre-requisite Skills – Steady-State Process Simulation
Document Set (2 of 3) – Case Study- Dynamic Simulation of
Naphtha Stabilizer

August 2009

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 Dynamic Simulation of Naphtha
Stabilizer

Contents

Contents .......................................................................................................... 4

Component List and Fluid Package.....................................................................5

Modeling the Naphtha Stabilizer........................................................................7

Modeling the Column Sump and Reboiler Section.............................................16

Modeling Column Overhead System.................................................................32

Chapter 5......................................................................................................... 48

Modeling Column bottom heat exchanger section............................................48

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 Chapter 1

Component List and Fluid Package

1. Create a new case and define the hypo components
2. Name the component list as NS and select the components
3. A base case for modeling the Naphtha Stabilizer can be provided
4. Enter Simulation environment. Use dynamic mode.

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5. Select Peng-Robinson as fluid package and save case

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 Chapter 2

Modeling the Naphtha Stabilizer

1. Model the C7507 in a sub flow sheet environment. Start with a blank flow sheet

2. Define all input streams for the stabilizer using the stream composition. Use dummy
controllers and valves to control flow
3. Size the valves for small pressure drops and required flow

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4. Start modeling the Stabilizer C7507 using custom column from the object palette. Start
with a blank flow sheet.

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5. Edit the number of trays. Add 22 trays to make a total of 32 trays. Use ‘Bottom Up’ way
of numbering the trays.
6. Enter Column environment. Use tray section to define the geometric details of the
column.
These details can be entered from the datasheet for the Naphtha Stabilizer.

*Note: The sump will be separately modeled.

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7. Connect the inlet and outlets of the column C7507. Define the Top and Bottom stage
pressure.

8. Specify the nozzle dimensions and their relative elevations from the tray.

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 9. Use a dummy controller to control column top pressure. Use SP = 8.3 kg/cm 2 (g).

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 10. Use tower diameter method and initialize holdup. Specify and tune the K values to
achieve the pressure profile.

11. Run the simulation and save case

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 Chapter 3
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 Modeling the Column Sump and Reboiler Section
1. Define the shell and tube side inlet streams from the available stream composition.
2. Size the valve for a pressure drop of 2.5 kg/cm 2
3. Now add the shell and tube heat exchanger from object palette

4. Input the exchanger details from the datasheet

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5. Calculate the conductance values for pressure drops provided in the datasheet

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6. Add the flow controller FIC055. Use the parameters as shown the figure below

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7. Run and save case
8. The column sump has weir and is modeled as two separators C7507-V1 and C7507-V2.
Their volumes together contribute the total sump volume.
9. Define input stream ‘From-Col’ with composition from stream 128
Pressure = 8.635 kg/cm2 (g)
Temp = 170 °C
10. Connect the stream 127-1 from reboiler shell side outlet to C7507-V1

11. Input the geometric details of C7507-V1 from Stabilizer datasheet

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12. Initialize holdup with the stream composition of stream 127-1
Pressure = 8.6 kg/cm2 (g)
Temperature = 176 °C

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13. Ensure that the static head calculations are enabled for modeling the thermo-siphon effect

14. Place and size valves on input and output streams to simulate proper dynamic behavior

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15. Model a tee ( stream – splitter) on the bottom stream of C-7507-V1 (Left side of sump
weir)
16. Run the simulation for some time. As the level builds up in the separator the static head is
added to the bottom stream pressure
17. Connect the heat exchanger shell side input to the tee.
18. Run the simulation and save case

19. Specify a steady state flow of about 26,600 kg/h for stream passing to C7507-V2

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20. Place a separator from object palette and name it as C7507-V2. Connect the vapor outlet
to C7507-V1. Input the geometric details as shown in the figure below.

21. Model a level control valve to maintain C7507-V2 level

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22. Run the simulation and save case
23. The overflow above the weir is calculated using a spreadsheet.
24. Lay out a spreadsheet from the object palette and change the number of columns to 5 and
number of rows to 20.

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25. Import variables in the connection tab

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26. Export the calculated mass flow to the simulation from cell E20 to stream 7

27. The imported variables appear in B column. These are black color coded.
28. Specify the Weir height, length, discharge coefficient, safety factor and time step.

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29. The calculated variables appear in red color. Calculations are specified in the cells of
column E. Refer the calculation details for modeling the flow over weir in spreadsheet.

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30. Run the simulation and save case

31. Connect the column bottom stream 128 to the sump C7507-V1. Connect the Vapor outlet
of C7507-V1 to the column tray section. Delete the dummy controllers and
unconnected streams. Run the simulation and save case.

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 Chapter 4

Modeling Column Overhead System

1. Remove the dummy control valves on column overhead vapor product and connect it to
the Condenser E7528.

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2. Use the heat exchanger data sheet to fill in the necessary details

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3. Run the simulation and save case

4. Place a three phase separator from the object palette and connect the inlet and outlet
streams

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5. Enter the vessel geometry from the datasheet for V7518

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6. Initialize holdup with inlet stream composition.
Pressure = 8 kg/cm2 (g)
Temperature = 41 °C

7. Model the pressure control valve PV101 on the vapor outlet of reflux drum

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8. Model Level control valve LV049 on the outlet of boot. Model a dummy level control
loop for the reflux drum. Specify level taps from the datasheet.

9. Run the simulation and save case

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10. Place a pump from the object palette. Enter the characteristic curve from the datasheet
11. Model the discharge check valve for pump P7516A/B

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12. Run the simulation and save case
13. Split the discharge in two streams

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14. Model level control valve LV053 on one stream. Disconnect the dummy control loop.

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15. Enable the pressure specs for outlet stream of the control valve

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16. Run and save case

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17. Model the flow control valve on the reflux stream

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18. Run the simulation. Connect the reflux stream to the column when the flow controller
reaches its set point. Remove all dummy valves and control loops.

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19. Run the simulation and save case

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 Chapter 5

Modeling Column bottom heat exchanger section

1. Start defining the input streams 117, 103, 59 and 48 using the stream composition.
2. Enable pressure specs for the streams

3. Use dummy control valves to control the feed flow. Size the valves for a small pressure
drop and flow specified in the stream data or PFD.

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4. Run the simulation and case.

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5. Use dummy flow controllers for all input streams. Use mass flow as input variable

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6. Run the simulation and save case after some time

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7. Connect the input streams to a mixer. Disable pressure specs at outlets of all valves. Use
default ‘equalize all’ option for the mixer.

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8. Activate pressure spec for stream 118 at 10.6 kg/cm 2(g)

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9. Run the simulation for some time and save case.

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10. Input stream composition for stream 5 same as for stream 128. Input conditions for this
stream from the heat exchanger E7527 B data sheet.

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11. Place shell and tube heat exchanger on flow sheet from the palette. Input data in design
and ratings tab. Calculate the conductance for required pressure drop on shell and tube
side.

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12. Use simple heat loss calculations

13. Model a dummy flow

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14. Model E7527 A on similar guidelines

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15. Model the trim cooler E-7530. Input the cooling water conditions from heat exchanger
E7530 datasheet

16. Remove the dummy control valve and model the flow control loop FIC056 running in
local automatic mode.

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17. Model the heat exchanger with details as shown in the figures below.

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18. Connect the feed stream to the column sub flow sheet

19. Run the simulation and save case.

20. Model the cascade controls for the column level control and temperature control

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21. Run the simulation to achieve a steady state solution and save case.

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