Process Plant Design & Simulation

Handbook
Ajay S. Satpute

Process Coach and Managing Director

Converge Engineering Pvt. Ltd.
www.converge.net.in
[email protected]

First Edition (Self-p ublished)

Designed and Printed at Hitech Graphics

77 Panvel Ind. Est., Panvel 410 206,
Maharashtra, INDIA.
Tel : +91-22-27451347

Copyright © 2020. All rights reserved.

No part of this publication may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopy, recording, or any information storage and
retrieval system, without permission in writing from the author.
 ABOUT THE AUTHOR
Mr. Ajay S. Satpute is a reputed name in the Chemical Engineering field with
18+ years’ experience in several industries like Oil & Gas, Chemicals,
Energy, Utilities, Fertilizers, Iron & Steel, and Pulp & Paper etc. in India,
Middle East, and the Far East. He has worked in the process industry in
production, technical services and design department.
He has trained several process engineers in the field of process calculations
and simulation.
He is an alumnus of the prestigious Indian Institute of Technology (I.I.T.),
Madras with Master’s Degree in Chemical Engineering.
He has shared several process calculation spreadsheets online. Over
50,000+ engineers worldwide have been benefited by his spreadsheets,
articles and his guidance.
Dedicated to all my students, from whom I have
learnt a lot.
 ACKNOWLEDGEMENT
During the lockdown period of Many thanks to my guru, Prof. (Dr.)
COVID-19 in the first week of Dhruvprasad Mishra Sir for
April, my wife, Surekha (my boss reviewing this book and providing
and director of CEPL ), suggested, valuable suggestions.
“Why don’t you write a book about I’m grateful to those wonderful
plant design and simulation that seniors, teachers who taught me
process engineers can use as a everything they knew about process
working guide?”. Then, the wheels engineering. Without them, I would
started spinning and I could not have never known how beautiful
sleep that night. Thanks dear, for process engineering is. Many names
that push (or kick) that kept me busy come to my mind, Mr. Bhikaji P.
for the next few months writing this Bhayye, Mr. SBVJ Rao, Prof. (Dr.)
book. K. Krishnaiah, Mr. Atul Goswami,
I’m very proud of my elder Mr. Sanjay B. Patil, Mr. Sudhir
daughter, Rhea, for working on Kumar Mittal, Mr. S. Niraipandian,
spell-check, formatting, drawing Mr. S. Chinnadurai, Mr. Raj K.
schematics & tables, numbering the Sahni, Mrs. Jayita Sen-Ray, Mr.
figures & tables after the draft copy Sivasubramanian N. and many more.
of this book was completed. I’m I remember my (late) dad on this
also thankful to my family day, who, as usual, would have been
members, my mom, sisters, and my very proud of me.
younger daughter, Riena for their
Thanks to the Almighty for
constant support and
everything.
encouragement, not just for this
book, but during the 20 years of my Thx.
professional life and even before Ajay S. Satpute
that. December 2020

Special thanks to my dear friends

and process design and simulation
experts, Mr. Rajesh Maguluri and
Mrs. Khushboo Thakur for their
time to meticulously checking the
contents of the book and adding
value to the same.
 PREFACE
Process engineering, and It has been a great challenge for me
especially, process design, in my to pen down my experience of
opinion, is the most interesting and designing, running and
beautiful subject, there is. This troubleshooting of the process plant
book is an honest attempt to share on paper. I hope the younger
the beauty of the subject with generation gets benefitted by this.
everyone. It will certainly help
become an excellent process Before entering process design, one
engineer. On purpose, it has been must
know what process
tried to keep the theoretical engineering is. The same has been
aspects at bay and focus mainly on explained in Chapter 1 (Getting
practical implications of process started ).
design. Once the “how to do” part Chapter 2 ( Design condition
is clear, then readers will be ready evaluation ) provides different
for figuring out the “why” part terms and their meaning related to
themselves. design pressure and temperature.
This is a must-have book for final Chapter 3 ( Process deliverables )
year engineering students and for discusses major process
practicing engineers in engineering deliverables like design basis,
consultancies. simulation or calculation report,
operating & control philosophy,
It must not be read like a
line list, datasheet, PFD, P&ID, and
storybook, because it is not one.
C&E matrix.
Rather, it should be referred to
while using spreadsheets or Nowadays there are several
software and solve the problems process simulation software which
with the help of this book. are used in process design. Chapter
4 ( Process simulation software )
I do not claim that this book will
provides a brief on different
provide all the aspects of process
software.
design, but I can guarantee that if
you follow this book thoroughly,
then you will gain enough
confidence to carry out any
process plant design using
simulation software.
Once the reader has a fair idea There is an important tool,
about process engineering, Optimizer, in Aspen HYSYS. The
deliverables, and software, the same is discussed in chapter 12.
actual sizing shall be initiated in
PSV sizing using Aspen HYSYS is
Chapter 5 (Line sizing using
Aspen HYSYS ) with line sizing in carried out in Chapter 13 ( PSV
sizing using Aspen HYSYS ).
Aspen HYSYS. Pump sizing is
discussed in Chapter 6 ( Pump A real project problem is solved
sizing using Aspen HYSYS ). using Aspen HYSYS in chapter 14 (
Aspen HYSYS is used for the Process plant design using Aspen
simulation. HYSYS ).
Chapter 7 ( Control valve sizing Chapter 15 ( Aspen HYSYS
using Aspen HYSYS ) provides a Dynamics – Simple problem )
step-by-step procedure to carry out discusses a typical Dynamic
control valve sizing using Aspen simulation problem.
HYSYS.
In the next chapter ( Aspen HYSYS
Orifice sizing using Aspen HYSYS Dynamics – Project Problem), the
is discussed in chapter 8 ( Orifice real project problem solved in
sizing using aspen HYSYS ). chapter 14 is converted into a
Chapter 9 ( Separator sizing using dynamic model and analyzed.
Aspen HYSYS ) discusses separator Typical interview questions are
sizing using Aspen HYSYS. listed in the last chapter.
Chapter 10 ( Heat exchanger There are several exercises
sizing using Aspen EDR ) provided. It would help more to the
discusses heat exchanger sizing reader if he/she prepares a
using Aspen EDR. presentation slides for each
Distillation column sizing using exercise and present in front of a
Aspen HYSYS is discussed in group of process engineers.
chapter 11 ( Distillation column
sizing using Aspen HYSYS ).

TABLE OF CONTENTS
CHAPTER 1: GETTING STARTED
 Process engineering
What does a Process Engineer do?
Skillset required for Process Engineers
Various packages used in industry
Concept / Feasibility Study
Front End Engineering Design
Detail Engineering Design
As-built drawings
Process Standards
Exercises
CHAPTER 2: DESIGN CONDITION EVALUATION
Temperature System
Operating Temperature
Maximum Operating Temperature
Upset Temperature
Design Temperature
Minimum metal temperature
Pressure System
Operating pressure
Maximum operating pressure
Design pressure
Vapor and vapor-liquid systems protected by relief
valves
Vapor and vapor-liquid systems protected by rupture
disks
Liquid-Full systems
Shell & tube heat exchangers
 Pipeline systems
Lower Design pressure
Maximum allowable working pressure
Maximum allowable incidental pressure
Hydrostatic Test Pressure
Exercise
CHAPTER 3: PROCESS DELIVERABLES
Process Design Basis
Block Flow Diagram
Process Flow Diagram
Piping & Instrumentation Diagram
Operating, Control & Safeguarding Philosophy
Process Datasheet
HAZID
HAZOP
Exercises
CHAPTER 4: PROCESS SIMULATION SOFTWARE
Aspen HYSYS
Aspen Flare System Analyzer
Aspen Exchanger Design and Rating
FluidFlow (from Flite Software NI Ltd.)
Bentley WaterGEMS
Bentley HAMMER
PIPESIM (from Schlumberger)
FlareSim (from Schlumberger)
OLGA (from Schlumberger)
VMGSim (from Schlumberger)
 UniSim (from Honeywell)
PIPENET (from Sunrise Systems Ltd.)
Flow Master (from TechNet Alliance)
EPANET (from EPA)
PRO II (from AVEVA)
MySep (from Kranji Solutions)
Pipeline Studio (from Emerson)
Petro-SIM (from Yokogawa)
Exercise
CHAPTER 5: LINE SIZING USING ASPEN HYSYS
Velocity criteria
Pressure drop criteria
Misc. criteria
Water service
Liquid and Gas service
Flow-induced vibrations
Pulsation and transient vibrations
High-frequency acoustic excitation
Transient/Surge analysis
Measures for mitigating surge pressure in pipeline
Simulation
Exercises
CHAPTER 6: PUMP SIZING USING ASPEN HYSYS
Centrifugal Pump
Positive Displacement Pump
PD Pump behavior and safety
PD Pump Types
 Minimum Flow By-Pass
Centrifugal Pumps Guidelines
Positive Displacement Guidelines
Capacity Adjustment for Metering Pumps
Pressure Relief for Positive Displacement Pumps
Pulsation Devices for Positive Displacement Pumps
Net positive suction head available
Net positive suction head required
Differential Pressure or Differential head
Pump Motor Brake Kilowatt
Typical Pump Curve
Simulation
Exercises
CHAPTER 7: CONTROL VALVE SIZING USING ASPEN HYSYS
What is a control valve?
What is a Cv?
Control Valve Sizing Criteria
Valve Sizing Criteria
Common flow characteristic curves
Control Valve selection process
Self-acting regulators
Types of self-acting regulators
Simulation
Exercises
CHAPTER 8: ORIFICE SIZING USING ASPEN HYSYS
Simulation
Exercises
CHAPTER 9: SEPARATOR SIZING USING ASPEN HYSYS
Types of Separators
Separator Basic Design Criteria
Mist Extraction Equipment
Souders-Brown Equation
Recommended values of k
Simulation
Exercises
CHAPTER 10: HEAT EXCHANGER SIZING USING ASPEN EDR
Simulation
Exercises
CHAPTER 11: DISTILLATION COLUMN SIZING USING ASPEN
HYSYS
Exercises
CHAPTER 12: OPTIMIZER TOOL IN ASPEN HYSYS
Exercises
CHAPTER 13: PSV SIZING USING ASPEN HYSYS
Terminology
When to provide a PRV?
Types of PSV
Chatter
Chatter solution
Rupture disc
quiz
Review of API 520 Part 1
Review of API 521
Review of API 526
 Simulation
Exercises
CHAPTER 14: PROCESS PLANT DESIGN USING ASPEN
HYSYS
Maximum design pressure
Minimum design pressure
Maximum design temperature
Minimum design temperature
Line sizing criteria
Separator sizing
Atmospheric tank design
Heat exchanger design
Operational drain, vent and flushing requirements
Plant design problem
Simulation
Exercises
CHAPTER 15: ASPEN HYSYS DYNAMICS (SIMPLE PROBLEM)
CHAPTER 16: ASPEN HYSYS DYNAMICS (PROJECT
PROBLEM)
CHAPTER 17: TYPICAL INTERVIEW QUESTIONS
CHAPTER 1: GETTING STARTED
Process engineering
Process engineering is the utilization of the laws of
physics and chemistry to convert less useful raw materials
to more useful products. This involves process plant
design, operation, optimization, and troubleshooting.
Process engineering is required in almost all industries
like agriculture, automotive, biochemical, chemical,
material development, mining, nuclear, oil & gas,
petrochemical, pharmaceutical, etc.

What does a Process Engineer do?

Design new equipment/plant as per

internationally accepted engineering practices
(Greenfield).
Check the adequacy of the existing system for
changed operating conditions (e.g. pressure,
temperature, flow, etc.) as per internationally
accepted engineering practices (Brownfield).
Verify new processes.
Work on optimization projects and troubleshoot
plant issues.
Use process simulation software like Aspen
HYSYS or FluidFlow to model the process plant.
Operate the process plant and equipment as per
design.
Size equipment and instrumentation to be
implemented and issue relevant Process
Datasheets.
Elaborate Process Flow Diagram and Piping &
Instrumentation Diagrams.
Perform hydraulic and thermal calculations on
piping systems, pipelines, flow lines in steady-
state and transient scenarios.
Define the utility requirements and design the
associated systems.
Define the quantity and quality of effluents to be
disposed of to the environment.
Participate in the preparation of the Operating
Manual.
Assess safety and environmental issues.
Identify process hazards and participate in
process safety reviews.
Skillset required for Process Engineers

Interest in physics, chemistry and mathematics

Analytical abilities
Software skills
Commercial skills
Multi-tasking skills
Good communication skills
Problem-solving skills
Tenacity

Various packages used in industry

There are mainly 3 packages/studies that are carried out in
industry, namely;

Concept / Feasibility Study

FEED
Detail Engineering

Concept / Feasibility Study

This is the beginning stage of any project. Before investing
money in any new project, the client needs to ensure that
the following concerns are addressed before the
investment is justified and the wiser decision can be taken
by the client.

The process must be technically feasible,

efficient, and safe.
Select between batch or continuous plant.
Budgetary cost of the project.
Selling plan for the product.

Typical activities during the Concept / Feasibility study

Evaluation of different process routes w.r.to

financial, environmental, and safety points of
view.
Best option recommendation.
 Develop preliminary process flow diagram and
heat & mass balance.
Equipment list.
Cost estimation (deviation of +50% / -30%).
Identify weak areas in process design such as
experimental design, insufficient laboratory or
pilot plant data, scale-up from pilot plant design,
and benchmarking against existing designs.

Front End Engineering Design

FRONT END ENGINEERING DESIGN (FEED) is
followed by Conceptual design or Feasibility study. FEED
design focuses on both, technical and approximate project
cost. FEED package forms the basis for the detailed
engineering stage.
Typical activities during FEED

Process Design Basis

Heat & Material Balance
Process Flow Diagrams
Piping & Instrumentation Diagrams
Line list
Equipment List
Hazardous Area Classification Schedule
Process Datasheets
Process Description
Operating, Control and Safeguarding Philosophy
Process simulation/calculation report
HAZID / HAZOP study

Detail Engineering Design

All the deliverables prepared during the FEED stage will
be reviewed and upgraded during this phase. Many
additional documents and drawings specific to this phase
are prepared.
Typical activities during Detail Engineering (in addition
to FEED)

Operation & control philosophy

HAZOP study and Close-out Report
Pre-commissioning and Commissioning Manual
Effluents and Emissions Summary
Single Line Diagrams
Instrument Loop Diagrams
Material Requisitions for Static Equipment
Material Requisitions for Rotary Equipment
Material Requisitions for Electrical Items
Material Requisitions for Instrument Items
Material Requisitions for Civil / Structural
Piping Key Plan, Piping GA Drawings, Piping
Isometric Drawings
Piping Bulk Material Take-Off (MTO)
Instrument Bulk MTO
Electrical Bulk MTO
Civil Bulk MTO
Review of Vendor Documents / Drawings (All
Disciplines)
Technical Bid Analysis
Fire Fighting MTO

As-built drawings
The constructed plant and designed plant do not match
exactly all the time. This happens due to many reasons
given as below;

Design stage errors

Changes in design basis during the construction
phase.
Instructions from the client that led to
minimization of equipment/instruments etc.
On the site changes recommended by
commissioning experts during the construction
 phase.

EPC contractor provides red mark-up on the P&IDs,

Isometric, GADs, etc. post-construction. The red mark-up
shall highlight the mismatch between the final design and
constructed plant. Engineering consultant updates
drawings in CAD and submits the package as “As-Built
Drawings”.
Process Standards
Standards are documents that describe the important
features of a product, service, or system. Standards are
prepared by a professional group or committee which are
believed to be good and proper engineering practice, and
which contain mandatory requirements and dimensions.
Following major process standards are listed below;

API 12J : Specification for

Oil and Gas Separators
API 14C : RP for Analysis, Design,
Installation, and Testing of Safety Systems for

Offshore Production Platforms

API RP 14E : RP for Design and

Installation of Offshore Production Platform

Piping Systems

API 520 – I & II : Sizing, Selection, and

Installation of Pressure-relieving Devices
API 521 : Pressure-relieving
and Depressuring systems
API 526 : Flanged Steel
Safety Relief Valves for Use in Petroleum
Refineries
ANSI/API 610 : Centrifugal Pumps for
General Refinery Service
API 537 : Flare details for
general refinery and petrochemical service
API 650 : Welded steel tanks
for oil storage
API 674 : Positive
Displacement Pumps – Reciprocating
API 675 : Positive
Displacement Pumps - Controlled Volume
API 681 : Liquid Ring
Vacuum Pumps and Compressors for Petroleum,
Chemical,

and Gas Industry Services

API 2000 : Venting Atmospheric and
Low-Pressure Storage Tank
API 2521 : Use of Pressure-Vacuum Vent
Valves for Atmospheric Pressure Tanks to

Reduce Evaporation Loss

ASME B 31.3 : Process Piping Guide

ASME sec. VIIIB Div. 1: Boiler & pressure
vessel code (Design pressure > 3.5 barg)
ANSI/ISA 75.01.01 : Flow equations for sizing
control valves
 EI Guidelines : Energy Institute
Guidelines for the Avoidance of Vibration
Induced Fatigue

Failure in Process Pipework

ISGOTT : International Safety Guide for

Oil Tankers & Terminals
ISO 5167-2 : Orifice plates
OCIMF : Oil Companies
International Marine Forum

Exercises

a. Ms. Bindu works in a production company in

shift. What would be her job profile?
b. Mr. Satish wants to shift from operating company
to engineering consultancy firm. What knowledge
he must acquire to work successfully in the new
company?
c. Ms. Brinda is a successful process engineer.
What skill-set she must have to be successful?
d. Ms. Reena is a billionaire in India. She wants to
set up the absolute alcohol production facility in
western India. Prepare a concept report with 3
options.
e. Ms. Archana is carrying out FEED for NGL plant
in Vizag. What deliverables may be there in the
FEED package that she would submit to the end
client?
f. Mr. Sanket is a project manager working for an
EPC contractor who has been awarded a detail
engineering project. What engineering documents
do you think he might receive from the
engineering consultant?
g. Mr. Gaurav is bidding for a detailed engineering
project. Is it wise not to consider any manhours
 for As-Built activity?
h. What are the different engineering standards used
by a process engineer?
CHAPTER 2: DESIGN CONDITION
EVALUATION
The most severe combination of coincident pressures and
temperatures normally determines design conditions. In
general, piping up to and including DN 600 shall be
designed for full vacuum at ambient temperature.
Temperature System
Operating Temperature
The operating temperature is the temperature at which the
equipment is operated.
Where equipment operation may be switched from a high-
pressure moderate temperature operation to a lower
pressure but higher temperature one, then the option of
designing for those separate operating modes may be
considered (e.g. dual pressure/temperature ratings for the
equipment).
Maximum Operating Temperature
The Maximum Operating Temperature (MOT) will be
established for operational flexibility and required control
system variations. It will be greater than or equal to the
operating temperature. The MOT can be used as the basis
for materials selection for long term corrosion and/or
material degradation.
Upset Temperature
The upset temperature is the maximum temperature that
can be reached under upset conditions assuming no
barriers are in place. Typical upset scenarios include
excessive process heat input (e.g. due to control failure)
and loss of cooling medium to the system (e.g. due to
power failure). The potential for upset temperatures
exceeding the MOT due to exotherms, decompositions, or
runaway reactions can be mitigated by one of the
following:

increased design temperature

instrument safeguards
Fire exposure is an emergency condition that can result in
wall temperatures higher than the equipment MOT. As all
the process equipment exposed to fire will be subject to
inspection, repair, or replacement, fire case temperatures
will not be used for establishing design temperature.
Upset conditions will be assumed to prevail only for the
time required to correct the situation. These conditions
will be considered both in materials selection and
mechanical design, recognizing that these conditions
prevail for a limited period and not indefinitely.
Design Temperature
The design temperature is used for the mechanical design
(e.g. determination of minimum wall thickness) of
equipment and piping. It is often referred to as the upper
design temperature. It is the highest temperature to which
equipment is designed at the design pressure. It will be
equal to or greater than the MOT. The design temperature
is typically at least 10 °C above the MOT.
Design temperature can be rounded up to the nearest 5 °C
increment.
For unfired heat exchangers, the design temperature of the
cold side can be set equal to the hot side to simplify
safeguarding. For tubes in fired equipment, the design
temperature can be either the temperature determined by
the rules specified above or the calculated maximum tube
skin temperature, whichever is higher.
For systems where steam out is intended, the steam out
pressure/temperature combination should be specified as
a separate design case. Typical steam-out conditions are a
temperature of 150 °C under a full vacuum.
For systems where a design temperature has been
specified at a value less than 120 °C, the Contractor may
elect to designate the design temperature as 120 °C since
often there is no increase in flange rating requirement.
Minimum metal temperature
The Minimum Metal Temperature (MMT) is the lowest
metal temperature that equipment could reach and will be
defined for all equipment, pipelines and piping systems.
The MMT will be specified based upon the minimum of
the following:

The lowest normal operating temperature

The lowest temperature during start-up or
shutdown
The lowest ambient temperature
The temperature during cool down events caused
by high rate depressurization

Pressure System
A pressure system is a single equipment or a group of
equipment along with associated piping that within its
boundaries remains open under all conditions, and with no
possibility of blockage due to freezing, , fouling,
sublimation, debris etc. It will not be higher than the
pressure rating of any system component. The effects of
static head will be considered.
When a system approach is taken, the hydraulics shall be
evaluated to ensure that no equipment exceeds its design
pressure before a pressure relief device activates, and
during relieving conditions, no equipment exceeds the
allowable accumulation permitted by either the applicable
code or local requirements.
Operating pressure
The Operating Pressure (OP) is the gauge pressure which
prevails inside equipment and piping during any intended
operation.
Maximum operating pressure
The Maximum Operating Pressure (MOP) is typically at
least 105% of the OP to provide adequate flexibility for
the control of the intended operations. The MOP may not
be less than 1.0 bar above the OP. For pipeline
application Maximum Allowable Operating Pressure
(MAOP) or MOP is the maximum internal pressure at
which a pipeline system or parts thereof can be operated.
MAOP will not exceed 80% of the hydrotest pressure.
Design pressure
The Design Pressure (DP) is the highest gauge pressure
that, according to mechanical design codes, an equipment
can be continually subjected to at or below the Upper
Design Temperature, and above the Lower Design
Temperature. It may be rounded up to the next 0.5 barg
increment. This pressure provides the basis for relief
valve set pressure.
Vapor and vapor-liquid systems protected by relief
valves
Equipment that is protected by a relief valve discharging
into a flare system or combined vent system shall have a
minimum design pressure of at least 3.5 barg due to the
potential back pressure exerted on the relief device. When
using sonic flare tips, the minimum design pressure will
be considerably higher than 3.5 barg. Design pressures
lower than 3.5 barg may be considered if the relief valve
discharges directly to the atmosphere or is routed to a
downstream system that has a design pressure of less than
3.5 barg.
If a DP of 110% MOP is substantially more costly than a
DP of 105% MOP, then 105% MOP can be applied,
subject to the approval of the client.
The DP is greater than MOP by adequate margin.
For pumps and compressors with an isolation valve
between it and upstream system, the suction lines from and
including the suction valve shall have the same design
pressure as on the discharge side.
The DP of compressor suction and intermediate stage
systems (e.g. coolers, condensers, knock-out drums) will
be sufficiently high to prevent the opening of pressure
safety valves through pressure equalization “settle out”
after the compressor has shut down.
Design pressure and temperature should be optimized to
eliminate and reduce relief cases where practically
possible, to provide an inherently safe and sustainable unit
design, and to reduce costs.
Vapor and vapor-liquid systems protected by rupture
disks
Rupture disks are highly stressed in service. To avoid
premature failure because of corrosion, creep and fatigue,
a substantial margin (at least 30% of the normal rupture
pressure for tension-loaded disks, and at least 10% of the
minimum rupture pressure for reverse-buckling disks) will
be allowed between the MOP and the design pressure of
the equipment.
Liquid-Full systems
Liquid-Full systems will be designed to withstand pump
shut-off pressure, if they can be “blocked in” while pumps
feeding them could continue to operate. The shut-off
pressure is the pressure at the discharge of a centrifugal
pump with the suction pressure at the maximum possible
value and the discharge system closed.
For systems that do not normally operate liquid full but
could become liquid fill during an upset condition, it may
be determined whether the system is to be designed for
shut-in pressure or whether some other means of
safeguarding is required.
For steam or gas turbine-driven pumps and variable speed
electric motor driven pumps, the maximum possible speed
during operation of the pump shall be evaluated since this
can influence the design pressure considerably.
Shell & tube heat exchangers
The most unfavorable combination of design pressures on
the shell and tube side that occur, will be used in the
calculations for tube sheets, floating heads and tubes.
The design pressure of the high-pressure side of the
exchanger should be lower than the corrected hydrotest
pressure of the low-pressure side of the exchanger or a
relief device is required to protect against tube rupture.
If design pressure is specified to eliminate the need for a
relief device for tube rupture, the (mechanical) design
pressure of the low-pressure side of the exchanger will be
extended up to and including the block valves.
Pipeline systems
The design pressure at any point will be equal to or
greater than the MAOP.
Lower Design pressure
The Lower Design Pressure (LDP) is the external design
pressure or the sub-atmospheric pressure at the top of the
equipment in its operating position.
LNG rundown, loading, and circulation lines, as well as
boil-off gas lines, will be designed for full vacuum to
enable vacuum drying during commissioning.
Vessels that are in steam service should be designed for
full vacuum at 150 °C.
For vapor with an atmospheric dewpoint of 0 °C or
above, it will be checked whether vacuum can develop in
the equipment if the heat input to the equipment fails.
If the pressure drops below atmospheric pressure due to
utility failure, instrument failure, etc., the minimum
possible absolute pressure shall be stated in the
documents for mechanical design.
Steaming-out and draining operations shall be evaluated
when determining the LDP.
Maximum allowable working pressure
The Maximum Allowable Working Pressure (MAWP) is
the maximum gauge pressure permissible at the top of the
equipment with the equipment installed in its operating
position and at a designated temperature. The MAWP is
equal to or greater than the DP.
Maximum allowable incidental pressure
Maximum Allowable Incidental Pressure (MAIP) is a
term used to describe infrequent short periods during
which the pipeline system may be subjected to pressures
greater than MAOP.
Examples of incidental pressure include surge, failure of
pressure controlling equipment, and cumulative pressure
during activation of overpressure protection devices. The
MAIP should not exceed 90% of the hydrotest pressure.
Hydrostatic Test Pressure
The test pressure shall be 1.5 times the design pressure.
Pressurizing of the system shall be carried out in
increments of 25% total pressure value or as designated
by the Client at the time of testing up to the test pressure.
There will be a hold for 15 minutes at each increment.
This is to ensure that the system is stabilized and to avoid
over pressurizing. Once the test pressure has been
attained, it is to be maintained for one hour before the
detailed inspection takes place. The test medium shall be
potable water.
Exercise

a. Mr. Umesh has a presentation next week to

explain different terms related to pressure and
temperature used in equipment design. You are
his subordinate. Prepare a 10-slide presentation
for your boss that will impress your boss' boss.
CHAPTER 3: PROCESS
DELIVERABLES
Major process deliverables are discussed in this chapter.
Process Design Basis
The process design basis document is the collection of all
the input parameters considered for process design. The
process parameters include feed composition, flow rate,
operating and design conditions, velocity criteria,
pressure drop criteria, process scheme, different process
scenarios etc. The client must approve a process design
basis before the designer starts any calculations or
simulation for process design.
Typically, this document is prepared by process engineer,
checked by a senior engineer, and approved by process
HOD.
Any change in process design basis will have a major
impact on several documents viz. PFD, P&ID, Process
calculations/simulation report, Equipment List, Heat
Exchanger Thermal Design, Equipment Datasheets, Relief
Valve Sizing & Datasheets, Electrical Load List etc.
Each document must undergo stringent quality checks. It
starts with self-check. The person generating the document
will first self-check his/her document. The same document
will then be checked by senior discipline engineers. The
document may also be checked by engineers from other
disciplines. This checking step is called as Inter-
discipline Check. The comments/corrections will be
discussed amongst the project team and if those are agreed
by the originator, then the same will be incorporated. If
there is disagreement, then the project manager will make
the final call.
A checklist is a list that guides the engineers to perform a
check of the quality of the document and ensure that major
criteria for the design are covered. A checklist will be
specific to a specific type of project. Many companies
have their checklist form specific to their projects.
A typical checklist for the process design basis document
is given below;
 Correct document titles and revision
Document number included
Consultant standard title block and job number
Consultant Disclaimer description block
All design information included.
Operating and design conditions specified
Requirements for references and are they
specified
Self-Discipline Check comments incorporated
Inter Discipline Check commented incorporated
Clients commented incorporated

Block Flow Diagram

A block flow diagram (BFD) is a process drawing used to
simplify the basic structure of a system. It is the simplest
form of the flow diagrams used in the industry. Blocks in a
block flow diagram represent anything from a single piece
of equipment to an entire plant.
A typical example is given below;
Figure 3.1: Block diagram
Process Flow Diagram
A process flow diagram (PFD) is a diagram commonly
used in engineering to indicate the general flow of the
plant process. The PFD displays the relationship between
major equipment of a plant facility and does not show
minor details such as piping details and designations.
Process flow diagrams of a single unit process will
include the following:

Major process piping

Major bypass & recirculation lines
Major equipment symbols, names, and
identification numbers
Process flow directions
Major control loops
Interconnections with other systems
Stream Identification
Heat & Mass Balance

PFDs generally do not include the following:

 Piping class or piping line numbers
Pipe size
Instrumentation
Minor bypass lines
Isolation and shut-off valves
Maintenance vents and drains
Relief and Safety Devices
Pipe fittings and flanges

Typical mass balance and PFD schematic are shown

below;
Figure 3.2: PFD (Refer https://cutt.ly/ohSKS5P for better
quality drawing)

A typical checklist for process flow diagram is given

below;
General
 Correct drawing titles and revision

Drawing number included

Consultant standard title block and job number

Consultant Disclaimer description block

Drawing continuation flags match before drawing

Scope of the project clearly defined by clouding

(but use of clouding kept to a minimum)

Original Master Drawing Number listed

Specific notes included and numbers matching

In line with standard drawing legend

SDC comments incorporated

IDC commented incorporated

Clients commented incorporated

Equipment and Packages

All equipment (operating and standby) included

Battery limits shown for packages

Equipment and Packages names and numbering

Design information data included and as per

datasheet
 Directional arrows on major process and utility
lines

Line sizes shown on major lines

Process Control

Control valves and selection (pneumatic, motor,

etc.)

Control valve failure positions

All control loops shown including any logic

All key Instrumentation shown and tagged

Control logic as per Operating & Control

Philosophy

Safeguarding

Overpressure protection

Process Shutdown Valves (PSD)

Emergency Shutdown Valves (ESD)

HP/ LP Interfaces

Non-Return valves

Emergency blowdown requirements

Miscellaneous Technical
Stream numbers on major process streams

Stream numbers match with Process Model

Heat and Mass Balance Table

Future facilities (shown dotted if required)

Revision triangles and Revision clouds shown on

drawing updates
Piping & Instrumentation Diagram
A Piping & Instrumentation Diagram (P&ID) is a pictorial
representation of the piping, equipment, instrumentation,
and control devices. P&ID preparation is initiated during
FEED and is further updated during detail engineering.
P&IDs are updated w.r.to vendor data, design review
comments, HAZOP recommendations, and as-built
changes.
P&ID shows the interconnection of process equipment and
the instrumentation used to control the process. In the
process industry, a standard set of symbols is used to
prepare drawings of processes. The instrument symbols
used in these drawings are generally based on the
International Society of Automation (ISA) Standard S5.1.

CAD system is used to develop the P&IDs.

Most details that are available from other types
of documentation (e.g., instrument loop diagrams,
vessel data sheets) are not recommended for
inclusion on P&IDs.
P&ID shows equipment with simple outline
representation.
Equipment is not drawn to scale, however
equipment relative to one another both in size and
general orientation must be maintained.
P&ID shows nozzles on equipment, including
spares, as single lines.
P&ID indicates nozzle sizes unless the size is
implied by piping connections.
P&ID shows equipment item number and
title/service as a minimum.
P&ID indicates internals for equipment as dashed
lines. Details of internals that have no significant
bearing on the piping design and layout or
equipment operation are omitted.
P&ID indicates auxiliary system requirements for
individual pieces of equipment (e.g. lube oil
 systems, seal flush systems, turbine gland leak-off
piping, sample systems) on auxiliary P&IDs.
P&ID indicates jacketing requirements for
equipment and jacketing/tracing requirements for
piping.
P&ID indicates the type of insulation (e.g.,
personnel protection, heat conservation) for
equipment as part of the equipment data.
P&ID indicates insulation thickness where
applicable.
P&ID indicates a piping serial number and piping
class.
A typical P&ID is shown below;
Figure 3.3: P&ID (Refer https://cutt.ly/ohSKS5P for better
quality drawing)
A typical checklist for Piping & Instrumentation diagram
is given below;
General

Correct drawing titles and revision

Drawing number included
Consultant standard title block and job number
Consultant Disclaimer description block
Construct and Demolition drawing numbers
match
Drawing continuation flags match before drawing
Scope of the project clearly defined by clouding
(but use of clouding kept to a minimum)
Original Master Drawing Number listed
Specific notes included and numbers matching
In line with Standard drawing legend
SDC comments incorporated
IDC commented incorporated
Clients commented incorporated

Equipment

All equipment (operating and standby) included

Equipment names and numbering shown
Equipment design information data included and
as per datasheet
Equipment and internals/externals as per
datasheet
Nozzles, manways and numbering as per
datasheet
Insulation and Trace Heating
Draining, Venting and Purging
Equipment Isolation including valves and spades
Overpressure protection, relief valves, bursting
discs
Equipment trim numbers
Packages

Package names and numbering

Package information data blocks completed
Piping & Instrument Connections as per datasheet
Battery limits shown
References to Suppliers PEF’S included

Piping

Directional arrows on major process & utility

lines
Line sizes on all lines
Line numbers on all lines including pipe specs
Requirement for slopes and avoiding pockets
shown
Tie-in Point numbers including spec breaks
Tie-in points between Construct and Demolition
drawing match
Insulation and Trace Heating
Pipe specifications breaks shown
Piping special items included and numbered
Overpressure protection, TRV’s, bursting discs
Valve selection in line with Pipe specs
Sample points and corrosion monitoring

Process Control and Instrumentation

Correct control valves selection (pneumatic,

motor, etc.)
Control valves sizes, tag numbers & failure
positions
Control valve isolation block valves &
drains/vents
Control valve bypasses (to be avoided where
possible)
All control loops shown including any logic
 All Instrumentation shown and as per PFS
including tag numbers
Alarm and trip setpoints
Vessel level alarm and trip setpoints
Tapping sizes on equipment/piping

Safeguarding

Relief valves and numbering

Relief valve set pressures and line sizes
Relief valve sparing, isolation and interlocks
Emergency shutdown valves and numbering
Non-Return valves
Emergency blowdown requirements
Line List:
A line list is a database that has the following information
for process and mechanical engineering teams.
One such example is given below.
Figure 3.4: Line list
A typical checklist for line list is given below;

Correct drawing titles and revision

Drawing number included
Consultant standard title block and job number
Consultant Disclaimer description block
Standard document front sheet included
Standard Hold List and action party (in brackets)
All lines/equipment included as per P&ID/PDS
All lines/equipment numbering matches
P&ID/PDS
All design information included and as per
P&ID/PDS
Operating and design conditions specified
For line list, “from” and “to” locations match
with P&ID
Requirements for references and are they
specified
Check that references to P&ID/PDS match with
P&ID
SDC comments incorporated
IDC commented incorporated
Clients commented incorporated
Operating, Control & Safeguarding Philosophy
Operating, control & safeguarding philosophy (OCSP) is a
document that covers the following aspects;

The operating philosophy of the plant/unit is

described in a detailed manner. The mode and
sequence of operations are mentioned. Equipment
description, tag numbers, normal operating
parameters of flow, pressure, and temperature,
and stand-by equipment availability may be
mentioned in this section.
Control Philosophy describes all controls
required for the safe, reliable, and uninterrupted
operation of the plant/unit. This could include
flow, pressure, and temperature and level control
of the plant/unit for the smooth operation of the
plant/unit. Controls required for start-up, planned
shutdown and to change plant/unit capacity
should be mentioned. High and Low alarms for
process operating parameters are also described
in this section.
Safeguarding Philosophy describes the
safeguarding functions that may be available for
the prevention of the uncontrolled process, risk
reduction or mitigation in case of external
hazards, manually initiation of an emergency
shutdown of the plant/unit by operator
intervention.

Typically, this document is prepared by process engineer,

checked by a senior engineer, and approved by process
HOD.
Any change in Operating & control philosophy will have a
major impact on the Cause and Effect diagram.
The checklist will be similar to the one given in the
earlier section.
Process Datasheet
The process data sheet PDS relates to a single item of equipment and
contains the essential process data for initiating the detailed design of an
item. It includes the overall size, number, approximate geometry and
identification of the connections, material of construction, and the full range
of operating conditions. The process data sheet generally includes a simple
diagram. Also, the process design includes Instrument process datasheets
which provide a similar level of detail.
Refer to the example below:
Figure 3.5: Process datasheet

Figure 3.6: Process datasheet (continued)

HAZID
HAZID (Hazard Identification) is a well-documented
qualitative technique for the early identification of
potential hazards and threats affecting people, the
environment, assets or reputation. The major benefit of a
HAZID study is to provide essential input to project
development decisions. It is a means of identifying and
describing HSE hazards and threats at the earliest
practicable stage of development or venture. HAZID is
used both as part of a Quantitative Risk Assessment and as
a standalone analysis for i.e. installation, modification,
replacement, upgrading, reduction, isolation and lifting
etc.
HAZID Study Objectives

Identify the potential hazards.

Reduce the probability and consequences of an
incident at a site that would harm the personnel,
plant, and environment.
Identify opportunities for inherent safety.
Identify Fire, explosion, toxic release scenarios,
and measure to prevent it.
Hazards involved in operating each equipment
can be enlisted at the beginning.
Early assessment of health, safety, and
environmental hazards.
Provide essential input to the project
development decisions.
HAZOP
HAZOP (Hazard and Operability) study is done to review
a process or operation systematically to determine
whether deviations from the design can lead to
undesirable consequences. HAZOP can be used for
continuous or batch processes and can be adopted to
evaluate written procedures. The HAZOP team lists
potential causes and consequences of the deviation as
well as existing safeguards protecting against the
deviation. When the team determines that inadequate
safeguards exist for a credible deviation, it usually
recommends the action to be taken to reduce the risk. The
minimum documents that are needed to carry out HAZOP
are Piping & Instrumentation Drawing, Cause & Effect
Matrix, and Operating & Control Philosophy. HAZOP
session is attended by the client (process, production,
maintenance dept.), EPC contractor (Project manager,
HSE engineer), Design Consultant (Process,
Instrumentation), Vendor (if any) and chaired by a third-
party safety consultant (called as HAZOP Chairman).
HAZOP Study Objectives

To assess the hazard potential of malfunction of

equipment and its impact on the facility.
To brainstorm how a process may deviate from
the design intent.
Identify potential problems w.r.to design. The
solution to those problems may or may not be
found in the HAZOP session.
Evaluate and question the purpose of every
control or safety items given in P&IDs.
To recommend adequate changes in the design
based on the HAZOP session participants’
agreement.
To improve the safety of existing facilities
To evaluate and minimize risks w.r.to personnel,
environment, material, and reputation.
Exercises

a. Mr. Yashpal is a fresher in a reputed consultancy

in Navi Mumbai. As his first assignment, his boss
has asked him to prepare a process design basis
for a cooling water supply system project. Can
you advise Mr. Yashpal on how to prepare such a
document?
b. Ms. Sayali needs to prepare a block diagram and
PFD of the BTX separation system. How would
she include in both the drawings?
c. Mr. Aditya is having trouble with the BTX system
P&ID. Can you help him draw such a system?
d. Mr. Nimesh is assigned to prepare a line list for
Mr. Aditya's project. Can you help him with this
activity?
e. Mr. Saurabh is also a part of your team who is
supposed to complete OCSP of BTX plant. He
has been reassigned to some other urgent project.
You are his replacement. Please submit his
deliverable.
f. Mr. Pradip is preparing a cooling water pump
datasheet. Can search on the internet and help him
with the template.
g. Mr. Prasad is the HAZID chairman. What exactly
are his job responsibilities?
h. Mr. Naresh is planning to conduct a HAZOP
session for the BTX plant designed by Mr.
Aditya. How exactly he will execute this activity?
CHAPTER 4: PROCESS SIMULATION
SOFTWARE
Process simulation software is used for the design, development, analysis,
and optimization of technical processes such as chemical plants, chemical
processes, environmental systems, power stations, complex manufacturing
operations, biological processes, and similar technical functions. There are
several commercial simulation software available. A few of those are
discussed below.

Aspen HYSYS
General process simulation and modeling software very commonly used in
the upstream oil and gas industry is HYSYS. HYSYS is extensively used for
developing PFD and mass and heat balance.

Aspen Flare System Analyzer

It is extensively used for modeling of flare or cold vent networks commonly
required in upstream oil and gas. It allows determining the type of relief
device and sizing of connected piping including individual tailpipes, flare
sub-header, and flare the main header.

Aspen Exchanger Design and Rating

Aspen Exchanger Design And Rating (EDR) enables you to easily design and
simulate the heat Exchangers. Deliver the optimum heat exchanger size and
rating when both cost and performance must be balanced with rigorous up-to-
date integrated modeling capabilities.
FluidFlow (from Flite Software NI Ltd.)
FluidFlow is the most comprehensive and easy to use pipe
flow software. It has an intelligent and easy-to-use
graphical interface. FluidFlow has following modules:

FluidFlow Liquid
FluidFlow Gas
FluidFlow Two-Phase
FluidFlow Non-Newtonian & Slurry

Bentley WaterGEMS
It is used for the analysis and design of water networks.
Create and manage customized reports that automatically
combine graphs, data tables, color-coded and annotated
plan views, and more into a single report. Fire flow,
hydraulics, operations, criticality, and water quality can
be modeled.
Bentley HAMMER
HAMMER determines appropriate surge control
strategies and reduce transients. It uses the Method of
Characteristics, the benchmark standard for hydraulic
transient analyses. One can run both transient and steady-
state analyses in HAMMER.
PIPESIM (from Schlumberger)
A simulation and modeling software used for steady-state
modeling of “pipelines” both for single-phase, two-phase
and three-phase flow.
FlareSim (from Schlumberger)
Flaresim provides full 3D flame-shape analysis with
complete flexibility in the location and orientation of
multiple stacks, and rapid evaluation of flare systems
under different wind speeds and directions. Shield options
can be included. Working from the opposite perspective,
Flaresim allows you to design stack or boom length to
meet specific radiation, noise, or surface-temperature
limits at defined receptor points.

OLGA (from Schlumberger)

The OLGA dynamic multiphase flow simulator models
time-dependent behaviors, or transient flow, to maximize
production potential. Transient modeling is an essential
component for feasibility studies and field development
design. Dynamic simulation is essential in deepwater and
is used extensively in both offshore and onshore
developments to investigate transient behavior in
pipelines and wellbores.
Transient simulation with the OLGA simulator provides
an added dimension to steady-state analyses by predicting
system dynamics such as time-varying changes in flow
rates, fluid compositions, temperature, solids deposition,
and operational changes.
From wellbore dynamics for any well completion to
pipeline systems with all types of process equipment, the
OLGA simulator provides an accurate prediction of key
operational conditions involving transient flow.

VMGSim (from Schlumberger)

VMGSim is a general process simulator and possesses a
complete suite of process unit operations which can be
configured to model virtually any process of interest in the
Gas processing, Refining/Petrochemical or Chemical
industries.
It is an advanced and fully interactive steady-state process
simulator that offers a modern and integrated flowsheet
environment, letting you study your plant in sections or as
a whole. It tracks all of your data inputs, making it
possible to immediately see what was added to the system
and the result.

UniSim (from Honeywell)

UniSim Design Suite is an intuitive process modeling
software that helps to create steady-state and dynamic
models for plant design, performance monitoring,
troubleshooting, business planning, and asset management.
Its major use:

Process flowsheet development

Utilizing case scenarios tool to optimize designs
against business criteria
Equipment rating across a broad range of
operating conditions
Evaluating the effect of feed changes, upsets, and
alternate operations on process safety, reliability,
and profitability
Accurately size and select the appropriate
material for blowdown systems
Monitoring equipment performance against
operating objectives.

PIPENET (from Sunrise Systems Ltd.)

PIPENET is the leading software for a rapid fluid flow
analysis of pipe and duct networks. Three modules
(Standard Module, Spray/Sprinkler Module, Transient
Module) ensure that, no matter how complex your
network, PIPENET software will perform flow simulation
fast and accurately.
Flow Master (from TechNet Alliance)
It is a 1D Computational Fluid Dynamics (CFD) software
that allows thermo-fluid system engineers to model and
analyze the fluid mechanics and pipe flow in complex
systems.

EPANET (from EPA)

It is a public domain, water distribution system modeling
software package developed by the United States
Environmental Protection Agency's (EPA) Water Supply
and Water Resources Division. It performs an extended-
period simulation of hydraulic and water quality behavior
within pressurized pipe networks.
PRO II (from AVEVA)
It is a steady-state process simulator for process design
and operational analysis for process engineers in the
chemical, petroleum, natural gas, solids processing, and
polymer industries. It includes a chemical component
library, thermodynamic property prediction methods, and
unit operations such as distillation columns, heat
exchangers, compressors, and reactors as found in the
chemical processing industries. It can perform steady-state
mass and energy balance calculations for modeling
continuous processes.
MySep (from Kranji Solutions)
MySep enables the user to effectively determine vessel
sizes, select internals, and assess the associated overall
performance of separation vessels. It can also be used to
evaluate existing designs and determine theoretical
performance based on actual or simulated operating data.
MySep can be used independently and in conjunction with
process modeling software as Aspen HYSYS, UniSim
Design, Petro-SIM, VMGSim, and PRO II.

Pipeline Studio (from Emerson)

Pipeline Studio is the industry-leading pipeline design and
engineering solution that combines graphical configuration
and reporting tools with industry-proven simulation
engines. It provides fast, accurate, robust, and reliable
answers to a wide range of steady-state and transient
analysis challenges.
Pipeline Studio delivers rapid and accurate offline design,
planning, and hydraulic analysis for natural gas and liquid
pipelines through advanced state-of-the-art simulation
techniques. The combination of both steady-state and
transient hydraulic simulation within a feature-rich
Windows graphical interface enables a better
understanding of even the most demanding problems by
providing an appropriate analysis of the process.
Use Pipeline Studio for:

Flow assurance
Designing, routing, sizing of pipeline networks
Upset, leak and survival time analysis
Strategic, operational and capacity planning
Rapid assessment of unscheduled changes in
operation
Operational prognosis
Compressor requirements
Fuel consumption calculations
Line pack management
 Assessment of storage requirements
Surge Analysis

Petro-SIM (from Yokogawa)

Petro-SIM is a process simulation software and
optimization platform for driving excellence in facility
performance and organizational productivity. At the core
of Petro-SIM’s technology are rigorous process simulation
models that generate dependable results in an intelligent,
user-friendly environment. Petro-SIM is the go-to
simulation platform for upstream, midstream, and
downstream refinery and petrochemical processes. For
upstream oil and gas, Petro-SIM is the only purpose-built
process simulation software that can ensure facility
processing capabilities meet long term reservoir needs.
In oil refining and petrochemicals, our Petro-SIM process
simulation software works in tandem with our world-
leading SIM Reactor Suite to create the only proven
simulator capable of scaling from reactor units to entire
facilities.

Exercise

a. Ms. Sushama needs to present in the next process

department knowledge sharing meeting. She has
been given a topic as different process simulation
software. Please help her with this activity.
CHAPTER 5: LINE SIZING USING
ASPEN HYSYS
Line sizing is perhaps the most widely used process
calculation activity and the most important as well. Line
sizing means to find out the adequate line or pipe size for
the given flow rate. There are mainly 2 line sizing criteria;
velocity criteria and pressure drop criteria.
The sizing criteria for liquid piping systems will depend
on the application. The function and application of the
piping system will determine the sizing criterion to be
selected. Where pressure drop is not a determining
parameter, the size should be determined by the velocity
constraints.
The velocities shall be kept low enough to prevent
problems with erosion, water hammer, pressure surges,
noise, and vibration, and reaction forces. In some cases, a
minimum velocity is required. When determining the
velocity of the medium in the lines, account should be
taken of the possible generation of static electricity.
Velocity criteria

Pump suction line (Typical velocity ~ 1 m/s)

Pump discharge line (Typical velocity ~ 3 m/s)
Gas line (< 18 m/s)
Gravity line (~ 1 m/s)
Two-phase line (V < Ve)

Pressure drop criteria

Sub-cooled liquids (0.25 bar / 100 m)

Boiling Liquids (0.05 bar / 100 m)

Misc. criteria

PSV inlet line (ΔP < 3% of set point pressure)

PSV outlet or tailpipe (Mach no. < 0.7)
Flare header (Mach no. < 0.5)
Flare lines (ρV² < 200,000 kg/ms²)
Depressurization line (Mach no. < 0.7)
 Vent line for atmospheric tank (MABP < 0.07
bar)

When sizing piping, the following constraints shall be

addressed:

Required Capacity / Available Driving Pressure

Noise / Vibration
Pressure Surges
Material Degradation – Erosion, Corrosion,
Cavitation
Solids Accumulation

Pipe Roughness
For all calculations of pressure drop, the following pipe
roughness values should be used:

Carbon steel (CS) corroded: 0.46 mm (0.018

inch) (Note-1)
Carbon steel (CS) non-corroded (for relief
system piping): 0.15 mm (0.006 inch)
Carbon steel (CS) non-corroded (other systems):
0.046 mm (0.0018 inch)
Stainless steel (SS): 0.046 mm (0.0018 inch)
Titanium and Cu-Ni: 0.046 mm (0.0018 inch)
Glass fiber reinforced polyester (GRP): Vendor
to provide
Polyethylene, PVC: Vendor to provide

Note 1 – The value of 0.46 mm (0.018 inch) shall be used

when hydraulic calculations are performed for existing
pipe installations including relief piping.

Water service
Hazen-Williams equation is used for pressure drop
calculation.
The Hazen–Williams equation is an empirical relationship
that relates the flow of water in a pipe with the physical
properties of the pipe and the pressure drop caused by
friction. It is used in the design of water pipe systems such
as fire sprinkler systems, water supply networks, and
irrigation systems. It is named after Allen Hazen and
Gardner Stewart Williams.
The Hazen–Williams equation has the advantage that the
coefficient "C" is not a function of the Reynolds number,
but it has the disadvantage that it is only valid for water.
Also, it does not account for the temperature or viscosity
of the water.

Where;

hf = head loss in meters (water) over the length of

pipe
L = length of pipe in meters
Q = volumetric flow rate, m3 /s (cubic meters per
second)
C = pipe roughness coefficient
d = inside pipe diameter, m (meters)

Liquid and Gas service

The pressure loss in pipe flow is calculated using Darcy-
Weisbach equation (equation 1).

Equation 1:
This equation is valid for both laminar and turbulent flow
regimes of any fluid with fully developed and
incompressible flow. It can be used for gas services as
long as there is only a negligible change in gas density
across the pipe length. The formula for calculating the
Darcy friction factor is different for laminar (equation 2)
and turbulent flow (equation 3 - Haaland equation).
Laminar flow meaning Reynolds number less than
2000.
Equation 2:

Equation 3:

The Haaland equation is used to solve directly for the

Darcy–Weisbach friction factor fD for a full-flowing
circular pipe. It is an approximation of the implicit
Colebrook–White equation, but the discrepancy from
experimental data is well within the accuracy of the data.
Where;

∆P : Pressure drop, Pa
fD : Darcy friction factor
L : Length of pipe, m
V : Velocity, m/s
NRe : Reynolds number
ϵ/ d : Relative roughness
d : Inside pipe diameter, m
ρ : Liquid density, kg/m3
n : Constant (n=1 for liquid services and
n=3 for gas services)
Flow-induced vibrations
Flow-induced vibrations are more predominant in turbulent flow regime
piping systems. The turbulent flow regime generates potentially high levels
of kinetic energy local to the turbulent source. This energy is distributed
across a wide frequency range, most of the excitation is concentrated at low
frequency. This type of vibration leads to displacement of the piping system
and in some cases also leads to damage to pipe supports.
Susceptibility to failure of piping systems due to flow-induced vibrations:
Table 5.1:
Piping system falls under medium and high susceptibility
failure categories shall be further assessed and designed
per Section 3, “Energy Institute guidelines for the
avoidance of vibration induced fatigue failure in process
pipework”.
If the piping system cannot meet detailed assessment
“Energy Institute guidelines for the avoidance of vibration
induced fatigue failure in process pipework” requirements
for medium and high susceptibility failure categories, the
piping system shall be evaluated using dynamic analysis
methods.
Pulsation and transient vibrations
Pulsation due to periodic flow-induced excitation, which
is only relevant for gas lines containing dead legs, is
defined as follows;

where

D is inside the diameter of the dead leg branch.

The above criteria are not met for dead legs, those dead
legs in piping systems shall be assessed and designed per
“Energy Institute guidelines for the avoidance of vibration
induced fatigue failure in process pipework”.
If there are piping systems that will experience slug flow,
or transient vibrations (flashing, cavitation, and
surge/momentum) then an analysis as per the “Energy
Institute guidelines for the avoidance of vibration induced
fatigue failure in process pipework” shall be conducted.
If the piping system cannot meet detailed assessment
“Energy Institute guidelines for the avoidance of vibration
induced fatigue failure in process pipework” requirements
for medium and high susceptibility failure categories, the
piping system shall be evaluated using dynamic analysis
methods.
High-frequency acoustic excitation
High-frequency acoustic excitation is more predominant in
gas piping systems with pressure reducing devices. This
type of vibration takes the form of local pipe wall flexure
resulting in potentially high dynamic stress levels at
circumferential discontinuities on the pipe wall,
fabricated tees or welded pipe supports, small-bore
connections.
Effect of “high-frequency acoustic excitation” on piping
systems, the sound power level of the piping system can
be calculated as follows;

SFF is a correction factor to account for multiple

occurrences of sonic flow in a line. If consecutive sonic
conditions exist, then SFF=6; otherwise SFF = 0.
Where:

P1 is upstream pressure (bara)

P2 is downstream pressure (bara)
W is flow rate (kg/s)
T is the upstream temperature (K)
Mw is molecular weight (grams/mol)
Piping systems with sound power level (PWL) > 155 dB
shall be further assessed and designed in accordance with
“Quantitative” methods of Section T-2, Energy Institute
guidelines for the avoidance of vibration induced fatigue
failure in process pipework.
Transient/Surge analysis
Surge is caused by rapid velocity changes of the fluid, e.g.
because of rapid valve closure, pump trip, or pump start.
Pressure surge calculations are relevant to pipe handling
incompressible fluids (liquids).
The magnitude of the pressure surge is determined by the
velocity of the fluid in the pipe and the rate at which this
velocity is changed. As a thumb rule, a sudden velocity
change of 1 m/s (3.3 ft/s) will generate a pressure surge of
10 bar. The effect of a sudden velocity change depends on
the length of the pipe and of the closing speed of the end
valve.
The maximum surge pressure develops when the valve
closes rapidly relative to the piping length. As per the
ASME B31.3, the maximum permissible surge pressure
shall be 1.33 times the system/piping design pressure.
Measures should be taken to avoid cavitation since the
collapse of a cavity could generate a high-pressure surge.
If the inlet pressure of a pipeline/piping system is
reduced, e.g. due to a pump trip or due to closure of an
upstream valve, a negative pressure wave travels through
the system. The local pressure could drop below the
vapor pressure of the fluid and a vapor cavity will form
locally in the pipeline. The location of the cavity depends
on the elevation profile of the pipe and will most likely be
directly downstream of the equipment causing the flow
reduction (e.g., pump or valve) and at high points in the
system.
Surge pressure in piping systems shall be calculated as
follows;

where:

L : Piping length between pump and valve

(m)
DN : Nominal diameter pipe (mm)
Veff : Effective valve closure speed
(m/s)
Psurge : Surge pressure (barg)
 Vfluid : Fluid velocity in pipe (m/s)
ρ : Density of fluid (kg/m3 )
Piping systems that fail to meet the above criteria shall be
subject to a detailed surge analysis, including evaluation
of the following surge scenarios:

Rapid valve closure with and without pump

tripping;
Pump(s) tripping;
Pump start-up;
Pump(s) trip followed by a restart.
Pump kickback.
In general, Surge analysis shall be performed and
documented for the following services:

LNG loading and rundown pipes.

LPG loading and rundown pipes.
All hydrocarbon condensate loading pipes.
Natural gas-liquid systems.
The main distribution headers for cooling water
systems.
The main distribution headers for fire water
systems.
Piping running to/from tank car, rail car, barge,
and ship loading arms and loading facilities.
Measures for mitigating surge pressure in pipeline

Stronger pipework to withstand the pressure

surge
Rerouting piping
Additional pipe supports
Change of pipe material to one with a lower
modulus (i.e. thermoplastic pipe materials)
Flow control valve
Air/Vacuum Release valves
Intermediate check valves
Non-slam check valves
Bypass Valves
Gas accumulators
Liquid accumulators
Surge tanks
Surge shafts
Surge anticipation valves
Relief valves
Bursting discs
Weak pipe sections
Increase diameter of pipeline to reduce average
velocity
Variable speed drives
Soft starters
Valve closure and opening times
Increasing the inertia of pumps and motors (i.e.
flywheels or by selection)
Simulation
Let’s start with an example of a centrifugal pump suction line. Water flowing
at 30 m3 /h at 15 o C and 0.3 barg pressure upstream pressure.
First select component Water and Fluid package IAPWS (International
Association for the Properties of Water and Steam) in Aspen HYSYS.
Figure 5.1: Component list

Figure 5.2: Fluid package

Use the model palette and model a material stream. Provide 15 o C, 0.3 barg,
1000 kg/h mass flow rate and mole fraction 1. This will get the material
stream converged.
Figure 5.3: Material stream

We will learn how to use the “Adjust” function. As per the problem
statement, the water flow rate is 30 m3 /h, so that will be the target and the
variable will be the mass flow rate value of stream “1”.
Select “Adjust” function from the model palette.
Figure 5.4: Adjust function
Double click on “ADJ-1” to open the Adjust window. Select “Target
Variable” and “Adjusted variable”.
Figure 5.5: Adjust function
Figure 5.6: Adjust function

Figure 5.7: Adjust function

Figure 5.8: Adjust function
Next, select the “Parameters” tab and provide adequate tolerance, step size,
and max. iterations values as shown below. Click “Start” to run the “Adjust”
function. It will do the trial & error w.r.to mass flow rate and calculate the
corresponding mass flow rate value to give 30 m3 /h volume flow rate.
Figure 5.9: Adjust function

The back-calculated mass flow rate value is 29973.3 kg/h which is equal to
30 m3 /h.
Figure 5.10: Adjust function
Use Model Palette to insert the Pipe segment, Material Stream and Energy
Stream.
Figure 5.11: Pipe segment
Use the “Attach” function to connect the streams.
Figure 5.12: Attach function
We will consider no heat loss or gain for this pipe segment. Double click on
energy stream and write heat flow value as zero.
Figure 5.13: Energy stream

Figure 5.14: Pipe segment

Provide 5 m as pipe length. Double click on Outer Diameter value to open a
new window, wherein you can input pipe schedule, Nominal diameter, and
pipe MOC data. One can add more segments as pipes or fittings using the
same “Append Segment” tab.
Figure 5.15: Pipe segment

Right-click on Pipe segment (PIPE-100) and select “Show table”.

Figure 5.16: Show table
Double click on the table.
Figure 5.17: Show table
It may be noted that pump suction velocity calculated is about 1 m/s and the
pressure drop is 0.005 bar.
Figure 5.18: Show table
As per API 14E, for the centrifugal pump suction line, the typical
velocity should be around 1 m/s. Hence selected 100 mm NB pipe
is adequate. Velocity criteria must be satisfied and pressure drop
criteria are nice to follow.
Table 5.2: Velocity criteria
Suction Discharge
Velocity Velocity
(feet per (feet per
second) second)
Reciprocating Pumps
Speeds up to 250 RPM 2 6
Speeds 251-330 RPM 1.5 4.5
Speeds above 330 1 3
RPM
Centrifugal Pumps 2-3 6-9

Now let’s change the problem statement from centrifugal pump

suction line to discharge line. Pipe length shall be 50 m. Our
objective is to decide an appropriate line size.
Double click on Material Stream “1” and change pressure from 0.3
barg to 5 barg (as this is pump discharge point).
Figure 5.19: Material stream
Double click on pipe segment, change the pipe length to 50 m, and change
line size from 100 mm to 65 mm. The calculated pipe velocity is 2.7 m/s and
the pressure drop is 0.6 bar. As per API 14E, the centrifugal pump discharge
pipe typical velocity is around 2.7 m/s. Hence 65 mm NB pipe is adequate.
Figure 5.20: Pipe segment

Now let’s change the problem statement again. Instead of feed as liquid, we
will change it to saturated steam at 5 barg pressure. Adjust function is
deleted. The mass flow rate of steam is 10000 kg/h. Temperature is deleted.
The vapor fraction is 1. Saturation temperature calculated by HYSYS is
158.9 o C.
Figure 5.21: Material stream
Double click on Pipe table. Replace liquid velocity by Outlet vapor velocity.
Figure 5.22: Show table
Double click on the pipe segment and change pipe NB from 65 NB to 300
NB. Pipe length shall be 100 m. The calculated velocity is 12 m/s and
pressure drop 0.005 bar. As per API 14E gas maximum allowable velocity is
18 m/s. As above velocity is less than 18 m/s, 300 mm NB pipe size is
adequate.
Figure 5.23: Pipe segment

Select “Flowsheet/Modify” tab and check “Temperature” and “Pressure”

boxes active in “Stream label”. This will make temperature and pressure
values displayed on the flowsheet.
Figure 5.24: Pipe segment
It may be noted that there is no temperature drop in this 100 m long pipe as
we had given Q-100 value as zero. Let’s make HYSYS calculate the heat
loss. Select expand “Heat Transfer” tab and delete heat loss value (zero) in
the “Heat Loss” tab. Then select “Estimate HTC”. Heat transfer coefficient
shall be calculated by HYSYS in this tab.
Figure 5.25: Pipe segment heat transfer
Provide ambient temperature, Insulation type and thickness, ambient medium,
and air velocity as shown below.
Figure 5.26: Pipe segment heat transfer
Now checkboxes for “Include Pipe Wall” and “Inner Wall HTC”. It can be
noted that a 100 m long pipe without any insulation would have considerable
temperature drop. Hence, insulation is needed in this case.
Figure 5.27: Pipe segment heat transfer
 If you check, 'include pipe wall" button it will
estimate the conductive heat transfer based on the
pipe material you specify.
If you check, 'include inner HTC" button, it will
estimate the convective heat transfer due to fluid
movement.
If you check, 'include insulation" button it will
estimate the conductive heat transfer based on the
insulation material you specify.
If you check, 'include outer HTC" button it will
estimate the convective/conductive heat transfer
to the surrounding. --> Outer heat transfer

With the insulation box checked, there is a

temperature drop on only 0.1 o C.
Figure 5.28: Pipe segment heat transfer

There is a quick way to carry out line sizing, that works

well for single-phase fluids. We will choose the
appropriate line size for stream “1”. This is the same
material stream as the last example (vapor line sizing).
Figure 5.29: Material stream

Double click on a material stream and select the

“Attachments\Analysis” tab.
Figure 5.30: Line sizing manager
Click on “Create\Line Sizing Manager”.
Figure 5.31: Line sizing manager
Below window will open.
Figure 5.32: Line sizing manager
Select “Calculation Type” as “Rating”.
Figure 5.33: Line sizing manager
Choose “Pipe Nominal Diameter” as 300 mm and check if velocity is as per
API 14E (< 18 m/s for vapor). Velocity calculated for 300 mm NB pipe is
12.1 m/s. Also, provide “Pipe Length” as 100 m (same as earlier problem).
Figure 5.34: Line sizing manager

Let’s now carry out two-phase line sizing. The material stream shall be 5%
(mole) Propane and 95% (mole) n-Butane at 7 barg and 66 oC. The mass
flow rate is 1000 kg/h.
Figure 5.35: Two phase line sizing
The fluid package used is Peng Robinson.
Figure 5.36: Two phase line sizing
BIP are available for these components.
Figure 5.37: Two phase line sizing
Figure 5.38: Two phase line sizing
Figure 5.39: Two phase line sizing
Double click on Pipe segment Select flow correlations as shown below.
Figure 5.40: Two phase line sizing
Pipe length is 1000 m with an elevation rise of 50 m. Pipe size selected is 80
mm NB.
Figure 5.41: Two phase line sizing
Heat transfer data is as below;
Figure 5.42: Two phase line sizing
Select “Flow Assurance” tab. Then choose the “Erosion”
tab. Check “Do Erosion Calc” box. It will calculate fluid
velocity and erosion velocity as per API 14E. Fluid
velocity should be comfortably less than erosion velocity.
For pipe size of 80 mm NB, fluid velocity is less than
erosion velocity for the given pipe length. Hence 80 mm
NB is adequate for this application.

Where,

Ve : Fluid erosional velocity, ft/s

C : Empirical constant (c=100 for continuous
system and c=125 for intermittent services)
pm : Gas/liquid mixture density at operating
conditions
Figure 5.43: Flow assurance
We can also carry out Slug analysis in HYSYS. In this
example for the first segment of 200 m, it can be noted that
slug length is about 7 m followed by a bubble length of 10
m. This means that there is going to be a very serious slug
problem in this pipe.
Figure 5.44: Flow assurance

In cases of intermittent flow, a higher design velocity

might be considered as the cumulative effect of the higher
velocities might not be an issue.
Exercises

a. Mr. Ravindra is designing a cooling water

system. Can you find adequate line size for pump
suction and discharge line, if the flow rate is 75
m3 /h? What input parameters will be required to
solve this problem? Can you make a reasonable
assumption in this case?
b. Ms. Kanchan needs to decide the natural gas line
size. Operating pressure, temperature, and flow
 rate are 5 barg, 40 o C, and 2500 kg/h
respectively. Can you find out the line size?
c. Mr. Sundararajan is finding it difficult to select an
adequate line size for 2 phase flow (methane and
decane) at 3 barg pressure and 5% vapor content.
Please help him.
d. Mr. Abdul is interested in finding out energy loss
in INR in your city, if 5 barg saturated steam line
(6", 500 m, 12 TPH) is kept uninsulated. What do
you think his approach would be?
e. Mr. Nilesh is presenting his paper on flow-
induced vibration. What this paper should
contain?
f. Mr. Akshay wants to learn about surge analysis.
Make a presentation file to help him learn.
CHAPTER 6: PUMP SIZING USING
ASPEN HYSYS
A pump is a mechanical device used to move fluids from one destination to
another. Fluids can mean either liquids, gases, or a combination of liquids
and solids (slurries).
Types of Pumps
Centrifugal Pump
A centrifugal pump is a roto-dynamic pump that uses a rotating impeller to
increase the pressure and flow rate of a fluid. Centrifugal pumps are the most
common type of pump used to move liquids through a piping system. The
fluid enters the pump impeller along or near to the rotating axis and is
accelerated by the impeller, flowing radially outward or axially into a
diffuser or volute chamber, from where it exits into the downstream piping
system. Centrifugal pumps are typically used for large discharge through
smaller heads.
Figure 6.1: Centrifugal pump

Positive Displacement Pump

A positive displacement (PD) pump causes a fluid to move by trapping a
fixed amount of it and then forcing (displacing) that trapped volume into the
discharge pipe.
Some positive displacement pumps work using an expanding cavity on the
suction side and a decreasing cavity on the discharge side. Liquid flows into
the pump as the cavity on the suction side expands and the liquid flows out of
the discharge as the cavity collapses. The volume is constant given each
cycle of operation.
PD Pump behavior and safety
Positive displacement pumps, unlike centrifugal or roto-dynamic pumps, will
in theory produce the same flow at a given speed (RPM) no matter what the
discharge pressure. Thus, positive displacement pumps are "constant flow
machines". However, due to a slight increase in internal leakage as the
pressure increases, a truly constant flow rate cannot be achieved.
A positive displacement pump must not be operated against a closed valve
on the discharge side of the pump, because it has no shut-off head like
centrifugal pumps. A positive displacement pump operating against a closed
discharge valve will continue to produce flow and the pressure in the
discharge line will increase, until the line bursts or the pump is severely
damaged, or both.
A relief or safety valve on the discharge side of the positive displacement
pump is therefore necessary. The relief valve can be internal or external. The
pump manufacturer normally has the option to supply internal relief or safety
valves. The internal valve should in general only be used as a safety
precaution, an external relief valve installed in the discharge line with a
return line back to the suction line or supply tank is recommended.
Figure 6.2: PD pump

PD Pump Types
A positive displacement pump can be further classified
according to the mechanism used to move the fluid:

Rotary-type positive displacement: internal gear,

screw, shuttle block, flexible vane or sliding
vane, circumferential piston, or liquid ring
vacuum pumps
Reciprocating-type positive displacement: piston
or diaphragm pumps.
Some illustrations for PD pumps are provided below:
Figure 6.3: PD pump

Design Flow Rate

The pump design flow rate shall include a minimum 10%
margin on the maximum flow rate except in the following
cases:

Intermittent service
Minimum flow bypass using orifice plate, in
which case pump design flow rate shall be the
process flow rate (as per heat and material
balance) plus the minimum flow bypass rate.
For reflux pumps, the design flow rate shall be at
least 120% of the operating flow rate.
Minimum Flow By-Pass
API STD 610 defines the following two minimum flows
for centrifugal pumps:

Minimum continuous stable flow:

It is the lowest flow at which the pump can operate

without exceeding acceptable vibration limits.

Minimum continuous thermal flow:

It is the lowest flow at which the pump can operate

without its operation being impaired by the
temperature rise of the pumped liquid.
Pump operations below these points can cause shaft
vibration and reduce the mechanical seal life.
To avoid such problems, high capacity pumps shall be
provided with a minimum flow bypass with the flow
controlled by a restriction orifice or a control valve. If a
restriction orifice is used, the operating flow rate of the
pump should be increased to account for the continuous
bypass flow.
The sizing of the minimum bypass flow circuit shall be
based on the higher of the two minimum flows.
If it is not possible to provide a minimum flow circulation
line, then adequate instrument protection shall be provided
to prevent pump operation below the minimum allowable
flow rate.

Centrifugal Pumps Guidelines

The head/capacity characteristic curve shall

continuously rise as flow is reduced to shut-off
(or zero flow). The minimum recommended rise
is 12% concerning the rated point. For parallel
 operation, the head rise shall be between a
minimum of 15% to a maximum of 20%.
The pump should be capable of a head increase at
the design conditions by installing a larger
impeller. The rated impeller diameter shall be
between 85% and 90% of the maximum impeller
diameter as per vendor datasheet.
Pumps should not be operated below the
minimum safe continuous flow as provided by the
pump manufacturer.
The installed power shall be adequate for
maximum impeller diameter plus 120% of rated
capacity.

Positive Displacement Guidelines

Reciprocating/Controlled volume pumps are

capable of handling very low flows (< 0.227 m3
/h) and are typically used for chemical injection
duties in oil and gas installations.
Reciprocating pumps should comply with API
STD 674.
Metering (or controlled volume) pumps should
comply with API STD 675.
Some selection guidelines for controlled volume
pumps are as follows:
“Packed Plunger Pumps” are
generally recommended for
pressures above 340 barg
Diaphragm pumps are generally
recommended for pressures up to
340 barg and temperatures up to
150 °C.
Double Diaphragm Pumps of the
sandwich-type construction are
generally recommended.
 Double Diaphragm pumps should
be used when:
Dilution of the product flow by hydraulic oil is
not acceptable.
Pumped fluid is extremely hazardous and/or
toxic.
Process leakage to the atmosphere is
unacceptable
Process fluid must not come in contact with air
Capacity Adjustment for Metering Pumps

Pump capacity shall be adjusted by changing the

actual or effective stroke length or the pump
stroking speed.
The pump shall be capable of accepting manual
or automatic capacity stroke control, either
factory mounted or by field conversion.
Integral pump devices used to vary capacity
either manually or automatically shall be
provided with a visual indication of capacity
setting, shown as a percentage of the nameplate
rated flow. Manual control shall include a
locking device to positively retain the capacity
setting.
The direction of movement to increase or
decrease pump flow shall be marked. All
adjustment means and indicators shall be easily
accessible with the pump installed.
Pressure Relief for Positive Displacement Pumps
Pressure relief will be provided at the pump discharge
upstream of any isolating valve. Where the nature of the
fluid would make relief valves unreliable, rupture discs
should be used either alone or in conjunction with relief
valves.
Pulsation Devices for Positive Displacement Pumps
When specified, the vendor will furnish pulsation
suppression devices to be located at the pump suction
and/or discharge connections. The following are three
basic types of pulsation suppression devices:

Volume bottles without internals.

Pulsation dampeners using a gas-filled chamber
isolated from the pumped fluid by a piston or
elastomeric diaphragm.
 Pulsation filters and attenuators, including
proprietary commercial designs based on
acoustical suppression techniques.

Reference is made to API STD 675 for the above.

Further Explanation of Key Terms Related to Pumps
Net positive suction head available
Net positive suction head available (NPSHa) is the
difference between the liquid pressure at the suction point
of the pump and vapour pressure of the liquid. It is
calculated by process engineer and is a aprt of information
in pump datasheet that is provided to the pump vendor.
Vendor selects the pump model based on NPSHa (given
by the user) and NPSHr (a function of pump model).
NPSHa should be greater than NPSHr by 1 m or more, as
the best engineering practice.
The formula for calculating NPSHa is:
NPSHa = Pp s - Hvp - Ha

Where:

Pp s = absolute pressure at the pump suction

nozzle, meter of liquid
Hvp = vapor pressure of the liquid at the pumping
temperature, expressed in meter of liquid
Ha = Acceleration head. Acceleration head needs
to be considered only for reciprocating pumps.
For centrifugal pumps and rotary pumps, the
acceleration head is zero.

Net positive suction head required

Net positive suction head required (NPSHr) is the
minimum pressure at the pump suction to keep the pump
from cavitating which causes erosion, noise and pump
damage. NPSHr is an intrinsic property of the pump and is
determined by pump vendor experimentally.
Differential Pressure or Differential head
It is the difference between the discharge pressure and the
suction pressure.

Pump Motor Brake Kilowatt

Pump requires a driver such as a motor or turbine to drive
the pump. The Brake Horse Power (BHP) or Brake
Kilowatt (BkW) needs to be provided by the process
engineer for the selection of the driver by the electrical
engineer. Expressed in equation form the BHP or BkW
would be:
BkW = Q x Pd (rated) x ρ x g / (3600 x η)
Where:

BkW : Brake Power in kW

Q : Rated volume flow rate of the pump,
m /h
3

Pd : Differential pressure, m
Ρ : Density of the liquid at the pumping
temperature, kg/m3
g : Acceleration due to gravity, 9.81 m/s2
η : Pumping efficiency, expressed as a
fraction
Typical Pump Curve
Figure 6.4: Pump curve (head vs flowrate)
Figure 6.5: Pump curve (head vs pump efficiency)
Figure 6.6: Pump curve (head vs NPSHr)

Simulation
Let’s now solve a pump sizing problem using Aspen HYSYS.
Water at 30 o C and 0 barg pressure is pumped to 3 barg pressure. The water
flow rate is 30 m3 /h.
To solve this problem, we need to first select water as a component and
IAPWS as Fluid Package.
Figure 6.7: Component list
Figure 6.8: Fluid package
Use model palette to get 2 material streams and a pump, connect those items,
and provide given data in the inlet stream as shown below. Use Adjust
function to achieve 30 m3 /h flow by varying the mass flow rate of stream
“1”.
Figure 6.9: Pump
Provide outlet pressure as 3 barg.
Figure 6.10: Pump
Double click on Pump P-100. In the Design\Parameter tab, default pump
efficiency is given as 75%. Change it to 60%.
Figure 6.11: Pump

Select “Rating\Nozzles” Tab and change Inlet and Outlet pipe diameter as 0.1
m and 0.065 m (considering velocity criteria).
Figure 6.12: Pump
Select “Rating\NPSH” and check the “NPSH activate” box. HYSYS
calculates NPSHavailable as 10 mlc.
Figure 6.13: Pump NPSHA
We can also provide pump curve data (H v/s Q and Efficiency v/s Q). Select
“Rating\Curves” tab. “Add Curve” and provide the flow rate, head, and
efficiency. This data should come from the pump vendor catalog.
Figure 6.14: Pump curve
Check the “Use Curve” box, so that the provided pump curve data is used in
the model. But HYSYS points out that it is “Overspecified”. That means we
have given more information than required.
Figure 6.15: Pump curve
It may be noted that we have earlier provided pump efficiency (60%) and
discharge pressure (3 barg) as input parameters. We will now delete these 2
input parameters. Also, provide a table for the pump as shown below.
Figure 6.16: Pump
Now if we use the same pump (with same pump
characteristic curves), but change the liquid from water to
benzene, then let’s see what would be the effect on pump
discharge pressure and NPSHavailable values. Use NRTL as
a fluid package.
Figure 6.17: Pump

It may be noted that discharge pressure and pump shaft

power has decreased. Can you justify these results?
Exercises

a. Ms. Sharvari has been given an assignment to

present types of pumps. Please help her in her
task.
b. Mr. Chirag works for an operating company as a
production engineer. During his round, he
observed that a cooling water pump was having
abnormal noise and vibrations. What are all the
possible causes for such a problem?
c. Mr. Hrishikesh was asked to collect 3 pump
curves from different pump manufacturers and
explain the same to his boss. Can you help him?
d. Ms. Sneha is simulating a fire water pump with
capacity 75 m3 /h and differential head as 45 mlc.
If pump and motor efficiencies are 70% and 90%
respectively, then what motor she would select?
e. Mr. Shivanand is production head and asks Ms.
Sneha if the fire water pump can be used for
benzene transfer temporarily due to some plant
upset. What are the concerns Mr. Shivanand
would have before using a fire water pump for
benzene? Benzene flow rate and differential head
required are 60 m3/h and 40 mlc respectively.
Will it work as per the process? If not, how
would you make it work?
f. Mr. Kalpesh has taken over from Mr. Hrishikesh
and was assigned to use 3 pump curve data in the
simulation model. Please help him.
CHAPTER 7: CONTROL VALVE
SIZING USING ASPEN HYSYS
 Three inter-dependent parameters work in tandem
whenever there is a flow across a system; viz. Flow rate
(Q), Pressure drop (∆P), and flow area (A).
It can be visualized in the below table.
Table 7.1: Interdependency of A, ∆P and Q

Flow area Pressure drop Flow rate

Constant Increases Increases
Constant Decreases Decreases
Increases Constant Increases
Decreases Constant Decreases
Increases Decreases Constant
Decreases Increases Constant

It can be read as, e. g. for the same cross-sectional area

available for flow, the flow rate will increase with the
increase in pressure drop across it. This is the basic
principle of fluid dynamics. A control valve also works
on the same principle of A, ∆P, and Q inter-dependency.
Choked flow is a limiting condition where the mass flow
doesn’t increase with a further decrease in the
downstream pressure environment for a fixed upstream
pressure and temperature. The choked flow of gases is
useful in many engineering applications because the mass
flow rate is independent of the downstream pressure, and
depends only on the temperature and pressure and hence
the density of the gas on the upstream side of the
restriction. Under choked conditions, valves and
calibrated orifice plates can be used to produce a desired
mass flow rate. A common example can be given as the
fuel gas supplied to pilot burners at the flare stack top is
tapped from a pressurized fuel gas header. This tapping
usually has a restriction orifice, that leads to a pressure
drop exceeding 50% of the inlet pressure. It ensures
choked flow, meaning unless there is any fluctuation in
fuel gas header pressure, flow to pilot burners would
remain the same. Orifice shall prove to be a cheaper
option in such cases as compared to the flow control
valve. The 50% figure mentioned above is easy to
remember. Each gas has a different value of Ideal Gas
Critical Flow Pressure Ratio, like Methane is 0.54, Steam
is 0.54 and Air is 0.53.
If the fluid is a liquid, a different type of limiting condition
(choked flow) occurs when the restriction in the valve
causes a decrease of the liquid pressure beyond the
restriction to below that of the liquid's vapor pressure at
operating temperature. At that point, the liquid will
partially flash into bubbles of vapor and the subsequent
collapse of the bubbles causes cavitation. Cavitation is
quite noisy and can be sufficiently violent to physically
damage valves, pipes and associated equipment. In effect,
the vapor bubble formation in the restriction prevents the
flow from increasing any further. If a control valve has
such a cavitation problem, then the vendor may choose
another valve with anti-cavitation trim (that has high FL
value or liquid pressure recovery factor). The control
valve with a high value of FL is costlier.

What is a control valve?

A control valve is a valve used to control fluid

flow by varying the size of the flow passage as
directed by a signal from a controller.
This enables the direct control of flow rate and
the consequential control of process quantities
such as pressure, temperature, and liquid level.

What is a Cv?
Cv is a flow coefficient that provides the capacity of a
valve.

Where;

Q : Flow rate (USgpm)

SG : Specific gravity of the fluid (for
water =1)
ΔP : Pressure drop across the valve (psi)

In more practical terms, Cv is the volume (in US gallons)

of water at 60° F that will flow per minute through a valve
with a pressure drop of 1 psi across the valve.
If a valve has a Cv of 20 that means we can pass 20
gallons of water per minute with a one-pound pressure
drop.
Let’s consider an example given in figure 1.
Saturated steam at 800 kPa enters the pressure control
valve (PCV-01). PCV-01 maintains a downstream
pressure of 600 kPa. The calculated capacity (Cv) of such
a control valve shall be 78.57. When the valve is 100%
open then for 200 kPa pressure drop, it shall allow 5000
kg/h steam to pass through.
If we use the same valve and decrease the pressure drop
across from 200 kPa to 100 kPa, what happens to the flow
rate using guidelines given in table 7.1. Less pressure
drop means less flow, right?
Figure 7.1: Control valve
Figure 7.2: Control valve
Control Valve Sizing Criteria

Valve shall be sized for normal operating flow at

normal pressure drop. The valve selected shall
have the capability to pass 1.3 times the normal
flow at the indicated differential pressure and 1.1
times the maximum flow at the indicated
differential pressure. The larger valve shall be
selected.
When only the maximum flow is specified, the
valve shall be sized for 110 % of maximum flow
(maximum expected flow rates at no more than
90% of the fully open position).
Normal flow rates at 50% to 80% of the
maximum opening of the valve and minimum flow
rate no less than 10% open position.
Butterfly valves shall be selected such that the
disc opening is not greater than 60° at maximum
flow and 30° for minimum flow. 90° is
permissible for on/off service only.
Control valve body size shall not be less than
two-line sizes smaller than line size. Often, the
valve body shall be one size less than the line
size.
Differential pressure for the valve shall not be
less than 10 psi. If the system cannot afford 10 psi
or more drop through the valve, a butterfly,
eccentric disc or ball valve should be
considered.

Valve Sizing Criteria

Non-Critical Service - Outlet velocity < 8 m/s

Non-Critical, corrosive Service - Outlet velocity
< 6 m/s
Partial Cavitation Service - Outlet velocity < 5
m/s
 Maximum and Severe Cavitation Service - Outlet
velocity < 3 m/s
Flashing Service - Inlet velocity < 5 m/s
Flashing Service - Outlet velocity < 60 m/s
Gas service (continuous) – Mach No. < 0.3
Gas service (intermittent) – Mach No. < 0.7

Common flow characteristic curves

Figure 7.3: Trim characteristics

The above figure provides the tentative shapes of the

valve plug or trim. Different shape of the valve plug
decides the flow characteristic w.r.to valve opening. For
example, if the valve characteristic is linear and for 100%
valve opening the flow rate is 1000 kg/h, if you throttle the
valve to 60%, then the flow rate will reduce to 600 kg/h,
provided pressure drop in both the cases remain same.
Linear:

Flow capacity increases linearly with valve

travel.
Mostly used in liquid level or flow loops.
Used in systems where the pressure drop
across the valve is expected to remain fairly
constant (i.e. steady-state systems).

Equal percentage:

Flow capacity increases exponentially with

valve trim travel; equal increments of valve
travel produce equal percentage changes in
the existing Cv.
Most commonly used control valve
Used in processes where large changes in
pressure drop are expected.
Used in temperature and pressure control
loops.

Quick Opening characteristic:

An inherent flow characteristic in which a

maximum flow coefficient is achieved with
minimal closure member travel
Used for frequent on-off service.
Used for processes where the "instantly"
large flow is needed (i.e. safety systems or
cooling water systems).
The typical trim characteristic can be plotted as below.
Figure 7.4: Trim characteristics

Linear trim would follow the equation y = x.

Equal percentage trim would follow the equation
y = x3 .
The quick opening trim would follow the
equation y = x0.5 .

It’s advisable to use the above equations when you are

working on concept or FEED level study when the control
valve vendor catalog is not available. However, if control
valve sizing is carried out in detail engineering stage,
where EPC contractor will buy the control valve, then it’s
mandatory that you use vendor catalog and do not rely on
the equations above. It may be noted that mostly the actual
valve behavior is different from the calculated one. One
such example is plotted below.
Figure 7.5: Trim characteristics curve comparison
Control Valve selection process

Determine service conditions.

P1, ΔP, Q, T1, Fluid Properties, etc.
Calculate preliminary cv required.
Select the trim type.
Select the valve body and trim size.

Self-acting regulators
Self-acting regulators shall only be used in services that
meet all the following requirements:
Fluid services that are all the following:

Clean.
Not very toxic.
Below its auto-ignition temperature.
Permanent installations that require no operator
intervention (e.g., changing of the setting).

All components downstream of the pressure-reducing

regulator shall meet one of the following:
 Rated for the upper design pressure of the
upstream piping, or
Provided with overpressure protection.

Adjustments to the setpoint of self-acting regulators

shall only be possible with a tool such as a wrench or
spanner and not by hand.
Types of self-acting regulators
Pressure-reducing regulators
Pressure reducing regulators should be used to control the pressure
downstream of the regulator. These valves are failed to open. The actuator
casing is connected to the outlet pressure, so in case of control failure, the
downstream piping and actuator casing will be exposed to the inlet pressure.
The non-pressurized side of the actuator normally has a breathing connection
which, in case of diaphragm failure will pass process fluid to the
atmosphere.
Back-pressure regulators
Back-pressure regulators should be used to control the pressure upstream of
the regulator. These valves are failed to close. The actuator casing is
exposed to the upper design pressure of the upstream piping. The non-
pressurized side of the actuator normally has a breathing connection which,
in case of diaphragm failure, will pass process fluid to the atmosphere.
Differential-pressure regulators
The pressure retaining components of the differential-pressure regulator shall
be rated for the upper design pressure of the upstream and downstream
piping, whichever is the highest.
Tank blanketing regulators
Tank blanketing regulators are used to feed blanket gas into a tank when the
pressure in the tank drops, for instance when the level is dropping. External
pressure sensing lines of tank blanketing regulators should be installed with
minimal bends and constant slope to allow for drainage back into the tank. In
fouling or dirty applications, the provision of a constant purge of gas into the
tank should be considered.
Temperature regulators
Self-acting temperature regulators shall only be considered for heating
applications where utilities (e.g., instrument air or gas) are not available.
Simulation
In the below example, 360 m3 /h of water is passed through an ON/OFF
valve (XV-01) at 90 o C. Inlet pressure is 680 kPa. A pressure drop value of
460 kPa is provided to XV-01.
Calculate the appropriate size of XV-01.

Figure 7.6: Control valve

Step by step procedure for simulating this system in Aspen HYSYS V11 is
provided below;
Create a new case in Aspen HYSYS.
Figure 7.7: New case
“Add” the “Component Lists”.
Figure 7.8: Component list
“Search for” Water as the “Pure Components” and “Add”. There are a total
of 5758 pure components in the HYSYS V11 library. The Full
Name/Synonym option makes finding components the easiest. To enter
components by HYSYS’s simulation names, or by chemical composition,
select “Sim Name” or “Formula” respectively.
Figure 7.9: Component list

In the “Fluid Packages”, click on the “Add” button to specify a fluid package.
Doing so will bring you to a list of all the different equations of state HYSYS
uses. The simplest fluid package, you might be aware of the Antoine equation
for calculating the vapor pressure of a fluid.
Figure 7.10: Fluid package
See the figure below for some general guidelines on picking the appropriate fluids
packages.
Figure 7.11: Fluid package selection guideline

Table 7.2: Recommended property package

TYPE OF SYSTEM RECOMMENDED PROPERTY METHOD

TEG Dehydration PR
Sour Water PR, Sour PR
Cryogenic Gas Processing PR, PRSV
Air Separation PR, PRSV
Ethylene Towers Lee Kesler Plocker
Atm. Crude Towers PR, PR Options, GS
Vacuum Towers PR, PR Options, GS(<10 mmHg),Braun K10,
Esso K
Hydrate Inhibition PR
High H2 Systems PR, ZJ or GS
Reservoir Systems Steam Package, CS or GS
Chemical Systems Activity Models, PRSV
HF Alkylation PRSV, NRTL
H2O solubility in HC is Kabadi Danner
important
TEG Dehydration with Aromatics PR
Systems with select gases and MBWR
light HC
Aspen HYSYS contains an assistant tool to help you in the selection for the
suitable FP, called Methods Assistant.
Figure 7.12: Methods assistant
Figure 7.13: Methods assistant

Figure 7.14: Methods assistant

Using “Methods Assistant” one can find out that the recommended fluid
package for the water-only system is IAPWS-IF97 or NBS-Steam or ASME
Steam. We have selected IAPWS-IF97.
Enter the simulation environment by clicking the “Simulation” tab.
Figure 7.15: Simulation

“Model Palette” is used to insert any unit operation, material or energy

stream, pump, compressor, control valve, distillation column, reactor, heat
exchanger, etc.
Figure 7.16: Model palette
Insert 2 “Material Streams” and 1 “Control Valve”.
Figure 7.17: Model palette
Connect both the material streams to the control valve. Click the
“Flowsheet/Modify” tab and use the “Attach” function to connect the streams.
Figure 7.18: Control valve

Double click on Material Stream “1” and provide temperature, pressure,

flow rate and composition as per problem statement.
Figure 7.19: Material stream
Figure 7.20: Material stream
Similarly, provide pressure value of material stream 2. And change the tags
of both the material streams and valve. Once all the minimum required input
parameters have been provided to HYSYS, it shall calculate instantaneously.
Material stream color shall change from cyan to blue and Valve color shall
change from yellow to gray. Save the file as “Example 1.hsc”.
Figure 7.21: Material stream
Right-click on stream “In” and select “Show Table”. Double click on the
table and use “Add Variable” and “Remove Variable” to select and remove
needed parameters as shown in the problem statement.
Figure 7.22: Show table
Do the same for other streams and valve as well.
Figure 7.23: Show table
As the system is converged, now we can proceed to
control valve sizing. In the simulation, the sizing of the
control valve is limited to Cv calculations. Double click
on XV-01. Change “Valve Opening” to 100% as XV-100
is ON/OFF valve.
Figure 7.24: Control valve sizing

Control valve sizing procedure is provided in the standard

ANSI/ISA 75.01.01. A few terms to ponder are as
following;

FP : Piping geometry factor.

It can be calculated by the formula given in

ANSI/ISA 75.01.01.

FL : Liquid pressure recovery factor of a control

valve without attached fittings.

Typical values are provided in ANSI/ISA 75.01.01.

Actual values shall be stated by the valve
manufacturer. Less Fl value means the valve is more
prone to choking.
 XT : Pressure differential ratio factor of a control
valve without attached fittings at choked flow.

Typical values are provided in ANSI/ISA 75.01.01.

Actual values shall be stated by the valve
manufacturer. Less Fl value means the valve is more
prone to choking.
Also, select the “Rating” tab and check the “Model Liquid
Choking” box. This will calculate if the valve has any
choking problem or not. This works when you click “Size
Valve” in the “Sizing” tab. In example 1, there is no
choking observed.
Figure 7.25: Control valve sizing
Now let’s go back to the “Rating” tab.
Cv calculated is 190.8. This would also mean that one can pass 190.8
gallons of water per minute with a one-pound pressure drop at 60 oF. Now
we need to select an appropriate valve size for this application. Since it has
been established that it is an ON/OFF valve, so trim characteristic suggested
is a Quick opening. We shall refer control valve vendor catalog. One such
table for Quick opening trim is given below;
Table 7.3: Cv table for quick opening trim

As the calculated Cv is 190.8, the adequate Cv as per the above table shall
be 225. This falls under 4” valve size and 3.5” trim size. This is how the
valve size is selected.
Now save this example as Example 2. In example 2, we will consider the
same process parameters, but instead of the ON/OFF valve, XV-01 shall be a
Flow control valve (FCV-01). Also, it is to be noted that the 360 m3 /h
(347608 kg/h) flow rate is the maximum or design flow rate. Most control
valve vendors recommend operating range from 20% to 80%, meaning for
minimum flow conditions, valve opening shall not below 20% and for
maximum flow conditions, valve opening shall not be more than 80%. This
helps better control of the process parameter. For the flow control valve, the
suggested
trim characteristic is Linear.
The model snapshot is given below;
Figure 7.26: Control valve sizing
The interpretation of the above results is as below;
Cv of 190.8 is required when the valve is at its maximum capacity, but in this
case, the actual valve opening shall be 80%. Hence, we need to first get the
vendor catalog for Linear trim and search for the Cv value equal or greater
than 190.8 in the 80% valve opening column. (100% valve opening in the
above snapshot is correct).
The below table is for the Linear trim control valve.
Table 7.4: Cv table for linear trim

As per the above vendor catalog, FCV-01 size is 6” and trim size is 3”.
Although Cv in 80% column is 190 (and not 190.8), 190 is selected as it is
very close to 190.8.
We will do one more exercise here. If instead of 3” trim size, you select 3.5”
trim (6” valve size), what will be the valve opening for the same pressure
drop and flow rate?
FCV-01 opening shall be around 60%. Can you figure out, how?
Now let’s change the problem statement again. Let the pressure be the same,
but instead of sub-cooled liquid, it shall be saturated steam. The flow rate is
changed to 10000 kg/h, which is the normal flow rate. It shall be a pressure
control valve. Double click on stream “In” and delete temperature value.
Provide vapor fraction as 1. It shall automatically calculate Tsat at 680 kPa.
Change flow rate to 10000 kg/h. Change valve tag to PCV-01.
Figure 7.27: Control valve sizing

Double click on PCV-01. The trim characteristic will be an equal percentage,

as it is the pressure control valve. Keep the valve opening at 100%. Select
“Sizing Methods” as Cv. Click “Size Valve”. The calculated Cv is 142.7.
Figure 7.28: Control valve sizing
Cv of 142.7 is required when the valve is at its normal capacity, but in this
case, the actual valve opening shall be about 50% to 60%. Hence, we need
to first get the vendor catalog for Equal percentage trim and search for 142.7
Cv value in 50% to 60% valve opening column. (100% valve opening in the
above snapshot is correct).
Table 7.5: Cv table for equal percentage trim
As per the above table, 6” valve with 5” trim shall be adequate for the given
application.
Now let’s open Example 1.hsc and change Fl value from 0.9 to 0.6, meaning
the control valve has less Liquid pressure recovery factor. This increases
valve Cv and makes the valve choked. Hence, whenever you encounter any
valve with the choking problem, first check its Fl value and calculate if that
is causing the choking. If yes, then replace the valve with anti-cavitation trim
(higher Fl value valve).
Figure 7.29: Control valve sizing
Figure 7.30: Control valve sizing
When the process engineer does not have access to vendor catalog for
concept or FEED stage study, then control valve size can be determined from
below rule of thumb.
Cv = 10 d2
Where d is valve size in inch.
For example, a 2” valve Cv will be around 40 and 6” valve Cv will be
around 360.
A word of caution, as a process engineer, you may be able to recommend the
adequate valve size, but you should not do that. The control valve vendor
should be the one responsible to use the input data given by the process
engineer and do the calculation and recommend the appropriate valve size.
The knowledge that you have gained here, must be used to verify/review
vendor design and make sure your valve size and vendor’s valve size is the
same. The vendor provides a process guarantee for the control valve, not
you.
ANSI/ISA 75.01.01 should be used to prepare control valve sizing
spreadsheets for compressible and incompressible fluids. All the formula,
methodology, and flow charts are given in the same standard.
Exercises

a. Ms. Vasantha is learning about cavitation in the

control valve. Please make a presentation file that
explains the same in detail.
b. Mr. Koteswararao is not sure how to find out the
Cv of a valve. Have a brainstorming session in
your class/office and try to find the answer.
c. Mr. Nitish is trying to select appropriate PCV
size for natural gas at 50 o C, 5000 kg/h (design
flow), 6.5 barg upstream conditions, and with 0.5
bar pressure drop across the valve. Can you help
him?
d. Mr. Abizer needs to make a presentation about
different trim characteristics for the control valve
and compare it with the ones given by valve
vendors. Please help him.
e. Mr. Rahul is trying to select appropriate LCV size
for toluene at 20 o C, 55 m3 /h (normal flow), 5
barg upstream conditions, and with 1 bar pressure
drop across the valve. Can you help him?
f. Mr. Uday is preparing a presentation about self-
acting regulators. Please help him to prepare such
a presentation file.
CHAPTER 8: ORIFICE SIZING USING
ASPEN HYSYS
An Orifice meter is a type of flow meter used to measure the rate of flow of
fluid using differential pressure measurement principle. An orifice plate is
nothing but a thin hole with a hole that is placed in a pipe in which fluid
flows. As fluid flows through the orifice, it causes pressure drop due to
reduced flow area. More flow rate means more pressure drop. Hence for a
constant flow area of the orifice, as pressure drop is measured, then flow
rate can be calculated.
Figure 8.1: Orifice
Figure 8.2: Orifice
ISO 5167-2 standard is used for calculation of orifice
sizing. It applies only to a flow that remains subsonic
throughout the measuring section and where the fluid can
be considered as a single phase. It does not apply to the
measurement of pulsating flow. It does not cover the use of
orifice plates in pipe sizes less than 50 mm or more than 1
000 mm, or for pipe Reynolds numbers below 5000. The
diameter d shall in all cases be greater than or equal to
12,5 mm. The diameter ratio, d/D, shall be always greater
than or equal to 0,10 and less than or equal to 0,75.
Flow orifice usually has a pressure drop of up to 0.5 bar.
Restriction orifice has a significant pressure drop.
Types of Restriction Orifice Plates

Single-stage restriction orifice

A single-stage restriction orifice is usually a plate or

a block with a bore (orifice) sized to the intended
permanent loss of pressure. It is installed between the
pipe flanges. Usually, it is not a thin orifice plate; it is
a thick orifice plate.

Single-stage multi-hole restriction orifice

A single-stage multi-hole restriction orifice plate is

used to abate the noise generated by the device due to
high velocity through the bore which offers restriction
to the incoming fluid.
The flow at the inlet is now channeled into several
streams through the multiple holes and this reduces
the noise which would be otherwise will be above
the acceptable limit if a single hole device is used.

Multi-stage restriction orifice plate assembly

These devices are used where the pressure reduction

ratio is very high and cannot be achieved by a single-
 stage orifice plate. Thus, a multistage device
essentially consists of several single-stage devices
built in a single spool.
Like a single-stage device, it can be of single hole
multistage design or multi-hole multi-stage design or
combination of both.
Simulation
Let’s solve an example using Aspen HYSYS.
Water flows at 60000 kg/h across a flow orifice with an
assigned pressure drop value of 0.5 bar. Water upstream
pressure is 5 barg. Pipe ID to be considered as 100 mm.
Calculate orifice area, orifice diameter, and beta ratio.
Select Water as a component and IAPWS as a Fluid
package.
Figure 8.3: Component list

Figure 8.4: Fluid package

Insert a Material Stream from Model Palette and provide temperature,
pressure, flow rate, and composition as shown below.
Figure 8.5: Material stream

Figure 8.6: Material stream

Insert “Relief Valve” from the Model Palette and connect the streams.
“Relief valve” can be used to simulate orifice.
Figure 8.7: Model palette
Provide outlet stream pressure as 4.5 barg.
Figure 8.8: Orifice sizing
Double-click on Orifice (RV-100) and provide a discharge coefficient (0.6)
in the Rating tab.
The orifice area calculated is 2784 mm2 . Hence 60 mm orifice diameter (d)
is calculated. Pipe inside diameter (D) is 100 mm. Beta ratio (d/D) is 0.6,
which is within the allowable range of 0.1 to 0.75 as per ISO 5167-2. Hence
calculated orifice size is adequate.
Figure 8.9: Orifice sizing
Exercises

a. Mr. Rajesh is trying to select appropriate orifice

size for natural gas at 50 o C, 5000 kg/h, 6.5 barg
upstream conditions, and with 0.5 bar pressure
drop across orifice. Can you help him?
b. Ms. Neeta is trying to select appropriate orifice
size for natural gas at 50 o C, 5000 kg/h, 6.5 barg
upstream conditions, and with 6 bar pressure
drop across orifice. Can you help her?
c. Mr. Swapnil is trying to select appropriate orifice
size for Benzene at 10 o C, 35 m3 /h, 3.5 barg
upstream conditions, and with 0.5 bar pressure
drop across orifice. Can you help him?
CHAPTER 9: SEPARATOR SIZING
USING ASPEN HYSYS
Separator is a pressure vessel used for separating well
fluids from oil & gas wells into gaseous and liquid
components. A separator for petroleum production is a
large vessel designed to separate production fluids into
the components of oil, gas, and water.
Types of Separators
Flash Vessel
A vessel used to separate the gas evolved from liquid
flashed from a higher pressure to a lower pressure.
Gas-Liquid-Solid Separator (Filter Separator)
A filter separator usually has two compartments. The first
compartment contains filter-coalescing elements. The
liquid particles coalesce into large droplets and when the
droplets reach sufficient size, the gas flow causes them to
flow out of the filter elements into the center core. The
particles are then carried into the second compartment of
the vessel (containing a vane-type or knitted wire mesh
mist extractor) where the larger droplets are removed.
Knock out drum (Gas-Liquid Separator)
A vessel designed to handle streams with high gas to
liquid ratios (GLR). The liquid is generally entrained as
mist in the gas or is free-flowing along the pipe wall.
These vessels usually have a small liquid collection
section.
Two-Phase Separator (Gas-Liquid Separator)
A vessel that separates the well fluid into gas and liquid.
A two-phase separator can be horizontal, vertical, or
spherical. The liquid leaves the vessel at the bottom
through a level control or dump valve. The gas leaves the
vessel at the top passing through a mist extractor to
remove the entrained liquid droplets in the gas.

Figure 9.1: Vertical separator

Figure 9.2: Horizontal separator (2 phase)

Liquid-Liquid Separator
Two immiscible liquid phases can be separated using the
same principles as gas-liquid separators except that they
must be designed for much lower feed velocities because
of the difference in density between two liquids is less
and the separation becomes more difficult.
Gas-Liquid (Oil)-Liquid (Water) Separator (Three
Phase Separator)
A vessel that separates the well fluids into gas and two
types of liquid oil & water. A three-phase separator can
be horizontal, vertical, or spherical. This type of separator
is commonly called a free water knock because its main
purpose is to remove free water that can cause problems
such as corrosion and formation of hydrates.
Figure 9.3: Horizontal separator (3 phase)

Classification by Application
Oil and gas separators are further classified according to
the application as below:
Test Separator
A test separator is used to separate and to meter the well
fluids. The test separator can be referred to as a well
tester. They can be permanently installed or portable. Test
separators can be equipped with various types of
measuring devices for measuring the Gas oil ratio (GOR),
Water cut, Basic sediments & water (BS & W).
Production Separator
Production separator is used to separate the produced
well fluid from a well on continuous basis.
Separator Basic Design Criteria
Following three main factors are to be considered in
separator sizing:

Vapor capacity:

The vapor capacity will determine the cross-

sectional area necessary for gravitational forces to
remove the liquid from the vapor. More vapor load
means bigger diameter separator.

Liquid capacity:

The liquid capacity is set by determining the volume

required to provide adequate residence time to “de-
gas” the liquid or allow immiscible liquid phases to
separate.

Operability:

Operability issues include the separator’s ability to

deal with solids if present, unsteady flow, turndown,
etc. The optimal design will usually result in an
aspect ratio that satisfies these requirements in a
vessel of reasonable cost.
One has to follow an iterative approach to the calculations
considering the above factors so that the best design is
obtained.
As per GPSA, typical vertical H/D ratios are normally in
the 2 to 4 range and that of horizontal L/D ratios are
normally in the 2.5 to 5 range.
Table 9.1: Function & Separation Device Combinations

Table 9.2: Separator Orientation

Mist Extraction Equipment
Mist extractors are used to separate the small liquid droplets from the gas
phase that were not removed by the inlet device or gas settling section of the
separator and the droplets are less than 150-500 microns in size. It is not
economic to separate these small droplets by gravity settling.
Wire mesh
Wire-mesh mist extractors, or pads, are made by knitting wire, metal or
plastic, into tightly packed layers which are then crimped and stacked to
achieve the required pad thickness.

Most mesh pads are 150 mm thick with 144 – 192 kg/m3 bulk density.
Minimum recommended pad thickness is 100 mm. Typical mesh pad
installation is shown below.
Figure 9.4: Mist extractor
Vane pack
Vane or chevron-type mist extractors (vane-pack) use
closely spaced blades arranged to provide sinusoidal or
zigzag flow paths. The changes in gas flow direction
combined with the inertia of the entrained liquid droplets,
cause impingement of the droplets onto the plate surface,
followed by coalescence and drainage of the liquid to the
liquid collection section of the separator.
Figure 9.5: Vane pack

Cyclonic Separator
Cyclonic separator removes particulates from an air, gas
or liquid stream, without the use of filters, due to vortex
separation. Gravity and rotational effects are used to
separate mixtures of solids and fluids. The method is also
used to separate fine droplets of liquid from a gaseous
stream.

Souders-Brown Equation
The Souders–Brown equation is used to calculate the
maximum allowable vapor velocity in vapor-liquid
separation vessels (variously called flash drums, knockout
drums, knockout pots, compressor suction drums, and
compressor inlet drums). The equation is given below;
Where:

V = maximum allowable vapor velocity,

m/s
ρL = liquid density, kg/m³
ρV = vapor density, kg/m³
K = mesh capacity factor
The separator has a vapor outlet at the top, liquid outlet at
the bottom, and feed inlet at about the half-full level. At
the vapor outlet, a mesh pad is provided. The liquid outlet
line may have a liquid level control valve.
Recommended values of k
The GPSA Engineering Data Book recommends the
following k values for vertical drums with horizontal
mesh pads (at the denoted operating pressures):

At a gauge pressure of 0 bar: 0.107 m/s

At a gauge pressure of 7 bar: 0.107 m/s
At a gauge pressure of 21 bar: 0.101 m/s
At a gauge pressure of 42 bar: 0.092 m/s
At a gauge pressure of 63 bar: 0.083 m/s
At a gauge pressure of 105 bar: 0.065 m/s

Notes:

k = 0.107 at a gauge pressure of 7 bar. Subtract

0.003 for every 7 bar above a gauge pressure of 7
bar.
For glycol or amine solutions, multiply above k
values by 0.6 – 0.8.
Typically use one-half of the above k values for
approximate sizing of vertical separators without
mesh pads
For compressor suction scrubbers and expander
inlet separators, multiply k by 0.7 – 0.8.
Some guidelines for separator design are provided below.
Table 9.3: Momentum & Velocity criteria for nozzles
(Source: DEP 31.22.05.12 - Gen.- 2008)
Table 9.4: Selection guideline for separator types

Table 9.5: Level setting in the separator

Table 9.6: Typical K factors for the sizing of wire mesh demisters (Source:
IPS-E-PR-880, 1997)
Table 9.7: Standard separator sizes as per API
D [in] x H or L [ft]
12¾ in x 5 ft 36 in x 7½ ft
3
6
i
n
12¾ in x 7½
x
ft
1
0
f
t
3
6
i
n
12¾ in x 10 ft x
1
5
f
t
4
2
i
n
16 in x 5 ft x
7
½
f
t
 D [in] x H or L [ft]
4
2
i
n
16 in x 7½ ft x
1
0
f
t
4
2
i
n
16 in x 10 ft x
1
5
f
t
4
8
i
n
20 in x 5 ft x
7
½
f
t
 D [in] x H or L [ft]
4
8
i
n
20 in x 7½ ft x
1
0
f
t
4
8
i
n
20 in x 10 ft x
1
5
f
t
5
4
i
n
24 in x 5 ft x
7
½
f
t
 D [in] x H or L [ft]
5
4
i
n
24 in x 7½ ft x
1
0
f
t
5
4
i
n
24 in x 10 ft x
1
5
f
t
6
0
i
n
30 in x 5 ft x
7
½
f
t
 D [in] x H or L [ft]
6
0
i
n
30 in x 7½ ft x
1
0
f
t
6
0
i
n
30 in x 10 ft x
1
5
f
t
36 in x 5 ft
Simulation
Let’s solve a separator sizing problem using Aspen HYSYS.
Inlet to the separator is a mixture of Methane and n-Butane. Separator
operating temperature and pressure are 80 o F and 814.7 psia respectively.
The flow rate is 3221 lbmol/h. Methane 81.32% (mole) and 18.68% (mole)
n-Butane. The fluid package is Peng Robinson.
Figure 9.6: Component list

Figure 9.7: Fluid package

Select the Separator from the model palette and connect the material streams.
Figure 9.8: Separator
Select “Home\Analysis\Equipment Design” drop-down box and
choose “Vessel Sizing”.
Figure 9.9: Separator sizing

Click on “Select Separator” as V-100 and select “Vertical”

separator. As per the best engineering practice, more vapor feed
should be sent to a vertical separator.
Figure 9.10: Separator sizing
Select the “Sizing” tab and add “Diameter” as an “Additional
Specifications”. For vertical separators, the H/D ratio is 2 to 4.
Liquid residence time will depend on the o API of the liquid. o API
can be calculated using the specific gravity of liquid using the
below formula.
Typical retention time v/s Oil gravity
is given in the below table.
Table 9.8: Retention time guideline
Retention time, minutes
Oil Gravities
(Typical)
Above 35 o
1
API
20 to 30 o API 1 to 2
10 to 20 o API 2 to 4
As per the above table, retention time in this example will be 1
minute as the specific gravity of a liquid is 0.49 as per HYSYS and
calculated o API shall be 157.
We will keep the separator diameter as 3.5 ft.
Figure 9.11: Separator sizing
Accordingly, results are displayed in the “Performance” tab. Total height
with dished end is 15.75 ft. Liquid level is 1.5 ft, meaning % liquid level
will be 1.5/15.75x100 = 10%.
Figure 9.12: Separator sizing
Now let’s choose a smaller diameter for the separator. Diameter is 3 ft.
Figure 9.13: Separator sizing
The new height is 13.5 ft and the liquid level is 1.9 ft (14%).
Figure 9.14: Separator sizing
We will further try to optimize the separator with 2.5 ft diameter.
Figure 9.15: Separator sizing
Separator height is 11.25 ft and the liquid level is 2.6 ft (23%).
Figure 9.16: Separator sizing
We will further try to optimize the separator with 2.5 ft diameter.
Figure 9.17: Separator sizing
Separator height is 9 ft and the liquid level is 3.9 ft (43%).
Figure 9.18: Separator sizing
But when we further try to reduce the separator diameter,
then HYSYS fails to find a solution.
Figure 9.19: Separator sizing

Hence, the solution to the given problem is to select either

2 ft diameter or 2.5 ft diameter separator.
Exercises

a. Ms. Srijita is supposed to discuss separator

design. Can you help her?
b. Ms. Shubhangi is trying to size the separator with
FEED flow rate 5000 lbmol/h (Methane 81.32%
and n-Butane 18.68% by mole), 85 o F and 900
psia. What would be the appropriate separator
size if the flow rate is doubled?
CHAPTER 10: HEAT EXCHANGER
SIZING USING ASPEN EDR
Aspen Exchanger Design and Rating (EDR) enables you to find the optimal
design for your heat exchanger needs based on cost. The seamless integration
between the thermal and mechanical design tools of Aspen EDR and process
simulation tools from AspenTech enables analysis of several different
alternatives before presenting you with the most optimal design. Use this
tutorial to get started using Aspen Shell & Tube Exchanger to create,
evaluate, and save designs.

Simulation
Let’s solve an example.
Design a shell and tube exchanger for the following duty 20000 kg/h of
benzene. It enters the heat exchanger at 90 o C and to be cooled to 60 o C. The
cooling medium is cooling water entering the exchanger at 30 o C and exits at
37 o C. Benzene inlet pressure is 5 bar and that of water is 6.5 bar.
A pressure drop of 0.8 bar is permissible on both the sides. Allowance
should be made for fouling by including a fouling factor of 0.0003 m2 .K/W
on the Benzene side and 0.0001 m2 .K/W on waterside.
We limit the exchanger length as 5 m.
Figure 10.1: Heat exchanger problem
SOLUTION
Open Aspen EDR new file. Check the “Shell & Tube” box and “Create” the
new file.
Figure 10.2: New case

Figure 10.3: New case

Provide available data (flow rate, pressure, pressure drop, temperature, and
fouling resistance) in the “Process” tab.
Figure 10.4: EDR

Select “Property Data\Hot Stream (1) Composition”.

Figure 10.5: Composition
Select “Physical property package” as “Aspen Properties”.
Figure 10.6: Property package
Click on “Search Databank” and “Find Now” Benzene and Water. You need
to “add selected compounds”.
Figure 10.7: Components

Figure 10.8: Components

Provide Weight percentage for a hot stream (Benzene) as 100% Benzene and
0% Water.
Figure 10.9: Components
The same procedure shall be repeated for “Cold Stream”.
Figure 10.10: Components
Since the problem statement has a constraint that the tube
length should be 5 m, the same shall be provided in
“Program Options\Design Options\Geometry Limits”.
Figure 10.11: Design limits

Tube length shall be provided as 5000 mm minimum and

5000 mm maximum.
Figure 10.12: Design limits
Click “Run” or press F5. Aspen EDR will Design the heat
exchanger as per input parameters. The results are
summarized in “Results\Result Summary\TEMA Sheet”.
Following can be noted from TEMA sheet;

Heat transfer area = 12.4

m2

CW required =
33218 kg/h

Heat exchanged =
250555 kcal/h

LMTD = 39.7 o C

UD = 509.8
kcal/(h.m2 .o C)

No. of tube = 42
 No. of tube passes = 2

Shell ID = 205 mm
Figure 10.13: TEMA sheet

Figure 10.14: TEMA sheet

From the “Thermal/Hydraulic Summary\Performance” tab, it is evident that
shell-side fluid (Benzene) has more resistance to heat transfer compared to
the Tube side (cooling water).
Figure 10.15: Performance

“Setting plan and Tubesheet layout” is given below.

Figure 10.16: Settling plan
Figure 10.17: Settling plan
“Cost/Weight” data is also calculated by Aspen EDR.
Weight result is, however, more reliable than the cost.
Figure 10.18: Cost/Weight

Exercises

a. Mr. Sai works in the technical services

department in an operating company. For a new
project, he is to design a heat exchanger with the
following data. Design a shell and tube exchanger
for the following duty 40000 kg/h of benzene. It
enters the heat exchanger at 100 o C and to be
cooled to 65 o C. The cooling medium is cooling
water entering the exchanger at 30 o C and exits at
35 o C. Benzene inlet pressure is 5.5 bar and that
of water is 5 bar. A pressure drop of 1 bar is
permissible on both sides. Allowance should be
made for fouling by including a fouling factor of
0.0002 m2 .K/W on the Benzene side and 0.0001
 m2 .K/W on waterside. What heat exchanger size
he would have calculated?
b. Mr. Sachin is Mr. Sai's boss and has chosen to
disregard his design and instead used a 50%
oversize heat exchanger. How do you think the
exchanger would perform in such a case?
c. Ms. Shweta believes that if tube length is
considered as 6 m, then the heat transfer area
would be minimum. Can you prove her wrong?
d. Mr. Sai's design was implemented finally. After 6
months, Mr. Nikhil (shift in-charge) realized that
the benzene flow rate was to be reduced to 30000
kg/h if he wanted to maintain the temperature out
of Benzene. Can you explain this?
e. Prepare a spreadsheet to calculate HTA with no
phase change system. Compare the results with
the Aspen EDR TEMA sheet.
CHAPTER 11: DISTILLATION
COLUMN SIZING USING ASPEN
HYSYS
Separation of light products is present in any
Hydrocarbons operations. In this chapter, a column will
be modeled to separate Light and heavy components from
each other using a distillation column with 12 trays.
We need to separate a mixture of five paraffins into light
and heavy fraction by using a distillation column with 12
trays, a full reflux condenser, and a Kettle reboiler. The
feed stream (2000 lbmol/hr) consists of 20% (mole %)
ethane, 20% propane, 20% n-butane, 20% n-pentane, and
20% n-hexane at 255 o F and 270 psia, which enters the
column on the sixth tray, counting from the top. The
condenser and reboiler pressures are 255 and 260 psia,
respectively.
The preliminary design specifications require a reflux
ratio of 2 and a vapor overhead product of 700 lbmol/hr.
Subsequently, the design is modified to ensure propane
overhead flow of 350 lbmol/hr and n-butane bottom flow
of 380 lbmol/hr.
Use SRK Fluid Pkg.
Calculate the following;

The Condenser, the Reboiler Temperatures & the

Reflux Ratio after modification
Condenser Temp
Reboiler Temp
Reflux Ratio
Define the components and Fluid package (SRK).
Figure 11.1: Components

Figure 11.2: Fluid package

Enter the simulation environment and define material stream “1” as below.
Figure 11.3: Material stream

Figure 11.4: Material stream

Add a distillation tower (with condenser & Reboiler).
Figure 11.5: Distillation column
Double-click on T-100.
Figure 11.6: Distillation column

Figure 11.7: Distillation column

Figure 11.8: Distillation column

Figure 11.9: Distillation column
Figure 11.10: Distillation column

Figure 11.11: Distillation column

Click “Run”.
Figure 11.12: Distillation column

We must make 2 specifications active to make the DOF

(degree of freedom) = 0 and to converge the column.
The two specifications are the target that you want to
achieve from the column. Although the column is
converged, it is not always practical to have vapor rate &
reflux ratio specifications. These specifications can result
in columns which cannot be converged or that produce
product streams with undesirable properties if the column
feed conditions change.
An alternative approach is to specify either component
fractions or component flow rates for the column product
streams.
Now we have to give the column another 2 new
specifications to run with (more practical)

Propane overhead flow of 350 lbmol/hr.

Butane bottom flow of 380 lbmol/hr.
Add 2 specifications, namely Column component flow of
propane in overhead product and n-Butane in bottom
product.
Figure 11.13: Distillation column
Uncheck earlier active specifications and check the new specifications.
Figure 11.14: Distillation column
 Condenser Temp. : 86.4 o F
Reboiler Temp. : 128.8 o C
Reflux Ratio : 3.1

Different plots can be generated in the “Performance” tab.

One such example is given below.
Figure 11.15: Distillation column

Let’s now design this distillation column for this

condition. Select “Internal” tab.
Figure 11.16: Distillation column
Click on “Auto Section”. It will divide 12 tray columns
into 2 sections (1 to 5 trays and 6 to 12 trays).
Figure 11.17: Distillation column

Change internal type as “Packed”, Tray packing type as

“IMTP” and Packing dimension as “1 inch”. Click on
“View”.
Figure 11.18: Distillation column

Select “Packed Height per Stage (HETP). HETP value of

1” IMTP packing is to be taken from the vendor. Assuming
HETP value as 0.5 m or 1.64 ft, the same value is
provided. Accordingly, total bed height will be calculated
for section 1 (from 1st to 5th tray region).
Check the “Messages” tab. All the warnings/errors will
be listed here.
Figure 11.19: Distillation column
Carry out the same procedure for CS-2.
Figure 11.20: Distillation column

Figure 11.21: Distillation column

Figure 11.22: Distillation column

The error message states that the pressure drop calculated per bed height is
less than the default value.
Figure 11.23: Distillation column
The default value can be changed with the consultation with the vendor.
Assuming the vendor-provided value for “minimum pressure drop per unit
packed height” is 0.01 inch H2 O/ft.
Figure 11.24: Distillation column

This change has resolved the error.

Figure 11.25: Distillation column
Column diameter for CS-1 and CS-2 are 6.149 ft and 6.071 ft respectively.
Figure 11.26: Distillation column

Different hydraulic plots can also be generated in Aspen HYSYS.

Figure 11.27: Distillation column
Clicking “Column Environment” will take you to column
flowsheet with internal streams.
Figure 11.28: Distillation column

Exercises

a. Mr. Nitin needs to simulate a distillation column

which has the same process parameters as given
in the solved example. He has, however, a tray
column with 36 actual trays with 50% efficiency,
available in his plant. What do you think would
be reflux ratio, condenser and reboiler duty in
this case? Without carrying out any simulation, is
it possible for you to answer that question
qualitatively?
b. Mr. Ranjit is Mr. Nitin's colleague and has been
tasked to convert the available tray column into a
packed column. What are the different options he
has with packings? Can the same column be used?
c. Mr. Amit wants to run the solved example with
same column and process parameters, but with
50% more feed flow rate. Do you expect to get
 50% more product yield? If not, what other
measures should be taken by him?
d. Mr. Himanshu is required to carry out a
comparative study of solved example w.r.to the
effect of reflux ratio on reboiler duty and
condenser duty. Can you help him with that
assignment?
e. Mr. Rohan wants to convert beer into whiskey.
Can you make a problem statement and solve it so
that Mr. Rohan can use it for reference?
f. Ms. Madhugandha needs to simulation the
ammonia absorption column. Can you make a
problem statement and solve it so that Ms.
Madhugandha can use it for reference?
g. Mr. Adeeb wants to learn about the gas
sweetening plant. Can you make a problem
statement and solve it so that Mr. Adeeb can use
it for reference? You may use MDEA as a
solvent.
h. Mr. Payas needs to design a column to
manufacture absolute alcohol. Can you make a
problem statement and solve it so that Mr. Payas
can use it for reference? This solution must not
have any solvent.
i. Mr. Viraj needs to design a column to
manufacture absolute alcohol. Can you make a
problem statement and solve it so that Mr. Viraj
can use it for reference? This solution should
have some solvent.
j. Mr. Anil wants to learn about the BTX
purification plant. Can you make a problem
statement and solve it so that Mr. Anil can use it
for reference?
CHAPTER 12: OPTIMIZER TOOL IN
ASPEN HYSYS
In this example, a simple distillation column to separate
Tetrahydrofuran (THF) from Toluene is simulated. The
object of the exercise is to select the product
specifications such that profit is maximized. A special
tool in HYSYS, the Optimizer, will be used to find the
optimum operating conditions.
HYSYS includes additional modeling and decision
support tools that can be used to enhance the usability of
your models. In this module, you will use the HYSYS
optimization tool available in HYSYS to investigate the
debottlenecking and optimization of a crude column.
Once you have completed, you will be able to;

Use the Optimizer tool in HYSYS to optimize

flow sheets
Use the Spreadsheet to perform calculations

5000 kg/hr mixture of Tetrahydrofuran & toluene (30

mass% THF) at 20 o C and 160 kPa is to be separated by
distillation to get each of them with a purity of 99.2
mass% of THF & 95 mass% of Toluene (THF is the more
volatile component).
Use Wilson fluid package.
The column specifications are:

The condenser & reboiler pressure are 113 kPa

& 117 kPa.
The condenser works on total condensation
conditions.
Number of stages = 16.
Feed enters from the 8 th tray.

Calculate:
The reflux ratio and the distillate rate under the specified
conditions.
Data:

Feed price = 0.04 $/kg

 Pure toluene selling price =
0.12 $/kg
Pure THF selling price =
0.35 $/ kg
Cooling Cost = 0.43 $/ kWh
Heating Cost = 0.75 $/kWh

Note:
Profit = (Total Toluene selling price + Total THF selling
price) - (Feed cost + Heating cost + Cooling Cost)
Use a range of 0.99 to 0.999 for the THF limit & 0.9 to
0.99 for the toluene.
Add components and select the fluid package.
Figure 12.1: Components

Figure 12.2: Fluid package

Figure 12.3: BIP
Now you can start drawing the flow sheet for the process by clicking the
Simulation button. Add a material stream to define the composition and the
conditions of the feed stream.
Figure 12.4: Material stream

Click on “Composition” >> “Basis”. Change Basis to “Mass Fraction”.

Figure 12.5: Material stream
Click Ok.
Add a “Distillation column”.
Figure 12.6: Distillation column

Double click on Column (T-100) and provide details.

Figure 12.7: Distillation column

Click “Next”.
Figure 12.8: Distillation column
Figure 12.9: Distillation column
Figure 12.10: Distillation column
Figure 12.11: Distillation column
Click “Done”.
Figure 12.12: Distillation column

Click “Monitor”.
Figure 12.13: Distillation column
Click “Add Spec.”.
Click “Column Component Fraction” and “Add Spec.”.
Figure 12.14: Distillation column

Provide specs. for THF and Toluene.

Figure 12.15: Distillation column
Select “THF Purity” and “Toluene Purity” as active specifications.
Figure 12.16: Distillation column

Optimization
We need to check if the operating conditions are optimum or not. The
Variables to check are: THF Purity & Toluene Purity.
Using the Optimizer tool.
Click “Home” >> “Optimizer”.
Figure 12.17: Optimizer
Select “Original” as “Data Model” and click “Variable”.
Figure 12.18: Optimizer
Click “Add”.
Figure 12.19: Optimizer
Figure 12.20: Optimizer
Click “Select”.
And do the same steps to add the other variable “Toluene Purity”.
Figure 12.21: Optimizer

Click “Select”.
Use a range of 0.99 to 0.999 for the THF limit & 0.9 to 0.99 for the toluene.
Figure 12.22: Optimizer
Click “Spreadsheet”.
Figure 12.23: Spreadsheet

Select the “Spreadsheet” tab.

Figure 12.24: Spreadsheet
Insert a column.
Figure 12.25: Spreadsheet
Type the text and data as given in below snapshot in columns A, C, D, and E.
Figure 12.26: Spreadsheet
Right click “B1” >> “Import Variable” >> “Qc” >> “Power”.
Figure 12.27: Spreadsheet
Click “Done”.
Right click “B2” >> “Import Variable” >> “Qr” >> “Power”.
Figure 12.28: Spreadsheet

Click “Done”.
Right click “B3” >> “Import Variable” >> “ovhd” >> “Mass Flow”.
Figure 12.29: Spreadsheet
The same procedure is to be used and other parameters are imported in the
spreadsheet.
Figure 12.30: Spreadsheet
Figure 12.31: Spreadsheet

Figure 12.32: Spreadsheet

Figure 12.33: Spreadsheet
Figure 12.34: Spreadsheet
Provide Sales, Cost, and Profit formula in cell D8, D9, and D10
respectively.
Figure 12.35: Spreadsheet
Figure 12.36: Spreadsheet
Figure 12.37: Spreadsheet
Close “Optimizer Spreadsheet”.
Click “Home” >> “Optimizer” >> Functions”.
Figure 12.38: Optimizer

Select “D10” in “Cell”. Select “Maximize”.

Figure 12.39: Optimizer
Click “Start”.
Figure 12.40: Optimizer

It can be noted that profit is increased from 155 $/h to 171

$/h using the optimization tool.
Now you can go to the monitor tab inside the column to
see the optimum values for the THF & Toluene purities.
Figure 12.41: Optimizer
Exercises

a. Mr. Shihad is curious about what changes the

optimizer tool has carried out to maximize the
profit in the solved example. Can you figure it
out?
b. Mr. Kartik is wondering what other problems
can be resolved using the optimizer tool. Can
you help him?
CHAPTER 13: PSV SIZING USING
ASPEN HYSYS
Before attempting to size the PSV, we must know what is a PSV. Consider a
vessel with a design pressure of 7.5 barg. Due to some reasons, if the vessel
pressure increases beyond 7.5 barg, then it may lead to vessel leakage or it can
burst also. To safeguard the vessel, a PSV is attached to the vessel top section.
PSV is set at 7.5 barg. So, when the pressure reaches 7.5 barg, PSV opens and
vessel pressure gets relieved. As pressure starts to go below 7.5 barg, PSV is
closed.
Any equipment with design pressure equal to or more than 15 psig can be
termed as a vessel. And the one with less than 15 psig is called a tank. A tank
may have relief devices called as breather valve or PVRV and sizing are done
as per API 2000.
The vessel may have a relief device called PSV or RD. There are the following
3 major standards that deal with PSV and RD.

API 520 Part 1 : PSV and RD sizing equations are provided in

this standard.
API 521 : Depressurization, Flaring, liquid expansion is
discussed in this standard.
API 526 : The selection of PSV size that is available in
the market is given in this standard.

Terminology

Operating pressure

It is nothing but the normal operating pressure of the vessel.

In our example, let’s assume operating pressure to be 5 barg. The
maximum operating pressure (MOP) is usually taken at a 1.7 bar above
normal operation. So MOP will be 6.7 barg. Vessels are often
overdesigned relative to the maximum operating pressure, i.e. 10% over
MOP. Hence design pressure value will be 7.37 barg or round figure 7.5
barg.

MAWP

The maximum gauge pressure permissible at the top of a completed

vessel in its normal operating position at the designated coincident
temperature specified for that pressure. The pressure is the least of the
values for the internal or external pressure as determined by the vessel
design rules for each element of the vessel using actual nominal
thickness, exclusive of additional metal thickness allowed for corrosion
and loadings other than pressure. The maximum allowable working
pressure is the basis for the pressure setting of the pressure relief devices
that protect the vessel. The MAWP is normally greater than the design
pressure but can be equal to the design pressure when the design rules
are used only to calculate the minimum thickness for each element and
calculations are not made to determine the value of the MAWP.
MAWP could be 7.5 barg or even more depending upon actual shell
thickness of the vessel.

Design pressure
 Pressure, together with the design temperature, is used to determine the
minimum permissible thickness or physical characteristic of each vessel
component as determined by the vessel design rules. The design pressure
is selected by the user to provide a suitable margin above the most
severe pressure expected during normal operation at a coincident
temperature. This pressure may be used in place of the maximum
allowable working pressure (MAWP) in all cases where the MAWP has
not been established. The design pressure is equal to or less than the
MAWP.
Design pressure here is calculated to be 7.5 barg.

Set pressure

The inlet gauge pressure at which the pressure relief device is set to open
under service conditions.
Set pressure in this example will be a 7.5 barg. As per API 520 Part 1,
we could have set it at less than 7.5 barg (say at 7 barg) also, but we
didn’t, to avoid unnecessary popping of PSV and loss of material. But if
the vessel is derated (due to aging leading to reduction of shell
thickness), then one may choose to set the PSV at even lower pressure.
If there are 2 PSVs (both working) protecting a single vessel, then the
first PSV can be set at 7.5 barg (max. 100% of design pressure) and
second will be set at 7.875 barg (max. 105% of design pressure).

Accumulation

The pressure increase over the maximum allowable working pressure of

the vessel expressed in pressure units or as a percentage of maximum
allowable working pressure (MAWP) or design pressure. Maximum
allowable accumulations are established by applicable codes for
emergency operating and fire contingencies.
Table 13.1: Accumulated pressure and set pressure guideline
Single Device Installations Multiple Device
Installations
Maximum Maximum
Contingency Maximum Maxim
Set Set
Accumulated Accumu
Pressure, Pressure,
Pressure, % Pressur
% %
Non-Fire Case
First Relief 100 110 100 116
Device
Additional - - 105 116
Device(s)
Fire Case
First Relief 100 121 100 121
Device
Additional - - 105 121
Device(s)
 Supplemental - - 110 121
Device
NOTE: All values are percentages of the maximum allowable working pres

The above table from API 520 Part 1 can be used to determine allowable
set pressure and maximum accumulated pressure. If there is a single PSV,
then for non-fire (blocked outlet) case, the vessel shall be allowed to
have a maximum pressure of 110% of design pressure. If design pressure
is 7.5 barg, then maximum pressure allowable shall be 110% of 7.5 barg
(8.25 barg).
For the fire case, maximum accumulated pressure shall be 121% of
design pressure, irrespective of the number of PSVs.
In the above table, the only variable is design pressure. Hence it is
advisable to prepare an excel sheet to calculate all the parameters given
in the table w.r.to design pressure. So whenever PSV sizing has to be
done, the same table can be referred.
Overpressure

The pressure increase over the set pressure of the relieving device.
Overpressure is expressed in pressure units or as a percentage of set
pressure. Overpressure is the same as accumulation only when the
relieving device is set to open at the maximum allowable working
pressure of the vessel.
Blowdown

The difference between the set pressure and the closing pressure of a
pressure relief valve expressed as a percentage of the set pressure or in
pressure units.
The closing pressure of PSV is a bit less than that of its set point. If the
set pressure is 7.5 barg, then closing pressure may be 7.4 barg (depends
on the PSV model). 0.1 bar shall be the blowdown.
Superimposed backpressure

Pressure in discharge header before the valve opens.

Can be constant or variable.
Figure 13.1: PSV at pump discharge
 Built-up back pressure
Pressure in discharge header due to frictional losses after the valve
opens

Total = Superimposed + Built-up

Figure 13.2: PSV

When to provide a PRV?

All pressure vessels subject to overpressure shall be protected by a

pressure-relieving device
Liquid filled vessels or piping subject to thermal expansion must be
protected by a thermal relief device
Multiple vessels may be protected by a single relief device,
provided there is a clear, unobstructed path to the device
At least one pressure relief device must be set at or below the
MAWP

Types of PSV
Conventional Spring-Loaded Safety Relief Valve
 Advantages
Most reliable type if properly sized and operated
Can be used in many services

Disadvantages
Relieving pressure affected by back pressure
Susceptible to chatter if built-up back pressure is
too high

Figure 13.3: PSV components

Balanced Bellows Spring Loaded Safety Relief Valve

Advantages
Relieving pressure not affected by
back pressure to a certain extent
Can handle higher built-up
backpressure

Disadvantages
Bellows susceptible to
fatigue/rupture
May release flammables/toxics to
atmosphere
Requires separate venting system

Figure 13.4: Balance bellow PSV

Piston Type Pilot Operated Safety Relief Valve

Advantages
Relieving pressure not affected by
back pressure

Disadvantages
Pilot is susceptible to plugging
Potential for backflow

Figure 13.5: Pilot operated PSV

Table 13.2: PSV selection guideline
PSV type When to use?
Conventional When built-up backpressure is less
than 10% of set pressure.
Balanced When total backpressure is between
bellow 10% to 50% of set pressure.
Pilot operated When total backpressure is greater than
50% of set pressure.

Chatter

Chattering is the rapid, alternating opening and

closing of a PR Valve.
Resulting vibration may cause misalignment,
valve seat damage, and if prolonged, can cause
mechanical failure of valve internals and
associated piping.
Chatter may occur in either liquid or vapor
services.

Chatter causes:

Excessive inlet pressure drop

Excessive built-up backpressure
Oversized valve
Valve handling widely differing rates

Let’s try to visualize the chattering problem caused by

excessive pressure drop.
Figure 13.6: Chattering
Figure a represents the normal operation, wherein the
vessel operates at operating pressure. Hence the pressure
at the pressure relief valve and the vessel is the same.
Let’s say that the operating pressure is 5 barg. As vessel
pressure increases due to process upset, relief valve
pressure will also increase. Relief valve will open at 10
barg, which the set pressure (figure b). So the pressure at
the vessel and the relief valve is 10 barg. Let’s assume
that 100 kg/h vapor flows from the vessel to the relief
valve. At the vessel, vapor pressure is 10 barg and due to
pressure drop (say, 0.5 bar) in the relief valve inlet pipe,
vapor will be left with 9.5 barg pressure. Since 9.5 barg
is less than the relief valve set pressure, the relief valve
will close and pressure at the relief valve will rise again
(figure c). When pressure reaches sept pressure, then the
relief valve opens again (figure d).
This cycle is repeated over and over. It causes vibration
and damage to the relief valve, pipes, and equipment.
Figure 13.7: Chattering
Chatter solution

Avoid long
piping runs
Avoid bends/turns
Minimize inlet loss
Install smaller PRV
Inlet line size must be at least equal to PRV inlet
flange size
Inlet piping should slope continuously upward
from vessel to avoid traps
Inlet piping should be heat traced if freezing
liquids could occur
A continual clean purge should be provided if
coke/polymer formation or solids deposition
 could occur
Discharge line diameter must be at least equal to
PRV outlet flange size
Maximum discharge velocity should not exceed
70% of sonic velocity
No check valves, orifice plates or other
restrictions permitted
Atmospheric discharge risers should have a drain
hole
The piping design must consider thermal
expansion due to hot/cold release
Auto-refrigeration and need for brittle fracture-
resistant materials
Closed discharge piping should slope
continuously downward to header to avoid liquid
traps

Figure 13.8: PSV and RD arrangement

 Rupture disc

A rupture disc is a thin

diaphragm (generally a
solid metal disc) designed
to rupture (or burst) at a
designated pressure.
It is used as a weak
element to protect vessels
and piping against
excessive pressure
(positive or negative).
A typical arrangement of
RD + PSV is shown. Such
arrangements are utilized
when the process fluid is
corrosive and it would be
quite expensive to use PSV
(alloy steel) without the
aid of RD. But one can use
alloy steel RD with carbon
steel PSV. This makes the
system quite cheap.

quiz
Q. If a single safety valve is present only for fire, it is
permissible to set it at 110% of the MAWP . (T/F)
A. False. A single safety valve must be set no higher than
the MAWP. Only if it is a second valve for a fire
contingency may it be set at 105% of MAWP. And a third
valve can be set at 110% of MAWP.
Q. The highest allowable set pressure of any safety
valve is the maximum allowable working pressure of
the vessel being protected . (T/F)
A. False. Under certain conditions, such as multiple
valves, additional safety valves may be provided set at
pressures higher than the MAWP. However, at least one
must be set no higher than MAWP.
Q. The Design Pressure and the Maximum Allowable
Working Pressure of a vessel are the same. (T/F)
A. False. Design Pressure is a process design term that
specifies the minimum pressure to which the vessel must
be designed. The MAWP, on the other hand, is a
mechanical design term. It goes with the vessel, i.e, it is
the pressure on the vessel’s nameplate and stays with the
vessel no matter where the vessel is used. In practice, the
two are often the same, but not necessarily.
Q. An oversized safety valve can be vulnerable to the
phenomenon known as chatter. (T/F)
A. True.
Q. Safety valve chatter in liquid service is potentially
more serious than in vapor service. ( T/F)
A. True. Because of the liquid hammer effect.
Q. For operating contingencies, the API Code allows
the capacity of a single safety valve to be calculated at
110% of the MAWP. (T/F)
A. True.
Q. Under a fire contingency, the vessel is allowed to
reach a higher pressure than under an operating
contingency. (T/F)
A. True. It is allowed to reach 121% of MAWP.
Q. Accumulation means the same as blowdown. (T/F)
A. False.
Q. If there are two safety valves on a vessel, pressure
during discharge is allowed to reach 116% of the
MAWP. (T/F)
A. True, assuming the second valve is set at 105% of
MAWP as permitted by the code. With 10% accumulation,
maximum pressure becomes 110% of 105%, or (rounded)
116%.
Review of API 520 Part 1
This standard applies to the sizing and selection of
pressure relief devices used in refineries and related
industries for equipment that has a maximum allowable
working pressure of 15 psig (103 kPag) or greater. The
pressure relief devices covered in this standard are
intended to protect unfired pressure vessels and related
equipment against overpressure from operating and fire
contingencies.
This standard includes basic definitions and information
about the operational characteristics and applications of
various pressure relief devices. It also includes sizing
procedures and methods based on a steady-state flow of
Newtonian fluids. One can refer sizing equations for PSV
and RD sizing for gas (critical and subcritical), steam,
liquid (with/without capacity certifications) from API 520
Part 1.
API 520 Part 2, however, deals with the installation
procedure for the PSV and RD. It also provides the line
sizing criteria for the PSV inlet line, which is that the
pressure drop in the PSV inlet line should be less than 3%
of set pressure.
Review of API 521
This standard applies to pressure-relieving and vapor
depressuring systems. Although intended for use primarily
in oil refineries, it is also applicable to petrochemical
facilities, gas plants, liquefied natural gas (LNG)
facilities, and oil and gas production facilities. The
information provided is designed to aid in the selection of
the system that is most appropriate for the risks and
circumstances involved in various installations.
This standard specifies requirements and gives guidelines
for the following:
 examining the principal causes of overpressure;
determining individual relieving rates;
selecting and designing disposal systems,
including such parts as piping, vessels, flares,
and vent stacks.

Pressure rise calculations due to hydraulic expansion and

sizing calculations of TSV are provided in API 521.
Review of API 526
This standard is a purchase specification for flanged steel
pressure-relief valves. Basic requirements are given for
direct spring-loaded pressure-relief valves and pilot-
operated pressure-relief valves as follows:

orifice designation and area;

valve size and pressure rating, inlet and outlet;
materials;
pressure-temperature limits;
center-to-face dimensions, inlet, and outlet.
Table 13.3: Orifice designation
Designation Effective Orifice Area
(in 2 )
D 0.110
E 0.196
F 0.307
G 0.503
H 0.785
J 1.287
K 1.838
L 2.853
M 3.60
N 4.34
P 6.38
Q 11.05
R 16.00
T 26.00

Simulation
Let’s solve an example. In this
example, the following relief requirements are given:

required hydrocarbon vapor flow, W, caused by

an operational upset, of 50,000 lb/h;
the hydrocarbon vapor is a 50/50 (by mole)
mixture of n-butane and propane.
the molecular weight of the vapor,
relieving temperature, T, of 167 o F,
PRV set at 75 psig, which is the design pressure
of the equipment;
backpressure of 0 psig
overpressure of 10 %.

Figure 13.9: PSV

Find out PSV size using Aspen HYSYS.
Select components and fluid package. It may be noted that
mostly for oil and gas problems, Peng Robinson fluid
package is used. However, one can refer “Methods
Assistant” tool to finalize the same as well.
Figure 13.10: Components
Figure 13.11: Fluid package
It may also be checked if binary interaction parameters are available for the
given components in the selected fluid package. In this case,
Figure 13.12: BIP

Enter Simulation environment and model a material stream. Provide pressure

as 50 psig (normal operating pressure), temperature (167 o F), 50,000 lb/h
flow rate and composition 0.5-mole fraction each for n-Butane and Propane.
Figure 13.13: Material stream
Figure 13.14: Material stream
Next to enter “Safety Analysis” and “Add PSV” to the material stream “1”. It
can be done by hovering the mouse over stream “1” and dragging the PSV
out.
Figure 13.15: Safety analysis

Double click on PSV and provide operating/design temperature/pressure

values as per the problem statement. “Reference” means the values will be
referred from the converged simulation model and “Manual” means the
values can be typed.
Figure 13.16: Equipment
Select the “Scenario” tab. One can have several scenarios created. But in
this example, there is only one scenario, hence it will be ticked as “Sizing
Case”. Scenario type selected is “Blocked outlet”, as the relief scenario is
triggered by operational upset as per problem statement. Double click on
“Scenario Name” to “Open Scenario” window.
Figure 13.17: Scenario

“Select” appropriate material stream. Provide “Relieving Temperature”

using “Reference”. Relieving pressure shall be Set pressure + Accumulation.
In this case 75 psig + 7.5 psi = 82.5 psig. One can view it by clicking on
“Edit”. Total backpressure shall be 7.499 psig as super-imposed back
pressure (maybe PSV is open to atmosphere) and built-up backpressure
considered as 7.499 psi (< 10% of set pressure for conventional PSV).
From the Relieving Phase - Method drop-down list, you can select the
calculation method used for the relieving device section. The Relieving
Phase is determined based on a flash to the relief pressure and temperature.
You can select the orifice sizing method. The following options are
available:
Vapor: Used for vapor phase systems when the vapor compressibility factor
is preferably within the range of 0.8<Z<1.1. If used for a mixed-phase
system, the vapor phase properties will be used for the sizing calculation.
Capacity-Certified Liquid: Method used for liquid relief through a valve
with a certified liquid capacity. An assumption of incompressible liquid is
used. For saturated liquids, a mixed-method can be used. If used for a mixed-
phase system, the liquid phase properties will be used for the sizing
calculation.
Non-Capacity-Certified Liquid: Method used for liquid relief through a
valve not requiring capacity certification. Recommended for valves built for
older API standards or valves that are not certified for liquid relief but may
encounter scenarios in which they must pass an all-liquid stream.
Steam: Method used for steam relief calculations at critical flow conditions.
For steam at temperatures above 1200 o F, the vapor phase calculation
method should be used instead.
Direct Integration (HEM): Sizing by the direct integration of the isentropic
nozzle flow. General-purpose calculation method applicable to all single-
phase and mixed-phase systems, for example, vapor cases where Z<0.8. This
is the default sizing method for all cases. This is the recommended method
for mixed-phase or supercritical fluids.
Notes:
For Fire scenarios using the Supercritical calculation method, make sure that
the Direct Integration (HEM) method is selected.
For Fire scenarios using the Semi-Dynamic Flash calculation method, make
sure that the Vapor or Steam method is selected.
“Required Relieving Flow” can be set “Manually” or by “Reference”.
Aspen HYSYS will calculate orifice size as per API 520 Part 1. By clicking
“Select” it will choose appropriate Orifice size and inlet and outlet PSV
flange size as per API 526. In this case, PSV designation is 4P6, meaning
inlet flange size is 4”, outlet flange size is 6” and PSV is “P”. PSV discharge
coefficient value should be referred from the vendor catalog. However, in the
absence of the same, one can use preliminary values as 0.975 for vapor, 0.65
for liquid, and 0.85 for the two-phase system.
Figure 13.18: Scenario setup
Now let’s carry out line sizing of PSV inlet and outlet line. “Flow Rate
Method” shall be “Required”, as we want to keep the flow rate 50,000 lb/h.
Pipe schedule of “Standard” is considered for inlet and outlet pipes. Line
size is considered as 4” and 6” for inlet and outlet respectively. Material,
length, and elevation data are also provided as shown in the below figure.
Then click “Run Line Sizing”. Aspen HYSYS checks if selected inlet line
size is adequate w.r.to pressure drop criteria i.e. less than 3% of set
pressure. In this case, set pressure is 75 psig, 3% of 75 is 2.25 psi. The
calculated pressure drop in the inlet line is 0.7945 psi, hence selected inlet
pipe size of 4” is adequate. It is always recommended to use PSV inlet pipe
size equal or greater than PSV inlet flange size.
There are 2 checks carried out by HYSYS for the PSV outlet line (tailpipe).
First, it calculates built-up backpressure, in this case, the value is 0.4006 psi,
and then it compares with maximum allowable built-up backpressure. For
conventional PSV it is 10% of set pressure (7.5 psi, in this example). Since
the actual pressure drop is less than the allowable value, the selected
tailpipe size is adequate. Additionally, it checks the Mach number and
compares if the Mach number is less than 0.7 for tailpipe or not. Mach
number is the ratio of fluid velocity to the sound velocity in that fluid. In this
example, the fluid velocity is 334.9 ft/s and sound velocity is 791.7 ft/s. So
Mach number is 0.42. Since it is less than 0.7, the tailpipe size is adequately
selected in this example.
Figure 13.19: Line sizing
Let’s now simulate PSV sizing for the fire case. The vessel is horizontal
separator (3 ft diameter, 9 ft length), the liquid level is 2 ft. There is some
change in temperature (80 o F) inlet stream to the separator. This will make
the vapor phase to 2 phase fluid. Separator is insulated vessel.
Figure 13.20: Material stream

Enter “Safety Analysis”. Provide operating/design temperature/pressure as

per the below figure. Select the “Scenario” tab.
Figure 13.21: Safety analysis
Select the “Scenario” tab and “Create Scenario”. This time we will choose
the “Fire” scenario.
Figure 13.22: Scenario
Select the stream (should be the inlet stream to the
separator). Relieving pressure includes 21% overpressure
as it is a fire case. Provide vessel dimensions. As per API
521, F or environment factor is 1 for a bare vessel, for an
insulated vessel, F is 0.3, for earth-covered or mounded
vessel, F is 0.03. PSV size for the fire case calculated is
1.5F2.
Figure 13.23: Fire scenario

HYSYS calculates heat absorbed using the below

formula.
Q = C . F . Aws 0.82

Where;
Q is the total heat absorption (input) to the wetted surface,
expressed in W (Btu/h);
C is a constant [= 43,200 in SI units (21,000 in USC units)
when adequate drainage and firefighting Equipment exist];
[= 70,900 in SI units (34,500 in USC units) when
adequate drainage and firefighting Equipment do not
exist];
F is an environmental factor;
Aws is the total wetted surface, expressed in m2 (ft2 ).
The heat absorbed by the wetted surface shall be used to
increase the liquid temperature (sensible heat) and to
vaporize liquid (latent heat). Accordingly, the vapor load
is calculated by HYSYS. In this example, if sensible heat
is excluded (which is negligible anyway), Q calculated to
be 34500 x 0.3 x 73.40.82 = 350600 Btu/h. Latent heat of
vaporization is 141.6 Btu/lb. Hence vapor load will be
2476 lb/h. Once the vapor load is calculated, the same
formulae from API 520 Part 1 can be used for PSV sizing.
Thermal Relief Valve (TRV)
Equipment and piping that can be blocked in and can be
exposed to increased temperatures shall be protected
against overpressure. TRVs may be installed with
pocketed inlet and outlet lines where plugging and
freezing within the inlet or outlet lines cannot occur or are
prevented from occurring with tracing and insulation.
TRVs shall discharge back into the process, the storage
system, or a plant disposal system.
TRVs shall not discharge to an open drain unless the
following are met:

The discharged liquid cannot be accepted back

into the process, storage, or plant disposal
system.
Any contained light hydrocarbon discharge is at a
location where it will safely disperse.
Stream does not contain any fluids defined as
very toxic substances.

Identified liquid thermal expansion overpressure

scenarios shall be mitigated with a pressure relief valve
with an orifice area no smaller than a D. These D sized
liquid relief valves are referred to as Thermal Expansion
Relief Valves (TRVs). If the liquid thermal expansion
application is caused by heat gain from the environment,
then relief load calculations and device sizing calculations
are not required. The relief rate due to heat input is
expected to be no larger than the rated flow of a nominally
sized relief valve.
If the liquid thermal expansion application is caused by
heat gain from heat tracing/jacketing, or the process, then
the liquid thermal expansion relief load shall be
calculated using the design duty of the equipment or heat
gain from chemical reactions and the relief device sized.
The relief device to mitigate liquid thermal relief should
be located close to the process. The relief device does not
need to be located at the highest point in the system.
Liquid thermal expansion overpressure protection shall be
provided for piping that can be blocked in and contains
more than 500 L (132 gals) of LPG or acute toxic liquids.
Per ASME B31.3, TRVs that protect only piping and
piping components may be set at 120 % of the piping
system design pressure. Depending on the design concept
of a project (particularly about its required expandability,
operability, and maintainability) may specify a lower
allowable setpoint, e.g. 110 %.
Exercises

a. Mr. Aravinth is trying to size a PSV for the

following scenario;
blocked outlet case,
50,000 kg/h flow rate,
hydrocarbon vapor is a 50/50 (by
mass) mixture of n-butane and
propane,
relieving temperature, T, of 90 o C,
design pressure of the equipment is
5 barg,
backpressure of 0 psig
single PSV
Can you help him get the adequate PSV? Also, find
out PSV inlet and outlet line sizes.

b. Mr. Pranit is trying to size PSVs for the following

scenario;
blocked outlet case,
50,000 kg/h flow rate,
hydrocarbon vapor is a 50/50 (by
mass) mixture of n-butane and
propane,
relieving temperature, T, of 90 o C,
design pressure of the equipment is
5 barg,
backpressure of 0 psig
2 PSVs
Can you help him get the adequate PSV? Also, find
out PSV inlet and outlet line sizes.
c. Mr. Omkar is trying to size a PSV for the
following scenario;
fire case,
hydrocarbon vapor is a 50/50 (by
mass) mixture of n-butane and
propane,
separator size is 20 m3 ,
design pressure of the equipment is
5 barg,
backpressure of 0 psig
single PSV
Can you help him get the adequate PSV? Also, find
out PSV inlet and outlet line sizes.

d. Ms. Genevieve is trying to size a PSV for the

following scenario;
Fire case,
operating temperature 10 o C,
hydrocarbon mixture of n-butane
and propane with 5% vapor content
(select operating pressure
accordingly),
separator size is 20 m3 ,
design pressure of the equipment is
5 barg,
backpressure of 0 psig
single PSV
Can you help her get the adequate PSV? Also, find
out PSV inlet and outlet line sizes.
e. Mr. Sanchit is trying to size a PSV for the
following scenario;
Fire case,
operating temperature 10 o C,
hydrocarbon mixture of n-butane
and propane with 5% vapor content
(select operating pressure
accordingly),
separator size is 200 m3 ,
design pressure of the equipment is
5 barg,
backpressure of 0 psig
single PSV
Can you help him get the adequate PSV? Also, find
out PSV inlet and outlet line sizes.

f. Mr. Vivek is trying to size a rupture disk for the

following scenario;
Blocked outlet case,
50,000 kg/h flow rate,
hydrocarbon vapor is a 50/50 (by
mass) mixture of n-butane and
propane,
relieving temperature, T, of 90 o C,
design pressure of the equipment is
5 barg,
backpressure of 0 psig
Can you help him get the adequate rupture disk size?
g. Mr. Ashutosh is trying to size a TRV for the
following scenario;
cross country (Qatar to Saudi
Arabia) uninsulated pipeline,
Above ground pipeline (6", Sch.
40, 1000 m)
Fluid is Benzene,
Initial pressure 2 barg,
design pressure of the pipe 10 barg,
Can you help him get the adequate TRV size? Also,
find out TRV inlet and outlet line sizes.
CHAPTER 14: PROCESS PLANT
DESIGN USING ASPEN HYSYS
Process plant design is the combination of theoretical aspects and practical or
experience-based aspects.
A process engineer must be able to consider appropriate numbers using the available
standards and experience on similar projects.
Maximum design pressure
Below table will come handy to arrive at design pressure value of pressurized system;
Table 14.1: Design pressure guideline
Maximum operating pressure, Design pressure, barg
barg
0 to 35 Maximum operating pressure + 3.5 bar
35 to 70 Maximum operating pressure + 10%
70 to 200 Maximum operating pressure + 8.5%, but between (7 to
10 bar)
200 + Maximum operating pressure + 5%
Figure 14.1: Pressure terms
Atmospheric tanks shall as a minimum be designed to be
liquid filled to the highest point of the overflow line and
with an overpressure of 0.07 bar.
For flare knock out drums, it is acceptable that the design
pressure is equal to the maximum operating pressure.
Minimum design pressure
For equipment where cooling or condensing vapors,
drainage or pump out may lead to less than atmospheric
pressure, the equipment shall be designed for full vacuum
or protected by vacuum relief.
Maximum design temperature
Where the maximum operating temperature can be
determined accurately, this temperature should be used as
maximum design temperature, without adding a safety
margin.
Where the maximum operating temperature cannot be
calculated accurately, the maximum design temperature
should be determined by adding 30 o C to the normal
operating temperature.
Minimum design temperature
The minimum design temperature determines the
requirements to the low-temperature characteristics of the
material, and shall be the most stringent of the following:

minimum operating temperature with a margin of

5 o C.
minimum ambient temperature
minimum temperature occurring during
depressurizing with a margin of 5 C
o

Line sizing criteria

Line sizing is carried out mainly w.r.to velocity criteria.

Centrifugal pump suction line typical velocity is

1 m/s and discharge velocity is 2.7 m/s.
 Pressurized gas velocity should be comfortably
less than 18 m/s.
Gravity line velocity is kept around 1 m/s.
Two-phase line sizing is carried out keeping fluid
velocity comfortably less than erosion velocity.
PSV inlet line pressure drop should be less than
3% of set pressure.
PSV tailpipe or Depressurization line Mach
number should not exceed 0.7.
Flare header Mach number should be less than
0.5.
Pressure drop in vent line for atmospheric tank
should be less than 0.07 bar.

Separator sizing
Oil retention time shall depend on o API of oil as per API
12J. If o API is more than 35, then retention time can be
considered as 1 minute. If it is between 20 to 30 o API, the
retention time may be taken as 1 to 2 minutes and if o API
is less than 20, then retention time may be considered as 2
to 4 minutes.
For mixed-phase feed with less vapor content, horizontal
separator may be suggested and vice versa.
Typical L/D ratio for horizontal separator is 2.5 to 5 and
H/D ratio for vertical separator is 2 to 4.
Atmospheric tank design
For atmospheric tanks containing flammable liquids, the
purge/blanketing gas flow rate shall be at least 5% higher
than maximum pumping capacity.
In some cases, flame arrestors are recommended for use
on atmospheric tanks. The use of a flame arrestor within
the tank’s relief path introduces the risk of overpressure
due to the flame arrestor clogging/fouling. Flame arrestors
shall be located for easy access and included in a rigorous
maintenance program. Continuous monitoring of
differential pressure across the flame arrestor is advised
if the process fluid is known to contain particulates or
substances which may block the flame arrestor. The
materials in the vent pipe should be corrosion resistant to
reduce the risk of plugging the flame arrestor.

Heat exchanger design

For all heat exchangers, both sides shall have the same
maximum design temperature determined by the hottest of
the fluids on either side.
The maximum continuous duty will determine the heat
exchanger area.
Fouling or extra heat exchanger area should be added as a
design margin.
Operational drain, vent and flushing requirements
All equipment and piping shall be provided with high
point vents and low point drains within isolation valves
isolating equipment or process sections. All such vents
and drains shall be fitted with a valve and blind flange.
For piping and headers, low point drain and high point
vent shall, in general, be provided.
Steam-out and utility connections shall be provided and
located to ensure efficient flushing and cleaning required
for inspection and maintenance.
Where provisions are made for chemical cleaning of heat
exchangers with the tube bundle in place, blind flange
connections shall be provided for chemical hose
attachments. The connections shall be minimum DN 80 (3
in), but not exceeding line size, and shall be located
between the exchanger nozzles and the block valves.
Plant design problem
So far, we have simulated control valve, PSV, line,
orifice, separator, and pump. We are now going to use this
skill to design a real plant.
Simulation
Problem statement is given below;
We need to design a separation system to separate gas
from oil in a 2 phase fluid, that is available at 40 o C, 4.5
barg pressure, and 20000 kg/h. Mole fraction of feed is
provided in the below table.
Table 14.2: Feed composition
Mole
Component
fraction
Methane 0.02
Ethane 0.04
Propane 0.04
i-Butane 0.10
n-Butane 0.10
n-Octane 0.40
n-Decane 0.30
The gaseous product shall be connected to the existing LP
flare header at 1 barg pressure. Oil shall be sent to the
existing header at 60 o C and 5.5 barg pressure. RVP of the
oil shall be less than 0.025 barg.
Figure 14.2: Schematic of problem

The black box signifies all the unit

operations/calculations/sizing that is needed to achieve
the project objectives.
What does the black box contain?

Separator sizing
Heater sizing
Pump sizing
 Line sizing
LCV sizing
PCV sizing
FCV sizing
Flow orifice sizing
PSV sizing

Let’s simulate.
First, get the components added and the fluid package
selected shall be Peng Robinson.
The feed stream is converged.
Figure 14.3: Material stream

Place all the equipment in order.

Figure 14.4: Process scheme
Connect all the equipment in order.
Figure 14.5: Process scheme
Provide all the available process parameters and get the model converged.
Figure 14.6: Process flowsheet
Let’s also add an ON/OFF valve and a pipe segment upstream of FCV.
Figure 14.7: Process scheme
Is this the best design possible?

Heater duty = 697 kW

Cooler duty = 307 kW

Can we optimize this design?

Remove the cooler and add a pre-heater (heat exchanger)
downstream of FCV. Feed shall be pre-heated first by hot
oil from separator before entering the heater.
Figure 14.8: Process scheme

Feed shall the shell side fluid and hot oil shall be the tube
side fluid in the pre-heater. Pressure drop across pre-
heater (E-100) and Heater is considered at 0.5 bar each.
Figure 14.9: Process scheme
Revised heat duty is given below;

Heater duty = 390 kW (from 697 kW, 40%

savings)
Cooler duty = 0 kW (from 307 kW, 100%
savings)

Let’s design.
Separator sizing (as per standard API 12J)
Figure 14.10: Separator sizing

Figure 14.11: Separator sizing

Figure 14.12: Separator sizing

Orientation = Vertical is selected because

the feed has more of vapors.
Diameter = 2.5 ft
Height = 10 ft (T/T)
Liquid % level = 35%

Heat Exchanger (E-100) sizing using Aspen EDR

Figure 14.13: Heat exchanger sizing
Figure 14.14: Heat exchanger sizing
Figure 14.15: Heat exchanger sizing
Figure 14.16: Heat exchanger sizing
Figure 14.17: Heat exchanger sizing
Figure 14.18: Heat exchanger sizing
Results

HTA = 28 m2
No. of tubes = 86
No. of passes = 4
Tube length = 5000 mm
Shell ID = 307 mm
UD = 622 W/m2 .K
Pump sizing
Figure 14.19: Pump sizing
Figure 14.20: Pump sizing

Figure 14.21: Pump sizing

Results

Pump duty flow = 29 m3 /h

Pump head = 87 mlc
 NPSHA = 0.05 m
Shaft power = 5.9 kW

Line sizing as per API 14E

Two phase line size = 80 mm (v << Ve

m/s)

Figure 14.22: Line sizing

Figure 14.23: Line sizing

Pump suction line size = 100 mm (v
~ 1 m/s)
Figure 14.24: Line sizing

Figure 14.25: Line sizing

Pump discharge line size = 80 mm (v ~ 2.7

m/s)
Figure 14.26: Line sizing

Figure 14.27: Line sizing

Vapor line size = 100 mm (v < 18

m/s)
Figure 14.28: Line sizing

Figure 14.29: Line sizing

LCV sizing as per ISA 75.01.01
Figure 14.30: Control valve sizing

Figure 14.31: Control valve sizing

Valve opening = 80%

Pressure drop = 1 bar
 Cv = 34
Valve size = 2” (Rule of thumb: Cv = 10
d2 )

PCV sizing as per ISA 75.01.01

Figure 14.32: Control valve sizing
 Valve opening = 80%
Pressure drop = 1.5 bar
Cv = 48
Valve size = 2” (Rule of thumb: Cv = 10
d2 )

FCV sizing as per ISA 75.01.01

Valve opening = 80%

Pressure drop = 1 bar
Cv = 58
Valve size = 2.5” (Rule of thumb: Cv = 10
d2 )

Flow orifice sizing as per ISO 5167-2

Select the “Rating” tab and provide the “Discharge
Coefficient” as 0.6.
Figure 14.33: Orifice sizing

Pressure drop = 0.5 bar

Orifice area = 1065 mm2
 Orifice diameter (d) = 37 mm
Pipe ID (D) = 78 mm
ꞵ ratio (d / D) = 0.47 ( 0.1 <
ꞵ < 0.75)

PSV sizing as per API 520 Part 1 and API 526

Select “Safety Analysis” environment. “Add PSV” at the
Separator top.
Figure 14.34: PSV sizing
Maximum operating pressure as per process is considered as 3.5 barg
(normal operating pressure is 2.5 barg). Maximum operating pressure + 3.5
bar = 7 barg, this will be considered as process design pressure of separator.
The same will be taken as PSV set pressure.
The normal operating temperature is 85 o C. 30 o C is added to 85 o C and
120 o C is considered as design temperature.
Figure 14.35: PSV sizing

Figure 14.36: PSV sizing

Figure 14.37: PSV sizing
Figure 14.38: PSV sizing
Figure 14.39: PSV sizing
 Set pressure = 6.5 barg
PSV size = 1.5G3
Inlet line size = 1.5”
Outlet line size = 3”

Exercises

a. Mr. Vishal needs to design a separation system to

separate gas from oil in a 2 phase fluid, that is
available at 40 o C, 4.5 barg pressure, and 30000
kg/h. Mole fraction of feed is provided below;

Methane : 0.04

Ethane : 0.02

Propane : 0.04

i-Butane : 0.15

n-Butane : 0.05

n-Octane : 0.40

n-Decane : 0.30

The gaseous product shall be connected to the

existing LP flare header at 1.5 barg pressure. Oil
shall be sent to the existing header at 50 o C and 4.5
barg pressure. RVP of the oil shall be min. 0.045
barg.
Please help Mr. Vishal to carry out the plant design.
Also, prepare BOQ and provide an approximate cost
estimate as well.
b. Mr. Rana needs to design a separation system to
separate gas from oil in a 2 phase fluid, that is
available at 40 o C, 4.5 barg pressure, and 90000
kg/h. Mole fraction of feed is provided below;

Methane : 0.04

Ethane : 0.02

Propane : 0.04

i-Butane : 0.15

n-Butane : 0.05

n-Octane : 0.40

n-Decane : 0.30

The gaseous product shall be connected to the

existing LP flare header at 1.5 barg pressure. Oil
shall be sent to the existing header at 25 o C and 4.5
barg pressure. RVP of the oil shall be min. 0.045
barg.
Please help Mr. Rana to carry out the plant design.
Also, prepare BOQ and provide an approximate cost
estimate as well.
CHAPTER 15: ASPEN HYSYS
DYNAMICS (SIMPLE PROBLEM)
In this chapter, we are going to discuss the dynamic
modeling of two-phase separator, which includes
modeling of the material stream, separator, valves, and
PID block. Also, one will be able to manipulate the
variables and check the dynamic response.
Once you have completed this module, you will be able
to:

Simulate valve in dynamic mode.

Simulate vessel in dynamic mode.
Simulate controller in dynamic mode.
Study the dynamic behavior of the model.
Prepare Cause and Effect Matrix
Please refer HYSYS model snapshot below;
A two-phase feed stream is sent to the separator.

SDV-1 acts as an emergency shutdown valve. A

negligible pressure drop of 5 kPa is to be
considered for the same.
FCV- controls the mass flow rate of the feed
stream. The pressure drop of 150 kPa is to be
considered for the same.
Separator separates vapor and liquid streams.
PCV- controls the separator pressure.
LCV- controls the separator level.
Vapor stream tie-in point pressure is 1.5 barg and
that of liquid stream is 2 barg.
Use Peng Robinson as a fluid package.
Figure 15.1: Steady-state model
Add components and fluid package.
Prepare the model as shown below.
Figure 15.2: Steady-state model

Select dynamic specifications as shown below; Flow rate is calculated w.r.to

pressure differential.
Figure 15.3: Dynamic specifications
Figure 15.4: Dynamic specifications
Figure 15.5: Dynamic specifications
Provide FIC-1, PIC-1, and LIC-1.
Figure 15.6: PID controller

Figure 15.7: PID controller

Provide details for FIC-1.
Figure 15.8: FIC

PID algorithm consists of three basic coefficients; proportional, integral, and

derivative which are varied to get an optimal response. Before the working
of the PID controller takes place, it should be tuned to suit with dynamics of
the process to be controlled. Designers give the default values for P, I, and D
terms, and these values couldn’t give the desired performance and sometimes
leads to instability and slow control performances.
Term P (Kc) is proportional to the current value of the SP − PV error. A high
proportional gain results in a large change in the output for a given change in
the error. If the proportional gain is too high, the system can become unstable.
In contrast, a small gain results in a small output response to a large input
error, and a less responsive or less sensitive controller.
Term I (Ti) accounts for past values of the SP − PV error and integrates them
overtime to produce the I term. The integral term accelerates the movement
of the process towards set-point and eliminates the residual steady-state
error that occurs with a pure proportional controller. However, since the
integral term responds to accumulated errors from the past, It can cause the
present value to overshoot the set-point value.
Term D (Td) is the best estimate of the future trend of the SP − PV error,
based on its current rate of change. Derivative action predicts system
behavior and thus improves the settling time and stability of the system.
Table 15.1: Effect of increasing parameter independently
Param Rise time Overshoot Settling Steady- Stability
time state error
Kc Decrease Increase Minor Decrease Degrade
change
Ti Decrease Increase Increase Eliminate Degrade
Td Minor Decrease Decrease No effect Improve
change

Use the below table to select tuning parameters.

Table 15.2: Tuning parameters
Control type Gain Integral Derivate
time time (min.)
(min.)
Flow 0.4 – 0.65 0.05 – –
(0.5 ) 0.25 (0.15
)
Level 2 – 20 1 – 5 (3 ) –
(10 )
Pressure 2 – 10 (5 2 – 10 (5 ) –
)
Temperature 2 – 10 (5 2 – 10 (5 ) 0 – 5 (0 )
)

Figure 15.9: FIC

Provide details for PIC-1.
Figure 15.10: PIC

Figure 15.11: PIC

Provide details for LIC-1.
Figure 15.12: LIC

Figure 15.13: LIC

It is not possible to analyze the performance of a dynamic system without
plotting different parameters w.r.to time. So we will provide a Strip chart for
FIC-1.
Figure 15.14: Strip chart

Figure 15.15: Strip chart

Provide a Strip chart for PIC-1.

Figure 15.16: Strip chart
Provide Strip chart for LIC-1.
Figure 15.17: Strip chart
Provide Strip chart as shown below;
Figure 15.18: Strip chart
Click Dynamics\Dynamics Mode
Figure 15.19: Dynamics

Click Dynamics\Integrator
Start the simulation for 120 minutes. This is to check, how much time it takes
to fill in the separator (14 m3 * 60% = 8.4 m3 ), when liquid in-flow is 5.4 m3
/h.
Figure 15.20: Integrator 1
Refer below the plot (blue curve). It shows the separator level from 0% to
60%. It takes around 95 minutes to fill the separator to a 60% level.
Figure 15.21: Strip chart
Similarly, refer below the plot for the FCV-1 valve opening (red curve) and
FCV-1 flow rate. Valve opening is around 64%, which means the considered
valve Cv and type is adequate.
Figure 15.22: Strip chart

Similarly, refer below the plot for the PCV-1 valve opening (red curve) and
PCV-1 flow rate. Valve opening is around 43%, which means the considered
valve Cv and type is adequate.
Figure 15.23: Strip chart
Let’s try to simulate a case, where the pressure at inlet stream increases from
5 barg to 15 barg for 1 min and comes back to normal condition (5 barg)
afterward.
Figure 15.24: Integrator

Figure 15.25: Material stream

Run the integrator for 1 minute. Change the inlet stream pressure back to 5
barg.
Run the integrator for 360 minutes.
Figure 15.26: Material stream

Figure 15.27: Integrator

As expected, FCV-1 shall get throttled to maintain the set flow rate.
Figure 15.28: Strip chart

There doesn’t seem to be much impact on PIC-1 or LIC-1 functioning as

well.
Figure 15.29: Strip chart
Figure 15.30: Strip chart
Let’s prepare a cause and effect matrix. When LIC-1 goes High, then it
should give an alarm. And when LIC-1 goes High High, then it should give an
alarm, and SDV-1 shall close.
Figure 15.31: Digital control point

Figure 15.32: Digital control point

Figure 15.33: Digital control point

A cause and effect diagram examines why may happen by organizing
potential causes into smaller categories. It can also be useful for showing
relationships between contributing factors. It is often referred to as a
fishbone diagram or Ishikawa diagram.
Let’s add the Cause & Effect Matrix for our system. Select “Cause-and-
Effect Matrix” available in Model Palette.
Figure 15.34: Cause & effect matrix
Double-clicking on CEM-1 shall open a window.
Figure 15.35: Cause & effect matrix

“Add Input” in “Input (Cause) Variables” and “Add Output” in “Output

(Effect) Variables” as shown below.
Figure 15.36: Cause & effect matrix

Separator level Alarm will sound at 70% level and Effect (SDV-1 closure)
will initiate at 80% level. In this case “High” checkbox is checked, as trip
happens at High High condition. If there was any trip action for Low Low
condition, then this box would be kept unchecked.
Figure 15.37: Cause & effect matrix

Figure 15.38: Cause & effect matrix

There may be several different Causes and their Effects on the plant.
Whatever relevant Causes and Effects shall be marked “X” as shown below.
Figure 15.39: Cause & effect matrix

Add SDV-1 valve opening parameter in the FCV plot.

Figure 15.40: Cause & effect matrix

Let’s increase the FIC-1 set point from 4000 kg/h to 8500 kg/h. It shall
increase the separator level. Change Kc of FIC-1 to 0.2.
Figure 15.41: FIC

Increase integrator end time to 1000 minutes.

Figure 15.42: Integrator

Start the Integrator.

Soon flow rate increases to 8500 kg/h. LIC-1 and PIC-1 OP reaches to
100%, as LCV-1 and PCV-1 CVs are not adequate for this high flow rate.
Separator level starts to increase.
Figure 15.43: Model analysis
C&E Matrix shows Alarm (yellow bar), when the separator level reaches
70% (High Alarm).
Figure 15.44: Model analysis
Further running of the integrator shall result in separator level rise exceeding
80% and closure of SDV-1. This results in mass flow rate dropping to zero.
Figure 15.45: Model analysis
CHAPTER 16: ASPEN HYSYS
DYNAMICS (PROJECT PROBLEM)
We have already designed a typical oil and gas separation facility in chapter
12.
In this chapter, we are going to convert that steady-state model into a
dynamic model.
Figure 16.1: Model

Make sure the Aspen HYSYS model is converged.

Boundary conditions specifications must be pressure active only.
Figure 16.2: Dynamic specification
Provide elevation of FCV & XV-01 and make sure that “Pressure Flow
Relation” is checked. As per line sizing done in steady-state, provide the
same pipe diameters in the “Rating\Nozzles\Nozzle Parameters” tab.
Figure 16.3: FCV

Figure 16.4: FCV

Figure 16.5: XV-1
Provide elevation and pipe diameters for the pre-heater (E-100).
Figure 16.6: Heat exchanger
Tube volume and shell volume are provided (it will be available in EDR
output) along with other details as given below.
Figure 16.7: Heat exchanger
Provide elevation and pipe diameters for heater (E-100).
Figure 16.8: Heater
For assigned pressure drop value, “Overall k” will be calculated by HYSYS
after clicking “Calculate k”. This enables HYSYS to calculate pressure drop
at different flow rates through the heater using the “Overall k” value.
Figure 16.9: Heater

Provide separator dimensions and elevation.

Figure 16.10: Separator

Figure 16.11: Separator
Provide PCV elevation and pipe in/out diameter.
Figure 16.12: PCV

Figure 16.13: PCV

Provide pump elevation, in/out pipe diameter and pump curve data.
Figure 16.14: Pump

Figure 16.15: Pump

Figure 16.16: Pump

Figure 16.17: Pump

Figure 16.18: Pump
Delete the pump efficiency and pump discharge pressure.
Figure 16.19: Pump

Figure 16.20: Pump

Figure 16.21: Pump

Figure 16.22: Pump

Provide flow orifice elevation and set pressure & full open pressure value as
0 barg.
Figure 16.23: Orifice

Figure 16.24: Orifice

Provide LCV elevation and pipe in/outsize.
Figure 16.25: LCV

Figure 16.26: LCV

Provide FIC-1, TIC-1, LIC-1, and PIC-1.
Figure 16.27: Controllers

Figure 16.28: FIC

There is a set of preliminary tuning parameters suggested. The same shall be
used in this example.
Figure 16.29: Tuning parameters
FIC-1 details are provided as below;
Figure 16.30: FIC

Strip charts are mandatory in dynamic simulation to analyze the model

performance.
Select “Strip chart” and “Create Strip chart”.
Figure 16.31: Strip chart
Uncheck the “SP” box and click on the “Display” tab.
Figure 16.32: Strip chart
Right-click on the plot and select “Graph Control”.
Figure 16.33: Strip chart
Figure 16.34: Strip chart

Figure 16.35: Strip chart

Figure 16.36: TIC

Figure 16.37: TIC
Figure 16.38: TIC

Figure 16.39: TIC

Figure 16.40: PIC
Figure 16.41: PIC
Figure 16.42: PIC
Figure 16.43: LIC
Figure 16.44: LIC

Provide the strip charts.

Figure 16.45: Strip chart
Figure 16.46: Strip chart

Increase the “Logger Size” to 5000.

Figure 16.47: Strip chart
Arrange all the 4 plots and the model as shown below.
Figure 16.48: Strip chart

Now we are ready to convert from steady-state to dynamic mode. Click on

“Dynamics Mode”. If there are some issues in the model that needs attention,
then it shall be pointed out by “Dynamics Assistant”.
Figure 16.49: Strip chart
The suggested remedies will be listed by “Dynamics Assistant”. One can
check each item and make changes, if needed, or click directly on “Make
Changes” so that “Dynamics Assistant” makes changes for you in the model.
Figure 16.50: Dynamic assistant

Figure 16.51: Dynamic assistant

Click “Dynamics Mode” to enter Dynamics mode.
Figure 16.52: Dynamic mode

Click on “Integrator”.
Figure 16.53: Integrator
We can assign run duration, speed, and Calculation step size in “Integrator”.
Figure 16.54: Integrator

Check “Enable static head contributions” in the “Integrator\Options\General

Options” tab.
Figure 16.55: Integrator
Run the model for 10 minutes and analyze the results.
Figure 16.56: Model analysis

The Transfer Function block is a logical operation that takes a specified

input, and applies the chosen transfer function to produce an output. A typical
use of the Transfer Function is to apply disturbances to a process, such as
varying the temperature of a feed stream.
Insert “Transfer Function Block” from the model palette.
Figure 16.57: Transfer function block
We will keep changing 2 Phase feed stream temperature between 20 o C to 60
o
C using “Transfer Function Block” (TRF-1).
Figure 16.58: Transfer function block
“PV” is a process variable (and the present value is 40 o
C). PV and OP
ranges will be kept as 20 o C to 60 o C.
Figure 16.59: Transfer function block

OP span is (45 – 35 = ) 10 o C. Amplitude (% of OP span) is 50% or 5 o C.

The total period is considered as 24 hours (1440 minutes) in the simulation,
meaning in 24 hours duration stream temperature will reach as high as 45 o C
or as low as 35 o C. “Active Transfer Functions” selected is “2nd Order” and
“2nd order Functionality Selection” is “Sine Wave Generator”.
Figure 16.60: Transfer function block
Provide a strip chart for “TRF-1” as well. The sample size for this strip
chart will be the same as the other 4 plots.
Figure 16.61: Transfer function block
Open “Integrator” and make changes as below.
Figure 16.62: Integrator
The temperature fluctuation is 24 hours for 2 Phase Feed stream is given in
the below plot. And also, the impact of the same on the other 4 controllers
are provided.
Figure 16.63: Model analysis
CHAPTER 17: TYPICAL INTERVIEW
QUESTIONS
The following are the most commonly asked technical
questions for a process engineering interview. The reader
is expected to write down all the answers for the same.

1. Please introduce yourself.

2. What is your present job profile?
3. Why do you want to switch jobs?
4. Why do you think this company (where you
have applied) is better suited for your career
goals?
5. What is your favorite topic in chemical
engineering? Why?
6. Have you designed a process plant before?
7. How good are you with MS excel?
8. How to carry out heat exchanger sizing?
9. What do you mean by pump hydraulic power?
10. What is NPSHavailable ?
11. Explain control valve sizing procedure.
12. What is cavitation in control valves?
13. What are the different standards used in the
process industry?
14. What are the different types of PSVs?
15. Explain Table 1 of API 520 Part 1.
16. Explain different line sizing criteria.
17. What is the L/D ratio of horizontal separator?
18. What are the different selection criteria for
separators?
19. What are the different constraints for orifice
sizing?
20. What do you mean by valve Cv?
21. What is meant by Critical Pressure and Critical
Temperature?
22. Why is reduced trim required in control
valves?
23. What are the different line sizing criteria?
24. Explain pump sizing steps with an example.
25. Explain control valve sizing steps with an
example.
26. What are the control valve flow
characteristics?
27. What is temperature cross in the heat
exchanger?
28. What are the different process standards used
in the industry?
29. Explain pressure safety valve sizing steps with
an example.
30. Why is typically TRV size D?
31. Explain orifice sizing steps with an example.
32. What is the compressor settle out pressure?
33. What do you mean by compressor surge?
34. Explain blow down criteria.
35. Explain the functioning of the cooling tower.
36. What are the different types of agitators?
37. Explain heat exchanger sizing steps with an
example.
38. How is the reactor size decided?
39. Explain Heat Exchanger control and Interlock
and Control Philosophy related to Fired
Heater? (Toyo Engineering)
40. Explain Feedback and Cascade Control? Draw
Feedback and Cascade Control Loop? (Toyo
Engineering).
41. Why Line Sizing is important? How Line
Sizing will be carried out? (Toyo Engineering)
42. Velocity guidelines for Liquid, Gas, Steam and
vacuum applications? (Toyo Engineering)
43. What is Schedule no. in Line Size? What
significance it has in line sizing? (Toyo
 Engineering)
44. What factors affect pressure drop? (Toyo
Engineering)
45. How to calculate Heat Duty of Heat
Exchanger? (Toyo Engineering)
46. Show P&ID representation of the vessel where
the control valve is controlling the level of the
vessel? (Toyo Engineering)
47. What is PSV? Criteria for sizing Inlet line of
PSV? (Toyo Engineering)
48. Criteria for sizing tailpipe of PSV and Flare
Header? (Toyo Engineering)
49. If Backpressure is <10%, which PSV shall be
used? (Toyo Engineering)
50. Draw Centrifugal and Positive Displacement
Head, Power, and Efficiency curves? (Toyo
Engineering)
51. What is the best efficiency point of the pump?
(Toyo Engineering)
52. Explain Heat Exchanger control and Interlock
and Control Philosophy related to Fired
Heater? (Toyo Engineering)
53. Explain in Detail Control Philosophy and
Interlock Philosophy of Fired Heater? Draw
entire P&ID for the same? (Toyo Engineering)
54. Explain IBR PSV? Which Code to be applied
for PSV related to IBR Pressure Vessel? (Toyo
Engineering)
55. What are the criteria to size PSV? (Toyo
Engineering)
56. What is the Overpressure? (Toyo Engineering)
57. Why Set pressure of PSVs are kept different?
(Toyo Engineering)
58. Draw P&ID of Fired Heater in detail and
explain each Interlock and explain control
philosophy in brief? (Jacobs India)
59. What role does DCS and PLC play? Which are
the symbols and how to represent in P&ID?
(Jacobs India)
60. How do you calculate Heat Duty of Heat
Exchanger? (Jacobs India)
61. What is NPSH required and cavitation?
(Jacobs India)
62. How to prevent cavitation in pumps? (Jacobs
India)
63. How do you calculate NPSH? (Jacobs India)
64. How to calculate the power of a pump?
(Jacobs India)
65. How do you calculate Line size and pressure
drop? (Jacobs India)
66. Which formula is used to calculate Pressure
drop? (Jacobs India)
67. How friction factor will affect pressure drop?
(Jacobs India)
68. What is roughness and does it change with the
MOC of pipe? If roughness is more, will pipe
pressure drop be more? (Jacobs India)
69. What is PSV? What is the overpressure
considered for the Fire case scenario? (Jacobs
India)
70. What are the different types of PSV? (Linde
India)
71. Blocked case or Fire case – which PSV is
bigger? (Linde India)
72. What are the different codes used in PSV?
(Linde India)
73. What is the pump shut off pressure? (Linde
India)
74. What is the formula for shut off pressure?
(Linde India)
75. What is depressurizing utility and the rule for
depressurizing? (Linde India)
76. What are the line size criteria for PSV tailpipe
& flare header? (Linde India)
77. What is the line sizing criteria for the
blowdown line? (Linde India)
78. What are the line sizing criteria for pump
suction & discharge line? (KBR India)
79. Discuss instrumentation and valves for area
around centrifugal pump. (KBR India)
80. Discuss Hazen Williams formula? (KBR India)
81. Is PSV set pressure and pop up pressure the
same? (KBR India)
82. Explain the refrigeration cycle. (KBR India)
83. What is the maximum velocity for the vapor
line before and after the compressor? (KBR
India)
84. What are the effects of the pump operating
away from BEP?
85. What is Bernoulli’s principle?
86. What is meant by the pipe schedule?
87. What is meant by the pump shut off head?
88. Explain the Froude number.
89. Write Mach number ranges for different types
of flow.
90. Is control valve is an on-off valve? (LoneStar
Technology)
91. What is a check valve? (LoneStar Technology)
92. What are the different types of valves?
(LoneStar Technology)
93. What are the input parameters inline sizing?
(LoneStar Technology)
94. How Orifice will work? (LoneStar
Technology)
95. Where the pressure levels are high at the
Orifice Upstream or the downstream?
(LoneStar Technology)
96. What are the input parameters in pump sizing?
(LoneStar Technology)
97. Why suction pressure has to be higher than the
flowing liquid vapor pressure? (LoneStar
Technology)
98. What is cavitation? (LoneStar Technology)
99. How can cavitation be eliminated? (LoneStar
Technology)
100. How many types of flow are there in the Heat
exchanger? (LoneStar Technology)
101. What is energy balance? (LoneStar
Technology)
102. On what principle distillation column work?
(LoneStar Technology)
103. What are the different outputs of the crude
distillation? (LoneStar Technology)
104. What is chromatography? (LoneStar
Technology)
105. What is PFD? (LoneStar Technology)
106. What are the differences between PFD and
P&ID? (LoneStar Technology)
107. What are the instruments you can provide in the
P&ID? (LoneStar Technology)
108. What is the purpose of the cause and effect
matrix? (LoneStar Technology)
109. What is FEED? (LoneStar Technology)
110. What is the role of process engineer?
111. What are the various unit operations used in
process industries?
112. What is the purpose of PFD?
113. List out the differences between PFD and
P&ID.
114. What is the difference between Cv and Kv?
115. Define compressible flow and incompressible
flow?
116. Define choked flow and non-choked flow?
117. What is Reynolds Number?
118. What are the input parameters required to size
the control valve?
119. Describe pressure drop criteria in the selection
of Control valve?
120. What is the objective of pressure safety valve
sizing?
121. Define set pressure and accumulation.
122. What are the set pressure and Accumulation
limits for pressure relief valves?
123. Differentiate between superimposed
backpressure and built-up back pressure?
124. What is meant by chattering? How can it be
eliminated?
125. What are the causes of chattering?
126. Write about Chattering solutions?
127. Is design pressure and MAWP same?
128. Differentiate between accumulation and
blowdown?
129. Is it good to use a single PSV for two
equipment/vessels? Why?
130. In which cases one selects multiple PSV?
131. What is the role of MAWP to design PSV?
132. What do you understand by the term
depressuring rate?
133. What are the input parameters required to
design a PSV?
134. What are the guidelines to follow in the line
sizing?
135. Is the pump suction line greater than the
discharge line? Why?
136. What is meant by erosion velocity?
137. What is the objective of line sizing?
138. What is Stokes law?
139. What is the friction factor?
140. What are STP conditions and NTP conditions?
141. What are the different types of pumps used in
the industry?
142. Explain the necessity of the performance
curves to size the pump.
143. Differentiate between pump and compressor.
144. Is total developed head and differential head
the same? What the units?
145. Define specific gravity.
146. How to calculate NPSHavailable ?
147. Should NPSHavailable is greater than NPSHrequired ?
Why?
148. Explain the effect of Specific Gravity to
calculate Head?
149. Explain VLE?
150. What is relative volatility?
151. How many types of separators are available?
152. How to design heat exchanger design using
Aspen EDR?
153. What is TEMA sheet?
154. When do we use heat exchangers in series or
parallel?
155. How to increase the turbulence on the shell
side and tube side?
156. What is temperature cross in the heat
exchanger?
157. What is meant by LMTD?
158. What is the role of baffles in the heat
exchanger?
159. What is fouling and its units?
160. How many types of baffles are available?
161. On what principle distillation column works?
162. What is Raoult's law?
163. Describe the use of the McCabe Thiele method.
164. What is the effect on the distillation column
load if the reflux ratio is increased?
165. Define diffusivity.
166. What are the units of molar flux?
167. What is superficial velocity?
168. For pure liquid, what is bubble point
temperature and dew point temperature?
169. What is relative volatility?
170. What is minimum boiling azeotrope and
maximum boiling azeotrope?
171. What are the different types of distillation?
172. Provide differences between partial reboiler
and total reboiler.
173. Provide differences between partial condenser
and total condenser.
174. What is meant by Azeotrope?
175. What are the advantages of distillation?
176. What are the limitations of the distillation
column?
177. Define vapor pressure and Reid vapor
pressure.
178. Define Sensible heat and latent heat.
179. What is the purpose of the flare header?
180. What are flare system components?
181. Write about aspen Flare System Analyzer.
182. What is a flare stack?
183. Differentiate between BDV and PSV.
184. What are the design criteria for BDV?
185. Is it necessary to provide BDV and why?
186. To which system is the BDV downstream
connected?
187. What is the purpose of an orifice plate?
188. What is the difference between flow orifice
and restriction orifice?
189. What is the best location for flow orifice,
upstream, or downstream of the control valve?
Why?
190. On what principle Orifice works?
191. What is heat exchanger fouling? Using
equations, please explain how heat exchanger
fouling impacts the duty of heat exchangers.
192. Using equations, explain the impact of the
viscosity of the heat transfer fluid on heat
exchanger duty.
193. In a pipe, consider that there is a turbulent flow
of fluid whose composition is known. If you
know the diameter of the pipe, as well as the
length of the pipe, can you calculate the
flowrate of through the pipe, if you know the
pressure at the inlet and outlet of the pipe?
Explain your answer.
194. Consider a compressor that is designed for a
certain gas mixture. What would happen if the
gas mixture is changed?
195. In a distillation column, consider that we have
a mixture of chemicals being fed. One of the
components is in a small amount. As you
perform a distillation column simulation, you
 find that the component is going in the bottoms.
However, your friend, who is working in the
plant which operates this column says that this
component is going to the top of the column,
what would you do to modify the simulation.
196. In a distillation column, you have a mixture of
benzene, toluene, and all the xylene isomers. If
you want to separate benzene and toluene at the
top, and xylenes at the bottom, can you estimate
the temperature which would be at the top of
the column and the temperature at the bottom of
the column? Explain your answer.
197. In a distillation column, you are feeding a
mixture of hydrocarbons with a vapor mass
fraction of 0.7 and 10000 m3 /h close to the
bottom of the column. If the column has no
reboiler, but the column bottom is fed with a
small amount of live steam, can you estimate
the liquid flow at the bottom of the column?
You can make some assumptions about the
steam rate.
198. In the distillation column above, there is a
condenser at the top of the column, but no other
side coolers / pump-around. The top condenser
condenses all vapor, and part of the condensed
vapor is used as reflux, and part is drawn as a
top product. What will the top distillate rate?
You can make some assumptions about the
reflux rate.
199. In the case of a reactor, we find that a set of
components A, B, and C react, and form
components D and E. If all the reactions are
very fast, what approach would you take to
 estimate the composition in the reactor
product?
200. In a combustion reactor, a mixture of methane,
ethane, and air is fed at roughly 50 o C. Due to
the combustion reactions, the temperature at the
outlet of the reactor will rise. How much air
will be required if an equimolar mixture of
methane and ethane at 1000 Nm3 /h are
reacted? What will be the outlet temperature?
Explain your approach to solving this problem.
201. In the above example, if we decide to use
enriched oxygen instead of air, what will it do,
and why?
202. In a process, we are reacting a liquid
hydrocarbon mixture with hydrogen gas in the
gas-liquid mixed reactor. The reactor is
followed by a separator, and the leftover gas is
separated, compressed and recycled back,
while the liquid leaves the system. Do you
need a purge gas stream? Explain your answer.
Do you need a makeup gas stream? How will
you calculate the makeup gas flow? (Jacobs
India)
203. What is the effect of flowrate on the head?
(Jacobs India)
204. Draw Pump characteristics curve. (Jacobs
India)
205. Explain different types of PSV? How does it
work? (Jacobs India)
206. Describe the pressure drop criteria of the
control valve. (Jacobs India)
207. Is PSV set pressure and design pressure the
same or not? (Jacobs India)
208. How to carry out the PSV inlet line? (Jacobs
India)
209. What information does the line list contain?
(TechnipFMC India)
210. What information does the equipment list
contain? (TechnipFMC India)
211. What does P&ID contain? (TechnipFMC India)
212. Why is PSV used? (TechnipFMC India)
213. What are the different types of PSVs?
(TechnipFMC India)
214. How to control surge? (TechnipFMC India)
215. Provide NPSHA formula (Saipem India)
216. Which should be higher NPSHA or NPSHR ?
(Saipem India)
217. What is shutoff pressure? (Saipem India)
218. Mark shutoff pressure in the graph. (Saipem
India)
219. Draw P&ID for storage tank with pump at
downstream and mention the instrument
needed. (Saipem India)
220. List of documents required for P&ID making.
(Samsung Engineering)
221. What are different safety valve sizing
scenarios? (Samsung Engineering)
222. What is meant by NPSH of the pump?
(Samsung Engineering)
223. What is the output of pump hydraulics study?
(Samsung Engineering)
224. Describe the principle of blowdown. (Samsung
Engineering)
225. Explain pressure drop criteria for line sizing.
(Samsung Engineering)
226. Describe gas sweetening process. (Samsung
Engineering)
227. Explain the procedure for control valve sizing.
(Bechtel India)
228. Explain the effect of higher velocities in the
pipeline. (Bechtel India)
229. Describe the PFD of the project you worked
on. (Bechtel India)
230. Explain different line sizing criteria. (Bechtel
India)
231. How one can reduce the pressure drop across
the control valve? (Bechtel India)
232. What is the formula for erosional velocity?
(Bechtel India)
233. What are pump curves? (Ingenero India)
234. How to carry out line sizing and pressure drop
calculation. (Ingenero India)
235. Explain any process by using a block diagram.
(Ingenero India)
236. Explain the distillation column control system.
(Ingenero India)
237. What are the causes of Overpressure in the
column? (Ingenero India)
238. What are the pump overpressure causes?
(Ingenero India)
239. Explain every unit of the refinery in with its
significance.
240. What are the simulation steps for distillation
column sizing?
241. Explain TEMA and the significance of its
parameters.
242. What is the significance of ρv2 in the heat
exchanger?
243. What is better; crossflow or counter-current
flow in a heat exchanger?