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Compressor Surge Analysis - Presentation

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0% found this document useful (0 votes)

115 views

Compressor Surge Analysis - Presentation

Uploaded by

Vineeth Vs

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 41

Analyze and Troubleshoot

Compressor Systems Easily

with Activated Dynamics in
Aspen HYSYS® V8.6
21 April, 2016

Engineering Business Consultant

APAC Region

© 2014 Aspen Technology, Inc. All rights reserved

Outline

 Business Challenge
 Compressor Overview
– Types
– Why worry?
– Surge
– Surge Protection
– Compressor Re-start
 Modeling Compressors in HYSYS
– Overview
 Activated Dynamics for Compressor Surge Analysis
– Activated Dynamics Overview
 Hands – on Exercise

© 2014 Aspen Technology, Inc. All rights reserved | 4

Business Challenges
Process Industry

Safety Operability

Maintenance Costs Downtime

Better Control
Dynamic Modeling
Systems

© 2014 Aspen Technology, Inc. All rights reserved | 6

Dynamic Modeling
Why Isn’t Everyone Employing It?

Intimidating

Expertise

© 2014 Aspen Technology, Inc. All rights reserved | 7

Compressors – Three Typical Types

Compressors are mechanical devices commonly used to increase

the pressure of a gas and transport it through a pipeline

105 Centrifugal
• Most common compressor
104 used in industry

Reciprocating Piston
Discharge
103
• Used for very high pressures
Pressure Centrifugal and low flow rates
(psia)
102
Axial
Flow
Axial
• Special compressor used for
10
Reciprocating very high flow rates and low
pressures
1
1 10 10 10 10 10
2 3 4 5 6
0
Inlet Flow
(acfm)
Reference – Compressor Handbook for the
Hydrocarbon Industries, Gulf Publishing Co., 1979

© 2014 Aspen Technology, Inc. All rights reserved | 8

Compressors – Why Worry?

From both a design and controllability / operability point of

view, compressors provide unique issues and challenges

Design Issues
• Expensive equipment
• Often customized with
long lead times to
replace

Operability Issues
• Very fast dynamics
• Compressor trips are
costly
• Compressor surge is very
hazardous
• Specialized anti-surge
control systems are
common

© 2014 Aspen Technology, Inc. All rights reserved | 9

What is Surge and Why is it Such a Problem?

Surge is the point where a centrifugal compressor cannot add enough

energy to overcome the system backpressure

Results
• Rapid flow reversals
(e.g., surge)
• Rapid changes in axial
thrust
• High vibration
• Potential damage to
rotor seals and bearings
• Catastrophic equipment
failures and release of
gases to atmosphere

© 2014 Aspen Technology, Inc. All rights reserved | 10

Two Operating Modes – Centrifugal & Reciprocating

Operating
Mode

© 2014 Aspen Technology, Inc. All rights reserved | 11

Centrifugal Compressor Performance Curves

 Typically available from the manufacturer as plots of efficiency and head vs.
flow capacity of a centrifugal compressor for one or more operating speeds
(e.g., RPM)
 Head vs. Flow Capacity

Decreasing Speed

© 2014 Aspen Technology, Inc. All rights reserved | 12

Input for Multiple Head and Efficiency Curves

The Enable Curves

checkbox must be
clicked

One curve per speed

All curves must use

the same efficiency
definition (Adiabatic or
Polytropic)

Individual curves may

be activated or
deactivated

Remove any input

value for efficiency on
the Parameters page

© 2014 Aspen Technology, Inc. All rights reserved | 13

Input for Multiple Head and Efficiency Curves
Able to Add Additional Curves for Other MW Gases

Compressor performance impacted by significant shifts in gas

molecular weight, particularly for low pressure compressors

Able to add performance

curves for the different
molecular weights, as
well as Quasi-
Dimensionless and Non-
Dimensional curves

© 2014 Aspen Technology, Inc. All rights reserved | 14

Centrifugal Compressor Performance Limits

 Surge Limit – Lower

Flow Capacity Limit
– Occurs at the upper end
of head vs. flow curve
(for a given speed)
where the performance
curve’s tangent becomes
zero

 Stonewall Limit – Upper

Flow Capacity Limit
– Maximum flow rate for a
given speed due to the
approach of sonic flow of
the gas within the
compressor
– Occurs at the lower end
of head vs. flow curve
(for a given speed)
– Important for capacity
control, but not as
critical as surge control

© 2014 Aspen Technology, Inc. All rights reserved | 15

Surge and Stonewall Curves

© 2014 Aspen Technology, Inc. All rights reserved | 16

Cubic Compressor Curves
Improve Operability Near Surge Region

Non-Dimensional
Curve input option to
model compressor
behavior near surge
region

Visualize compressor
operation near the surge
region