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4528.07.R380.02
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C e d op u e r
Compressor
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C e d op u e r
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Compressor
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Al igh lia h ry
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Compressor 3
Workshop
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In this module we will model high-pressure gas compressors using
compressor performance curves. Using curves to model these unit
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operations allows UniSim Design to accurately simulate actual plant
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equipment.
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Learning Objectives
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Once you have completed this module, you will be able to:
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Specify head and efficiency curves to compressors
Use multiple curves to model compressors
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Make changes/additions to the dynamic model
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Prerequisites
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Process
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Compressor
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Compressor 5
Compressor Curves
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Using compressor curves in your UniSim Design simulation allows
you to accurately model existing plant equipment. With an accurate
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simulation, you can determine if an existing compressor is able to
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meet the specifications of your process.
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The compressor curves also allow UniSim Design to calculate heads
and efficiencies that are dependant on the flow rate.
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If the flow rate through the compressor is known to be
constant, a single flow rate and efficiency can be supplied.
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If the flow rate is expected to change, using a compressor
curve will allow UniSim Design to calculate new heads and
efficiencies based on the current flow rate.
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ht n te p This results in greater accuracy in the simulation, and allows
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Retype them
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Only.usc and
In this case the Excel spreadsheet includes VBA code which will
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copy/paste the
automatically create a compressor on the flowsheet and set the
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compressor to your
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6 Compressor
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C e d op
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Compressor 7
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Figure 2) and the Dynamics tab Specs page (Use
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Characteristic Curves: Figure 4).
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Figure 3
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Figure 4
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8 Compressor
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8. Add a discharge valve (Comp valve) to the compressor outlet.
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9. Remove the pressure specification of the compressor suction
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and move it to the outlet of the discharge valve. Set it to
6900 kPa (1000 psia).
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10. Size the valve.
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What Cg value was calculated for the discharge valve?
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11. Add a pressure controller to control the compressor discharge
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pressure (recorded above).
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Connections
Name PC-KO
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Action Direct
Range PV Minimum 6000 kPa (870 psia)
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You may want to start the pressure controller in manual. Start the
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Compressor 9
Surge
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On centrifugal compressors operating curve there exists a point of
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minimum flow and maximum head where the developed head is
insufficient to overcome the system resistance - the surge point.
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When this point is reached in compressor operation, the gas in the
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discharge piping back flows into the compressor. Without discharge
flow the discharge pressure drops until it is within the capacity of
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compressor, and then the cycle repeats.
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UniSim Design Limitations
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The surge curve as implemented in UniSim Design pre-multiplies
the compressor head curve with a random number. While this
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implementation does cause the compressor flow to be erratic
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(mimicking surge) it may also, in some situations, lead to
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section.
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Stonewall
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point when sonic velocity is reached. When this point is reached for
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any given gas, flow can only be further increased if the compressor
is modified, or for a variable speed compressor, the speed is
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increased.
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Q 2 = a speed + b (1)
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10 Compressor
The flow units entered for the stonewall curve are based on the
compressor inlet conditions. When used, the stonewall option
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bounds the compressor flow, but not head.
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Before using the stonewall curve it is suggested that the operating
curves for the compressor be extended into the expected stonewall
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regime as this can aid in the modeling of stonewall.
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Compressor Surge Control
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If the flow through a centrifugal compressor falls below the surge
limit at a given head, the rapid flow oscillations and associated
vibrations can be extremely damaging to the compressor
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equipment. Hence most centrifugal compressors have a protection
mechanism that ensures a minimum throughput by opening a
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recycle valve. This mechanism is a Surge Controller.
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Add an Anti-Surge
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(Recycle) Line
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2. Size the new valve such that it has a Cg value that is 10% of
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Compressor 11
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7. Connect the outlet of the anti-surge valve to the
Knockout Drum.
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The Surge Controller is used exclusively for compressors. When
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in Auto(matic) mode, the Set Point is calculated by the
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controller itself; it is not set by the user.
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The surge line for the compressor model is entered as speed vs.
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flow rate curve in a tabular form.
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For the purpose of the surge controller the surge line is calculated
from the formula:
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A,B,C,D = parameters
For this module you should assume that constants B and D are
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zero, thus reducing the equation (2) to its quadratic form. Linear
regression of Head versus Vol Flow squared provides parameters
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regression results
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12 Compressor
In addition to the surge line, the user must also supply Control and
Backup lines.
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Control Line
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The control line is the primary set point for the controller. This line
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is set at some percentage above the surge flow (typically 10%),
and the controller tries to maintain the compressor flow above this
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control line. If the flow is above the backup line then the control
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action is the normal PID action. The control line set point can be
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determined with equation (3):
100 + x (3)
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100
QSurge
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Where: Q = Control flow rate in [m3/s]
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Backup Line
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The points of the backup line are located between the surge line
and the control line.
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algorithm is used. However, when the flow drops below the backup
line, more aggressive control action is taken to prevent surge. The
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If the compressor flow drops below the backup line then a Quick
Opening Algorithm replaces the PID algorithm, and the recycle
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11. The control line and backup line are set at 10% and 5%
respectively above the surge line. The recycle valve will be
opened with a Quick Opening rate of 3% per second.
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C e d op u e r
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Figure 5
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Al igh lia h ry
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PV Minimum and PV Maximum.
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Compressor
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12. Add the PID Tuning parameters for the controller and the
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14 Compressor
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Save your case!
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UniSim Design
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Spreadsheet
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With complete access to all process variables, the Spreadsheet is a
very powerful tool in the UniSim Design environment. The power of
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the Spreadsheet can be fully realized by the addition of formulas,
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functions, logical operators, and basic programming statements.
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simulation.
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Variables
Any variable in the simulation case can be imported into the
Spreadsheet. The contents of any Spreadsheet cell can be exported
to any specifiable (blue) variable in the simulation case. There are
three ways of importing values into the Spreadsheet:
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Compressor 15
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window; then right click and hold the right mouse button.
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Move the cursor over to the Spreadsheet. Once over the
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Spreadsheet, the cursor's appearance will change to a
"bull's eye". Release the right mouse button when the
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Note that it is not
possible to import into, "bull's eye" cursor is over the desired cell. The specific
se e l u 00 fid
and export from, the information about the imported variable will appear in the
same cell. Instead use Current Cell group. Before attempting a drag and drop
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two cells: one for the
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import and one for the
import the window containing the variable to be imported
and the spreadsheet window should be arranged so that
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export. Link them
together with a simple both are easily visible on screen.
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=A1 formula.
Variable Browsing. A variable may also be imported into
the Spreadsheet by placing the cursor on an empty cell in
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ht n te p Variable Navigator.
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type. Move the "bull's eye" cursor over the desired variable
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16 Compressor
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On the parameters tab of Spreadsheet property view, the user can
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choose a Units Set to be used by the Spreadsheet. This
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If a unit set is being determines the units used for all cells in the spreadsheet and can
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used by a spreadsheet be set independently of the Unit Set currently in use in UniSim
it is locked and so
cannot be modified. To
Design.
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modify the unit set any
Figure 7
objects using it must be
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temporarily modified to
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use a different set.
Pressing the View
Users button on the
Units page of the
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Variables tab of the
Session Preferences
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window shows which
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objects are using a unit
set. ht n te p
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The user can also set the following on the Parameters tab:
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Note that if you make the dimensions of the Spreadsheet (Number of Columns,
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Compressor 17
Spreadsheet in Dynamics
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When using the spreadsheet in dynamics there are a several
considerations to make:
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The spreadsheet can be calculated before the pressure flow
step, after the pressure flow step or on the composition
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step. This is set on the Parameters tab of the spreadsheet.
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Spreadsheets calculate once per calculation step. Therefore
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if you pass a value from spreadsheet A to spreadsheet B,
use the value in spreadsheet B in a calculation and pass the
results back to spreadsheet A the value will be passed back
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to spreadsheet A on the next step and thus will be one step
behind. You can use this fact to your advantage to
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implement a counter using spreadsheets or to view values
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Spreadsheet Comparison
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Functionality Comparison
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Symbol to define = =
mathematical
(+ also works)
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expressions
Symbol to define = @
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Find information on logical expressions
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more functions in the
UniSim Design Mathematical functions function() @function()
spreadsheet in the
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sin(), ln(), abs(), sqrt() @sin(), @ln(), @abs(),
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Operations Guide @sqrt()
section 12.10.2.
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Logical expression =if(condition,then,else) @if(condition,then,else)
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UniSim Design Limitations
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A collection of functionalities which the UniSim Design spreadsheet
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When cells are copied only the value of the cell is copied,
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formula.
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Compressor 19
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Design Spreadsheets
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It is possible to use to use Microsoft Excel to create spreadsheets
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for use in UniSim Design. The steps for this procedure are:
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1. Create the desired spreadsheet in Excel ensuring that only
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functions which are supported by UniSim Design are used (e.g.
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In Microsoft Excel, you sum() is not a function in UniSim Design).
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can also show formulas
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from the Tools menu, 2. In Excel, use Ctrl (grave accent) to show the formulas rather
Options and on the than results.
View tab check the
Formulas box.
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3. For any functions (if statements, ln, abs, etc.) change the
Excel cell to text by placing an apostrophe at the beginning and
add the required @ symbols.
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ht n te p 4. Highlight the desired cells in Excel and copy them into the
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You should find that the Excel formulas which have been converted
to text with the apostrophe are imported as regular formulas into
UniSim Design - the apostrophe is not imported.
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C e d op
Adding a Spreadsheet
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Spreadsheet icon
equation (4) and the corresponding control and backup flow
rates. Remember these are both greater than the surge flow
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rate.
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20 Compressor
Make sure the calculated flow rates display in the correct units.
Remember that the flow rates in the equation are in m3/s.
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When you have finished the spreadsheet should look like the
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following:
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Figure 8
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C e d op
position;
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Compressor 21
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When performing multiple experimental runs it helps to save a
copy of the case in the steady state condition with the flow control
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SPs zeroed so that you can reload this case, make modifications
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and quickly see the effects of the changes.
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1. Try setting all the feed flow controllers SPs to zero at once.
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Can the model cope?
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ht n te p controllers open very quickly. Try setting the Integrator
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22 Compressor
Advanced Modeling
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Pipe Segment
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se e l u 00 fid
The pipe segment can be used in steady state and dynamics to
simulate a wide variety of piping situations ranging from single or
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multiphase plant piping with rigorous heat transfer estimation, to
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large capacity looped pipeline problems. It offers the common
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pressure drop correlations developed by Gregory, Aziz, and
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Mandhane, and Beggs and Brill. In addition there are a large
number of specialist pressure drop correlations available. Consult
the on-line help and the manual for more information on these
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For dynamics there is also a simplified pipe friction model which
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Correlation
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On the Parameters page of the Design tab you can select the
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Parameters page is
set to Pipe Model Gregory, Aziz, Mandhane Tulsa99
Correlations.
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For single phase streams, the Darcy equation is used for pressure
drop predictions, regardless of the correlation selected on the
Parameters page. The Darcy equation is a modified form of the
mechanical energy equation, which takes into account losses due
to frictional effects as well as changes in potential energy. The
pipe in this section will be single phase so the Darcy equation is
used automatically.
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Compressor 23
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On the Sizing page of the Rating tab, the length-elevation profile
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for the Pipe Segment is defined. Each pipe section and fitting is
labeled as a segment. To fully define the segments, you must also
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specify pipe schedule, diameters and pipe material.
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At least one segment is Figure 9
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required.
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C e d op
pipe schedule and a nominal diameter. UniSim will then fill in the
correct inner and outer pipe diameters after the Specify button is
pressed. Figure 10.
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Figure 10
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24 Compressor
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This is set up on the Heat Loss page of the Rating tab. As
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covered in Module 5, there are three options: None, Simple or
Detailed.
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Dynamic Specifications
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The Parameters page on the Dynamics tab contains the
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remaining parameters required to configure the pipe segment for
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dynamic operation.
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The following table lists and describes the objects available:
Object Description
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Pipe Flow model Allows you to select between turbulent and full range
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Simple Pipe Friction
Dynamics mode.
Model Method
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Pipe flow model Allows you to select the pipe flow model based on the
C e d op
entire pipe.
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Pipe Holdup type Allows you to calculate the holdup values for each segment
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accurate.
Model Holdup If checked then the Holdup volume inside the pipe is
Volume checkbox modeled. The volume used is calculated based on the pipe
lengths and diameters entered.
Generally the pipe volumes are ignored or lumped together
in a single holdup volume, unless a model of the
composition lag is required. The lumped volume approach
is a simpler more robust option, and often the pressure
drop result is the main interest. Having to consider many
holdups with small volumes may lead to instabilities.
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Compressor 25
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Adding a Pipe Segment
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1. From the Object Palette, add a Pipe Segment to the simulation.
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2. Connect the inlet of the pipe to the outlet of valve To Pipe.
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Pipe Segment icon
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3. On the Sizing page, Rating tab of the pipe specify the
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following:
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In this cell... Enter...
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Connections
Name Pipe-100
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Parameters
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Fitting or Pipe Pipe
Length 200 m (656.2 ft)
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4. On the Heat Loss page, enable the Simple model and leave
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Since the pipe is single specify a pressure of 6640 kPa (963 psia).
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equation will be used 8. Start the Integrator and run the model.
regardless of the Pipe
Flow Correlation
9. Save the case as 4528.07.CompE.usc.
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selected.
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26 Compressor
Advanced Modeling
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Since there are a relatively large number of components we will
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observe the effective change in composition by measuring the
molecular weight of the fluid entering the pipe and leaving the
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pipe.
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1. Create a new strip chart and add the pipe inlet and outlet
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molecular weights and flow.
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2. Open the property view for the air cooler and on the
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Ratings tab, turn off both fans by unchecking the Fan is On
box.
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3. Start the Integrator.
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0%.
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5. Observe the change in molecular weight for the inlet and outlet
of the pipe.
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9. Increase the pipe length and diameter and continue to vary the
OP of FC-Alpha between 0% and 55%. Observe the lag in
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