Process and Control Validation

By: Macse  09-12-2011
Keywords: Process Design, Dynamic Simulation

Traditionally process design has been done using steady state simulators. Many process design decisions requires knowledge about transient response and process interactions. Also process designs based only on steady state simulations may lead to inadequate sizing of some equipment. Dynamic simulation can identify transient process bottlenecks and avoid process design mistakes. Here a few examples:

FURNACES

For units with a lot of heat integration between the preheat section and the separation section, process designers can under-estimate the heat capacity of a furnace during start-up making the steady state almost unachievable.

SECONDARY PROCESS LINES

Recirculation lines can sometimes be under-sized when steady states simulation are used. Dynamic simulation can cover all the process dynamics, from start-up to shutdown.

COMPRESSOR STABILITY

Insufficient hold-up in vessels around compressors may lead to process instabilities during start-up. Dynamic simulation can help prevent these issues.

Dynamic simulators can be used early in a project to identify important operability and control issues. Instead of using only rules of thumb to develop control strategies, a control engineer can easily evaluate, test and tune a control strategy.

Advanced control development can also be performed with a dynamic simulation, avoiding excessive plant testing.

The effect of planned or unplanned disturbances can also be studied with a dynamic model. It allows to see the effect on the plant operability. For example, one might be interested to see the control in action when ambient conditions changes, when a production switch is done or when there is a sudden pressure loss.

Keywords: Dynamic Simulation, Process Design

Other products and services from Macse

09-12-2011

Simulation Training - Web Tutorials

MACSE now offers web tutorials for process simulation training using HYSYS, UniSim Design, Unisim Operations or ShadowPlant. We can also create specific web tutorials based on YOUR training objectives (steady state mode. Other subjects available on demand.


09-12-2011

Extension and Development of Custom Unit Operations

Simulation software offers a wide variety of unit operations, and by combining basic units together you can build a more complex unit that can be re-used as a template. Still you may face situations where you need to use in-house model and integrate it into your simulation model. Extension to protect intellectual property of Hysys (or Unisim Design) in spreadsheet blocks. Extension to convert a Unisim Design case to a PRO/II case.


09-12-2011

Dynamic Relief Valve Sizing

This is mainly due to the fact that conventional calculations methods are very conservative, to poor estimation of relieve properties and because transient effects are not considered. Many studies have shown that, in most cases, conventional methods were highly over-estimating relieving flows compared to dynamic methods.


09-12-2011

Steady State Studies

Process engineers are frequently involved on field surveys and are sometimes confronted to apparent contradictions between field data and Historian/DCS data. These studies can be done using your models or we can build new models with Hysys, Unisim Design or any other simulation software available in the market.


09-12-2011

Operator Training Simulators (OTS

We help companies to develop their operator training simulator using the tools available on the market or using their own modelling tools. Our engineering team works with the most effective and reliable operator training simulators tools in the market. The operator training simulator softwares commonly used are UniSim® Operations Suite, ShadowPlant and HYSYS®. Validation of new control startegies or multivariable control applications.


09-12-2011

Dynamic studies using Hysys, Unisim Design, Unisim Operaions

These studies can be done using your models or we can build new models with Hysys, Unisim Design, Unisim Operations or any other simulation software available in the market. These studies are used to avoid plant tests, to verify different operating scenarios, to compare different process designs or control strategies. One example that recently came to us was to develop a dynamic simulation for a Steam Generation Plant.