S.A.T.E S.A.T.E. SDV3 OUTLET
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1 SUMMARY APPLICATION OF DYNAMIC PROCESS SIMULATION AND NUMERICAL OPTIMIZATION TECHNIQUES IN THE DESIGN OF RECYCLE ANTISURGE LOOPS FOR CENTRIFUGAL COMPRESSORS Attilio Brighenti, Anre Pvn, Cristin Vnzin S.r.l. SURGE PROTECTION OF CENTRIFUGAL COMPRESSORS COMMON DESIGN CRITERIA ANALYSIS OF AN EMERGENCY SHUT-DOWN (ESD) TRANSIENT DYNAMICS HBPV SIZE SELECTION SIMPLIFIED ALGEBRAIC APPROACH SIMULATION BASED OPTIMIZATION COMPARISON OF RESULTS PROCESS, Bologn 6 th - 8 th Februry PROCESS, Bologn 6 th - 8 th Februry Slie /7 SURGE PROTECTION OF CENTRIFUGAL COMPRESSORS COMMON REFERENCE POINTS FOR ASV SIZING BASIC COMPRESSION SYSTEM UNIT Surge zone B Comressor m in correcte coorintes (t reference conitions) INLET SDV NRV SD HBPV KS FT V DRIVER FV V COMP NRV HE V NRV SDV OUTLET Polytroic he PHcorr (kj /kg) A MOS Qcorr (m /s ) Volume flow rte MCS C Stonewll zone D ref T Nc N N T ref ref Tref Qc Q Q T ref Tref H c H H T AS line + vlve chrcteristic PROCESS, Bologn 6 th - 8 th Februry Slie / PROCESS, Bologn 6 th - 8 th Februry Slie 4 /7 Oerting oint th uring ESD Polytroic he P Hcorr (kj /kg) ESD FROM THE NORMAL OP ERATING POINT Surge zone 86.% (@.7 s) 89. % (@. s) Qcorr (m /s) Volume flow rte 9.6 % of MCS 9. % (@ s) Initil conition (NOP) Comressor m in correcte coorintes (t reference conitions) Comressor see (% of MCS) Comr. See (% MCS ) Accelertion (% of NS/s) Driver Accelertion (% of NS /s) - 8 Driver Torque (% of mx) s h-ot: correcte Actul Correcte sh-ot: correcte 9.. time (s) PROCESS, Bologn 6 th - 8 th Februry Slie / PROCESS, Bologn 6 th - 8 th Februry Slie 6 /7
2 Mss flow [kg/s] Disch. Press. [br] Suct. Press. 4 [br] Suct. Tem. [ C] Soli blue: V Ds he re: V Com. NRV FV HBPV V V Soli Blue: Comr. Ds he Re: NRV Ds h-ot Green: FV Dot Blck: HBP V Soli blue: V Ds he re: V Mss flow rtes [kg/s] Soli Blue: Comr. Ds he Re: NRV Ds h-ot Green: FV Dot Blck: HBP V 9. t PROCESS, Bologn 6 th - 8 th Februry Slie 7 / PROCESS, Bologn 6 th - 8 th Februry Slie 8 /7 MAP CHANGE WITH INLET CONDITIONS (soun see) Stretch with Higher temerture Polytroic he Polytroic he (kj/kg) SLL Minimum Oerting See ref /.9 otte lines Norml See ref /.9 she lines Volume flow (m /s) Actul volume flow rte ref /. soli lines Stretch with Lower temerture Mximum Continuous See SWL Comressor m in bsolute coorintes (t ctul suction conitions) Definitions Polytroic he PHcorr (kj /kg) Trget 86.% o f MCS 9. % of MCS Qcorr (m /s ) Volume flow rte Initil con. NOP 9.6 % o f MCS Comressor m in correcte coorintes (t reference conitions) PROCESS, Bologn 6 th - 8 th Februry Slie 9 / PROCESS, Bologn 6 th - 8 th Februry Slie / Dischrge temerture [ C] T T t PROCESS, Bologn 6 th - 8 th Februry Slie /7 MAIN DATA: Trnsient execte urtion t [s] Lume ischrge volume V V [m ] Vlve oening time (incl. e-time) t oen [s] Vlve e time t e [s] Trin inerti J t [kg m ] Initil comressor see (@ oint ) N [r/s] Comressor/river torque (@ oint ) T c [Nm] Trget olytroic he (@ oint ) H ol [J/kg] PROCESS, Bologn 6 th - 8 th Februry Slie /7
3 MAIN GAS CONDITIONS DATA & ASSUMPTIONS: Suction ressure (. &.) s [P] Suction temerture (. &.) T s [K] Suction comressibility (. &.) z s [--] s T s [P] [K] z s [--] Averge isentroic exonent (c /c -) γ ve [--] Dischrge ressure (. ) [P] Dischrge ensity (. ) ρ [kg/m ] MAIN GOVERNING EQUATIONS FOR DERIVED QUANTITIES: Trin oint N [r/s] Averge olytroic exonent (-) (ssumtion: n ol n ol ) n ol [--] Dischrge ressure (. ) [P] Dischrge ensity (.) (ssumtion: T T ) ρ [kg/m ] Averge mss flow rte uring trnsient (-) m frve [kg/s] m N n ol Tc N t J γ ve η olγ ve n ol H olµ w + nol Rz sts s frve ρ ρ M t t oen e t n ol n ol ( ρ ρ ) V t t oen e PROCESS, Bologn 6 th - 8 th Februry Slie / PROCESS, Bologn 6 th - 8 th Februry Slie 4 /7 High sensitivity to estimtes (@ oint ) Require Cv chnge - SENSITIVITY SENSITIVITY TO POLYTROPIC HEAD AND PRESSURE VARIATION DURING TRANSIENT (from to ) Suction ressure rise.%.%.% % 8% 4% % -.% -.% -.% -.% -.%.% -4% HIGH SENSITIVITY TO ASSUMPTIONS Then? -8% olytroic he mx. roximity to surge PROCESS, Bologn 6 th - 8 th Februry Slie / PROCESS, Bologn 6 th - 8 th Februry Slie 6 /7 DYNAMIC PROCESS SIMULATION by COMPSYS fetures: Rel gs thermoynmics n trnsort roerties Comressible flow & st orer inerti & ynmics through vlves n orifices Comressor D & 4D ynmic ms ω Rotting shft ynmics ( egree of freeom) J M t M Coolers with convection coefficient clculte t ech ste Full moelling of control systems (yet reunnt for HBPV sizing on ESD) Numericl rmeters otimiztion roceure running itertive DPS c M All vrying rily with time f COMPSYS Rel gs thermoynmics n trnsort roerties: CRITICAL ISOTHERMAL GAS DRY VAPOUR WET VAPOUR CRITICAL LIQUID POINT PROCESS, Bologn 6 th - 8 th Februry Slie 7 / PROCESS, Bologn 6 th - 8 th Februry Slie 8 /7
4 COMPSYS Comressor D & 4D ynmic ms Ate surge zone MCS MOS ESD th from NOP η oly PROCESS, Bologn 6 th - 8 th Februry Comlete comressor m in correcte coorintes (t reference conitions) ref T Nc N N T ref ref Tref Qc Q Q T ref Tref H c H H T Slie 9 /7 COMPSYS Numericl otimiztion of esign rmeters Polytroic he PHcorr (kj/kg) Q min Q < Q csll Q > 86.% of MCS Qcorr (m /s ) Volume flow rte 9. % o f MCS 9.6 % of MCS Q * c c csll err Q min min min[ S ( t) ] Q ( t) Q ( t) QcSLL ( t) PROCESS, Bologn 6 th - 8 th Februry Proximity to surge Comressor m in correcte coorintes (t reference conitions) s Slie /7 Sequentil trget roching by chnging the Cv vlue ( Cv % of otimum) Polytroic PHcorr he (kj/kg) Cv - 9.% Cv - 9.% Otimize vlue % -6.% DPS & OPTIMIZATION BY COMPSYS & MATLAB +.% +.% Selecte size +.4% SLL +8.% +9.6% Qcorr (m /s) +8.% 9.6 % of MCS 9. % (@ s) 89. % (@. s) 86.% (@.7 s) Volume flow rte Comressor m in correcte coorintes (t reference conitions) Require Cv chnge SIMPLIFIED APPROACH vs. OPTIMIZATION by DPS SENSITIVITY TO DISCHARGE PIPING VOLUME & SUCTION PRESSURE RISE % Suction ressure rise 8% 6% 4% %.%.%.% Simot. % % -% -% % % % % 4% -% Dischrge volume Difference from bse vlue Otimiztion by DPS PROCESS, Bologn 6 th - 8 th Februry Slie / PROCESS, Bologn 6 th - 8 th Februry Slie /7 SENSITIVITY TO DEAD TIME & DISCHARGE VOLUME BY DPS SENSITIVITY TO OPENING TIME & TRIM CHARACTERISTIC REQUIRED Cv SENSITIVITY TO VALVE DEAD TIME & DISCHARGE VOLUME All vlues obtine by otimiztion / DPS Require Cv Chnge 8% 6% 4% % De time [s]... % -% % % 4% -% Dischrge volume Difference from bse vlue Cv (ref. bse cse) % % % % % Trim tye liner oening quick oening % HBPV oening time [s] All vlues obtine by otimiztion / DPS PROCESS, Bologn 6 th - 8 th Februry Slie / PROCESS, Bologn 6 th - 8 th Februry Slie 4 /7 4
5 . Sizing HBPV consiering only comressor m is not relible, s generl metho. Imortnt rmeters tht the engineer cn influence re lso ischrge iing volumes vlve trim chrcteristic vlve oening time vlve e time. The ttemte simlifie lgebric clcultion metho is too sensitive to estimte rmeters n cn only rovie st estimte vlues Dynmic rocess simultion, e.g. by COMPSYS, combine with numericl otimiztion roceures is the cost-effective solution PROCESS, Bologn 6 th - 8 th Februry Slie / PROCESS, Bologn 6 th - 8 th Februry Slie 6 /7 OPTIMIZATION by DPS is recommene t the erly esign stge of comression fcilities, to revent: Lte evience of inequte rotection from surge Incresingly costly remeies when they re tken uring etile esign, construction on oertion Thnk you for your ttention PROCESS, Bologn 6 th - 8 th Februry Slie 7 / PROCESS, Bologn 6 th - 8 th Februry Slie 8 /7
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