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Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.

4
A Brief Tutorial (and supplement to training and online documentation)
Lauren Sittler, Product Management, Aspen Technology, Inc.

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Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.4

Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 New Capabilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Overview of the User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Starting Activated EDR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 The EDR Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Flowsheet Highlights and Flyovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operational Risk Flowsheet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 The Activated EDR Summary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Summary Table Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Converting Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Model Types Supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Converting a Simple Model to Rigorous EDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Rigorous to Simple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.4

Introduction
Activated Exchanger Design & Rating (EDR) is a new Activated Analysis tool available within AspenTechs V8.4 simulators Aspen Plus and Aspen HYSYS. Like Activated Energy Analysis and Activated Economic Evaluation, Activated EDR helps process engineers quickly evaluate feasible design alternatives and immediately assess the impact on flowsheet capital and operating expenditures. Activated EDR provides an easy way to convert simple heat exchanger models to rigorous models, and provides quick access to rigorous model details. The EDR dashboard uses visual indicators to convey information about heat exchangers model status and shows all operational risks, if any, that have been detected in rigorous heat exchanger models.

New Capabilities
Convert simple heat exchanger models into rigorous designs from the flowsheet to obtain a fully rigorous, costoptimized geometry that accurately models thermal and hydraulic performance Easily track and change the model-type for all heat exchanger equipment in the simulation Instantly view operational risks, such as vibration and erosion, right from the flowsheet

Overview of the User Interface


Starting Activated EDR
EDR Activation is turned on and off from the Activated Analysis panel. Open the Analysis Panel by clicking on the Activated Analysis button on the Home ribbon (Figure 1).

Figure 1. Opening the Activated Analysis panel

Click the heat exchanger icon to turn it on and click the close button to turn it off (Figure 2). Opening and closing the EDR dashboard does not affect the EDR models in your flowsheet; it will not automatically convert a simple model to rigorous and vice versa. It will simply reveal more information about the heat exchanger models in your flowsheet.

Figure 2. The Activated EDR icon

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Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.4

The EDR Dashboard


The dashboard is the first component displayed when you activate EDR. It contains two pie charts: Model Status and Operational Risk (Figure 3).

Color Grey Blue Red

Model Status Simple heat exchanger Rigorous exchanger Rigorous exchanger, calculation error

Color Grey Green Yellow Red

Operation Risk Level Simple heat exchanger Rigorous exchanger, no warnings Rigorous exchanger, operation warnings detected Rigorous exchanger, serious risks detected

Figure 3: The EDR dashboard

The Model Status Pie Chart


The Model Status Pie Chart shows relatively how many exchanger models in the flowsheet are rigorous EDR and how many are simple. Rigorous EDR models provide greater accuracy in modeling the actual operation of heat exchanger equipment in a process as compared to simple models. The percentage of grey in this chart represents an opportunity to improve the fidelity of the process model. Simple models provide a very limited amount of sizing data that is only accurate within a small range of operating points. Rigorous models provide full heat exchanger geometry, and model heat transfer and hydraulic performance as process conditions change.

The Operational Risk Pie Chart


The Operational Risk Pie Chart shows the proportion of exchangers in the flowsheet that contain identified risks. Only rigorous models can predict when an operational risk is present, therefore no operational risk status is given for simple models. For rigorous models, the yellow section of the pie chart indicates a warning was detected by EDR. All of the operational risk warnings that are identified by EDR have been classified into categories for Activation. The yellow categories for each model type are shown below, as well as a sample of the red risks for Shell&Tube exchangers. Red risks are the most serious risk types and are extremely rare.

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Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.4

Yellow Operational Warning Categories Identified by Activation


Shell&Tube, AirCooled, Plate Pressure Temperature Vibration Erosion: RhoV2 Heat Transfer Pressure Drop Flow Other (all other risks in EDR that do not fall into the above categories)

Red Risks Identified by Activation for Shell&Tube Exchangers


Choking will occur in one of the nozzles. This exchanger cannot operate within the specified flow. The calculated nozzle pressure drop exceeds the absolute pressure. This exchanger cannot operate with the specified flow. The calculated total nozzle pressure drop exceeds the inlet pressure. The total calculated bundle pressure drop exceeds the bundle inlet pressure. The bundle outlet pressure has been reset, artificially. The large nozzle pressure loss, at the specified temperature and vapor fraction, suggests the flow will be choked. All or part of the pressure drop may be scaled to permit the calculation to proceed. The difference between inlet and outlet pressure will then be inconsistent with the calculated pressure loss.

Flowsheet Highlights and Flyovers


Flowsheet components can be turned on by clicking on the dashboard panels. Clicking on the Model Status panel will turn on Model Status highlights and flyovers. Clicking on the Operational Risk panel will turn on Operational Risk highlights and flyovers (Figure 4).

Figure 4: Turning on flowsheet components

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Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.4

Model Status Flowsheet Components


Model Status highlights circle rigorous exchangers in blue (Figure 5) and simple exchangers in grey (Figure 6). Hover over a blue highlight to see a setting plan for the EDR design, as well as key geometry and heat transfer information. Hover over a grey highlight to see information about the simple model and convert the model to rigorous.

Figure 5. Rigorous Model Status flyover

Figure 6. Simple Model Status flyover

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Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.4

Operational Risk Flowsheet Components


Click on the Operational Risk panel of the dashboard to reveal which exchangers contain operational risks detected by EDR. Mouse over the highlight to show which kinds of warnings are present for that exchanger (Figure 7). Click on the traffic light at the top to reveal a 2nd level flyover that shows the exact warning found by EDR (Figure 8).

Figure 7. Operational Risk highlights and flyovers

Figure 8. Operation warnings

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Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.4

The Activated EDR Summary Table


The Summary table is an organized list of all heat exchangers in your flowsheet. From this table you can access rigorous exchanger forms, convert models from simple to rigorous and rigorous back to simple, and view operation warnings for all models in your flowsheet (Figure 9). All of the columns in this table can be sorted ascending or descending. The last three columns can also be filtered. This allows you the flexibility to look at all models in a particular flowsheet, sort by model status, look at only heat exchangers that contain risks, and etc.

Figure 9. The Activated EDR Summary table

Summary Table Organization Column 1: Exchanger Name Displays the title of the unit operation block for that exchanger. If the model is rigorous, this title will be a link to open the unit operation form.

Column 2: Contains the location of an exchanger if its in a subflowsheet or hierarchy block. Subflowsheet: Contains a toggle button that displays either the EDR model type or reads Convert for Column 3: simple models. Click on this button to go directly to the form that allows you to convert this Model Status exchanger from simple to rigorous or rigorous back to simple. For rigorous models, a traffic light shows the risk status for the exchanger. Click on the traffic Column 4: light to go directly to the EDR risks. Click on the heading of this column to view a summary of Operation Risk Status all exchanger risks.

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Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.4

Converting Models
The conversions supported in Activation are the same as those allowed in previous versions of Aspen Plus. The chart below in Figure 10 shows the possible conversions between simple unit operations and rigorous EDR models.

Model Types Supported


Rigorous Model Types Supported in Aspen Plus:

Aspen Plus Unit Operation

Rigorous EDR Model Supported Shell&Tube

HeatX

AirCooled Plate

Figure 10. Simple to Rigorous Model conversions

Converting a Simple Model to Rigorous EDR


Convert forms for simple models can be accessed from the activated summary table or the Model Status flowsheet flyovers (Figure 11).

Figure 11. Accessing Convert forms

Click on the Convert button from either of these locations to begin model conversion. The form shown below will open.

Convert Forms in Aspen Plus


HeatX models can be converted to Shell&Tube, AirCooled, and Plate EDR model types (Figure 12).

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Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.4

1. Select a model type.

2. Select a sizing method on the right. For Plate models, interactive sizing is not supported, only EDR file imports. 3. Click the Convert button to continue.
Figure 12: Steps to complete Model Conversion

Rigorous to Simple
You can access the form to convert rigorous models back to simple from the activated summary table. Click on a button in the 3rd column for an EDR model type (Figure 13).

Figure 13. Exchanger Summary Table

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Jump Start: Activated Exchanger Design & Rating in Aspen Plus V8.4

When you click on this button, instructions for the particular model will appear. Read the steps to achieve the conversion. Then click on the Convert button (Figure 14) to go to the forms where those steps can be completed.

Figure 14. Convert to Simple Dialogue

Figure 15. Convert to Simple

2013 Aspen Technology, Inc. AspenTech, aspenONE, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-4606-1113

Additional Resources
Public Website:
www.aspentech.com/products/activation

Aspen Online Training:


www.aspentech.com/products/aspen-online-training

On Demand Short Presentations:


www.brainshark.com/aspentech1/activated-edr

Aspen YouTube Channel:


www.youtube.com/user/aspentechnologyinc

Jump Start Tutorial Series:


www.aspentech.com/Activated_EDR_HYSYS_V84.pdf

About AspenTech
AspenTech is a leading supplier of software that optimizes process manufacturingfor energy, chemicals, engineering and construction, and other industries that manufacture and produce products from a chemical process. With integrated aspenONE solutions, process manufacturers can implement best practices for optimizing their engineering, manufacturing, and supply chain operations. As a result, AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become more energy efficient. To see how the worlds leading process manufacturers rely on AspenTech to achieve their operational excellence goals, visit www.aspentech.com.

Worldwide Headquarters
Aspen Technology, Inc. 200 Wheeler Road Burlington, MA 01803 United States phone: +17812216400 fax: +17812216410 info@aspentech.com

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For a complete list of offices, please visit www.aspentech.com/locations