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Nuovo Pignone

CLIENTE - CUSTOMER
Daelim
LOCALITA' - PLANT LOCATION
FIRENZE
Kuwait
COMMESSA - JOB IMPIANTO - PLANT
1102680-81 MAA Refinery
TITOLO - TITLE

Dynamic Simulation Study

(Feed Gas Service 231-001A/B)

Electronically approved draw. GE NuovoPignone Confidential DT-'C'


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Table of Contents
Table of Contents..........................................................................................................................................2
List Of Figures...............................................................................................................................................3
Acronyms ......................................................................................................................................................4
1 Introduction...........................................................................................................................................5
1.1 Modelling Inputs and Assumptions ...............................................................................................................5
1.1.1 Equipments...........................................................................................................................................5
1.1.2 Gas Compositions ................................................................................................................................5
1.1.3 Volume Specifications ..........................................................................................................................5
1.1.4 Boundary Conditions ............................................................................................................................6
1.1.5 Assumptions .........................................................................................................................................6
1.2 Steady State Validation.................................................................................................................................7
2 Emergency Stop Analysis ....................................................................................................................8
2.1 Emergency Stop Event Description ..............................................................................................................8
2.2 Additional Assumptions.................................................................................................................................8
2.3 Run 1 Results.............................................................................................................................................9
2.4 Run 2 Results...........................................................................................................................................10
2.5 Conclusions.................................................................................................................................................12
Reference List .............................................................................................................................................13
3 Appendix A Volume Table...............................................................................................................14
4 Appendix B ESD Acceptance Criteria .............................................................................................17

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List Of Figures
FIGURE 1. Run 1 Operative Path...........................................................................................................................9
FIGURE 2. Run 2 Operative Path.........................................................................................................................10
FIGURE 3. Run 2 Rotational Speed .....................................................................................................................10
FIGURE 4. Run 2 Suction and Discharge Pressure .............................................................................................11
FIGURE 5. Run 2 Suction and Discharge Temperature.......................................................................................11
FIGURE 6. Run 2 ASV Mass Flow .......................................................................................................................11
FIGURE 7. Run 2 HGBV Mass Flow ....................................................................................................................12
FIGURE 8. Plant Simplified PFD .............................................................................................................................14

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Acronyms
ASV, Anti Surge Valve
ESD, Emergency Shut Down
HGBV, Hot Gas Bypass Valve
MCS, Maximum Continuous Speed
SCL, Surge Control Line
SLL, Surge Limit Line

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1 Introduction
Feed gas compression plant (unit 231) is composed of 2 gas turbine driven compressor trains running in
parallel. Each compression train comprises the following major equipments for train A(see Ref. 2):

Feed Gas Compressor Suction Drum (V-231-004A).


Feed Gas Compressor (C-231-001A).
Debutanizer Side Reboiler (E-233-012A/B) process gas in shell side.
Feed Gas Compressor Discharge Air Cooler (E-231-001A).
Feed Gas Compressor Discharge Water Cooler (E-231-002A/D) process gas in tube side.
Feed Gas Subcooler (E-231-006A/B) process gas in shell side.
Feed Gas Compressor Discharge Drum (V-231-005A).

Each compressor train includes MS5002C gas turbine and BCL607.

1.1 Modelling Inputs and Assumptions


Train modeling for simulation study purpose, mainly refers to schematic of FIGURE 8. Dynamic model has
been built with HYSYS 2006.5. Standard HYSYS Peng-Robinson Property package has been used. The
Lee-Kessler option for the calculation of enthalpies outside of the EOS is employed.

1.1.1 Equipments

2
Train Inertia: 382.5 kg-m
Mechanical and Friction losses: Hysys Friction loss factor parameter is set in order to match
mechanical and frictional losses at rated speed, see Ref. 1.
Compressor Maps: CASE 5 compressor maps of Ref. 3 have been used in the simulation.
Anti Surge Valve (FCV-5001): CV - C1 - have been adjusted based on HYSYS Fisher universal
sizing method in order to match the process condition reported in Ref. 10. Anti surge valve
characteristic as per Ref. 10.
Coolers-Heat Exchangers (E-233-012A/B, E-231-001A, E-231-002A/D, E-231-006A/B): volumes,
outlet temperatures and pressure drops are in accordance to Ref. 5, Ref. 6, Ref. 7, Ref. 8.
Scrubbers (V-231-004A- V-231-005A): volume as per Ref. 4,Ref. 9.
Suction Isolation valve (XV-2041): 30 valve body size. Closing time 30s.
Pressure Safety Valves Set (PSV-2082/3 PSV-2102): 1300 psig.
Discharge Isolation valve (XV-2101): 24 valve body size. Closing time 24s.

1.1.2 Gas Compositions


See Ref. 1.

1.1.3 Volume Specifications


See Section 3.

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1.1.4 Boundary Conditions


Boundary conditions, for dynamic modeling purpose, are imposed in terms of pressure temperature and gas
composition on compressor suction header stream. Boundary condition in terms of pressure only is
imposed on compressor header discharge stream.

1.1.5 Assumptions

Pressure drops due to pipe fittings, swages, elbows and tees are not considered since these values
are considered negligible compared to compressor normal operating range of pressure.
Air coolers and heat exchangers have been modelled as heat exchanger with maximum available
duty in accordance to Ref. 5, Ref. 6, Ref. 7, Ref. 8.

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1.2 Steady State Validation


The model has been validated with reference to CASE 5 of Ref. 1. The general acceptance criterion is that
the deviation between simulated values and steady state conditions values shall be within +/- 3 %.

TABLE 1. Steady State Validation Results CASE 5

Parameter HYSYS Model Data sheet % Deviation


Suction Pressure (psia ) 518.9 518.8 0.02
Suction Temperature(deg.F) 101.8 101.6 0.05
Discharge Pressure (psia) 1154.0 1156.0 -0.17
Discharge Temperature (deg.F) 213.6 211.0 0.54
Av. Molecular weight (kg/kgmol) 24.99 24.98 0.04
Mass Flow (lb/h) 1086922 1106357 -1.76
Actual Vol Flow (ACFM) 7045 7170 -1.74
Compressor Speed (rpm) 3840 3875 -0.90
Compressor Duty (bhp) 18510 18362 0.81

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2 Emergency Stop Analysis


In this section dynamic simulation analysis is discussed with respect to compressor emergency stop.
Additional protection, other than ASV (eg. HGBV), if required, is investigated. Surge excursion acceptance
criterion is stated in Section 4.

CASE 5 has been selected because of the higher molecular weight.

Three simulation runs are reported below:


Run 1 refers to emergency shut down event with ASV only as surge protection system. Compressor
state initial condition is assumed to be on the limit of SCL at MCS (if applicable), or at a speed that
allows not exceeding PSV pressure limit (see Section 2.3).
Run 2 refers to emergency shut down event with ASV and HGBV as surge protection system.
Compressor state initial condition is assumed to be on the limit of SCL at MCS (if applicable), or at a
speed that allows not exceeding PSV pressure limit (see Section 2.4). HGBV Hysys CV (for
simulation purpose only) value is equal to 850 USGPM.

2.1 Emergency Stop Event Description


The ESD event is simulated as follows:

Compressor trip is raised.


Driver Power is lost.
ASV (FCV-5001) opens.
Suction/Discharge isolation valves (XV-2041/XV-2101) close.

2.2 Additional Assumptions


Upon train trip compressor driver power starts decreasing after 0.5s and then drops linearly to 0MW
in 1s.
Upon train trip ASV (FCV-5001) is forced to open in 1 sec (linearly with time) with the addition of 0.3s
of delay after the signal is raised.
Upon train trip air coolers and heat exchangers duty is reduced of 90% in 1s.

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2.3 Run 1 Results

FIGURE 1. Run 1 Operative Path

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2.4 Run 2 Results

FIGURE 2. Run 2 Operative Path

FIGURE 3. Run 2 Rotational Speed

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FIGURE 4. Run 2 Suction and Discharge Pressure

FIGURE 5. Run 2 Suction and Discharge Temperature

FIGURE 6. Run 2 ASV Mass Flow

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FIGURE 7. Run 2 HGBV Mass Flow

2.5 Conclusions
Run 1 (Section 2.3). Simulated shut down event shows that operative point passes SLL and does
not recover until the end of simulation.
Run 2 (Section 2.4). Simulated shut down event shows that operative point does not pass SLL thus
the compressor coast down is considered safe with respect to surge event. Addition of HGBV is
mandatory.

TABLE 2 reports three operating conditions obtained from Run 2 at different time to be used for HGBV CV
definition. Data reported in the table are obtained with a HGBV recovery factor of 0.9. Gas composition is in
accordance with Case 5 of Ref. 1.
The results are relevant to a HGBV with a quick opening characteristic and with an opening time of 1 s.

TABLE 2. HGBV Sizing Process Conditions <1>

Condition 1 Condition 2 Condition 3


@ t = 1.3 s @ t = 10 s @ t = 30 s
HGBV inlet pressure (psia) 1160 617 700
HGBV outlet pressure (psia) 550 581 677
HGBV inlet temperature(F) 223.7 221.3 231.3
HGBV mass flow (lb/h) 2122760 495647 420529
Inlet Heat Capacity Ratio, Cp/Cv (-) 1.397 1.287 1.295
Inlet Compressibility Z Factor (-) 0.841 0.904 0.899
HGBV opening (%) 100 100 100

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Reference List
Document GE Doc.# Rev. Customer Doc # Rev.
Ref. 1 Compressor Data Sheet (Feed Gas
SOK7352885 1 VP-18-101-231-001A/B-D-003 2
Service) BCL607

Ref. 2 Piping and Instrumentation Diagram for


NA NA 090768.231/235 C
LPG Train-4 Project (ISBL)

Ref. 3 Feed Gas Compressor Expected


SOS241793 1 VP-18-101-231-001A/B-C-003 1
Performance Curve BCL607

Ref. 4 Feed Gas Compressor Suction Drum


NA NA S090768.231-3.51-004-A-E A
Datasheet (V-231-004 A/B)

Ref. 5 Debutanizer Side Reboiler Datasheet


NA NA S090768.233-3.53-012-A-E A
(E-233-012A/B)

Ref. 6 Feed Gas Compressor Discharge Air


NA NA S090768.231-3.53-001-A-E A
Cooler (E-231-001A/B)

Ref. 7 Feed Gas Compressor Discharge Water


NA NA S090768.231-3.53-002-A-E A
Cooler (E-231-002 A~H)

Ref. 8 Feed Gas Subcooler Datasheet NA NA S090768.231-3.53-006-A-E A

Ref. 9 Feed Gas Compressor Discharge Drum NA NA S090768.231-3.51-005-A-E A

Ref. 10 Anti Surge Control Valve Datasheet for


RV-90260 0 NA NA
FCV-5001, FCV-5101

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3 Appendix A Volume Table


Piping volumes are in agreement with isometric drawings provided by DAELIM (TABLE 3 and TABLE 4).
Dynamic model includes the equipment reported in FIGURE 8.

FCV-5001

E-233-012

E-231-006 XV-2101
PSV-2041

MOV-2062 E-231-001

PSV-2102
MOV-2061
XV-2102
V-231-004

XV-2081/83

V-231-005
XV-2041
E-231-002

XV-2055 LCV-2107

XV-2042 LCV-2047 XV-2082/84


LCV-2101

LCV-2041

FIGURE 8. Plant Simplified PFD

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TABLE 3. Pipe Volume Table <1>


Line No. From To Line Size( Inch) Line ID (mm) Line Length (m)
P-231-02303-CD5 P-231-02201-CD5 XV-2041 30 762 43.3
P-231-02401-6R1D XV-2041 P-231-02408-6R1D 30 762 3.9
P-231-02401-6R1D P-231-02408-6R1D P-231-02807-6R1D 30 762 13.8
P-231-02401-6R1D P-231-02807-6R1D V-231-004A 30 762 3.7
P-231-02402-6R1D V-231-004A MOV-2061 30 762 58.2
P-231-02402-6R1D MOV-2061 P-231-02503-GRW5 30 762 1.6
P-231-02402-6R1D P-231-02503-GRW5 C-231-001A 30 762 8.2
P-231-02501-GRW5-24" C-231-001A P-231-02503-GRW5 24 609.6 10.0
P-231-02501-GRW5-24" P-231-02503-GRW5 NRV 24 609.6 7.9
P-231-02503-GRW5-24" P-231-02501-GRW5-24" XV-2055 24 609.6 11.4
P-231-02503-GRW5-24" XV-2055 P-231-02402-6R1D 24 609.6 4.1
P-231-02501-GRW5-24" NRV MOV-2062 24 609.6 2.8
P-231-02501-GRW5-24" MOV-2062 P-231-02502-GRW5-24" 24 609.6 45.5
P-231-02502-GRW5-24" P-231-02501-GRW5-24" E-233-012A 24 609.6 360.9
P-233-03910-GRW5-24" E-233-012A P-231-02501-GRW5-24" 24 609.6 360.8
P-231-02501-GRW5-24" P-231-02502-GRW5-24" SP-1601 24 609.6 5.4
P-231-02501-GRW5-24" SP-1601 P-233-03910-GRW5-24" 24 609.6 2.0
P-231-02501-GRW5-24" P-233-03910-GRW5-24" E-231-001A 24 609.6 44.6
P-231-02601-GRW5-24" E-231-001A P-231-02701-GRW5-18" 24 609.6 37.6
P-231-02701-GRW5-18" P-231-02601-GRW5-24" XV-2081 18 457.2 6.9
P-231-02702-GRW5-18" P-231-02601-GRW5-24" XV-2083 18 457.2 6.9
P-231-02701-GRW5-18" XV-2081 E-231-002A/B 18 457.2 9.2
P-231-02702-GRW5-18" XV-2083 E-231-002C/D 18 457.2 9.2
P-231-02703-FRW5-18" E-231-002A/B XV-2082 18 457.2 6.2
P-231-02704-FRW5-18" E-231-002C/D XV-2084 18 457.2 6.2
P-231-02703-FRW5-18" XV-2082 P-231-02705-FRW5-24" 18 457.2 8.3
P-231-02704-FRW5-18" XV-2084 P-231-02705-FRW5-24" 18 457.2 8.3
P-231-02705-FRW5-24" P-231-02704-FRW5-18" P-231-02808-FRW5-24" 24 609.6 2.4
P-231-02808-FRW5-24" P-231-02705-FRW5-24" E-231-006A/B 24 609.6 22.5
P-231-02809-FRW5-24" E-231-006A/B P-231-02705-FRW5-24" 24 609.6 19.0
P-231-02705-FRW5-24" P-231-02808-FRW5-24" CSO-VALVE 24 609.6 3.2
P-231-02705-FRW5-24" CSO-VALVE P-231-02809-FRW5-24" 24 609.6 10.3
P-231-02705-FRW5-24" P-231-02809-FRW5-24" V-231-005A 24 609.6 8.6
P-231-02801-FRW5-24" V-231-005A P-231-02805-FRW5-20" 24 609.6 7.1
P-231-02801-FRW5-24" P-231-02805-FRW5-20" NRV 24 609.6 16.0
P-231-02801-FRW5-24" NRV XV-2101 24 609.6 1.9
P-231-02805-FRW5-20" P-231-02801-FRW5-24" FCV-5001 20 508 16.7
P-231-02807-6R1D-24" FCV-5001 P-231-02401-6R1D-30" 24 609.6 18.3

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TABLE 4. Equipment Volume Table <1>

Eq. No Description Volume (m3)


FEED GAS COMPRESSOR
V-231-004A
SUCTION DRUM 50.7
FEED GAS COMPRESSOR
V-231-005A
DISCHARGE DRUM 52.8
FEED GAS COMPRESSOR
E-231-001A DISCHARGE AIR COOLER 16.6
FEED GAS COMPRESSOR
E-231-002A DISCHARGE WATER 3.9
COOLER
FEED GAS COMPRESSOR
E-231-002B DISCHARGE WATER 3.9
COOLER
FEED GAS COMPRESSOR
E-231-002C DISCHARGE WATER 3.9
COOLER
FEED GAS COMPRESSOR
E-231-002D DISCHARGE WATER 3.9
COOLER
E-231-006A FEED GAS SUB COOLER 9.2
DEBUTANISER SIDE
E-233-012A
REBOILER 10.7

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4 Appendix B ESD Acceptance Criteria


ESD event is considered potentially unsafe for equipment (risk of compressor surge) whenever simulation
study results in compressor operative point excursion beyond compressor map Surge Limit Line, for more
than 1s at speed above 60% of rated.

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