SimSci®

DYNSIM® 5.3.2
Compressor Modeling
Guidelines

December 2016
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 Table of Contents

Introduction ......................................................................................................................... 5
Reciprocating Compressor ................................................................................................ 6
Compressor Modeling in DYNSIM ..................................................................................... 7
Centrifugal Compressor ................................................................................................................................... 7
Basic Tab ..................................................................................................................................................... 7
Curves Tab ................................................................................................................................................... 9
Solution Options Tab .................................................................................................................................. 11
External Inputs Tab .................................................................................................................................... 11
Thermo Tab ................................................................................................................................................ 12
Reciprocating Compressor............................................................................................................................. 14
Basic Tab ................................................................................................................................................... 16
Solution Options Tab .................................................................................................................................. 17
External Inputs Tab .................................................................................................................................... 17
Thermo Tab ................................................................................................................................................ 18
Disclaimer
This document is based upon proven project work performed using earlier versions of DYNSIM® application.
New capabilities introduced in DYNSIM 5.0 and 5.1 are not yet covered in the Best Practices documents.
These documents will be updated in future releases of DYNSIM application.
Introduction

Compressor is a flow device that is used to model a centrifugal compressor. The Compressor calculates the
head based on the pressure differential across it. The volumetric flow rate is interpolated from the user
provided performance curve, based on the calculated head. Power is calculated from the user provided
efficiency.

The user can characterize Compressor performance by specifying three or more points from the manufacturer-
provided characteristic curve or use DYNSIM® supplied default curve and specify only the design point.
DYNSIM software provides several options to configure the performance curves. The flow data can be
provided on volumetric, mass, or corrected mass basis. Similarly, the head data can be provided in pressure
head (kJ/kg), pressure difference, pressure ratio, or static head of the fluid being compressed. The speed data
can be provided in actual speed or corrected speed basis. The equations for corrected mass flow and corrected
speed are given below:

In all cases, a cubic spline or a linear curve fit may be chosen for the performance curve. The parameters
DHScale and QScale are used to scale the Compressor performance. Fan laws are used to scale Compressor
curves with speed. As an alternative to fan laws that represent performance at different speeds, users may also
specify multiple performance curves for different Compressor speeds. The curve is also modified with change
in inlet guide vane (IGV) position. The user also has a choice to specify performance curves at multiple IGV
positions.

There are three operating regions for a Compressor:

• Normal Compressor operation where the head is always positive.

• Surge condition that occurs at low flow or high head. Furthermore, reverse flow can result when the
head developed is not sufficient enough to compress the fluid against the discharge pressure.
• Stonewall begins where the last performance curve point is provided and is modeled past the point
where the suction pressure is higher than the discharge pressure.

Compressor can indicate when it is in surge. However, the model is designed to perform smoothly in the surge
region and does not exhibit any sudden flow instability when entering surge.

Compressor calculates the shaft power, fluid flow, and fluid enthalpy rise. The speed is calculated externally
from a Shaft or Motor and is transferred to the Compressor by a mechanical stream. The Compressor sets the
power required in the mechanical stream. Alternatively, speed can be kept constant. Compressor does not
include either fluid or metal thermal holdup.

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Compressor Modeling Guidelines in DYNSIM
Reciprocating Compressor

Reciprocating Compressor is a flow device that is used to model a Reciprocating Compressor or a Positive
Displacement Pump. Reciprocating Compressor calculates the volumetric flow based on the pressure
difference, Shaft speed, and volumetric efficiency.

This type of Compressor calculates the shaft power, fluid flow, and fluid enthalpy rise. The speed is calculated
from a Shaft or Motor and transferred to the Reciprocating Compressor by a mechanical stream. The
Reciprocating Compressor sets the required power in the mechanical stream. Alternatively, speed can be kept
constant.

Reciprocating Compressor can be loaded and unloaded where the volumetric flow is proportional to the
number of cylinders in service. The loading controls are not modeled hence the loading must be set externally.

Reciprocating Compressor has an option of activating built-in check valve such that forward flow is not
possible when the discharge pressure is lower than the suction pressure. However, a small reverse flow is
allowed to take care of gland and seal leakages.

Pulsation is not modeled. Reciprocating Compressor does not include either fluid or metal thermal holdup.

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Compressor Modeling Guidelines in DYNSIM
Compressor Modeling in DYNSIM

Centrifugal Compressor
The data required for modeling a Compressor are Compressor Curve, Compressor Data Sheet, and Power
Curve (if available).

Basic Tab
Design Conditions
The flow curve scale corresponds to the QScale parameter. To configure the default performance curve, set
the design flow with this parameter. It is also used for scaling user-defined performance curve if one is
provided.

The head curve scale corresponds to the DHScale parameter. To configure the default performance curve, set
the design head value with this parameter. It is also used for scaling user-defined performance curve if one is
provided.

The efficiency curve scale corresponds to the ETAScale parameter. The default efficiency curve assumes a
uniform efficiency of ONE. It can be used to scale the default curve or user-defined efficiency curve.

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Compressor Modeling Guidelines in DYNSIM
The reference Shaft speed corresponds to the SpeedRef parameter. The design speed of the Compressor is set
here. It is used in adjusting the Compressor curves based on fan laws. The actual value is only required if
speed is set by a Motor or Shaft using a mechanical stream.

Parameter Value
Basic
Flow curve scale ‘1’, if curve is available, else Rated Capacity from data sheet/PID
Head curve scale ‘1’, if curve is available, else Rated Pressure Differential from data sheet/PID
Efficiency curve scale ‘1’, if curve is available, else 0.6 (assumption). Tune “efficiency” for tuning
compressor discharge temperature. Increase in efficiency decreases discharge
temperature and vice-versa.
Reference shaft speed Setting additional reference shaft speed of base curve (in curves tab) sets the
reference shaft speed
Flow conductance Conductance at zero speed operation. Leave at default 0.05
Reverse flow factor ‘0’, if the line has check valve in PID, else 1

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Compressor Modeling Guidelines in DYNSIM
Wind Milling and Reverse Flow
The flow conductance corresponds to the J parameter. The Pump performs like any simple flow device when
operating at zero speed or when wind milling. The default value can be used if flow at zero speed or wind
milling is not important.

The reverse flow factor corresponds to the KJr parameter. If there is a check valve in line with the Pump, use
the default value of zero.

Curves Tab
Use default curve corresponds to the UseDefaultCurve parameter. Select Use Default Curve check box to
use the default performance curve. The design flow and head can be set through the parameters QScale and
DHScale when default curve is used.

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Compressor Modeling Guidelines in DYNSIM
When the check box to use default performance curve is not checked, the user-specified performance curve
can be set for the base curve at the reference speed specified on the Basic Tab. The flow rate, head, and
efficiency correspond to the parameters QData, DHData, and ETAData, respectively. A minimum of three
data points should be specified. The user can add more points by adding new rows to the existing table. It is
not possible to specify the UOM of the QData, DHData, and ETAData curves, because the curve UOM is
defined by the scale parameters on the Basic tab.

If the number of additional curves is not zero, the user must specify an additional curve speed reference and
data for the additional curves. The number of additional curves corresponds to the NAddCurves parameter.
The reference speed, flow rate, head, and efficiency curves for the additional curves correspond to the
SpeedRefN, QDataN, DHDataN, and ETADataN parameters, where N refers to the number of the additional
curves.

The parameters QScale, DHScale, and ETAScale adjust the default curve or the user-defined curve. Either the
curve data can be normalized or the scale values can be normalized. It is important that the product of the
curve data and the scale parameters equal the user-defined curve.

Use surge curve corresponds to the UseSurgeCurve parameter. Select Use surge curve check box to use the
custom surge curve. When default curve is used, the design flow and head can be set through the parameters
QScale and DHScale.

The surge flow point corresponds to the QSurge parameter. Set this value according to the point where the
surge line intersects the performance curve at the reference speed.

The speed data and surge data in the surge curve table corresponds to SpeedData and SurgeData parameters,
respectively. SpeedData is the normalized speed data for plotting surge curve against surge flow data.
SurgeData is the normalized surge flow data for plotting surge curve against speed data. Surge flow will be
calculated by interpolating the curve at Compressor speed.

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Compressor Modeling Guidelines in DYNSIM
Solution Options Tab
Calculation Options
The calculation method corresponds to the CalcMethod parameter.

Rigorous method
The head is calculated based on isentropic flash calculations. The actual enthalpy change is calculated based
on the isentropic efficiency.

Adiabatic method
In this method, a direct equation is used to estimate the head across the Compressor. It uses the
compressibility factor, specific heat ratio, and the ratio of inlet and exit pressures for estimating the head.

Polytropic method
It is the industry-accepted method for Compressors with high compression ratios and multiple stages. The
polytropic process by definition means there are heat losses thereby requiring additional energy to perform the
same amount of work on the gas. This heating effect comes from gas friction, turbulence, conduction, or
radiation. The extent of these losses is dependent on the gas polytrophic exponent and the polytrophic
efficiency.

External Inputs Tab

External Inputs Tab is used to set dynamic parameters. Only the initial value of these parameters can be set
through the data entry window. Parameter references and equations can be attached to these parameters. The
numerical value of these parameters cannot be changed in the running engine through data entry window and
will have no effect on the running model.

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Compressor Modeling Guidelines in DYNSIM
Thermo Tab
Thermo Options
Component slate corresponds to the CompSlate parameter, Method slate to the Methodslate parameter, Local
thermo options to the LocalThermoOption parameter, and Local flash options to the LocalFlashOption
parameter. To avoid having set these parameters for all the new equipment on the flow sheet, specify the
defaults in the SIM4ME™ Thermo GUI.

Phase Options
Internal Phases corresponds to the Internal Phases parameter. Use this to specify the kind of flash performed
by SIM4ME Thermo. The default value is VLE. However, pump execution speed should be faster if this
parameter is changed to Liquid.

Notes:
1. To convert differential head from “meters” to kJ/kg:
Head in kJ/kg = Head in “m” * g (Acceleration due to gravity= 9.81m/s2)/1000
2. When the Compressor head curve scale and flow curve scale is not available and only PRO/II model
is available, then:
• Use default curve for Compressor
• Use the SS head and flow from PRO/II as the head curve scale and flow curve scale, respectively.

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Compressor Modeling Guidelines in DYNSIM
 3. Entered performance curve is adjusted to get a monotonic curve. For example, if a curve with
following points is given in DYNSIM application, the curve is manipulated as given in the table
below.

Flow (m3/sec) Head (kJ/kg)

0 13124
0.8 13044
1.6 12964
2.4 12884
3.2 12804
3.4 12568
3.6 12169
3.8 11581
3.9 11200
4 10651
4.19 8766
4.24 6575
4.29 4383
4.35 2192
4.4 0

4. In the manipulated curve, it is seen that zero flow head is around 14,000 kJ/kg, whereas, in the data
entered, head is 13,124 at zero flow. For getting exact head at zero head, KHmax (in Advance edit )
can be increased to a maximum of 20 and KHmin can be reduced to 0.05; Increasing KHmax and
reducing KHmin can lead to network instability, so use these parameters with caution and only if
required.

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Compressor Modeling Guidelines in DYNSIM
 When KHmax is increased to 10 and KHmin is reduced to 0.1, you get the required curve as per the
data entered.

5. For configuring IGV to Compressor, connect a graphical valve.pos to compressor.pos. Practically,

completely closed IGV allows 10-30% flow through Compressor, so change compressor. FGMIN (in
advance edit, default-0.1 fraction) to 0.2 - 0.3 if required.

6. To know the nearness to surge (surge proximity), check compressor.surgeprox

• Surgeprox < 1, Compressor is operating in safe region
• Surgeprox = 1, Compressor is at surge
• Surgeprox > 1, Compressor is operating at left of surge line
7. Entering multiple Compressor curves:
• Select a curve at operating speed as base curve. Setting additional reference shaft speed of base
curve sets the reference shaft speed of Compressor in Basic Tab.
• Enter the number of additional curves and same number of rows in surge data when using surge
curve data. For example, if there are four Compressor curves (including base curve), take four
surge points for surge curve.
8. For surge curve, enter speed data as
• Speed data1 = base curve reference shaft speed (1) /reference shaft speed
• Speed data2= curve1 reference shaft speed / reference shaft speed
• Speed data3= curve2 reference shaft speed / reference shaft speed

Reciprocating Compressor
Reciprocating Compressor is a flow device that is used to calculate the volumetric flow based on the pressure
difference, shaft speed, and volumetric efficiency.

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Compressor Modeling Guidelines in DYNSIM
Reciprocating compressor calculates the shaft power, fluid flow, and fluid enthalpy rise. The speed is
calculated from a Shaft or Motor and transferred to the reciprocating compressor by a mechanical stream. The
reciprocating compressor sets the required power in the mechanical stream. Alternatively, speed can be fixed.

Select reciprocating compressor in DYNSIM application.

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Compressor Modeling Guidelines in DYNSIM
Basic Tab
Design Conditions

Piston displacement refers to the Disp parameter. Clearance fraction is calculated from the clearance volume
divided by the piston displacement and should be provided by the manufacturer.

Valve losses refer to the L parameter. GPSA recommends a typical value of 0.04.

Specific heat ratio refers to CpCv.

Isentropic efficiency refers to ETA.

Zero Speed Operation

Flow conductance corresponds to the J parameter. Reciprocating compressor is sized like any simple flow
device when operating at zero speed. The default value can be used if the flow at zero speed is not important.

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Compressor Modeling Guidelines in DYNSIM
Solution Options Tab
Calculation Options
Calculation method corresponds to the CalcMethod parameter. In Rigorous method, the head is calculated
based on isentropic flash calculations. In GPSA method, the head is calculated by a direct formula from the
GPSA handbook.

External Inputs Tab

External Inputs Tab is used to set dynamic parameters. Only the initial value of these parameters can be set
through the data entry window. Parameter references and equations can be attached to these parameters. The
numerical value of these parameters cannot be changed in the running engine through data entry window and
will have no effect on the running model.

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Compressor Modeling Guidelines in DYNSIM
External Speed Calculation
Shaft speed corresponds to the Speed parameter. No entry is required if the reciprocating compressor is
connected with a mechanical stream.

Cylinder Loading and Unloading

Number of operating cylinders corresponds to the Loading parameter. By default, the Compressor behaves as
a single cylinder in operation. Attach a parameter reference to this parameter to load and unload the
Compressor.

Thermo Tab
Thermo Options
Component slate corresponds to the Comp Slate parameter, Method Slate to the Method Slate parameter,
Local thermo options to the LocalThermoOption parameter, and Local flash option to the
LocalFlashOption. To avoid having to set these parameters for all the new equipment on the flow sheet,
specify the defaults in the SIM4ME Thermo GUI.

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Compressor Modeling Guidelines in DYNSIM
Phase Options
Internal Phases corresponds to the Internal Phases parameter. Use this to specify the kind of flash performed
by SIM4ME Thermo.

Notes:
• To get the required head of the reciprocating compressor, tune the clearance fraction, valve losses,
isentropic efficiency and put an equation in piston displacement.
• In a Compressor, the main process objective is to maintain a constant volumetric flow independent of
pressure variations (up to a certain limit) upstream and downstream of the compressor.
• The reciprocating compressor calculates Q through the following equation:

Q (m3/h) = Loading * (speed / 60) * Displacement * Volumetric efficiency

• It turns out that by attempting to fix the volumetric efficiency = 1.0, the Q estimated by this equation
will be overwritten by a Q calculated by the pressure flow solver especially in cases that suction
pressure is very low (around 1KPa). Adjusting the CVs of the valves will make the volumetric flow
consistent calculated from the above equation and the one calculated by the pressure/flow solver.
• You can either adjust the available tuning parameters to neutralize the pressure effect on the
volumetric efficiency or add an equation on the L factor that will keep the volumetric efficiency close
to 1.
• Considering that the efficiency is calculated as follows:

• If you want to have ETA = 1 in all conditions, put the following equation for the valve loss term:

L = -0.01 * (Px/Pi)

where:
Px is the P parameter of the outlet stream (ex: E004S_002.P)
Pi is the P parameter of the inlet stream (ex: E004S_001.P)

• In this way you can remove the first term:

• Remember to switch the L parameter to Dynamic after configuring the equation.

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Compressor Modeling Guidelines in DYNSIM
 • It is also important to set the clearance (C parameter of the reciprocating compressor) as 0%. You can
therefore remove the second term:

• In this way the resulting equation for the efficiency will be:

• After configuring the reciprocating pump, you can ensure that the setting is right by monitoring the
PUMP.ETAV parameter and ensure that it is always 100%.
• The final equation of the volumetric flow rate can now be written as follows:

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Compressor Modeling Guidelines in DYNSIM
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