Improve Safety, Operability &

Controllability of Your Plant Operations

Using Dynamic Process Simulation
Erika Belmont
Sandeep Mohan
Today’s Presenters

Erika Belmont
Product Manager, AspenTech

Sandeep Mohan
Sr. Product Marketing Manager, AspenTech

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Register Today!

Marriott Marquis, Houston, TX | April 29 - May 3, 2024

Registration Now Open!

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AGENDA
▪ Introduction to Dynamic Simulation

▪ Key Applications of Dynamic Simulation

▪ Solution Demonstration

▪ Case Studies

▪ Key Takeaways

▪ Next Steps To Get Started

▪ Q&A

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Why Use Dynamic Simulation?

▪ Process plants are never truly at steady state

– Feed and environmental disturbances
– Heat Exchanger Fouling
– Equipment/Instrument Malfunctions

▪ Transient behavior are best studied using Dynamic Simulation

– Transition between operating conditions
– Start-up, Normal/Emergency Shut-down Testing

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Steady State Vs Dynamic Simulation
Steady State Simulation Dynamic Simulation

Design/Rating/Optimization Rating/Design Support/Validation

Accumulation = 0 Accumulation <> / = 0

Linear Equations Differential Equations

Flow Driven Pressure Driven

Modular non- sequential algorithm Modular sequential Algorithm

No Process Control Process Control

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Aspen HYSYS Dynamics
▪ Dynamic process simulator integrated into Aspen HYSYS
– Conservation equations account for process changers over time (material, energy, and composition)
– Accumulation term differentiated with respect to time

𝐴𝑐𝑐𝑢𝑚𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝐼𝑛 − 𝑂𝑢𝑡 + 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑜𝑛 − 𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛

▪ Offers unique functionality not available through steady state operation alone
– Event scheduler
❑ Simulate startup, shutdown, disturbances, etc.
– Process Control (PID, Ratio, MPC, etc.)
❑ Pre-tune control loops, DCS checkout, etc.
– Strip Charts
❑ Data Trends, Exporting to Excel, etc.

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Aspen HYSYS Dynamics
Interactive Environment

Multiple Trends real time

Modify most of the

specified variables while
the integrator is running

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Equipment Supported in Aspen HYSYS Dynamics
▪ Rotating equipment
– Pumps
– Compressors (Centrifugal and Positive displacement)
– Expanders

▪ Static Equipment
– Heat Exchangers (Shell & Tube, Air Cooler, Fired Heater)
– Tanks
– Reactors (CSTR, Plug flow, Conversion, Equilibrium, Kinetic)
– Columns

▪ Valves
– Control Valves
– Pressure Relief Valves

▪ Pipe Segment
– Complex pipelines Including pressure drop and heat transfer

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Controller & Logical Operations Supported in Aspen HYSYS Dynamics

▪ Used to replicate control logic and strategies used in the

actual plant DCS system

▪ Accessible in Dynamics & Control group of the Model

Palette
– Split Range Controller
– Ratio Controller
– PID Controller
– Feedforward Controller
– MPC Controller
– Transfer Functions (Integrator, Lag, Lead, Delay, 2nd Order, Ramp, Rate Limiter)
– Boolean (Not, And, Or, Xor, Off Delay, On Delay, Latch, Count Up, Count Down)
– Cause & Effect Matrix

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Key Applications of Dynamic Simulation

Safety System Evaluation

Operator Training Simulator

Operational Decision Support : Compressor Surge Analysis

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Safety System Evaluation
Dynamic Relief Load

Accurately predict stream

conditions during plant upsets

Enables site-wide analysis of all

possible ‘what-if’ scenarios

Ensure safety while avoiding

overdesign of equipment

Uncover unsafe operating

conditions

Best-in-class dynamic process

simulation
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BLOWDOWN
Ensure safety while reducing CAPEX by pinpointing
exact piping locations requiring expensive materials

Rapid emergency depressurization of vessel and

equipment

Superior thermodynamic predictions for supercritical

fluids

Industry-proved and validated with experimental data

Developed by professors at Imperial College London

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Operator Training Simulator
Operator Training
▪ Challenges:
– Retirement of experienced operators leave the plant with inexperienced
operators increasing the operational risks as well as deteriorating the
performance of the plant
– Operation of new plants or process units would require training of operators
to perform unfamiliar processes
– Maintain operational best practices

▪ Solution:
– Aspen Operator Training used to develop OTS solutions based on Aspen
HYSYS Dynamics
– Provides the same experience as with control room DCS displays
– Enables connection between dynamic simulation models for different
operating units

▪ Benefits:
– Reduce time and effort required for development of OTS solutions using
same simulation models across the assets lifecycle
– Train operators earlier, Bring plant online faster, Reduce safety incidents &
Maximize production
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Operator Training System Applications

Operator Training
• Emergency scenarios training
• Plant Startup training
• Operators' familiarization with the process and the DCS displays

DCS Checkup and Validation

• DCS logic checkout: make sure the DCS logic works correctly before going live with the actual plant
• Emergency Shutdown (ESD) Logic Checkout
• DCS Alarm settings
• DCS Control Loop Tuning
• Check the DCS Displays

Engineering Test Simulators

• Plant Engineers (not familiar with Process Simulators) study aspects of their plant using a rigorous dynamic simulator
• OTS Systems provide a display that emulates the control screens that plant engineers are familiar with

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Operational Decision Support:
Compressor Surge Analysis
Operational Decision Support : Compressor Surge Analysis
▪ Challenges:
– Compressor surge can damage expensive equipment and affect the
whole process operation resulting in high temperature, vibration &
flow reversal.
– Hard to determine safe operating conditions for the compressor
based on the operation of the anti-surge controller

▪ Solution:
– Aspen HYSYS Dynamics offers rigorous dynamic simulation of
compressor and adjoining equipment operations including anti-
surge controller enabling
❑ Evaluation of safe operating conditions for the compressor
❑ Analysis of current anti-surge controller strategy & effect of anticipated
operational changes on compressor performance

▪ Benefits:
– New users supply minimal inputs with pre-made templates,
scenarios & results forms
– Empower everyone to use dynamics
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Activated Compressor Surge Analysis

Dynamic model
automatically built
from steady state
compressor model

Automatically generate
results forms

Pre-defined Emergency
scenarios

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Dynamic Sub-flowsheet
Independent Dynamic Analysis, “within” steady-state model

Simplified Dynamics ribbon

Dynamic Subflowsheet Subflowsheet generated

independent of parent with defaults for quick
flowsheet simulation

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Templates
Three pre-built templates for compressor configuration + ability to create custom templates

Three pre-made templates

Image updates depending on

template selected

Ability to create custom

templates

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Innovations in V14
New Equipment Malfunction Scenarios
▪ Allow OTS trainers and dynamics users to model automated
equipment failures or performance deterioration scenarios.

▪ Execute via OTS applications or the Event Scheduler within HYSYS.

▪ New malfunction scenarios in V14:

– Compressor: Total failure, performance deterioration
– Expander : Total failure, performance deterioration

▪ Some examples of pre-defined equipment failures/deterioration

implemented in previous versions:
– Pump: Overheating, trip or performance deterioration
– Valve: Actuator failure, plugging, leakage, stickiness, offset and deadtime
– Relief Valve: Leakage, fail to open, fail to close
– Heat exchanger: Performance deterioration, tube fouling, shell fouling
– Air Cooler: UA Performance deterioration, fan deterioration and fan failure

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Demonstration
 SUCCESS
Success Stories From Across the World STORIES

50% Reduction
Production & Safety
in flare peak relief load
improvements of $16M/Yr.
from more accurate estimates

Reduced start up time by Better sizing of recycle &

40% bypass valves

Reduce
Saved $2.6M/Yr. using OTS
Execution Time By 30%

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Key Takeaways

▪ Save costs and ensure smooth operations by confidently designing and analyzing for
transient conditions using dynamic simulation with trusted accuracy and built-in
templates.

▪ Complete process control schemes design verification, safety studies, relief valve sizing
and failure analysis. Develop policies for startup, shutdown and other transitions.

▪ Use the industry-standard dynamic simulator for design, engineering verification, DCS
checkout, OTS deployment and operational improvement studies.

▪ Easily convert steady-state Aspen HYSYS models to dynamic process simulation models
entirely within Aspen HYSYS.

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Next Steps To Get Started…
Click on the below links for step-by-step guidelines
How can you get started?
Viewlet: Getting Started with Aspen HYSYS Dynamics
Webinar Recording: Never the Same-Using Aspen HYSYS Dynamics to Predict Processes
Jump Start Guide: Using Aspen HYSYS Dynamics with columns
Viewlet: Activated Dynamics - Single Stage Compressor Modeling
Jump Start Guide: Compressor Modeling in Aspen HYSYS Dynamics
Tutorial Guide: Aspen Operator Training V11
Webinar Recordings: Transform Operations, Manage Risks by Combining Process (from
AspenTech) and 3D Immersive (from Emerson) Digital Twins

Visit our website at: https://www.home.aspentech.com/

Additional Support Customer Support site at: https://www.esupport.aspentech.com

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What is New in Aspen HYSYS V14

Integrated Crude Oil to Built-In Electrolyzer Models Emissions Dashboard for

Bio-fuel & Co-feed Processing
Chemicals Processes for AEM & PEM Scope-1 &2

Specialized H2 Optimize Carbon Capture with Improved OTS & Improved access to AI
Property Packages Benfield Process Dynamic Simulations technology

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 Upgrade Acceleration Program
Unlock the value of our latest releases with upgrade
assistance from a dedicated expert

Program Includes:
▪ Free remote upgrade support
▪ Sample Upgrade Plan
▪ Guidance on customer specific plan
▪ Priority Support for Upgrades
▪ Assistance with Model Validation
▪ 60 days of free eLearning
▪ 25% discount off training at OPTIMIZE 24
▪ Free User Certification and Organizational
learning plan for competency development
Sign up today!
learn.aspentech.com/upgrade-acceleration-program
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Q&A

▪ Email Contact:
– Erika.Belmont@aspentech.com
– Sandeep.Mohan@aspentech.com

▪ For Additional Information Visit:

– https://home.aspentech.com/
– https://esupport.aspentech.com

© 2024 Aspen Technology, Inc. All rights reserved. 31

Thank You!
How Aspen Operator Training Works?
Components of an Operator Training System
(1) Dynamic process model or models (large models are broken
into sections to improve performance)
(2) OTS executive (or “framework”) manages model execution
and communications between the segregated models and 1 Dynamic Models 4 DCS Emulator
other solution components
(3) DCS Console graphics emulate the control room screens – in
some cases the operator graphics may be the actual
operator screens from the DCS solution provider 2 OTS Executive

(4) DCS emulator(s) – emulate the distributed control system

solutions (may also be actual DCS hardware)
(5) Instructor station – allows the instructor to create & launch
scenarios such as “power failure”, to monitor user sessions,
and may provide some level of “grading” 5 Instructor Station

HYSYS Dynamics
3 DCS Console Graphics
Aspen Operator Training

© 2024 Aspen Technology, Inc. All rights reserved. 33