Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.
: 00
TABLE OF CONTENTS
1.0 SCOPE ............................................................................................................................ 3
2.0 ASSOCIATED GUIDELINES .......................................................................................... 3
3.0 BACKGROUND .............................................................................................................. 3
3.1 GENERAL DESCRIPTION .............................................................................................. 3
3.2 PLANT CONFIGURATIONS............................................................................................ 4
4.0 PERFORMANCE SEQUENCE ....................................................................................... 4
5.0 PERFORMANCE INSTRUCTIONS ................................................................................. 4
5.1 DEFINE THE MINIMUM FLOW CONDITIONS TO AND FROM THE COMPRESSOR: . 4
5.2 DEFINE FLOW SCHEME DURING KICKBACK CONDITIONS. ..................................... 5
5.3 ESTABLISH THE PRESSURE PROFILE OF THE SYSTEM. ......................................... 5
5.4 DEFINE THE PERCENTAGE OF VAPORIZATION ........................................................ 5
5.5 ESTABLISH THE BASIS AND CONTROL SCHEME FOR THE SIMULATION. ............. 5
5.6 DRAW SIMULATION BLOCK DIAGRAMS...................................................................... 6
5.7 DEVELOP THE SIMULATION INPUT FILE. ................................................................... 7
5.8 RUN SIMULATION AND VERIFY RESULTS .................................................................. 7
5.9 ISSUE RESULTS ............................................................................................................ 7
6.0 REVISION HISTORY ...................................................................................................... 7
7.0 APPENDICES ................................................................................................................. 7
7.1 APPENDIX A ................................................................................................................... 8
7.2 APPENDIX B ................................................................................................................... 9
7.3 APPENDIX C ................................................................................................................. 12
7.4 APPENDIX D ................................................................................................................. 14
7.5 APPENDIX E ................................................................................................................. 28
7.6 APPENDIX F ................................................................................................................. 29
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
1.0 S COP E
This Design Guideline specifies the method to be used to produce a preliminary
simulation of a refrigeration (ethylene/propylene) system during kickback conditions
for sizing the suction drums and the kickback lines. This effort is required prior to
the finalization of the compressor minimum flow conditions, which is later specified
by the compressor vendor.
This guideline is applicable to the thermosyphon – type of minimum flow cooling
only, and does not apply to liquid atomizing quench or sparging into liquid –
containing drums.
2.0 AS S OCIATED GUIDELINES
Ethylene Plant Design Standards (DTS-T-P-03001, old No. 3410P001A)
Ethylene Refrigeration Guidelines (DDG-T-P-03328, old No. 3410S018A) - Later
Propylene Refrigeration Guidelines No. (DDG-T-P-03329, old No. 3410S018B) -
Later
In execution, refer to the Process Design Guidelines for the current job.
3.0 BACKGROUND
3.1 GENERAL DESCRIPTION
During plant start-up, temporary shut-down, and times when the plant is not in full
operation, the Ethylene and Propylene Refrigeration Systems require additional
vapor flow through kickback lines to the suction drums to provide the required
saturated vapor overhead to the compressor.
When the users at any level of refrigeration are unable to provide the normal heat to
the suction drum feed, its overhead vapor flow is reduced, possibly causing the
compressor to go into surge and then shutdown. The kickback line contains
superheated vapor from the final stage(s) of the compressor and is available to
each suction drum to provide for the necessary amount of vapor flow to the
compressor to prevent shutdown.
To prevent overheating from kickback operation, it is necessary to desuperheat the
vapor feeding the compressor, using liquid refrigerant liquid. To avoid liquid
entrainment in the overhead stream feeding back to the compressor, the kickback
vapor is desuperheated just before the suction drum instead of the overhead line.
This is accomplished by mixing it with a liquid recycle stream which is drawn from
the drum. The liquid recycle flowrate is based on a specified amount of vaporization
when mixed with the kickback line.
(See Appendix A - Page A-2, for an example of a Propylene Refrigerant System
PFD)
The kickback lines are at full capacity during start-up or any other time when all user
exchangers are down. The only exchangers required for minimal compressor
operation are the desuperheater(s) and condenser(s). Therefore, it is important to
note that the operation of the compressor is dependent on the availability of the
utility fluid to these exchangers.
The purpose of these calculations is to determine the maximum flow through the
kickback lines and liquid recycle lines at each level of refrigeration. Therefore, the
system will be simulated under full kickback conditions.
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
The following conditions define the refrigeration system during full kickback:
a) Minimal flow through the compressor - typically 80 wt% of normal flows to/from
each stage of compression.
b) All exchangers, except for the refrigerant desuperheater(s)/condenser(s), are
not in operation.
3.2 PLANT CONFIGURATIONS
The flow configurations of the Ethylene and Propylene Refrigerant Systems may
vary on each project. This design guideline will use the Propylene Refrigerant flow
scheme of the Maoming Ethylene Project as an example for describing the
simulation and calculation procedure (see Appendix A – Page A-2). Although flow
schemes may deviate from this example, the philosophy of the simulation is the
same and can be used for both Ethylene and Propylene Refrigerant Systems. The
requirement to do this exercise is system dependent, i.e., integrated or stand alone
system. An example of a refrigerant heat pump/compressor system is given in
Appendix F, Page F-2
4.0 P ERFORMANCE S EQUENCE
a) Obtain flow conditions to and from each stage of compressor for normal
operating conditions.
b) Define the flow conditions to and from the compressor during full kickback.
c) Specify exchangers as operating or non-operating.
d) Define flow scheme of kickback lines.
e) Establish pressure profile for the system.
f) Define percentage of vaporization of liquid recycle streams when mixed with the
individual kickback lines.
g) Establish basis and control scheme for simulation.
h) Draw simulation block diagram.
i) Develop simulation input file.
j) Run the simulation.
k) Verify that the calculated flow conditions agree with the defined flow conditions
to and from the compressor.
l) Obtain approval of results and issue.
5.0 P ERFORMANCE INS TRUCTIONS
The following is a guideline to simulate a refrigerant system during full kickback
conditions. The instructions are based on the PC-based simulation package SimSci
Pro/II Version 3.1, the guideline will be updated when a Provision example is
obtained.
5.1 DEFINE THE MINIMUM FLOW CONDITIONS TO AND FROM THE
COMPRESSOR:
a) Obtain the flow conditions to and from the compressor during normal operating
conditions. Consult with the lead engineer if there are more than one normal
operating cases.
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
b) Determine the minimum flow rates through the compressor during full kickback.
Typically 70-80 wt% of the normal flowrates is used. Consult with lead engineer
and rotating equipment division.
c) Flow compositions: Consult with lead engineer about refrigerant composition(s)
to be used in the simulation. Typically the normal case stream composition is
also used for the kickback case. However, it may be necessary to consider
more than one stream composition for the kickback case (i.e. start-up
composition).
See Appendix B, Pages B-2 through B-4, Simplified Diagrams of Propylene
Refrigeration System.
5.2 DEFINE FLOW SCHEME DURING KICKBACK CONDITIONS.
Specify exchangers as operating or non-operating. By definition, maximum kickback
flow occurs when all exchangers, except for the desuperheater(s)/condenser(s), are
not in operation.
Define flow scheme of kickback lines. Refer to Process Flow Diagrams and
Process and Instrumentation Diagrams from previous projects when defining the
kickback flow scheme. Consult with the lead engineer, and Rotating Equipment
division. Refer to Appendix B, Page B-2 through B-4, for simplified flow diagrams of
a refrigerant system during normal (2 cases) and full kickback conditions.
5.3 ESTABLISH THE PRESSURE PROFILE OF THE SYSTEM.
The pressure profile of the system during kickback is the same as the normal
operating case. The pressure conditions and efficiencies of each stage of
compression are assumed to be the same unless stated otherwise.
5.4 DEFINE THE PERCENTAGE OF VAPORIZATION
Define the percentage of vaporization for the liquid recycle streams when mixed
with the individual kickback lines. Typically 25% (mol) vaporization is used. Verify
with the lead engineer.
5.5 ESTABLISH THE BASIS AND CONTROL SCHEME FOR THE SIMULATION.
Due to convergence difficulties with the simulation package, the system is simulated
in two separate sections: 1) main simulation; 2) detailed simulation of suction
drums.
5.5.1 Main Simulation
The main simulation simulates the refrigerant system as a whole excluding the
liquid recycle streams off of each suction drum. The purpose of this simulation is to
calculate the required kickback flowrates at each stage while balancing the liquid
streams to/from the 2nd, 3rd, and 4th stage suction drum. See Appendix C – Page
C-2, for the block flow diagram of the Main Simulation.
a) Define the flowrate and composition of the 4th stage compressor discharge.
b) Specify the first splitter unit (SP01) by estimating the total required kickback
flow through the main kickback line.
c) Simulate the desuperheater(s)/condenser(s) similar to the normal case.
d) Specify the main kickback line splitter units (SP2, SP3, SP4) based on
estimated individual kickback line flowrates to the suction drums.
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
e) Simulate the 2nd, 3rd, and 4th stage suction drums as adiabatic flash units with
zero pressure drops. The pressure at each suction drum is established by
defining the operating pressure of the valve units upstream of each drum.
f) Define control units at the 2nd, 3rd, and 4th stage suction drums to vary the rate
of kickback flow from the splitter units to achieve the specified overhead vapor
flowrates to the compressor.
g) Because there are no liquid bottoms from the 1st stage suction drum, simulate
this drum as a dew point flash unit at the specified pressure.
h) Define a control unit to maintain the duty of the 1st stage suction drum as zero
by varying the amount of kickback flow to the drum. The kickback flow for this
stage is varied at the first splitter unit (SP01).
5.5.2 Detailed Simulations
The detailed simulations simulate each suction drum separately with the liquid
recycle streams. The purpose of these simulations is to calculate the required
liquid recycle based on the percentage of vaporization and based on the two feeds
flowrates (the liquid and kickback flows) calculated in the main simulation. See
Appendix C – Pages C-6 through C-6, for the block flow diagrams of the Detailed
Simulations.
a) The feed streams are referenced from the main simulation. Due to round-off
errors in the program, referenced stream properties may get transferred
inaccurately, and could make a significant difference when dealing with a
mixed-phase stream. When referencing streams it is better to reference single
phase streams rather than mixed-phase streams. Therefore, for the detailed
simulations, streams are referenced upstream of the valve units and then
flashed again in valve units at the same operating pressures to ensure accurate
pressure conditions in the flash units.
b) For the 2nd, 3rd, and 4th stage suction drums, the bottoms stream is split into
two streams - the liquid recycle stream and the net bottoms stream. Specify the
liquid recycle rate from the splitter based on an estimated value.
c) The 1st stage suction drum is not simulated again because there are no net
liquid bottoms generated. The liquid recycle stream is based on an
accumulated level of liquid at the suction drum pressure. Therefore, reference
only the 1st stage kickback line from the main simulation and create a new
stream as the liquid recycle at the suction drum pressure. Estimate the liquid
recycle flowrate.
d) For each stage, mix the liquid recycle stream and the kickback line using an
adiabatic flash unit with a zero pressure drop. For stages 2, 3, and 4, the
overhead and bottoms of this mixing flash unit feed back into the suction drum.
e) Define a control units for each stage to control the liquid bottoms from the
mixing flash unit as a ratio of the liquid recycle stream by varying the recycle
rate. This ratio is based on the specified percentage of vaporization of the
liquid recycle stream.
5.6 DRAW SIMULATION BLOCK DIAGRAMS.
Refer to Appendix C for examples of the block diagrams.
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
5.7 DEVELOP THE SIMULATION
The simulations as described above are written as one input file. See Appendix D
for an example input file. The simulation can be developed from a .prz file.
Due to the control units in this closed loop system, the calculation sequence should
be specified at the beginning of the input file as shown in the example input file.
Use comment statements throughout the simulation so that it easy to follow. Insert
comments where key flowrate estimates are made.
5.8 RUN SIMULATION AND VERIFY RESULTS
After successfully running the simulation, verify that the calculated flows conditions
agree with the defined flow conditions to and from the compressor. See Appendix E
for the results of the example simulation.
If the flows calculated in the main simulation do not match up with those specified,
the initial estimated kickback line splits need to be adjusted.
Verify correct stream referencing in the detailed simulations. Check that the
calculated feed and product flowrates of the detailed simulations match those of the
main simulation.
Note: The simulation can converge improperly and still reach a solution. Therefore,
it is important to verify all results.
Discuss simulation results with lead engineer, Rotating Equipment Division, and
Process Technology Division.
5.9 ISSUE RESULTS
With the lead engineer's approval, issue the results for the sizing of kickback lines,
liquid recycle lines, and suction drums.
6.0 REVIS ION HIS TORY
Revision
Revision Description
Level
Guideline is reformatted to match Shaw Aug. 2010 guideline template.
00
Minor updates in red font.
Prior 0 Previously issued as 3410P013A, Rev. 0, 8/31/99, by ABeall.
7.0 AP P ENDICES
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
7.1 APPENDIX A
EXAMP LE P ROCES S FLOW DIAGRAM OF P ROP YLENE REFRIGERATION S YS TEM
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7.2 APPENDIX B
S IMP LIFIED FLOW DIAGRAMS OF P ROP YLENE REFRIGERATION S YS TEM DURING NORMAL AND FULL KICKBACK
MODE
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7.3 APPENDIX C
EXAMP LE S IMULATION BLOCK DIAGRAMS
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
7.4 APPENDIX D
EXAMP LE S IMULATION INP UT FILE
**************** ***************
*************** PRO/II Keyword File ***************
*************** 2.01 ***************
TITLE PROJECT=JO NUMBER,PROBLEM=C3RKB, *
USER=ASDickson
DESC *
DESC DESIGN GUIDELINE SIMULATION FOR
DESC PROPYLENE REFRIG SYSTEM IN FULL KICKBACK
DESC *
DESC *
DESC *
DIMEN SI,TIME=HR,WT=KG,TEMP=C,PRES=KPA, *
ENER=KJ,WORK=KW,LIQV=M3,VAPV=M3,VISC=CP, *
COND=WMC,SURF=DYNE,PBAS=101.325,STDV=23.6902,XDEN=SPGR
PRINT RATE=M,STREAM=ALL,INPUT=ALL,MBAL
CALC TVPBasis(C)=37.778,TRIAL=100
TOLE MISC=0.001,PRES=0.001,TEMP=-0.055556,STREAM=0.001,-0.0555,0.001, *
0.001,DUTY=0.001
$
$
$
$
$********************************************************************************
$***************** PROBLEM DEFINITION ***********************************
$********************************************************************************
$
$ 1. NORMAL FLOWS CONDITIONS TO/FROM COMPRESSOR:
$ TO 1ST STG 116250 KG/HR
$ TO 2ND STG 121250 KG/HR
$ TO 3RD STG 53750 KG/HR
$ TO 4TH STG 133750 KG/HR
$ FROM 4TH STG 425000 KG/HR
$
$ 2. REDUCED FLOW TO/FROM COMPRESSOR = 80 WT% OF NORMAL FLOWS
$ TO 1ST STG 93000 KG/HR
$ TO 2ND STG 97000 KG/HR
$ TO 3RD STG 43000 KG/HR
$ TO 4TH STG 107000 KG/HR
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
$ FROM 4TH STG 340000 KG/HR
$
$ 3. REFRIGERANT COMPOSITION: 99.65% PROPYLENE; 0.35% PROPANE
$
$ 4. OPERATING EXCHANGER: DESUPERHEATER/CONDENSER (E699)
$ 30 kPa(a) PRESSURE DROP; TEMP=38.809 DEG C.
$
$ 5. PRESSURE PROFILE: kPa(a)
$ 4TH STG COMP DISCH p(4) = 1715.256
$ 1ST STG SUCTION DRUM P(1) = 140.7
$ 2ND STG SUCTION DRUM P(2) = 295.2
$ 3RD STG SUCTION DRUM P(3) = 473.4
$ 4TH STG SUCTION DRUM P(4) = 722.0
$
$ 6. SPECIFY 25%(MOL) VAPORIZATION OF LIQUID RECYCLE STREAMS.
$
$ 7. ESTIMATE 66% OF TOTAL REFRIGERANT TO MAIN KICKBACK LINE
$ TO BE SPLIT EQUALLY TO EACH STAGE INITIALLY.
$
$********************************************************************************
$
$
$
$********** ESTABLISH THE CALCULATION SEQUENCE FOR THE **************************
$********** MAIN & DETAILED SIMULATIONS **************************
$
SEQU SP01,DPA1,E699,DPA2,V695, *
CV01,SP02,CV02,V690,CT1,DP1, *
CV03,SP03,CV04,V680,CT2,DP2, *
CV05,SP04,CV06,V670,CT3,DP3, *
CV07,CV08,V660,DP4,CT4, *
CP1,MX1,CP2,MX2,CP3,MX3,CP4, *
CVA,CVB,FL90,690V,SP0A,CT0A, *
CVC,CVD,FL80,680V,SP0B,CT0B, *
CVE,CVF,FL70,670V,SP0C,CT0C, *
CVH,FLBU,FL60,CT0D
*
DBASE DATA=PC1,IDATA=3,SDATA=65H0B1
*
COMPONENT DATA
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
LIBID 1,H20/2,HYDROGEN/3,CO/4,METHANE/ *
5,ACETYLN/6,ETHYLENE/7,ETHANE/8,MACETYLN/ *
9,PROPDIEN/10,PROPENE/11,PROPANE
*
THERMODYNAMIC DATA
METHOD KVALUE=SRK,ENTH(V)=SRK,ENTH(L)=SRK,ENTR(V)=SRK, *
ENTR(L)=SRK,DENS(V)=SRK,DENS(L)=LK,COND(V)=PURE, *
COND(L)=PURE,SURF=PURE,VISC(V)=PURE,VISC(L)=PURE,*
SET=SET01,DEFAULT
*
STREAM DATA
$
$********** DEFINE THE 4TH STG DISCH FLOW FOR THE MAIN SIMULATION *************
$
PROP STRM=6500,TEMP=69.534,PRES=1715.256,PHASE=V,RATE(W)=340000, *
COMP(M)=10,0.9965/11,0.0035
$
$
$********** REFERENCE STREAMS FOR DETAILED SIMULATION OF 4TH STG ****************
$********** 4TH STAGE SUCTION DRUM **********************************************
*
PROP STRM=690A,REFS=6504
PROP STRM=690C,REFS=002
$
$********** REFERENCE STREAMS FOR DETAILED SIMULATION OF 4TH STG ****************
$********** 3RD STAGE SUCTION DRUM **********************************************
*
PROP STRM=680A,REFS=6601
PROP STRM=680C,REFS=009
$
$********** REFERENCE STREAMS FOR DETAILED SIMULATION OF 4TH STG ****************
$********** 2ND STAGE SUCTION DRUM **********************************************
*
PROP STRM=670A,REFS=6701
PROP STRM=670C,REFS=016
$
$********** REFERENCE STREAM FOR DETAILED SIMULATION OF 4TH STG *****************
$********** 1ST STAGE SUCTION DRUM. DEFINE LIQ BTMS FLOW AT P(1). **************
*
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
PROP STRM=660C,REFS=022
PROP STRM=660G,PRES=140.7,PHASE=L,RATE(M)=1700.0, *
COMP(M)=10,0.9965/11,0.0035
*
*
UNIT OPERATIONS
*
$
$********************************************************************************
$********** MAIN SIMULATION **********************
$********************************************************************************
$
$
$********** SPLITTER FOR MAIN KICKBACK LINE *************************************
$********** ESTIMATE TOTAL REQ'D KICKBACK FLOW **********************************
$
SPLITTER UID=SP01,NAME=MINFL SP01
FEED 6500
PROD M=001,M=650A
SPEC STRM=001,RATE(M), *
VALUE=5200
$
$********** LINE PRESSURE DROP **************************************************
$
FLASH UID=DPA1,NAME=COMPR OUT DP
FEED 650A
PROD V=6501
ADIA DP=7.0
$
$********** DESUPERHEATER/CONDENSER *********************************************
$
FLASH UID=E699,NAME=DESUPERHTR
FEED 6501
PROD L=6502
ISOTH DP=30.0,TEMP=39.8090
$
$********** LINE PRESSURE DROP **************************************************
$
FLASH UID=DPA2,NAME=COMPR OUT DP
FEED 6502
PROD M=6503
ADIA DP=13.0
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
$
$********** SURGE DRUM **********************************************************
$
FLASH UID=V695,NAME=RECEIVER
FEED 6503
PROD L=6504
ADIA DP=0.0
$
$********** 4TH STG SUCTION DRUM LIQUID FEED VALVE ******************************
$
VALVE UID=CV01,NAME=V690 CV01
FEED 6504
PROD M=6514
OPER PRES=722.0
$
$********** SPLITTER FOR 4TH STG KICKBACK LINE **********************************
$********** ESTIMATE REQ'D KICKBACK FLOW TO 4TH STG SUCTION DRUM ****************
$
SPLITTER UID=SP02,NAME=1ST MINFL SP
FEED 001
PROD M=002,M=008
SPEC STRM=002,RATE(M), *
VALUE=1300
$
$********** 4TH STG KICKBACK LINE VALVE *****************************************
$
VALVE UID=CV02,NAME=V690 MIN CV
FEED 002
PROD M=003
OPER PRES=722.0
$
$********** 4TH STAGE SUCTION DRUM **********************************************
$
FLASH UID=V690,NAME=LL4 DRUM
FEED 6514,003
PROD V=6900,L=6601
ADIA DP=0.0
$
$********** 4TH STAGE CONTROL UNIT **********************************************
$
CONTROLL UID=CT1,NAME=MIN FL CTR
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SPEC STRM=6900,RATE(W), *
VALUE=107000
VARY SPLIT=SP02,SPEC(1)
CPAR ITER=100
$
$********** 4TH STG OVERHEAD LINE PRESSURE DROP *********************************
$
FLASH UID=DP1,NAME=OVHD DP
FEED 6900
PROD M=6533
ADIA DP=10.0
$
$********** 3RD STG SUCTION DRUM LIQUID FEED VALVE ******************************
$
VALVE UID=CV03,NAME=V680 CV03
FEED 6601
PROD M=6611
OPER PRES=473.4
$
$********** SPLITTER FOR 3RD STG KICKBACK LINE **********************************
$********** ESTIMATE REQ'D KICKBACK FLOW TO 3RD STG SUCTION DRUM ****************
$
SPLITTER UID=SP03,NAME=2ND MINFL SP
FEED 008
PROD M=009,M=015
SPEC STRM=009,RATE(M), *
VALUE=1300
$
$********** 3RD STG KICKBACK LINE VALVE *****************************************
$
VALVE UID=CV04,NAME=V680 MIN CV
FEED 009
PROD M=010
OPER PRES=473.4
$
$********** 3RD STAGE SUCTION DRUM **********************************************
$
FLASH UID=V680,NAME=LL3 DRUM
FEED 6611,010
PROD V=6800,L=6701
ADIA DP=0.0
$
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$********** 3RD STAGE CONTROL UNIT **********************************************
$
CONTROLL UID=CT2,NAME=MIN FL CTR
SPEC STRM=6800,RATE(W), *
VALUE=43000
VARY SPLIT=SP03,SPEC(1)
CPAR ITER=100
$
$********** 3RD STG OVERHEAD LINE PRESSURE DROP *********************************
$
FLASH UID=DP2,NAME=OVHD DP
FEED 6800
PROD M=6802
ADIA DP=10.0
$
$********** 2ND STG SUCTION DRUM LIQUID FEED VALVE ******************************
$
VALVE UID=CV05,NAME=V670 CV05
FEED 6701
PROD M=6721
OPER PRES=295.2
$
$********** SPLITTER FOR 2ND STG KICKBACK LINE **********************************
$********** ESTIMATE REQ'D KICKBACK FLOW TO 2ND STG SUCTION DRUM ****************
$
SPLITTER UID=SP04,NAME=3ND MINFL SP
FEED 015
PROD M=016,M=022
SPEC STRM=016,RATE(M), *
VALUE=1300.0
$
$********** 2ND STG KICKBACK LINE VALVE *****************************************
$
VALVE UID=CV06,NAME=V670 MIN CV
FEED 016
PROD M=017
OPER PRES=295.2
$
$********** 2ND STAGE SUCTION DRUM **********************************************
$
FLASH UID=V670,NAME=LL2 DRUM
FEED 6721,017
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PROD V=6700,L=6801
ADIA DP=0.0
$
$********** 2ND STAGE CONTROL UNIT **********************************************
$
CONTROLL UID=CT3,NAME=MIN FL CTR
SPEC STRM=6700,RATE(W), *
VALUE=97000
VARY SPLIT=SP04,SPEC(1)
CPAR ITER=100
$
$********** 2ND STG OVERHEAD LINE PRESSURE DROP *********************************
$
FLASH UID=DP3,NAME=OVHD DP
FEED 6700
PROD M=6719
ADIA DP=10.0
$
$********** 1ST STG SUCTION DRUM LIQUID FEED VALVE ******************************
$
VALVE UID=CV07,NAME=V660 CV07
FEED 6801
PROD M=6829
OPER PRES=140.7
$
$********** 1ST STG KICKBACK LINE VALVE *****************************************
$
VALVE UID=CV08,NAME=V660 MIN CV
FEED 022
PROD M=023
OPER PRES=140.7
$
$********** 1ST STAGE SUCTION DRUM **********************************************
$
FLASH UID=V660,NAME=LL1 DRUM
FEED 6829,023
PROD V=6600
DEW PRES=140.7
$
$********** 1ST STAGE CONTROL UNIT **********************************************
$
CONTROLL UID=CT4,NAME=MIN FL CTR
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SPEC FLASH=V660,DUTY, *
VALUE=0.0
VARY SPLIT=SP01,SPEC(1)
CPAR ITER=100
$
$********** 1ST STG OVERHEAD LINE PRESSURE DROP *********************************
$
FLASH UID=DP4,NAME=OVHD DP
FEED 6600
PROD M=6828
ADIA DP=10.0
*
$
$**************************************** 1ST STG COMPRESSOR ******************
$
*
COMPRESS UID=CP1,NAME=1st STG COMP
FEED 6828
PROD V=6901
OPER POLY=83,PRES=285.2
*
MIXER UID=MX1,NAME=MX 1 'N 2 RT
FEED 6901,6719
PROD M=6902
$
$**************************************** 2ND STG COMPRESSOR ******************
*
COMPRESS UID=CP2,NAME=2nd STG COMP
FEED 6902
PROD V=6903
OPER POLY=84,PRES=463.4
*
MIXER UID=MX2,NAME=2OUT 'N 3 RT
FEED 6802,6903
PROD M=6904
$
$**************************************** 3RD STG COMPRESSOR ******************
*
COMPRESS UID=CP3,NAME=STG 3 COMPR
FEED 6904
PROD V=6905
OPER POLY=83.6,PRES=712.0
Page 22 of 29
Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
*
MIXER UID=MX3,NAME=3OUT 'N 4 RT
FEED 6533,6905
PROD M=6906
$
$**************************************** 4TH STG COMPRESSOR ******************
*
COMPRESS UID=CP4,NAME=STG 4 COMPR
FEED 6906
PROD V=6500
OPER POLY=81.8,PRES=1715.2562
$
$*****************************************************************************
$********* DETAILED SUCTION DRUMS ***************
$*****************************************************************************
$
$********** 4TH STAGE *********************************************************
$
$********** LIQUID FEED VALVE *************************************************
$
VALVE UID=CVA,NAME=690V CVA
FEED 690A
PROD M=690B
OPER PRES=722.0
$
$********** KICKBACK LINE VALVE *************************************************
$
VALVE UID=CVB,NAME=690V CVB
FEED 690C
PROD M=690D
OPER PRES=722.0
$
$********** KICKBACK AND LIQ RECYCLE MIXER FLASH UNIT ***************************
$
FLASH UID=FL90
FEED 690D,690H
PROD V=690E,L=690F
ADIA DP=0
$
$********** SUCTION DRUM ********************************************************
$
FLASH UID=690V
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
FEED 690B,690E,690F
PROD V=690J,L=690G
ADIA DP=0
$
$********** SUCTION DRUM BTMS SPLITTER ******************************************
$
SPLITT UID=SP0A
FEED 690G
PROD L=690I,L=690H
SPEC STRM=690H,RATE(M), *
VALUE=500
$
$********** LIQUID RECYCLE CONTROLLER *******************************************
$
CONTROLL UID=CT0A
SPEC STRM=690F,RATE(M), *
RATIO, *
STRM=690H,RATE(M), *
VALUE=0.75
VARY SPLIT=SP0A,SPEC(1)
CPAR ITER=100
$
$********** 3RD STAGE ***********************************************************
$
$********** LIQUID FEED VALVE *************************************************
$
VALVE UID=CVC,NAME=680V CVC
FEED 680A
PROD M=680B
OPER PRES=473.4
$
$********** KICKBACK LINE VALVE *************************************************
$
VALVE UID=CVD,NAME=680V CVB
FEED 680C
PROD M=680D
OPER PRES=473.4
$
$********** KICKBACK AND LIQ RECYCLE MIXER FLASH UNIT ***************************
$
FLASH UID=FL80
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
FEED 680D,680H
PROD V=680E,L=680F
ADIA DP=0
$
$********** SUCTION DRUM ********************************************************
$
FLASH UID=680V
FEED 680B,680E,680F
PROD V=680J,L=680G
ADIA DP=0
$
$********** SUCTION DRUM BTMS SPLITTER ******************************************
$
SPLITT UID=SP0B
FEED 680G
PROD L=680I,L=680H
SPEC STRM=680H,RATE(M), *
VALUE=500
$
$********** LIQUID RECYCLE CONTROLLER *******************************************
$
CONTROLL UID=CT0B
SPEC STRM=680F,RATE(M), *
RATIO, *
STRM=680H,RATE(M), *
VALUE=0.75
VARY SPLIT=SP0B,SPEC(1)
CPAR ITER=100
*
*
$
$********** 2ND STAGE *********************************************************
$
$********** LIQUID FEED VALVE *************************************************
$
VALVE UID=CVE,NAME=670V CVE
FEED 670A
PROD M=670B
OPER PRES=295.2
$
$********** KICKBACK LINE VALVE *************************************************
$
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Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
VALVE UID=CVF,NAME=670V CVF
FEED 670C
PROD M=670D
OPER PRES=295.2
$
$********** KICKBACK AND LIQ RECYCLE MIXER FLASH UNIT ***************************
$
FLASH UID=FL70
FEED 670D,670H
PROD V=670E,L=670F
ADIA DP=0
$
$********** SUCTION DRUM ********************************************************
$
FLASH UID=670V
FEED 670B,670E,670F
PROD V=670J,L=670G
ADIA DP=0
$
$********** SUCTION DRUM BTMS SPLITTER ******************************************
$
SPLITT UID=SP0C
FEED 670G
PROD L=670I,L=670H
SPEC STRM=670H,RATE(M), *
VALUE=500
$
$********** LIQUID RECYCLE CONTROLLER *******************************************
$
CONTROLL UID=CT0C
SPEC STRM=670F,RATE(M), *
RATIO, *
STRM=670H,RATE(M), *
VALUE=0.75
VARY SPLIT=SP0C,SPEC(1)
CPAR ITER=100
*
*
$
$********** 1ST STAGE ***********************************************************
$
$********** KICKBACK LINE VALVE *************************************************
Page 26 of 29
Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
$
VALVE UID=CVH,NAME=660V CVH
FEED 660C
PROD M=660D
OPER PRES=140.7
$
$********** LIQUID RECYCLE FLASH UNIT *******************************************
$
FLASH UID=FLBU
FEED 660G
PROD L=660H
BUBB PRES=140.7
$
$********** KICKBACK AND LIQ RECYCLE MIXER FLASH UNIT ***************************
$
*
FLASH UID=FL60
FEED 660D,660H
PROD V=660E,L=660F
ADIA DP=0
$
$********** LIQUID RECYCLE CONTROLLER *******************************************
$
CONTROLL UID=CT0D
SPEC STRM=660F,RATE(M), *
RATIO, *
STRM=660H,RATE(M), *
VALUE=0.75
VARY STRM=660G,RATE(M)
CPAR ITER=100
*
*
*
*
*
END
Page 27 of 29
Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
7.5 APPENDIX E
EXAMP LE S IMULATION RES ULTS S UMMARY
Suction drum product flowrates:
Specified Main Simulation Detailed Simulation
OVERHEAD OVERHEAD BOTTOMS OVERHEAD BOTTOMS
kg/hr kg/hr kg/hr kg/hr kg/hr
1st Stage 93000 93005 n/a n/a n/a
2nd Stage 97000 96999 23162 96999 23162
3rd Stage 43000 42999 46449 42999 46450
4th Stage 107000 106997 59043 106997 59043
Kickback line flowrates:
Main line 5748 kmol/hr 241906 kg/hr
To 1st Stage 1614 kmol/hr 67945 kg/hr
To 2nd Stage 722 kmol/hr 30405 kg/hr
To 3rd Stage 3411 kmol/hr 143555 kg/hr
To 4th Stage 1659 kmol/hr 69844 kg/hr
Liquid recycle flowrates:
At 1st Stage 1984 kmol/hr 83522 kg/hr
At 2nd Stage 1857 kmol/hr 78142 kg/hr
At 3rd Stage 695 kmol/hr 29240 kg/hr
At 4th Stage 1410 kmol/hr 59357 kg/hr
Page 28 of 29
Refrigeration Kickback Simulation Guideline No.: DDG-T-P-03208 Rev.: 00
7.6 APPENDIX F
S IMP LIFIED FLOW DIAGRAM OF A HEAT P UMP /COMP RES S OR S YS TEM DURING FULL KICKBACK
Page 29 of 29
