2. SSE TSS-4 New Features in DYNSIM 5.0
Bryan C. McAlister, Ph.D.
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3. DYNSIM 5.0 Overarching Goals -
DYNSIM® Software version 5.0 is a major release and introduces a rich set of features and enhancements
The product has been in development for the last 18 months with a investment of approximately US$3 million
Overarching Goals -
Ensure DYNSIM remains the Best Available Technology for Dynamic Simulation and OTS by expanding the existing product capabilities
Enable OTS Engineers to be more efficient and competitive when executing Operator Training Simulator projects
Improve the long term sustainability /total cost of ownership of our solutions for both clients and Invensys

4. Install New Redesigned, WIX Installers NEW OLD
Advantage – WiX is script based. Customers could potentially re-script install for internal deployment.
2. The DYNSIM Prerequisites i.e., Windows Installer 4.5 and .NET 3.5 SP 1 are now part of the main setup. The third party installations like jre _23, SQL Express 2008 etc are also part of the main setup.
NEW
OLD
32 bit DYNSIM Installer (includes prerequisites)
Prerequisites Installer
32 bit DYNSIM +
OTS Engines installer
32 bit OTS Custom Engines Installer
64 bit DYNSIM Engine Installer

5. Install
3. The Typical Install option installs only the regular DYNSIM and Excel engines. The Custom option allows the user to add other DYNSIM engines like DYNSIM–P, DYNSIM-All, OPCServer, OPC-UA, etc.

6. Install
4. Support for FlexNet11.8 security option (Windows 7, 64 bit machines) 5. The Custom OTS Engines is now a separate installer and it is no longer required to install DYNSIM 5.0 for custom OTS engines (just need the Activation Manager)

7. DYNSIM 64-bit Install
Starting DYNSIM 5.0, 64-bit version of DYNSIM engines namely DYNSIM, DYNSIM-All, DYNSIM-P, DYNSIM-Checkout, DYNSIM- Lite is available as a separate install and can be installed on a 64-bit machine
However, SimExecutive and other components would remain 32-bit and would be used on both 32-bit and 64-bit machines.
The regular DYNSIM 5.0 application is a pre-requisite for installing the 64-bit DYNSIM engines.
64 bit engines can be selected via “Simulation Configuration” just like any other engine

8. Install SimExecutive Licensing
In DYNSIM 5.0, a new licensing mechanism has been implemented. The SimExecutive checks for a valid license and returns it after finding one.
This feature has been implemented for all products, which use the SimExecutive framework i.e., DYNSIM, DYNSIM-P, OTS Engines, DYNSIM Checkout, FSIM, TRISIM etc.
If the SimExecutive finds a valid license, the message window will display a message “SimExecutive has obtained a runtime license”.
If the SimExecutive does not find a valid license, an appropriate message “SimExecutive could not start successfully” will be displayed.

9. PFR Enhancements Summary
Compressible Reaction Pass
Model Catalyst Phase Separately in Energy Balance
Rigorous Pressure Drop Correlations
Ergun and Turpin & Huntington
Model Liquid Hold-up and Liquid Slip
Backward compatible
Support all existing features. No schema evolution required for migrating existing simulations

10. Holdup Dynamic Calculation
Holdup Dynamic calculation (Pressure calculation) – Limit to incompressible holdup dynamic calculation. Unrealistic pressure response when vapor exists, for example hydrocracker, shift reactor,…, etc.
Compressible Reaction Pass (CRPass) – Add a new CRPass like DYNSIM Pipe to support both compressible and incompressible holdup dynamic calculations.
Solution tab

11. Pressure Response
CO shift reactor – One reaction Pass and One compressible reaction pass with compressible option, 5 segments
Pressure response – (a) Pressuring (b) Depressuring

12. Catalyst Effect (Energy Balance)
Energy balance on existing PFR
No separate energy balance on catalyst phase, Require to combine catalyst to wall
Unrealistic temperature responses in fluid and catalyst phases
Energy balance on catalyst phase
add a separate energy balance on catalyst phase. More realistic temperature response on fluid and catalyst phases

13. Catalyst Effect (Pressure Drop)
Pressure drop calculation on existing PFR
Based on simple flow conductance, doesn’t include catalyst effect (void fraction, catalyst diameter etc.)
Pressure drop result may be unrealistic
Rigorous pressure drop calculation
Including catalyst effect, and fluid physical properties (density, viscosity, molecular weight, etc.)
Predictive approach

14. Catalyst Effect (Pressure Drop)
Ergun correlation
Commonly used correlation, can be applied to gas, liquid, and gas-liquid systems.
Turpin and Huntington (1967)
Vapor-liquid Two phase system
Upward and downward flows

15. Liquid Holdup and Liquid Slip
Liquid holdup and Liquid Slip – Relationship among liquid-holdup in the catalyst bed, liquid, vapor flows, and pressure drop. Strongly impact pressure response, pressure drop, and liquid holdup.
General form – Turpin and Huntington
DEW – Liquid Slip tab

16. More Accurate Trends
Trend Reactor pressure, liquid saturation, fluid temperature, wall temperature and catalyst temperature

17. Stream Send – Stream Receive
Large Simulations
Engine 2 SR
Engine 3
Engine 1 SS
Better Performance – Utilize Multi-Cores
Stream Send calculates how sensitive upstream flow is to downstream pressure.
Stream Receive calculates how sensitive downstream pressure is to upstream flow
Explanation about the test case – There are four parallel trains in the simulation to compare different modes of stream data transfer:
First train - Entire network in the same engine. This is the base case for comparison.
Second train – Network split into two engines and connected using explicit cross referencing using Source models. Open the second flowsheet to show the split network.
Third train – Network split into two engines and connected using Stream Send-Stream Receive pair using local sensitivities.
Fourth train – Network split into two engines and connected using Stream Send-Stream Receive pair using network sensitivities.
Steady state run – Load the simulation and load IC 2. Open two trends – MASS_IMBALANCE and PRESSURE_IMBALANCE. There are total of 7 points in each of these trends. As the name of these points indicate, they represent mass flow and pressure on the two sides of the network. The seventh point belongs to the single engine case. There are two things that need to be compared:
Comparison of mass flow and pressure on the two sides of the network. For this, the comparison should be between two consecutive points (in pairs) For example, XREF_SEND.W should be compared with XREF_RECEIVE.W. The closer the match, the better it is.
Comparison of values with the single engine case which is the seventh point on each of the trends. The closer the match with the single engine case, better it is.
               At steady state, everything is perfectly fine in this case.
Dynamic run – Open the Valve XV2 50% in the first network. This will open the corresponding Valve in the other three networks. Keep the two trends mentioned above open. Run the simulation for a few seconds and pause it. Now do the same comparison as mentioned above. Here the Stream Send and Stream Receive has a much better mass balance and then other cases. You will have to notice it very carefully as the difference in different modes is apparent only for a few time steps. However, Stream Send and Stream Receive with local sensitivities will be seen to be quite away from the single engine case very clearly.
Old Approach –> Local Sensitivity
New Approach –> Network Sensitivity

18. Limitations of Local Sensitivity
Currently, the flow and pressure sensitivities are calculated locally for the concerned flow devices and pressure nodes.
Ignores the impact of other network elements on the sensitivity calculations.
As a result of this, the sensitivities at times are quite a bit off compared to the actual sensitivities. At times, this results in following two issues:
Mass imbalance and pressure inequalities across the network.
Flows and pressures quite different compared to single network in a single engine.

19. New Approach – Network Sensitivity
Takes the entire network into account for the calculation of the sensitivity
Much more robust than the local sensitivity but computationally much more intensive
Rest of the things regarding the usage of sensitivity and communication between different engines remain the same
Backward Compatible

21. Reassignment of Engines
User-friendly way to remap simulation from one hardware configuration to another hardware configuration by using hosts mapping data
Easier deployment / transfer of simulations across different hardware setups
Mapping of remote and local host data will be kept in editable text file: HostsConfig.txt
Existing DYNSIM 5.0

22. Color coding to indicate host resolution
Green –mapped host supports the required engine type and will be used to launch the engine.
Amber – mapped host was not found and so is being automatically remapped to the local host
Red – mapped host (or simexec host) doesn’t support the configured engine type (e.g. TRISIM)
Valid host found.
Valid host not found. Not loaded.
Host not found. Mapped to SimExec host

23. HostsConfig.txt

24. Additional Messaging

25. New Integrator Model
The Utilities library provides a collection of standalone objects for various custom calculations.
Integrator provides the integration of a process variable.

26. Data Entry Window

27. Overfill Robustness Implementation
Drum model – DYNSIM 4.5.1
Tower, Pipe, PFR (CRPass) and Header models – DYNSIM 5.0
Remaining model - Separator
Holdup Dynamic Options
Holdup Calc Type (Simple, Rigorous, Global )
Algorithm
Note
Compressible
Rigorous
Overfill robustness algorithm
Robust, speed may slow down
Simple
Legacy compressible algorithm
Incompressible
Incompressible Volume Balance
Legacy incompressible algorithm

28. Overfill Robustness Implementation
Global option (default - Simple) – Drum, Pipe, PFR (CRPass), Header and Tower models
Global option can be overwritten by individual model
For example: pipe model – OEV – AdvEdit

29. Text based/Editable Ics
Checkbox option to save ICs in text
Format  same as states.dat. Default remains “binary”
Will be managed / handled just like binary ICs (via Snapshot Summary table)
Existing DYNSIM 5.0
Option to save the IC as text

30. Custom Point Description
Points and parameter names in DYNSIM can be very cryptic and hard to remember what they are and why they are needed. DYNSIM 5.0 adds a custom description to points and indirectly to point references
Users will be able to display custom descriptions for:
Trends on screen, printing and exporting to CSV data
Point Monitor
Trainee Performance Monitoring (TPM)
Malfunctions
Miscellaneous Equations

31. Custom Point Description
In DYNSIM vs 5.0
Points on Trends
Point Monitor

32. Custom Point Description
TPM
Malfunction
In DYNSIM versus 5.0
Malfunctions & TPM
Point Monitor
TPM
Malfunction

33. Default Trends for Select Unit Operations
DYNSIM 5.0 will include default trends in the following models:
PID Controller
Heat Exchanger
Utility Exchanger
Pump
Compressor
Utility Exchanger
PID
Pump

34. Mass Fraction in Stream
Display mass fraction in individual stream (existing feature) – Select “Component mass fraction” through Stream “Special Properties” list

35. Mass Fraction in Stream
Display mass fraction in all streams (new feature) – Set “Calculate stream mass fraction option” to 1 through “Engine Configuration” window. Default is “0”.

36. DYNSIM Power Migration in DYNSIM 5.0
DYNSIM enhancements to support Steam and Gas Turbine modeling:
Enhancements in Compressor model
Compressor performance curve bases
Flow basis, Head basis and Speed basis
Support for performance curves at multiple IGVs
Performance curves
Surge point
Enhancements in Expander model
Efficiency curves
Leaving losses
Heat Streams
Metal Casing model

37. Compressor performance curve bases
Current DYNSIM compressor supports performance curve input as pressure head (Energy/Mass) versus volumetric flow only
User needs to convert vendor data to equivalent pressure head versus volumetric flow for using DYNSIM Compressor model
In DYNSIM 5.0 new options have been added to support different curve formats.
XY plots display in user configured curve bases

38. Compressor performance curve bases - Options
Flow Basis
Volumetric
Mass
Corrected Mass
Head Basis
Pressure Head
Pressure Difference
Pressure Ratio
Static Head
Speed Basis:
Speed
Corrected speed

39. Inlet Guide Vane (IGV) positions
Compressor model already supports performance curves at multiple speeds.
With IGV implementation
Curves at different IGVs can be taken
User can specify curves at different IGVs at each speed
In XY plots, 3 radio buttons are added
All
Speed
IGV

40. Inlet Guide Vane (IGV) Curves tab
New
Current

41. Inlet Guide Vane (IGV) XY Plot

42. Surge point definition at multiple IGV positions
Surge variation with IGV is considered
User can provide surge data at different IGVs

43. Expander - Efficiency Constant efficiency
The efficiency is equal to the reference efficiency provided by the user. The default value of efficiency is 1.0.
Built-in efficiency curve for Steam Turbine
  In this method the reference efficiency is compensated for speed and flow rate using the correlation given below:

44. Expander – Leaving Losses
In typical turbine operations, the losses associated with carry over velocity are called ‘Leaving Losses’.
Leaving Losses are associated with last stage in a multi-stage turbine operation especially in low pressure turbines.
DYNSIM has two methods to calculate leaving losses: 
Fixed leaving losses   
Fixed value. The losses are considered to be independent of flow or turbine speed conditions
Built-in leaving losses curve
There is a built in curve which is based on a typical GE LP turbine.
Used in calculation of Work of Expansion as shown below:

45. Expander – Heat Streams
Heat Stream port is provided to connect Expander model to Metal Casing.

46. Metal Casing model
Metal casing model is used to predict temperatures of metal casing and rotors in turbine.
Casing/Rotor temperatures can be used:
Calculation of differential axial expansion between rotor and casing.
As critical parameter for startup/shut down of turbine
Monitored for stress and life management.
Metal casing model needs to be connected to equipment through heat streams for which metal wall temperature is required.
Metal casing / rotor may be subdivided into any number of axial and radial segments.

47. Metal Casing model
Each metal casing / rotor may be subdivided into any number of radial divisions representing slices parallel to the fluid flow.
Metal casing model as rotor:
There is no heat loss to ambient.
External heat input is not allowed.
Casing
Radial Seg-1
Radial Seg-2
Axial Seg-1
Rotor
Axial Seg-2

48. Compressor Model Demo

49. DYNSIM 5.0 Pipe Model Improvements
Global database
Beggs-Brill Moody two phase flow correlation
Elevation profiles
Kinetic energy effects for high velocity fluids

50. Global Database Editor
Powerful and flexible way to centralize
common pipeline data (ID, Schedule,
Roughness, etc.).
Heat transfer coefficients can also be
stored / specified in the same way.
The data can be easily accessed by any pipe model.
Ease of configuration and maintenance!

51. Beggs-Brill Moody Two Phase Flow Correlation
Objective
Model multiphase flow more accurately in DYNSIM.
Developed from Air/Water two phase flow experiments. Its widest application has been in the area of pipeline modeling/design.
Key Benefits
Well recognized in the upstream industry.
Applies to pipes of all inclination angles.

52. Key Output Parameters Flow Patterns [parameter name: FLOWPATTERSEG
Segregated (Stratified, Wavy, Annular)
Intermittent (Plug, Slug)
Distributed (Bubble, Mist)
Transition (between Segregated and Intermittent flow patterns)
Slip Holdup [parameter name: HLSSEG]
Defined as the fraction of an element of pipe occupied by liquid at a given time. It accounts for the ‘slip’ effect.
Mass Flow Rate

53. Pipeline Elevation Profile
Objective
More accurate spatial definition of pipe inlet/outlet elevations.
Key Benefit(s)
Long/irregular pipeline profiles descriptions in one single pipe model.

54. Kinetic Energy Effects for High Velocity Fluids
Objective
Modify the energy balance equation to account for high velocity changes in the pipe model.
Key Benefits
Useful for flare systems. Sudden temperature changes due to high velocity changes inside the pipe are accounted for more accurately.

55. Pipe Model Demo

56. Ejector Model New Model under the Process Equipment Library.
Simplified Ejector design based on performance curves.
Can be used to model steam Ejector.
Suction side flow is determined by the performance curves.

57. Design Parameters - DEW

58. DYNSIM 5.0 – Thermo Features
DYNSIM 5.0 uses Thermo Component TH3.5. The features in this version include:
Move TDM from a shared component to completely contained functionality of SIM4ME Thermo
Each Product has a self-contained copy of TDM
No coexistence problems: Install and uninstall for one product/version does not interact with installation for another product/version
Binary Interaction Parameter Update
Models solubility of Mercury with hydrocarbons (nC1 – nC10).
The parameters are stored in the databanks available for SRK, PR, SRKM and PRM methods in Edlib library.
Phase Envelope Utility
This functionality is similar to PRO/II but it supports any EOS or LACT model

59. Quality Improvements 5 year low for total defects! # Criteria
Target Value
End of Beta
Apr 2, 2012 1
5.0 introduced CRs++ (no new technical debt allowed) 57 2
Past Customer Reported Defect CRs 61
(20% reduction) 76 3
Open Internal Defects from past releases
<= 240
289
199

60. DYNSIM 5.1 in March 2013
To be released in combination with PRO/II and ROMeo in March 2013 as one common release
All products will share common component versions like SIM4ME Thermo and SIM4ME Portal
Areas of focus:
Second Phase of Engineering Productivity Improvements
New and Enhanced Instructor and Training Capabilities and Services
GUI Enrichment for Improved Ease of Use
Infrastructure Improvements
Thermodynamic updates and additions

61. Event Logger Instructor Capability available under Tools Menu
12/01/2011
Event Logger
Instructor Capability available under Tools Menu
Actions are recorded in chronological order and stamped with simulation time
Actions are stored in log file 61

62. Event Logger In DYNSIM GUI Instructor actions appear in Blue
12/01/2011
Event Logger
In DYNSIM GUI
Instructor actions appear in Blue
Operator actions in Dark Grey
Non-differentiable actions appear in Green.
Captures info in FSIM Plus
Will support other DCS emulations in the future 62

63. Backtrack Replay Enhancements
Record and replay the actions taken by the operator during a training session
Instructor Capability in Tools Menu
Start Backtrack Action Recording
Select Backtrack to Replay Actions
View Backtrack Action Log

64. Backtrack Replay Enhancements
Ground zero backtrack saved at the instance of changing to Backtrack record mode.
Backtrack recording in engineering units with units in curly braces
Backtrack Action Log – can be saved in DYNSIM Scenario syntax
In User folder

65. Backtrack Replay Enhancement
12/01/2011
Backtrack Replay Enhancement
New column added in backtrack summary table to indicate whether actions are associated with the backtrack.
Whether back track replays are possible or not
Simulation time at which backtrack is saved. 65

66. Scenario Enhancements
12/01/2011
Scenario Enhancements
Existing Scenario Summary Table enhanced to provide more detail to the engineers.
Value for the point is now based upon current UOM slate rather than internal units
 Step number   (current step number which the  scenario is executing)
 Current point value  (current point value for the WAIT UNTIL command)
 Target point value  (Target point value for the WAIT UNTIL command)
 Step Elapse Time  (individual step  elapsed time for WAIT command)
 Scenario Elapse Time  (elapsed time since start of the scenario) 66

67. TPM Enhancements Trainee Name TPM Template ID New Column Exercise ID
12/01/2011
TPM Enhancements
The instructor monitors and evaluates trainee's performance in operating a simulated process plant based on a set of pre-defined criteria
TPM exercise saved automatically for a scenario without stop TPM command
TPM feature is enhanced to include trainee name, ability to allow multiple TPM’s session
Trainee Name
TPM Template ID
New Column Exercise ID 67

68. TPM Enhancements
Ability to filter by Templates of Exercises Browse capability to save TPM report as excel and PDF. Option to change trainee name available in tools menu.

69. Opportunities Beyond DYNSIM 5.1
Investment in SIM4Me Thermo for new Applications
Look Ahead or Online Simulators
Complete merge of DYNSIM Power & DYNSIM
Auto-model Generation of Dynamic Models from SmartPlant P&IDs
Improved User Added Model Capabilities
Improved InTouch Engine for End User Model Deployment etc.
Many possibilities……….