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Inprocess References List

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• Introduction to Steady State Simulation
• Introduction to Dynamic Simulation
• Dynamic Simulation of Rotating Equipment
• Dynamic Simulation of Distillation Columns
• Process Control for Process Engineers using
• Dynamic Simulation

Author(s)
Miguel-Ángel Navarro and Miquel-Àngel Alós (Inprocess)

Magazine
2020. Hydrocarbon Engineering. October, Pages: 81 – 84

Abstract / Summary
During a flare release, the temperature of the flare network has a strong dependence on the relief source and on ambient conditions. During a relief of hot gases, contraction of the gases could occur due to the cool-down to ambient conditions. The rate of contraction velocity is accelerated if cooling leads to condensation of the contained gas components. The risk associated with this contraction is the depression of the header below atmospheric pressure, allowing outside air to enter into the flare system. Infiltration of air can lead to flame burn back, which in turn could initiate a destruction detonation in the system. The most common method for the prevention of air infiltration through the stack exit is to introduce purge gas. The amount of purge gas required depends on the released gas and on the gas purge composition, as well as the size and design of the flare.

Author(s)
Martin Skarle (Preem), Manel Serra, Jesús Gil Vilda, and Josep-Anton Feliu (Inprocess)

Magazine
2020. Hydrocarbon Engineering, January, Pages: 45-49

Abstract / Summary
For more than a decade, refinery panel operators at Preemraff have been coached on safety and operation excellence through hands-on training with an operator training simulator (OTS). The fluidised catalytic cracker (FCC) at the Lysekil Refinery was the first refinery unit for which an OTS was built. In 2016, it was decided to extend the use of this training tool to two other existing units: the hydrogen production unit (HPU) and the Isocracker unit (ICR). In addition, the existing FCC OTS also had to be updated with recent plant changes. The authors also examine modern training methods for operators and look at how these have been successfully rolled out.

Author(s)
JoseMaria Ferrer, Gerard Campanyà, Manel Serra, José María Nougués

Congress
2019 EMEA UniSim Design® Technology Forum

Abstract / Summary
Inprocess oral contribution to Honeywell’s EMEA Users Conference held in Amsterdam (The Netherlands), in October 2019

Base your design decisions on rigorous engineering calculation results:

• Check the design size of critical equipment
• Determine adequate protection systems
• Validate proposed control strategies and philosophies
• Design and test operational procedures
• Determine the operational envelop, check the safety limits and select piping material
• Use the digital plant as a process intelligence repository

Train operators earlier in their careers. Be independent of DCS database delivery:

• Detect operational limits of the system
• Familiarize operators with the processes in the plant-to-be
• Train operators to become accustomed to the designed Human Machine Interface
• lnvolve experienced operations personnel in testing and enhance initially proposed operational procedures, already under timing and transitions conditions

Ensure DCS database is error free before plant commissioning:

• Use the plant model to check out and debug the configuration of the logic in the Distributed Control System
• Also check out the logic implemented in the Emergency Shutdown system and the procedures in Automated Sequences
• Decide the values of the alarms against simulated plant responses
• Pre-tune control loops before commissioning
• Check operability of HMI screens configuration

Train your operations staff with an exact replica of the control room configuration.

• Train your control room operators trained on start-up procedures sufficiently in advance
• Train operators on plant normal operation; on load changes; on emergency situations; on planned plant shutdowns and start-ups, from hot- and cold­- conditions
• Coach staff on how to react faced with equipment and instrumentation malfunctions
• lnvolve field operators with 3D lmmersive Training Simulators and Virtual Reality

Author(s)
Jose Maria Ferrer, Jesus Juan, Jordi Pla (Inprocess)

Congress
Aspentech Users Group Meeting (Optimize2019)

Abstract / Summary
Inprocess oral contribution to Aspentech's Users Conference Optimize 2019 held in Houston, TX (USA) in May 2019

Avoid delays in plant start-ups using the expertise of Inprocess' OTS engineers

• Establish the knowledge and know­-how requirements for the operations team; design a training program to fill the gaps, and then implement it
• Evaluate on-site alternative procedures for start-ups
• Troubleshoot potential issues with controllers tuning, alarms settings, start-up procedure, safety systems ...
• lntegrate the control room and the field operators into a single operations team

Achieve Operational Excellence using the digital plant to support your O&M decisions

• lmprove procedures
• Monitor plant performance and detect bottlenecks
• Troubleshoot operations
• lncorporate the lessons learned during incidents into the OTS training content
• Train new hires and re-train existing personnel on low-frequency events
• Test and approve proposed plant changes and train operations staff before their implementation
• Use the dynamic model for surveillance and real-time look-ahead predictions

ITOP is the Inprocess approach to the education of operators and young engineers in subjects such as Process Engineering and Unit Operations. This approach combines process simulation-based exercises with classroom training, motivating attendees to experience complex theory subjects through hands-on exercises. Through ITOP the operators gain better process understanding, leading to increased plant reliability and improvement in overall operator performance, as well as an improved ability to operate the plants in a safe way. ITOP can be adapted to support any company’s existing training strategy. ITOP proves to the authorities the company’s investment in the operators's knowledge and ability to be able to operate safely.

Bring together all information about pressure relief devices and store it in a single, centralized database.

Functionalities

• Store valve mechanical data together with the contingencies that were used to determine it.
• Update the database whenever new information becomes available (re-validation of existing devices, sizing of new ones etc.).
• Generate consistent documentation when designing or validating valves and associated piping.
• Import calculation results from commercial process simulators or from comma separated values files.
• Export documents and customized company reports to MS Word, MS Excel and Adobe Acrobat.
• Use user-friendly GUI allowing direct screen access to all valves and services protecting a unit.
• Work in a unified environment thus facilitating teamwork.

Lead Training Sessions.
Configure Interfaces.
Connect Data Nodes.

Functionalities
One of the key components of an Operator Training System is the station from where the instructor leads and monitors the training sessions. Inprocess has developed an instructor station software that allows users to:

• Mentor and Lead Training Sessions.
• Configure interfaces for the Instructor and the Operators.
• Connect the different data nodes in an OTS.
• Model split management in multi-core computers.

Is the current equipment size appropriate for safe plant operation?

Save CapEx without compromising safety by benefiting from previously oversized flare networks.

Benefits

• Revalidation, or new design, of flare equipment.
• Available simulation model for any future what-if study
• Updated and revalidated pressure relief devices sizing
• Single repository database with easy access from anywhere in the organization
• Consistent generation of any documentation related to safety devices

Assure and maximize the operation of your production system while minimizing risks

Benefits

• Avoid production shutdowns and downtimes
• Reduce flaring episodes
• Save Capex in expensive thermal-resistant materials
• Optimize sequences for wells start-up and shutdown
• Save in inhibitors consumption
• Plan ahead for production contingencies
• Assess environmental risk

Simulate, predict and optimize product and production during plant lifecycle

Benefits

• Create efficient production methodologies
• Prevent costly downtimes to equipment and production lines
• Predict when preventive maintenance will be necessary
• Enable faster, more efficient and more reliable production operations

Author(s)
Martin Skarle (Preem) and Jesús Gil (Inprocess)

Congress
Aspentech Users Group Meeting (Optimize2019)

Abstract / Summary
Joint oral contribution to Aspentech's Users Conference Optimize 2019 held in Houston, TX (USA) in May 2020

Author(s)
Josep-Anton Feliu and Miquel Àngel Alós (Inprocess) and Michele Manzulli (Virtual Materials Group Europe)

Magazine
2018. Cutting-Edge Technology for Carbon Capture, Utilization and Storage (CETCCUS), Pages: 135 - 146

Abstract / Summary
The associated gas of an oil-producing field in off-shore Brazil is treated to remove water, hydrocarbon condensate, H2S and CO2. For environmental reasons, the CO2-rich permeate stream from the gas treatment process must be re-injected into the reservoir. Several compression systems boost the pressure of the permeate stream (2.5 bara) to a pressure in the range of 450–550 bara, pressure level suitable for reinjection. Many blowdown valves are installed along the compression systems, the associated pipelines and equipment. Hazard analysis did identify the potentiality for solid CO2 (dry ice) formation during depressurization (blowdown) in, basically, any section of the different process units. The formation of dry ice during depressurization constitutes a threat to the safety integrity of the system. Several simulation studies have been carried out to determine if in current process conditions the depressurization of the process sections could lead to the formation of dry ice. VMGSim, from Virtual Materials Group (VMG), was the dynamic process simulator of choice due to the availability of the APR-SolidCO2 property package, which allowed for the quantitative determination of the dry-ice formation. The dynamic analysis performed with the simulator allowed to determine the amount of dry ice formed, the time when the CO2 started to appear, and the time when CO2 melted back and disappeared. Once the formation of dry ice was confirmed by the different dynamic analysis, several mitigation techniques were planned and tested with additional dynamic simulation runs that helped to diminish the dry-ice appearance and its impact on plant performance.

Author(s)
Leonardo Carpio

Congress
The Rapidly Changing World of LNG: Finding your Competitive Advantage in 2018

Abstract / Summary
Inprocess contribution to the Aspentech's hosted seminar entitled: The Rapidly Changing World of LNG: Finding your Competitive Advantage in 2018, held in Houston, Texas (USA), on March 2018

Author(s)
Manel Serra

Congress
Energy Simulation Technology Exhibition and Conference (2018)

Abstract / Summary
Inprocess oral contribution to the ESTEC: Energy Simulation Technology Exhibition and Conference hold in Barcelona, from May 30th to 31st, 2018

Author(s)
Josep Anton Feliu, Sergio Linuesa and Miquel A. Alós,

Magazine
2018. Oilfield Technology, July, Pages: (online)

Abstract / Summary
Inprocess authors discuss the application of dynamic simulation to the analysis of potential trips of the HIPPS system at the flare header of a central processing facility during trunkline pigging operations.

Author(s)
Stefano Signor and Miquel Àngel Alós (Inprocess) and José Ramón Ferrer (Espindesa)

Magazine
2018. World Fertilizer, September, Pages: 45-49

Abstract / Summary
The authors present the results of the collaboration between Espindesa and Inprocess in order to develop a software tool that acts as a digital twin of a real nitric acid plant. The tool contains a dynamic simulation model built in HYSYS of one of the Espindesa licensed processes, with the control system and most of the EDS system embedded into the process model. An HMI for control room operator training was also developed and incorporated into the digital twin.

Author(s)
Kari Berte (Yinson), Leonardo Carpio, Sergio Juan, JoseMaria Nougues, Jesus Gil and Josep-Anton Feliu (Inprocess)

Congress
3rd Oil & Gas Training and Simulation Forum

Abstract / Summary
Joint oral contribution to the Oil & Gas Training and Simulation forum held in June 2017 in Aberdeen (Scotland), UK

Author(s)
JoseMaria Ferrer, Josep-Anton Feliu

Magazine
2017. Automazione e Strumentazione, March, pages: 88 - 90

Abstract / Summary
The definition of a Control System in Chemical and Petrochemical Plants requires specific know-how with the target of optimizing and improving existing systems and designing new ones. When designing a system, it is necessary to follow some basic steps such as modelling the system, analysing such model, designing the system/controller and finally, implementing and testing it. In order to bridge the gap between the industry’s in-depth knowledge of classical control techniques and the new process simulation features, Inprocess proposes a simulation-based course, targeting process control engineers, where the right combination of theory and practical exercises allows the meeting of such professional needs. Training could be extended to Multivariable model predictive control (MPC) topics

Author(s)
Dieter Krenz (Linde), Manel Serra (Inprocess), Theron Strange (Simplot Phosphates)

Magazine
2017. World Fertilizer, September-October, pages: 94 - 98

Abstract / Summary
Process simulation is a technology used in many areas and project phases. Its usage ranges from the design stage of a plant (initial concept and front-end engineering) to assistance in daily plant operations, including planning, optimisation and monitoring. To a certain extent, the simulation lifecycle is similar to the lifecycle of a process plant, bringing support and value to multiple stages in the lifetime of a process plant.

Author(s)
Leonardo Carpio, Sergio Juan and José Maria Nougués (Inprocess), and Kari Berte Bye (Yinson Production)

Magazine
2017. World Oil, November, Pages: 33-38

Abstract / Summary
This case study presentation shows a Dynamic Simulation Study (DSS) carried out for the Floating Production Storage and Offloading (FPSO) designed and operated by Yinson Production for the OCTP development project in Ghana. The Aspen HYSYS Dynamics model was used extensively to run about 15 transient conditions (Start-up, Emergency Shutdown, Blocked inlet/outlet, load sharing, ramp-up, etc.) to verify the sizing, process layout, control layout, operating procedures, etc. During a second project stage, the detailed model was re-used to create a Lifecycle Direct-Connect Operator Training Simulator (OTS) by connecting it with the Integrated Control and Safety System (ICSS).

Author(s)
José María Ferrer

Magazine
2017. Inprocess’ White Paper, December, Pages: 1-15

Abstract / Summary
Operator Training Simulators (OTS) have become an integral element in the Operator Competency Development Programs of the process industry. The dynamic simulation technology has evolved from the early days, incorporating new training functionalities and communication capabilities. On the other hand, modern Integrated Control and Safety Systems (ICSS) include independent soft-controller tools to allow an exhaustive check-out of the ICSS and the OTS development. This has enabled flexible and customizable OTS architectures, which significantly reduce the development costs and maximizes the value of the OTS investment. The main focus of this article is to provide recommendations and advice to Operating Companies (OpCo) and Engineering Procurement & Construction (EPC) Companies when they embark on a tender process to procure an OTS.

Author(s)
María J. Guerra, Manel Serra & Josep-Anton Feliu (Inprocess)

Congress
6^th TRC-JCC / IDEMITSU International Symposium – Abu Dhabi, February 2016

Abstract / Summary
Inprocess’ experts detailed in this Oral Contribution how it is possible to save OpEx by minimizing the amount of hydrogen that is sent to the fuel network. An advisory tool, based on an optimizer put on top of a simulation model, is used by operating companies to send the correct amount of hydrogen, at the correct purity, to refinery consumers while benefiting from the one generated by producers. Simultaneously, the required external hydrogen is reduced and the one discarded to fuel network is as well minimized. The advisory tool is connected online with the plant real time database in order to regularly update the simulation model with operating data before every optimization step is launched.

In this day and age it has become necessary to seek maximum efficiency and speed in executing any process, obtaining the desired results with a minimum investment and the highest quality. For this reason, control systems have become very important, and considerable time and resources have been dedicated to studying them to ensure their efficient start‐up and operation. Thus, for a process to function within the required margins, an adequate control system must be implemented, regulated in accordance with the parameters that govern it. Within this context, a distinction is established between different types of controllers:

• Proportional (P) controllers.
• Proportional‐integral (PI) controllers.
• Proportional‐derivative (PD) controllers.
• Proportional‐integral‐derivative (PID) controllers.

Author(s)
Sebastien Osta (TOTAL) and JoseMaria Ferrer (Inprocess)

Congress
16th AIChE Spring Meeting (2016)

Abstract / Summary
Joint oral contribution to the 16th AIChE Spring Meeting, in Houston (TX, USA) in May 2016

Author(s)
Miquel Àngel Alós

Magazine
2016. Oilfield Technology, May, pages:
2016. Engineer Live, February, pages:

Abstract / Summary
Miquel Angel Alós, PhD, Inprocess, explains how operations teams in the oil and gas industry can use dynamic simulation to avoid disruptions and minimise the impact of unnecessary costs on real plant operations.

Author(s)
Miquel Àngel Alós

Magazine
2016. Control Engineering Europe, May, pages: 16-17

Abstract / Summary
Miquel Angel Alós, explains how dynamic simulation can help maximise plant performance and deliver cost savings on new plant projects.

Author(s)
Miquel Àngel Alós

Magazine
2016. Hydrocarbon Processing, October, pages:

Abstract / Summary
The oil and gas industry has witnessed seismic downward shifts in barrel prices and uplifts in market competitiveness.

http://www.hydrocarbonprocessing.com/magazine/2016/october-2016/process-control-and-instrumentation/use-dynamic-simulation-to-maximize-plant-operating-performance

Author(s)
Marc Massó and Miquel Àngel Alós

Magazine
2016. Hydrocarbon Engineering, October, pages: 88 - 90

Abstract / Summary
The paper describes the steps that should be taken during a flare network capacity assessment, using both a conventional approach and dynamic simulation.

The absorption process is based on the transfer of a pollutant from a gaseous current in which it is present in a high concentration, to a liquid with a low vapour pressure and a lower concentration of the compound, in which it is highly soluble. So the driving force that generates the separation will be the difference in the concentrations. Absorption may be physical if the separation is by dissolution or chemical, if the compound to be eliminated reacts to the selected solvent.

To achieve maximum efficiency, it is necessary to find the maximum contact surface between the residual gas and the eliminator liquid. In addition, the materials used to build the equipment must be resistant to corrosion, due to the acidity of the pollutants. There is a wide range of equipment designed for this purpose, including tray columns, packed columns, aspersion boxes, Venturi separators, etc. In this particular case, the study is conducted in a packed column fitted with a plate at the bottom of the column (sump) that acts like a hydraulic seal and allows the liquid level to be controlled.

Author(s)
Johan Ronnberg and Oleg Pajalic (Perstop AB) and JoseMaria Ferrer, JoseMaria Nougues, Rodolfo Tona and Andres Crespo (Inprocess) 

Congress
Aspentech Users Group Meeting (Optimize2015)

Abstract / Summary
Joint oral contribution to the Aspentech Users Group Meeting (Optimize2015) held in May 2015 in Boston, USA

Author(s)
Manuel Pedraza, Pierre Lahaie, Zhen Li (CEPSA Chemical Shanghai), JoseMaria Ferrer, JoseMaria Nougues, Rodolfo Tona, Carlos Alcoverro (inprocess) 

Magazine / Congress
Aspentech Users Group Meeting (Optimize2015)

Abstract / Summary
Joint oral contribution to the Aspentech Users Group Meeting (Optimize2015) held in May 2015 in Boston, USA

Author(s)
Jose Maria Ferrer 

Congress
Aspentech Users Group Meeting (Optimize2015)

Abstract / Summary
Inprocess oral contribution to the Aspentech Users Group Meeting (Optimize2015) held in May 2015 in Boston, USA

Author(s)
Josep-Anton Feliu, JoseMaria Ferrer and José-María Nougués

Magazine
2015. Hydrocarbon Engineering, March, pages: 105-109

Abstract / Summary
An Operator Training System (OTS) is one of the best methods to train staff in operations before a producing plant start-up. Carrying out this training before plant commissioning ensures a fast learning curve of the new process and control and instrumentation systems. Moreover, the operators can be exposed to emergency situations or process upsets that are not part of the daily operation. This will facilitate the operator response to normal and abnormal process conditions.

Author(s)
Josep-Anton Feliu

Magazine
2015. Industria Química, July-August, pages: 44-49

Abstract / Summary
Safety and productivity in processing plants depend greatly on the accurate performance of the control and safety systems, normally centralized in control rooms, through the distributed control systems and safety instrumented systems (DCS, SIS). In order to ensure the plant production, it is key to have staff well trained in the operation of such automated systems.

Author(s)
JoseMaria Ferrer, Ron Beck (AspenTech Inc.) and Manel Serra

Magazine
2014. The American Oil & Gas Reporter, January, pages: 44-49

Abstract / Summary
Dynamic simulation of processes using rigorous models offers a wide range of applications for process engineering, process control, instrumentation, operation, training, and health, safety and environmental projects.

Author(s)
Jose Naranjo, Edgar Goitia (TR, Chile), JoseMaria Nougues, Rodolfo Tona, Josep Davi, JoseMaria Ferrer (Inprocess)

 

Congress
Aspentech Users Group Meeting (Optimize2013)

Abstract / Summary
Joint oral contribution to the Aspentech Users Group Meeting (Optimize2013) held in May 2013 in Boston, USA

Author(s)
Manel Serra, JoseMaria Ferrer (Inprocess), JG Vega, F Cifuentes, Marta Yugo and MLuisa Suarez (Repsol)

Congress
Aspentech Users Group Meeting (Optimize2013)

Abstract / Summary
Joint oral contribution to the Aspentech Users Group Meeting (Optimize2013) held in May 2013 in Boston, USA

Author(s)
Stephen Wagner, Hiren Shetna (Saudi Aramco), Manel Serra and Maria Jesus Guerra (Inprocess)

Congress
Aspentech Users Group Meeting (Optimize2013)

Abstract / Summary
Joint oral contribution to the Aspentech Users Group Meeting (Optimize2013) held in May 2013 in Boston, USA

Author(s)
José María Nougués, Michael Brodkorb and Josep-Anton Feliu

Magazine
2012. Hydrocarbon Engineering, May, pages: 92-96

Abstract / Summary
Over the past 10 years the use of dynamic process simulation has been established as a reliable and effective tool to analyse transient behaviour of process systems.

Centrifugal compressor systems show performance characteristics that mainly depend on the operating point imposed on them by the process units and the connection piping around the compressor.

Large compression systems often have several compressors operating in parallel, with some of them in standby. Therefore, even in normal operation there are frquent start up and shut down operations while switching between compressors: to accommodate throughput changes, for example. The transient analysis of these operations is critical in the evaluation of the dynamic behaviour of the compressor system and the associated control and safety systems.

Author(s)
Prabhat Panigrahy, Jens Balmer, Miquel Àngel Alós, Michael Brodkorb and Brian Marshall

Magazine
2011. Hydrocarbon Engineering, September, pages: 93-95

Abstract / Summary
Flare and relief systems commonly found in processing plants in the oil, gas and petrochemical industries are constantly under examination.

New constructions, the extension of existing plants or changes in safety regulations all require a detailed analysis of several aspects of the flare and relief system. In many cases, steady state analysis will suffice; but, more often than not, complex or marginal problems require dynamic analysis to resolve an apparently bottlenecked flare system.

This approach has recently been successfully applied to analyse and improve the blow down strategy for an existing gas utilisation plant (GUP) owned and operated by Wintershall in Libya.

Author(s)
Marta Yugo, Amaia de Manueles, Francisco Alonso, Martin Santos, Miguel A. García, and Antonio López-Rodríguez (Repsol), Michel Manzulli (Aspentech), and Josemaria Ferrer (Inprocess)

Magazine
Aspentech’s Industry White Paper (2011 - The content of this paper originally appeared in Oil & Gas Journal, October 4, 2010)

Abstract / Summary
The European Union 10-ppm sulfur fuel regulations present various challenges for operating and controlling refinery desulfurization units. Repsol has been using simulation to mitigate some of these challenges.

In a joint project with AspenTech, the two companies developed a rigorous steady-state and dynamic Aspen HYSYS® model of Repsol’s Puertollano refinery’s hydrodesulfurization (HDS) unit. This model was further integrated with the unit multivariable predictive controller (MPC), Aspen DMCplus®, which helped investigations of reactor conditions and operations to establish better control strategies. This paper presents an account of the project and some lessons learned.

Author(s)
Detlef Gruber and Dietmar-Uwe Leipnitz (BP Lingen Refinery), Prasad Sethuraman (BP Refining Technology), Miquel Àngel Alós, José María Nougués and Michael Brodkorb (Inprocess)

Magazine
2010. Petroleum Technology Quarterly (PTQ), January, pages: 93-95

Abstract / Summary
There are different situations in which it is necessary to re-evaluate the capacity of a site's existing flare system. In general, this is necessary following a potential increase in flare load, e.g. when:

• Relief Valves that currently blow to air and that need to be connected to the flare header,
• Changes in regulation that redefine the scenarios for which the flare system has to be designed,
• New plants that are connected to the existing flare header, or
• Throughput increase / revamps of existing plants that might increase the flare load through higher hold-up or higher heat load.

In this article, the authors give an overview of the advantages of the approach of using dynamic simulation to calculate flare loads following API 521, give guidance on when and where to apply it, and describe a case study of a recent study at BP’s Lingen refinery in Germany.

Author(s)
Josep-Anton Feliu and Miquel Àngel Alós

Magazine
2008. Ingeniería Química, July, pages: 102-107

Abstract / Summary
La estimación de los caudales de alivio de presión en la cabeza de las columnas de destilación resulta de cálculo complicado debido a la naturaleza de estas unidades, donde la composición cambia a lo largo de la columna y del tiempo. En el presente artículo se compara la aplicación del método convencional y del basado en simulación dinámica para la estimación en una unidad atmosférica de destilación de crudo.