Base Checkout Equipment

SimSci®
®
DYNSIM 5.3.2
Base Checkout
Equipment
December 2016
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Table of Contents
Medium Fidelity Fundamentals ...................................................................................................... 1
Introduction ................................................................................................................................. 1
Additional Reading ................................................................................................................. 1
Why Dynamic Simulation for Control Checkout?...................................................................... 2
How Medium Fidelity Simulation Saves Project Cost ........................................................... 3
Medium Fidelity Suitability for Operator Training ................................................................ 3
Thermodynamics......................................................................................................................... 4
Pressure-Flow Solver .................................................................................................................. 4
Networks ................................................................................................................................. 5
Flow Paths ............................................................................................................................... 5
Flow Path Parameters WLin and DPLin ................................................................................. 5
Internal Units of Measure ........................................................................................................... 6
Process Equipment Model Types................................................................................................ 7
Pressure Node Attributes ........................................................................................................ 7
Flow Device Attributes ........................................................................................................... 8
Basic Unit Operations ................................................................................................................. 8
Definition of Reference State...................................................................................................... 9
Modeling Philosophy .................................................................................................................. 9
Modeling Fundamentals............................................................................................................ 10
Configuring and Parameterizing Models .............................................................................. 10
Checkout Equipment Material Characterization ................................................................... 10
Flow Networks ...................................................................................................................... 11
iii
Base Checkout Equipment
Project Considerations .............................................................................................................. 12
Tuning to the Process Flow Diagram........................................................................................ 13
Stream Structure........................................................................................................................ 18
Process Stream .............................................................................................................................. 18
Parameters ................................................................................................................................. 19
Mechanical Stream........................................................................................................................ 21
Features ..................................................................................................................................... 21
Parameters ................................................................................................................................. 21
Bin ................................................................................................................................................. 22
Introduction ............................................................................................................................... 22
Bin Fundamentals ..................................................................................................................... 22
Fundamentals General .......................................................................................................... 22
Bin Fundamentals Material Balance ..................................................................................... 22
Bin Fundamentals Phase Fractions ....................................................................................... 23
Bin Fundamentals Temperature ............................................................................................ 24
Bin Fundamentals Other State Derivatives ........................................................................... 24
Example .................................................................................................................................... 25
Data Entry Window .................................................................................................................. 27
Bin Input ............................................................................................................................... 27
Bin Notes .............................................................................................................................. 29
Parameters ................................................................................................................................. 29
FAQ........................................................................................................................................... 33
Component List ............................................................................................................................. 34
iv
Table of Contents
Introduction ............................................................................................................................... 34
Fundamentals ............................................................................................................................ 34
Fundamentals ........................................................................................................................ 34
Example .................................................................................................................................... 34
Component List Input ........................................................................................................... 36
Component List Notes .......................................................................................................... 37
Parameters ................................................................................................................................. 38
Conveyer ....................................................................................................................................... 39
Introduction ............................................................................................................................... 39
Fundamentals ............................................................................................................................ 41
Fundamentals ........................................................................................................................ 41
Gate Fed Conveyer ............................................................................................................... 42
Self -Fed Conveyer ............................................................................................................... 45
Motor Connection ................................................................................................................. 45
Time Delay............................................................................................................................ 46
Example .................................................................................................................................... 46
Example 1 ............................................................................................................................. 46
Example 2 ............................................................................................................................. 48
Conveyer Input...................................................................................................................... 51
Conveyer Feeds ..................................................................................................................... 52
Conveyer Notes ..................................................................................................................... 52
v
Parameters ................................................................................................................................. 53
FAQ........................................................................................................................................... 60
Header ........................................................................................................................................... 61
Introduction ............................................................................................................................... 61
Fundamentals ............................................................................................................................ 61
Fundamentals ........................................................................................................................ 61
Material Balance ................................................................................................................... 61
Phase Fractions ..................................................................................................................... 63
Composition Balance ............................................................................................................ 63
Holdup................................................................................................................................... 64
Relationship between Pressure, Fluid Density and Bulk Modulus ....................................... 64
Holdup Fluid Temperature .................................................................................................... 65
Other State Derivatives ......................................................................................................... 65
Example .................................................................................................................................... 66
Header Input.......................................................................................................................... 70
Header Properties .................................................................................................................. 71
Header Notes ......................................................................................................................... 72
Parameters ................................................................................................................................. 72
FAQ........................................................................................................................................... 80
Mechanical Screen ........................................................................................................................ 81
Introduction ............................................................................................................................... 81
Fundamentals ............................................................................................................................ 81
vi
Table of Contents
Fundamentals ........................................................................................................................ 81
Inlet Particle Size .................................................................................................................. 81
Outlet Particle Size ............................................................................................................... 81
Amount going to Accept and Reject Stream......................................................................... 82
Example .................................................................................................................................... 83
Mechanical Screen Input....................................................................................................... 86
Mechanical Screen Notes ...................................................................................................... 87
Parameters ................................................................................................................................. 87
FAQ........................................................................................................................................... 92
Mill................................................................................................................................................ 93
Introduction ............................................................................................................................... 93
Fundamentals ............................................................................................................................ 94
Fundamentals ........................................................................................................................ 94
Grinding ................................................................................................................................ 94
Power .................................................................................................................................... 95
Exit Flow of Solids ............................................................................................................... 95
Example .................................................................................................................................... 95
Mill Input .............................................................................................................................. 98
Mill Notes ............................................................................................................................. 99
Parameters ................................................................................................................................. 99
FAQ......................................................................................................................................... 105
vii
Pipe ............................................................................................................................................. 107
Introduction ............................................................................................................................. 107
Fundamentals .......................................................................................................................... 107
Fundamentals ...................................................................................................................... 107
Equations for Flow and Flow Conductance ........................................................................ 107
Example .................................................................................................................................. 109
Data Entry Window ................................................................................................................ 111
Pipe Input ............................................................................................................................ 111
Pipe Properties .................................................................................................................... 112
Pipe Notes ........................................................................................................................... 113
Parameters ............................................................................................................................... 113
FAQ......................................................................................................................................... 116
Pulverizer .................................................................................................................................... 117
Introduction ............................................................................................................................. 117
Fundamentals .......................................................................................................................... 118
Fundamentals ...................................................................................................................... 118
Grinding .............................................................................................................................. 118
Power .................................................................................................................................. 119
Exit Flow of Solids ............................................................................................................. 119
Example .................................................................................................................................. 119
Pulverizer Input ................................................................................................................... 122
Pulverizer Notes .................................................................................................................. 123
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Table of Contents
Parameters ............................................................................................................................... 123
FAQ......................................................................................................................................... 129
Screen .......................................................................................................................................... 130
Introduction ............................................................................................................................. 130
Fundamentals .......................................................................................................................... 130
Fundamentals ...................................................................................................................... 130
Inlet Particle Size ................................................................................................................ 131
Outlet Particle Size ............................................................................................................. 131
Amount going to Reject Stream .......................................................................................... 131
Amount going to Accept Stream......................................................................................... 133
Adjustment of Phase Fractions ........................................................................................... 133
Flow Equations ................................................................................................................... 134
Example .................................................................................................................................. 135
Screen Filter Input............................................................................................................... 137
Screen Filter Notes .............................................................................................................. 139
Parameters ............................................................................................................................... 139
FAQ......................................................................................................................................... 143
Sink ............................................................................................................................................. 144
Introduction ............................................................................................................................. 144
Fundamentals .......................................................................................................................... 144
Fundamentals ...................................................................................................................... 144
Boundary Specifications ..................................................................................................... 144
ix
Feed Streams ....................................................................................................................... 144
Reverse Flow ...................................................................................................................... 144
Example .................................................................................................................................. 145
Sink Basic ........................................................................................................................... 148
Sink Notes ........................................................................................................................... 149
Parameters ............................................................................................................................... 149
FAQ......................................................................................................................................... 150
Source ......................................................................................................................................... 151
Introduction ............................................................................................................................. 151
Fundamentals .......................................................................................................................... 151
Fundamentals ...................................................................................................................... 151
Boundary Specifications ..................................................................................................... 151
Feed and Product Streams ................................................................................................... 153
Reverse Flow ...................................................................................................................... 153
Example .................................................................................................................................. 153
Source Basic........................................................................................................................ 157
Source Properties ................................................................................................................ 158
Source Notes ....................................................................................................................... 159
Parameters ............................................................................................................................... 159
FAQ......................................................................................................................................... 162
Stream Modify ............................................................................................................................ 163
x
Table of Contents
Introduction ............................................................................................................................. 163
Fundamentals .......................................................................................................................... 163
Fundamentals ...................................................................................................................... 163
Forced Parameter Specifications......................................................................................... 163
Connected to Streams ......................................................................................................... 164
Connected to Holdups ......................................................................................................... 164
Example .................................................................................................................................. 164
StreamModify Basic ........................................................................................................... 168
StreamModify Properties .................................................................................................... 169
StreamModify Notes ........................................................................................................... 169
Parameters ............................................................................................................................... 170
Stream Receive ........................................................................................................................... 172
Introduction ............................................................................................................................. 172
Fundamentals .......................................................................................................................... 172
Use as a Boundary .............................................................................................................. 172
Making Connections within the Same Engine .................................................................... 173
Making Connections between Different Engines ............................................................... 173
Flow Device Equations ....................................................................................................... 173
Data Transfer ...................................................................................................................... 175
Example .................................................................................................................................. 176
Stream Receive Basic ......................................................................................................... 179
xi
Stream Receive Notes ......................................................................................................... 180
Parameters ............................................................................................................................... 181
FAQ......................................................................................................................................... 184
Stream Send ................................................................................................................................ 185
Introduction ............................................................................................................................. 185
Fundamentals .......................................................................................................................... 185
Use as a Boundary .............................................................................................................. 185
Making Connections within the Same Engine .................................................................... 185
Making Connections between Different Engines ............................................................... 186
Pressure Node ..................................................................................................................... 186
Data Transfer ...................................................................................................................... 188
Example .................................................................................................................................. 189
Stream Send Basic .............................................................................................................. 192
Stream Send Notes .............................................................................................................. 193
Parameters ............................................................................................................................... 194
FAQ......................................................................................................................................... 196
Valve ........................................................................................................................................... 197
Introduction ............................................................................................................................. 197
Fundamentals .......................................................................................................................... 198
Fundamentals ...................................................................................................................... 198
Valve Flow Conductance .................................................................................................... 198
Valve Actuator Design ........................................................................................................ 200
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Table of Contents
Valve Diaphragm Actuator ................................................................................................. 200
Valve Motor-Operated Valve ............................................................................................. 201
Malfunctions ........................................................................................................................... 203
Analog Malfunctions .......................................................................................................... 203
Discrete Malfunctions ......................................................................................................... 204
Example .................................................................................................................................. 205
Importance of Parameters ................................................................................................... 207
Valve Sizing ........................................................................................................................ 210
Valve Actuator .................................................................................................................... 211
Valve Properties .................................................................................................................. 212
Valve Notes ......................................................................................................................... 213
Parameters ............................................................................................................................... 213
FAQ......................................................................................................................................... 219
xiii
Medium Fidelity Fundamentals
Introduction
DYNSIM® Checkout model is a library of simplified process engineering models used to

simulate plant processes and unit operations for control checkout, and as an operator
familiarization tool. DYNSIM Checkout differs from standard DYNSIM application in that the
underlying models are greatly simplified, do not rely on complicated thermodynamics, and are
easy to configure using readily-available plant data. The trade-off, of course, is limited model
fidelity: the models may not be capable of accurately simulating, for instance, startup or trip
conditions or other off-design operation. High-fidelity DYNSIM models are capable of this
accuracy, however it requires specialized process knowledge and modeling experience. The
DYNSIM Checkout model, so called because its primary usage is the validation and testing of
simulation-based Distributed Control System (DCS) and Safety Systems, is ideally-suited for
putting the power of simulation in the hands of non-simulation specialists.
DYNSIM Checkout models are split into two libraries:
• Base Checkout Equipment

• Process Checkout Equipment
Base Checkout Equipment will be available when DYNSIM, DYNSIM-C or DYNSIM-All

engine is installed. Process Checkout Equipment will be available only when DYNSIM-C engine
is installed.
This chapter describes the model development strategy for the Base Checkout Equipment
Library models.
Additional Reading
Depending on the final application, the user may want to consult the following documentation:
• DYNSIM Auto-Model Generation User Guide – for automatically converting SmartPlant

P&IDs into Medium Fidelity Checkout models
• FSIM Plus User Guide – necessary if the user is performing a Foxboro® I/A DCS control
checkout project
• TRISIM Plus User Guide – necessary if the user is performing a Triconex® Safety System
checkout project
• Tieback Simulation Bulk Configurator User Guide – information on using simulation for
control checkout via tieback models
• Dynamic Simulation Suite Users Guide – contains information about the DYNSIM
application for all users of dynamic simulation
These documents are available in PDF format, or on-line from the DYNSIM Graphical User
Interface (GUI) under the Help menu.
1
Additionally, various free web information sources, such as Wikipedia®, can be very useful in
helping to understand aspects of process engineering or control.
Why Dynamic Simulation for Control Checkout?
Using Dynamic Simulation for control and safety system checkout has two main benefits:
• It allows the project hardware and software development to be independent of each other:
using FSIM Plus® or TRISIM Plus® virtual control system simulation means that real
control hardware is not needed for factory testing, and the control cabinets and I/O panels
can be built, tested, and shipped while the control application is still under development.
• Validating the control system design against some process model exposes control
configuration errors that could not be found by any method, other than by an
actual installation. Doing so early in the project reduces risk to the project team, as well
as to the end client, by finding and fixing errors before installation in the plant. The
simulation test bed has time control (freeze and run) and snapshots (save and restore)
functions that are ideal for tracking down logic and control problems.
Using Dynamic Simulation of any sort has benefit, however the amount of benefit, and the
amount of effort to implement the benefit, is directly related to the level of simulation fidelity:
• Low fidelity, tieback simulation

• tests only single loops
• is easy to implement by control and safety engineers
• uses simple math functions to emulate plant process, such as lag block
• identifies easy control errors (inverted contacts, incorrect graphics, inverted
controller sense)
• is cheap
• is useful as an operator orientation tool
• Medium Fidelity simulation
• tests multiply-interacting control loops
• requires very basic process knowledge
• uses Unit Operation models (defined later)
• can be automatically created from Intergraph SmartPlant Piping and
Instrumentation Diagrams (P&IDs)
• has features to assist model tuning
• identifies easy and medium control errors (process interlocks, cascaded control,
sequence logic)
• has a moderate cost
• is useful as an operator orientation tool
• High fidelity simulation
• tests all aspects of control design, and plant design
• requires very high degree of skill to build and use
• uses rigorous physical and thermodynamic relations
• identifies easy, medium, and difficult control errors, such as runback and trip
recovery, dynamic load changes, cold metal to full load
• is expensive
2
• uses an Operator Training Simulator (OTS)
Tieback simulation is already widely available, and generally familiar, to control and safety
application engineers. Dedicated OTS engineering groups deploy high-fidelity training
simulators, which are also often used in control checkout projects by working in tandem with the
control team. Medium Fidelity simulation seeks to bridge the gap, both in terms of skill and
capability, between low and high fidelity, and puts the power of simulation in the hands of
control and safety engineers.
How Medium Fidelity Simulation Saves Project Cost
Controls Projects are typically structured as the control vendor having responsibility for design
and development of specific control logics, graphics, and applications, and also responsibility for
testing, installation, and commissioning in the plant. Depending on the contract, field
commissioning may be fixed price, time and material, or some combination of both.
Simulation saves project cost by finding and fixing system “bugs” before the system is installed
in the plant. A bug is defined as any misconfiguration or parameterization that causes the control
system not to work as specified. The savings come from the fact that it is much easier and faster
to diagnose and repair these bugs on a simulated system, in the comfort of the IPS factory, rather
than to diagnose and fix these bugs on a live unit.
The savings can be calculated by comparing the time it takes to fix easy, medium, hard, and
severe-category bugs on the simulated system, to the time it takes to fix those bugs in the field
(easy bugs are five minute fixes in either the factory or field; severe bugs take a few hours to fix
in the simulated environment but eight or more in the field).
The higher the fidelity of simulation, the higher the project cost savings; medium fidelity
simulation balances project savings against the skill level required to build the simulation.
Medium Fidelity Suitability for Operator Training
Medium Fidelity Simulation’s secondary goal is as an Operator Familiarization tool. The term
Familiarization is used since industry expectations for Operator Training Simulators (OTS)
usually involve a high degree of rigor and validation. OTS is often used for Operator
qualification and certification, and a big concern for OTS is not to provide “negative” training –
training which would cause the Operator to take the wrong steps during an event on the real unit.
That said, the models developed for control checkout could provide a high degree of basic or
even intermediate training for plant personnel. Not only can they learn the ins and outs of the
control system operation (graphics, control blocks, tools, alarms, reports, and so on), they can
learn this with the system interacting in a realistic and approximately correct manner, with the
process that the Operator will ultimately supervise; the Operator can learn how to startup certain
pieces of equipment, how to satisfy interlocks, how to manipulate the process, and how to
recognize the operating state of the process by interpreting the various sensor readings. This
level of training ability is called Operator Familiarization.
3
General Expectations for an Operator Familiarization Simulator
• Plant operation above approximately 30% (typically below 30%, much of the operation is
done manually and not directly with the control system anyway)
• Increasing or decreasing capacity demand to within +/-30% from a certain starting point
• Operating under different load conditions (low, medium, high), but not necessarily in one
continuous operation
• Resetting interlocks
• Observing trip conditions, although depending on the severity of the trip event, the post-
trip sensor readings may be very inaccurate
Thermodynamics
The medium fidelity models do not use rigorous thermodynamics. Although the models allow for
different phases, they all have the same density and specific heat; the desired physical behavior
of the unit operations is determined by back-calculating effective flow coefficients, thermal
capacity, and heat transfer coefficients. This removes from the user the burden of having to
perform specific design and detailed thermodynamic property calculations that would otherwise
be required to obtain working models.
The back calculations are based on user-specified reference parameters. These reference
parameters are typically measured by instrumentation, or are generally easily available, such as
from Process Flow Diagram (PFD) reference data. These reference parameters can be either
scalar values, meaning they are always constant, or they may be a user-defined table lookup
based on percentage of load or some other independent variable. For instance, to display the
pressure of a stream drum, the user could enter the reference pressure as a function of
temperature using steam tables as inputs.
There is rudimentary tracking of individual material components, represented by name only (no
thermodynamic properties). In addition, the model tracks the solid, liquid, and vapor fraction
component phases, as well as a parameter that characterizes the particle size distribution for the
solid phase. Phase separations (i.e. liquid to vapor, solid to liquid) and chemical reactions are
empirically modeled and do not rely on detailed thermo-physical data.
Pressure-Flow Solver
The DYNSIM application has a pressure flow solver that calculates flow rates driven by changes
in pressures at pressure nodes. Unlike the steady state solution, flow rates are determined by the
pressure profile in the system, rather than the other way around. In this way for example, a
DYNSIM model can calculate the flow in a plant from the power fed to Compressors at the end
of the process.
The DYNSIM 4.5.3 application uses a new Simultaneous pressure flow solver. The
Simultaneous solver calculates all pressures and flows in a network using an iterated matrix
technique. The Simultaneous solver is now the default option, and should be the preferred choice
for all new simulations. This section of the manual describes the Simultaneous solver
exclusively.
4
Networks
The Simultaneous pressure flow solver views a simulation as a group of networks. Each network
includes a group of pressure nodes joined by flow devices and surrounded by explicit pressure
boundaries.
• The boundaries to a network have a constant pressure for the duration of the integration
time step. A boundary can be a Source, a Sink, or other pressure node with a pressure
boundary flag set, or an explicitly integrated pressure node. By definition, the network is
completely bounded by explicit state or boundary pressure nodes.
• A Stream Send or Stream Receive also acts as a network boundary if it is not linked to
anything, or if it is linked to a different engine. If it is linked within the same engine, the
contiguous network seamlessly extends across the link.
The network solver builds a matrix for all the flows and pressures in the network and updates the
pressures and flows simultaneously, so that at the end of each time step all the pressure and flow
relationships are satisfied.
Flow Paths
A flow path is a chain of flow devices between pressure nodes. The flow path is referenced by
the name of the first stream that enters the first flow device. When the Simultaneous solver
discovers a flow path, it inserts incompressible pressure nodes between the flow devices, so as to
determine the intermediate pressures. These intermediate pressure nodes do not appear as model
objects on the flow sheet, but they do show up as extra pressure nodes in the Network Statistics
display.
Flow Path Parameters WLin and DPLin
WLin is the flow path property linearization mass flow. If the mass flow rate is less than WLin
then upstream and downstream properties of a stream are blended to achieve a continuous
transition between forward and reverse flow.
DPLin is the flow path flow linearization delta pressure. If the ΔP across a flow device is less
than the global DPLIN, the ΔP term is linearized i.e. ΔP/sqrt(DPLIN) is used instead of sqrt(ΔP)
in the Darcy flow equation. The default value of DPLIN is 10 kPa. It can be modified from
Engine Configuration editor. The modified Darcy equation is represented as:
R
F = J ⋅ ∆P ⋅
DPLIN
Where:
F - Mass flow (kg/sec)
J - Flow conductance ((kg/sec)/sqrt(kPa-kg/m3))
5
ΔP - Pressure drop across the flow device (kPa)
R - Flow mass density (kg/m3)
Internal Units of Measure
The DYNSIM control Checkout Equipment models and streams have the following internal units
of measure.
UOM Type UOM

Composition fraction
Density kg-mol/m3
Flow kg-mol/sec
Energy,
kJ/kg-mol /K
specific
Energy, total kJ
Level m
Length m
Power kW
Mass kg
Rotation rpm
Pressure kPa
Temperature K
Time sec
Volume m3
These scientific internal units are not typically used in field engineering, however the user can
employ the Units-of-Measure utility in the DYNSIM application to display common units, like
SI or English. The user can also customize the UOM using the tool. Once the user has selected
the desired unit of measure, then all display and editing values appear in the selected units. The
Dynamic Simulation Suite User Guide gives more details.
6
Process Equipment Model Types
Medium Fidelity models include pipes, valves, vessels, heat exchangers and other common
process models. In the lumped parameter modeling approach used in the DYNSIM application,
there are three basic types of equipment models. These include pressure nodes that determine
pressure, flow devices that determine the flow between pressure nodes, and solids handling
devices that move and store solid materials. The CCHeat Exchanger, the CCFired Heater, the
CCConveyer, the CCPulverizer, the CCMill and the CCScreen are hybrid models that include
attributes of both flow devices and pressure nodes.
Pressure Nodes Flow Devices Solids Handlers Utility Models

CC Pipe
CC Valve
CC Source
CC Relief Valve
CC Sink
CC Compressor
CC Header
CC Combustor CC Conveyer
CC Drum
CC Pump CC Mech Screen CC Component List
CC Fired Heater
CC Heat Exchanger CC Mill CC Shaft
CC General Reactor
CC Utility Exchanger CC Pulverizer CC Stream Modify
CC Black Box
CC Expander CC Screen CC Transmitter
CC Bin
CC Three-Way Valve
CC Tank
CC Ejector
CC Stream Send
CC Stream Receive
CC Recip Compressor
The individual equipment model documentation gives a detailed description of each equipment
model.
Pressure Node Attributes
• Pressure nodes set the pressure of all inlet and exit streams. Pressure nodes do not set or
calculate flows in or out of the pressure node.
• Pressure nodes set all exit stream properties when the flow is forward, and they set all
inlet stream properties when the flow is reversed.
• Pressure nodes cannot be connected to each other through a stream. Between each pair of
pressure nodes there must be at least one flow device, which calculates the flow between
them.
• Pressure nodes usually include holdup. Holdups represent the accumulation of mass and
energy within a Pressure Node
7
Flow Device Attributes
• Flow devices have one inlet and one exit stream

• The combination of flow devices in a piping network set the flow of the inlet and exit
stream. Flow devices do not set pressures
• Simple flow devices typically pass the stream properties from the inlet stream to the exit
stream. Information on temperature and density passes from the inlet stream to exit
stream conditions for forward flow, and from the exit stream to the inlet stream for
reverse flow.
Basic Unit Operations
The following is a list of the types of unit operations that the Checkout models simulate, and a
general description of their basic capabilities:
• Valve – opens, closes, limit switches. Controls flow, change in pressure, upstream or
downstream pressure, temperature, or level
• Pump/Fan – displays inlet and exit pressure and flow, has a linear pump or fan curve to
vary head as a simple function of flow
• Motor/Breaker – opens, closes, trips, resets. Displays current and voltage
• Heat Exchanger – one-sided or two (shell-tube). Co-current flow and countercurrent
flow. Displays inlet and outlet temperatures on both sides of exchanger. Uses efficiency
calculations that account for hot and cold-side inlet temperatures and flows
• Tank – fills, drains, displays level and temperature
• Header, Tee – branches or joins pipe flow paths. Calculates pressure, flow
• Drum (separator) – separates incoming liquid into liquid and vapor fractions based on
inlet temperature and user-tuned boiling factor; calculates liquid level, temperature, and
pressure as a simple function of temperature
• Reactor – models heat of reaction (exothermic or endothermic, depending how the user
configures it). Calculates pressure and temperature; can have provision for jacketed
cooling
• Conveyer – moves solid material from start to end, with associated dead time response.
Variable speed, variable feed, configurable length.
• Bin – accumulates solid material, calculates level
• Mill / Pulverizer– grinds solid feed and mixes with transport fluid, either water or air.
Outlet percentage of ground solids, represented by composition, is a function of fluid
flow and accumulation of solids mass within the mill
• Combustor/Burner – mixes air and fuel, represented by inlet composition, and combusts
the mixture; calculates temperature based on air/fuel ratio and flow
• Turbine Expander/Compressor – produces/consumes mechanical power based on inlet
flow and energy, represented by pressure and temperature. Calculates rotational speed
• Screen/Filter/Cyclone – separates solids from fluids based on inlet percentage of solids,
represented by composition, and efficiency
8
Definition of Reference State
When a typical Engineering and Construction (E&C) company designs a plant, they run
simulations that calculate conditions during normal operating conditions. Sometimes, these are
called design operating conditions. Within this set of unit-operation models, these types of
values are called reference conditions. Thus, if you see parameters such as Tsiz or Psiz , it is
implied that the reference temperature and pressure are the expected values at normal operating
conditions.
Modeling Philosophy
The unit operations use simple forms of conservation of mass and energy to formulate a
response to inputs, and may employ empirical correlations appropriate to the unit operation type.
However, to meet the basic requirements of robustness and ease of configuration, these will not
be rigorously or physically-based.
Robustness, meaning that the model really does resist crashing, requires that certain hard limits
be enforced, such that the model never goes into an inoperable condition. So, for instance a tank
will never overfill nor completely drain dry, pumps will not cavitate, columns will not flood, and
physical parameters such as pressures and temperatures will not exceed go past the maximum
and minimum limits.
Certain plant processes can be very difficult to model, due to their physical nature. For instance,
processes that have a high degree of recycle flow between unit operations, or have tight heat
integration, such as an LNG heat exchanger, may be difficult to model with medium fidelity or
even high-fidelity simulation. In these cases, one or more of the following options may be
necessary:
• break the simulation down into smaller pieces, by removing some unit operation
integration and specifying fixed boundary conditions to simplify the problem
• have simulation specialists analyze the process and suggest changes to the model
configuration, parameterization and tuning to handle the situation
• create a hybrid model to integrate a high fidelity simulation with the current medium
fidelity simulation
The models are designed to be parameterized with information that is commonly-available, and
matched to typical instrumentation, such as pressure, temperature, flow, and so on. Pre-
processors within the models adjust internal scale factors to try and make the answer match the
desired input, even if this would mean that energy is not conserved, or that internal fluid
properties must be adjusted. The next section discusses this point further.
9
Modeling Fundamentals
Configuring and Parameterizing Models
Models may be configured in one of two ways: manually using the DYNSIM Graphical User
Interface, or automatically using the Auto-Model Generator. For manual configuration, refer to
the Dynamic Simulation Suite User Guide. For automatic configuration, refer to the Auto-Model
Generation User Guide. For details how to use the DYNSIM GUI, tools, and features, refer to
the Dynamic Simulation Suite User Guide.
Checkout Equipment Material Characterization
The Checkout Equipment models perform actions on working material. The material may be
solid, liquid, or vapor, or a combination of these. Unlike DYNSIM rigorous high-fidelity
modeling, the material type is not explicitly defined as water, methane or the like. Instead, the
materials are user-defined to have constant density, constant specific heat, constant molecular
weight, and so on. In many, perhaps most, applications, it is not necessary for the user to modify
these properties: the unit operations internally scale density, specific heat, and other parameters
to drive the calculated outputs to the desired value. However, advanced users can specify these if
desired, which incrementally increases realism, but still within the expectations of medium
fidelity. The Advanced Applications section gives further details.
This table lists the model parameters that define the material:
Parameter Meaning Comments

In flow networks, this is computed by flow in/flow out and
P Pressure
resistance. In pressure vessels, it is a function of temperature.
T Temperature
W Mass Flow Material flow within a network
Liquid Fraction Percentage of material that is represented by the main working
LF1
1 fluid
Liquid Fraction Percentage of a secondary working fluid, usually water, that is
LF2
2 extracted out of a vessel boot (specialized application)
SF Solids Fraction Percentage of material that is in solid phase
Percentage of material that is in vapor phase.
VF Vapor Fraction
LF1 + LF2 + SF + VF = 100%
In the solid phase, this number represents the average particle
Solids Average size. It is an arbitrary and relative number between 1 – 10 (1
SPS
Particle Size being the smallest); used with solids operations such as milling
and screening.
10
Flow Networks
Material is transferred from unit operation to unit operation via flow networks. The networks are
collections of unit operations connected together via streams. The unit operations fall into one of
two categories: a pressure node, or a flow device.
A piece of equipment is defined as a pressure node when it has internal storage capacity or
holdup. A pressure node can have one or more inlet flow and outlet flow, although inlet flow
may not always equal outlet flow.
A piece of equipment is defined to be a flow device when it has only one inlet and only one
outlet, and no holdup.
This table gives examples of model equipment in each category:
Equipment
Category Comments
Examples
Pressure is either constant, as in an atmospheric tank, or a
Pressure Tank, Drum, function of fluid temperature, as in a drum. Can have one or more
Node Reactor inlet and outlet flows. The sum of flows in may not always equals
the sum of flows out
Pressure A piping tee, a collection of tees together, or a piping header. The
Header
Node sum of flows in always equals sum of flows out
Pressure
Source, Sink Constant pressure and temperature boundaries
Node
One inlet flow, one outlet flow, with a pressure drop. The flow in
Flow
Valve, Pipe always equals the flow out. Any number of flow devices can be
Device
connected in series
One inlet flow, one outlet flow, with a pressure rise in the case of
Pump, the pump or the compressor, or a pressure drop in the case of the
Flow
Compressor, expander. The relationship between pressure and flow is
Device
Expander established by a curve, defined about an operating design point
specified by user
Flow One- or two-sided flow device, with pressure drop on each side.
Heat Exchanger
Device One side transfers heat to the other side.
Rules for Flow Networks
• A flow network must either start or end at one or more pressure nodes
• A pressure node cannot be directly connected to another pressure node; at least one flow
device must be in between the pressure nodes.
• Pressure nodes are connected to flow devices, and flow devices are connected to other
flow devices, via process streams (there are also mechanical streams, electrical
streams, and heat streams used to connect rotating machinery, electrical grids, and heat
transfer devices respectively, but these do not apply to pressure-flow networks).
11
• Flow can be either forward or backward; a negative sign (-) indicates flow in reverse
direction.
• For Checkout Equipment, material flows are constant density, constant phase
Project Considerations
The Auto Model Generation (AMG) feature automatically creates or instantiates the models
based on the appearance of unit operations on a Piping and Instrumentation Diagram, as
described in the Auto-Model Generation User Guide. However, the user, either the controls
engineer or the engineer with assistance from a simulation or process expert, must, at a
minimum, parameterize the model’s Transmitters, and possibly the model’s design conditions.
To Configure means to create the model objects and connect them together. To Parameterize
means to enter in design information, such as expected flow, pressure, or temperature at
percentage of capacity.
This leads to the anticipation that the model will be exceedingly easy and simple to parameterize
and tolerant of bad guesses. Bad guesses result in unrealistic behavior but not in loss of
simulation control. Fortunately, the simplicity of the Medium Fidelity approach means that any
source of information can be used (even guesses, educated or not); the sources need not be
consistent or even accurate; although the resulting display values may look quite odd.
An excellent source for most of the required information will be Process Flow Diagrams (PFDs);
these are usually created early in the lifecycle of the plant and are accurate enough for the
purposes of Medium Fidelity simulation. For other data (such as “motor running amp
indications”), the user will have to consult vendor data sheets, operating manuals, or make
inquiries with plant personnel. However, it should be recognized that this is a crucial part of the
controls engineering process (such as setting transmitter ranges), and represents an opportunity
to ask the right questions and get the right answers and to assist in the validation process.
The project workflow using DYNSIM Checkout Equipment models proceeds roughly as follows:
1. Build Simulation Platform

• DYNSIM Checkout model
®
• FSIM Plus application
®
• TRISIM Plus application
• other (if applicable)
2. Load controls and operator graphics onto simulation platform
3. Obtain plant Piping and Instrumentation Diagrams
• if automatically generating the model, process the P&IDs through the IPS
Engineering Workbench to generate the AMG input files, run AMG, then import
the simulation into DYNSIM application
• if manually generating the model, highlight the equipment of interest, create a
New Simulation in the DYNSIM application, and drag-and-drop items of
Checkout Equipment onto model flowsheets using P&ID as a guide.
4. Load the model and resolve any errors or warnings. Running model in this condition is
called out-of-the-box; that is, running but not tuned.
12
5. Line up the process to the desired operating conditions, such as pumps on or off, main
process block valves open, startup or auxiliary valves closed, control valves at 50%, and
so on.
6. Parameterize the Transmitter model objects with the reference values that represent the
desired steady-state values that are to appear on control system operator screen. As a rule
of thumb, in cases where process data is lacking, choose a value for analog signals that is
at the midway point in the signal range; for example, reference value = “125” if signal
low limit is 100 and high limit is 150.
7. Update cross reference table with control system I/O points
8. Update cross reference table with Transmitter-to-I/O mapping file, which was created
during the AMG process.
9. Tune each transmitter as desired by toggling the reference commit tuning flag. This re-
scales the model data reading up to the desired reference value, so that the control system
will read a signal that is within the expected range, without the operator having to
perform detailed model tuning.
10. See that correct value appears on control system operator screens.
11. Manipulate the process by starting and stopping equipment, changing the control
setpoints. See that the process responds, although it may not respond with the correct
magnitude until after the next step is performed.
12. Using process data, usually in the form of a Process Flow Diagram, enter the required
information into the model objects, as described in the section “Tuning to the Process
Flow Diagram ”. As data is entered and loaded into the model, the process model
calculated values should begin to approach those of the PFD, and model response to
process changes should begin to approach an expected magnitude.
13. Perform control checkout
Tuning to the Process Flow Diagram
This figure shows an example of a Process Flow Diagram:
The corresponding DYNSIM Checkout model might look like the following:
13
The task is to take the stream information in the PFD, and interpret it correctly to parameterize
the Drum, Valve, Source, and Sink models shown in the diagram. The first step, as described in
the “Project Considerations” section, is to line up the equipment in the desired configuration. In
this example, the startup block must be full-open, the bypass closed, and the control valve set to
approximately 50%:
The next step is to parameterize the flow sheet Sources and Sinks. At a minimum, set the
Pressure and Temperature set. For the Feed Source to the drum, set boundary pressure to 300
psia and 220F, as shown by Stream S1 in the PFD table above:
14
Do the same for the remaining Sink pressure boundaries.
For each flow piping leg, enter the steady-state mass flow and pressure drop. This information is
determined by using the information from two streams in the PFD. For instance, the mass flow of
the feed to the drum is given by S1 in the PFD as 321,000 lb/hr. The pressure drop is found by
taking the feed pressure 300psia from S1 and subtracting the drum pressure defined by S2 of
150psia, for a total pressure drop of 150psi. Configure the feed control valve with this
information:
Do the same for the other valves.
Note that in the model for the vapor coming off the top of the drum, it is not clear how to
configure the block and bypass valves. However, it is possible to use judgment: these valves are
15
for startup or bypass operation, so the block valve can reasonably have a negligible pressure drop
with the rated mass flow, such as a pressure drop of 0.1 psi; while the bypass valve can
reasonably carry half the capacity of the control valve. The PFD gives a total pressure drop for
this flow leg of 50psi with a mass flow of 96,000 lb/hr. The figure below shows the resulting
model configuration:
For the drum itself, the required information comes from Stream S2:
16
The drum vessel dimensions are often found as an equipment description on the P&ID. In the
sections that follow, the Model Object documentation provides further tuning details.
17
Stream Structure
DYNSIM application uses Process Streams, Mechanical Streams and Heat Streams to
interconnect between the models. Process Streams, Heat Streams, and Mechanical Streams are
part of checkout Equipment Library. Control Streams are not required, because the user can
employ connectors and default connectors to connect control models, such as a PID, through
parameter assignments.
Process Stream
The Process Stream connects equipment models. The stream structure is designed to meet the
following objectives:
• Support for reverse flow

• Reduce model complexity and overhead by using mixed property and enthalpy basis
• Include density and molecular weight to pass to downstream flow devices
18
Parameters
Parameter Default Default Equation Array

Description UOM
Name Class Value Allowed? Size
Liquid 1 mass fraction
Dynamic User
LF1 Liquid1 fraction set by the No fraction
Double Defined
upstream model
Mole flow.
This value is negative when Dynamic kg-mol
F No
flow is in the reverse Double / sec
direction.
Molar Heat Capacity Dynamic kJ/kg-
CP No
CP in the direction of flow. Double mol-K
Liquid 2 mass fraction
Dynamic User
LF2 Liquid2 fraction set by the fraction
Double Defined
upstream model
Molecular weight
Dynamic kg/kg-
MW Molecular weight in the No
Double mol
direction of flow.
Pressure Dynamic
P No kPa
Stream pressure Double
Volume flow
This value is negative when Dynamic
Q No m3/sec
flow is in the reverse Double
direction.
Mole Density
Density in the direction of
flow. Density is set by the
upstream model. If the Dynamic kg-
R upstream model is a flow No
Double mol/m3
device, the density is
approximate unless the flow
device FlashFlag is set to
true.
19

Description UOM
Mass Density
Mass Density in the
direction of flow. Density is
set by the upstream model. If Dynamic kg-
Rmass the upstream model is a flow Double No
mol/m3
device, the density is
true.
Average particle size of
solids
Dynamic
SPS It is an arbitrary and 5.0 No
Double
relative number between 1 –
10 (1 being the smallest)
Temperature
Temperature in the direction
of flow. Temperature is set
by the upstream model. If Dynamic
T the upstream model is a flow Double No K
device, the temperature is
true.
Vapor Fraction
Vapor mass fraction in the
direction of flow. Vapor
fraction is set by the
upstream model. If the Dynamic
VF No fraction
upstream model is a flow Double
device, the vapor fraction is
true.
Mass flow
This value is negative when Dynamic
W No kg/sec
flow is in the reverse Double
direction.
20
Mechanical Stream
Features
Mechanical Streams connect units that are connected by a mechanical Shaft, such as a Pump,
Compressor, Expander, or a Motor. The Medium Fidelity mechanical stream is exact replica of
the high-fidelity counterpart except for the class name. It is replicated only to group under
checkout library, and it avoids dependency of the DYNSIM-C engine on the DYNSIM engine.
For constant speed motors, the Motor object sets the mechanical stream speed. The equipment
attached with the mechanical stream, such as the Pump, the Compressor, or the Expander,
calculates the power produced or consumed. A Shaft is not required in case of a Motor connected
directly to a Pump or a Compressor, unless more than one instance connects to the same Shaft.
For variable speed drivers such as Expanders, the driver calculates the power and a Shaft
calculates the speed. The Shaft model documentation gives more details.
Parameters

Description UOM
Calculated power
Power calculated by turbine, Dynamic
Power 0.0 No kW
Compressor, Motor, or other Double
rotating equipment.
Shaft speed Dynamic
Speed 0.0 Yes rpm
Speed set by Shaft Double
Set Speed Signal
SetShaftSpeed If true, the mechanical stream Dynamic
will set the speed of the Shaft. Boolean False No
Motors use this parameter to
set the Shaft speed.
21
Bin
Introduction
The CCBin stores solids in much the same way that the CCTank stores liquids, with the
exception that all flows exiting a CCBin have solids fraction of 1.0. To model mixtures of solids
and liquids, use the CCTank model instead. The unit calculates level based on the mass
contained inside the CCBin, the material density, and the CCBin geometry. Material can
overflow onto the ground, liquid entering the unit is ignored and vapor can vent to the
atmosphere, so in these cases the model does not conserve mass. The CCBin supports changes to
the molar average phase split.
This unit lacks a direct mechanism for transferring heat between the material fluid and the
surroundings. To simulate a heat loss or gain, you must use the imposed heat-transfer parameter
Qimp.
The CCBin can take any number of feed streams. The Product is drawn from the bottom of the
unit.
Despite the similarity of names, the CCBin model is not associated with one of the internal
compartments that move along the belt of a CCConveyer.
For the purpose of solving a pressure-flow network, the Pressure Flow Solver considers this unit
to be a pressure node.
Bin Fundamentals
Fundamentals General
The CCBin model uses incompressible flow network assumptions to calculate flow into and out
of the CCBin. Thus, you can model a solids flow network using CCSources, CCSinks,
CCValves, CCPipes and so on; and the models calculate the flow based upon pressure
difference. You can fix the CCBin pressure as needed to obtain the desired flows. However, most
solids-handling flow networks use conveyers to move material. In these cases, the CCConveyer
model object fixes the flow in to or out of the CCBin based on design capacity and speed.
The calculations for this unit use stream information when it is available. However, if complete
stream information is not available, such as when the unit stands alone, then the calculations use
reference condition parameters in place of the missing stream data.
This model does not use Thermodynamics.
Bin Fundamentals Material Balance
22
Bin
The model calculates vessel material balance using these equations:
dMT/dt = dMS/dt Σ(Fi * SFi) - Σ(Fx * SFx)
dMV/dt = 0.0 (The CCBin assumes the material is all solids.)
dML/dt = 0.0 (The CCBin assumes the material is all solids.)
MT = MS
Bin Fundamentals Phase Fractions
The model calculates phase fractions using these equations:
SF = MS / MT = 1.0
VF = 0.0 (The CCBin assumes the material is all solids.)
LF = 0.0 (The CCBin assumes the material is all solids.)
Where:
Fi = Flow of inlet stream
Fx = Flow of exit stream
SFi = Solid fraction of inlet stream i
SFx = Solid fraction of exit stream x
dMS/dt = Derivative of solid moles in holdup fluid
dMV/dt = Derivative of vapor moles in holdup fluid
dML/dt = Derivative of liquid moles in holdup fluid
MT = Total moles of holdup fluid
MS = Solid moles in holdup fluid
SF = Solids Fraction
LF = Liquid Fraction
VF = Vapor Fraction
23
Bin Fundamentals Temperature
The model calculates the temperature using a simplified weighted average energy balance:
dT/dt = (Σ((Ti - Th) * Cpi * Fi) + Qimp) / (Mh * Cph)
where:
dT/dt = Derivative of holdup solid temperature
Ti = Temperature of the solids in stream i
Th = Temperature of holdup solid
Fi = Molar flow of inlet stream i
Mh = Total molar holdup in the vessel
Qimp = Duty imposed on the vessel
Cph = Specific molar heat capacity of inlet stream i
Cph = Specific molar heat capacity of holdup solid
Bin Fundamentals Other State Derivatives
The model calculates other state derivatives using molar averages of incoming fluids for e.g.,
molecular weight derivative is calculated by following equation:
dMW/dt = (Σ((MWi - MWh) * Fi) / Mh
where:
dMW/dt = Derivative of holdup fluid molecular weight
MWi = Molecular weight of the fluid in stream i
MWh = Molecular weight of holdup fluid
Mh = Total molar holdup in the unit
24
Bin
Example
This example demonstrates the use of CCBin to simulate the drying and transport of solids. The
material flows from the CCSource WET_FEED through CCValve LCV into the CCBIN
DRYER_HOPPER. From there, it flows onto CCConveyer PROD_CONVEYER and into the
CCSink DRY_SOLIDS. The boundary pressure of WET_FEED is maintained at 150 kPa, and
the boundary pressure of DRY_SOLIDS is maintained at 100 kPa. A PID controller, LC,
manipulates the feed rate to maintain the DRYER_HOPPER level.
Source: WET_FEED
Parameter Assignment UOM Description
Source CCSRC1 product stream connecting to the
OProdStream[0] CCS1
Valve CCXV1.
VFB 0.0 fraction Boundary vapor fraction
LF1B 0.05 fraction Boundary liquid 1 fraction
Pb 150 kPa Boundary pressure
Tb 298.15 K Boundary temperature
SFB 0.95 fraction Solids fraction
SPSB 1 Solid Average Particle Size
Valve: LCV
Valve feed stream connecting from
OFeedStream CCS1
Source CCSRC1.
Valve CCXV1 product stream
OProdStream CCS2
connecting to Bin CCB1.
FlowType Mass
Wsiz 50 Kg/Sec Mass flow rate
DPsiz 50 kPa Delta pressure
25
TimeOP 10 sec Time to Open

TimeCL 10 sec Time to Close
ActType Diaphragm Actuator Type
Bin: DRYER_HOPPER
Feed stream connecting from Valve
OFeedStream CCS2
CCXV1.
Product stream connecting from Bin
OProdStream CCS3
CCB1 to Valve CCXV2
Dia 1 M Inside diameter of the Bin
Len 5 M Length of of Bin
Pb 101.32 kPa Boundary Pressure
Tb 298.15 K Boundary Temperature
Qimp 1000 kJ/sec Imposed duty
Conveyer: PROD_CONVEYER
OFeedStream CCS3
Bin CCB1.
Valve Product stream connecting to
OProdStream CCS4
pipe PIP1.
BeltSpeedSiz 0.50833 m/sec Design Speed
Capacity 2 kg/sec Mass capacity of Conveyer
Length 30.5 m Length of Conveyer
Pb 101.325 kPa Boundary Pressure
SelfFedFlag False Self-fed
Pipe: PIP1
OFeedStream CCS4 Feed Stream from CCXV2
Product stream connecting from
OProdStream CCS5
PIP1 to CCSNK1.
FlowType Mass
Wsiz 1 Kg/Sec Wsiz
26
Bin
Sink: DRY_SOLIDS
Sink feed stream connecting from
OFeedStream[0] CCS4
PIP1.
The simulation will reach a steady-state with the following values:
Process Parameter Description Value UOM

LC.SP DRYER_HOPPER level control setpoint 3.0 m
LC.PV DRYER_HOPPER level control process value 50.0 kg/sec
LC.OUT DRYER_HOPPER level control output 0.072 fraction
CCS2.W Wet Feed flow into DRYER_HOPPER 7.05 kg/sec
DRYER_HOPPER.T DRYER_HOPPER temperature 333.86 K
CCS3.W Dry Solids flow from DRYER_HOPPER 6.70 kg/sec
This simulation show two notable aspects of the Bin. First, the liquid entering with the feed
(LF1 = 0.05) is lost – the Bin does not store Liquid. This feature is used to simulate drying of
the solid feed (Feed flow = 7.05 kg/sec, Product flow = 6.70 kg/sec). The second notable aspect
is that the temperature of DRYER_HOPPER is ~35 K higher than the feed, as a result of the
Qimp applied in the input.
Data Entry Window
Bin Input
Boundary Conditions
Enter the Pressure in kPa.

27
Enter the Temperature in degrees Kelvin.
Sizing
Enter the long dimension of the unit in meters. For horizontal units, this dimension is the
Length. For vertical units, it is the Height.
Enter the Diameter in meters.
28
Bin
Bin Notes
Enter an optional Description of the component.
Enter any optional Notes about the component.
Parameters
Advanced
Description UOM
Name Class Value Allowed Size
Dynamic response lag (not Static
KLag 1.0 No
used for Bin) Double
Specified heat input or output
This parameter represents the Dynamic
Qimp 0 Yes kJ/sec
external heat imposed on the Double
material or lost to ambient.
29
Basic
Description UOM
Static
Dia Diameter of the CCBin 1 No m
Double
Static
Len Length of the CCBin 5 No m
Double
Orientation of vessel (not used for Static
Orientation 1 No
Bin) Int
Calculated Values
Description UOM
Liquid Level
This parameter represents the
L level of the liquid as the height Dynamic 0.0 No m
of the material from the bottom Double
of the vessel.For Bin this will
always be 0.0
Liquid Level
level of the liquid 2 as the Dynamic
L2 No m
height of the material from the Double
bottom of the vessel. For Bin
this will always be 0.0
Pressure
P pressure within the unit, as Pb No kPa
Double
calculated by the Pressure
Flow Solver.
Solids level
S level of the solids as the height Double No m
of the material from the bottom
of the vessel.
Dynamic
T Holdup temperature Tb No K
Double
Dynamic
Vol Vessel volume No m3
Double
30
Bin
Derivatives
Parameter Default Default Equation
Description Array Size UOM
Name Class Value Allowed
Holdup specific heat Dynamic kJ/k-
dCp 0 No
capacity derivative Double mol/K/sec
Holdup total moles Dynamic
dMT 0 No k-mol/sec
derivative Double
Holdup molecular Dynamic
dMW 0 No
weight derivative Double
Holdup molar density Dynamic k-
dR 0 No
derivative Double mol/m3/sec
Holdup solids particle Dynamic
dSPS 0 No
size derivative Double
Holdup temperature
derivative Dynamic
dT 0 No K/sec
Double
Holdup fluid mass Dynamic Defined in

dZMASS 0 No
fractions derivative Double ComponentList
Intial Values
Description UOM
Static
Pb Boundary Pressure 101.325 No kPa
Double
Static
Tb Boundary Temperature 298.15 No K
Double
States
Description UOM
Dynamic kJ/k-
Cp Holdup specific heat capacity 0 No
Double mol/K
Total moles
MT 0 No k-mol
total holdup moles in the Double
CCBin for all phases.
Dynamic kg/k-
MW Holdup molecular weight 0 No
Double mol
31

Description UOM
Dynamic k-
R Holdup molar density 0 No
Double mol/m3
Dynamic
SPS Holdup solids particle size 0 No
Double
Dynamic
ZMASS Holdup fluid mass fractions 0 No
Double
Topology
Parameter
Description Default Class
Name
Feed Stream
This array of object references identifies the feed streams, also
called the inlet streams, and their associated fluid properties.
This unit can connect only from flow devices.
This entry must be unique among all other feed streams in the
flowsheet. However, this entry can be the same as a product
OFeedStream CCSTREAM
stream identifier from another flow device. OFeedStream and
OProdStream cannot be the same.
Any number of feed streams can connect to this unit.
The feed stream’s phase fraction parameters VF, LF1, LF2 and
SF determine the amounts of vapor, liquid and solid. These
fractions must sum to 1.0
Product Stream
This parameter identifies the product stream, also called the
outlet stream, and its associated fluid properties. This unit can
connect only to flow devices.
OProdStream This entry must be unique among all other product streams in CCSTREAM
the flowsheet. However, this entry can be the same as a feed
Any number of product streams can connect from this unit.
32
Bin
FAQ
Q, Can I provide external heat inputs to the CCBin Model?
A. Yes, you can model the CCBin to simulate external heat inputs and losses. The software uses
the Qimp parameter to impose heat duty on the model. The holdup fluid temperature and
stream properties change according to the magnitude of Qimp.
Q. What purpose do the boundary conditions serve in the CCBin model?
A. The CCBin model derives from the pressure-flow network models. While pressure does not
typically drive flow in a solids-handling network, this is a Medium Fidelity convenience for
building up simple networks. Therefore, for solids networks that do not use conveyers, choose
boundary pressure PB in order to obtain the desired flow into and out of the CCBin, as shown
in the example. For networks that use conveyers, the CCConveyer object sets a fixed flow.
33
Component List
Introduction
CCComponentList allows users to create a named list of components. Checkout Equipment

models do not assign physical or thermodynamic properties to individual components; therefore,
the list is only used for simple tracking of composition.
Only one CCComponentList may be instantiated per DYNSIM engine. This ensures that each
model uses the same list of components. The system will always use the name
“CC_COMPLIST” for CCComponentList objects.
The CCComponentList does not directly affect the pressure-flow network.
Fundamentals
Fundamentals
This model does not connect directly to any other DYNSIM models. All Checkout Equipment
models will use the CCComponentList object to populate composition vector labels (typically in
a ZMASS parameter).
Example
This example configures a CCComponentList CC_COMPLIST and creates a CCSource

CCSRC1, connected to a CCValve CCXV1, which is also connected to a CCSink CCSNK1.
The flowsheet is presented below:
34
Component List
The model parameters are set to default conditions, except as indicated below:
CCComponentList: CC_COMPLIST
Number of components (sets ComponentName
NComponents 5
vector size)
ComponentName[0] Water Component name
ComponentName[1] Gasoline Component name
ComponentName[2] Jet Fuel Component name
ComponentName[3] Diesel Component name
ComponentName[4] Gas Oil Component name
CCSource: CCSRC1
CCSource product stream connecting to the
OProdStream[0] CCS1
CCValve CCXV1.
WB[Water] 1 kg Mass of component 1 (Water)
WB[Gasoline] 39 kg Mass of component 2 (Gasoline)
WB[Jet Fuel] 20 kg Mass of component 3 (Jet Fuel)
WB[Diesel] 30 kg Mass of component 4 (Diesel)
WB[Gas Oil] 10 kg Mass of component 5 (Gas Oil)
CCValve: CCXV1
CCValve feed stream connecting from CCSource
OFeedStream CCS1
CCSRC1.
CCValve CCXV1 product stream connecting to
OProdStream CCS2
CCCombustor CCB1.
CCSink: CCSNK1
CCSink feed stream connecting from tube side of
OFeedStream[0] CCS2
H.E CCE1.
Pb 100 kPa Boundary pressure.
When the model is run, the simulation should reach a steady state flow of 50 kg/sec with each
stream having the following composition:
ZMASS[Water] = 0.01
35
ZMASS[Gasoline] = 0.39
ZMASS[Jet Fuel] = 0.20
ZMASS[Diesel] = 0.30
ZMASS[Gas Oil] = 0.10
Data Entry Window
Component List Input
Input Tab
Enter the Number of Components.
Enter the Component Name(s).
36
Component List
Component List Notes
37
Parameters
Basic
Default Default Equation
Parameter Name Description Array Size UOM
Class Value Allowed
Number of Static 1
NComponents 1 No
Components Integer
Labels to be used to
identify each
component in
ComponentNames Checkout Equipment COMP_ No NComponents
models.
38
Conveyer
Introduction
The conveyer has two basic configuration options.
1- Self fed conveyer.

2- Gate fed conveyer (not self fed).
Following is an illustration of a self fed conveyer. Material in the hopper is always available and
the conveyer speed sets the intake rate of the conveyer. There is no inlet gate for the self fed
conveyer.
Following are two illustrations of a conveyer fed by a gate (the conveyer is NOT self fed). The
inlet gate controls the conveyer flow and conveyer speed only affects the lag time that material
resides on conveyer. Inlet spilling when the gate flow exceeds conveyer capacity is not modeled.
The gate fed conveyer model has adequate capacity to carry whatever is delivered through the
inlet gates.
39
Note that there may be multiple inlet gates that admit flow at various positions on the belt.
One frequently encountered configuration is self fed conveyer(s) (whose speed sets the system
flow) that feeds a second conveyer that creates a transport lag. This may be modeled with a self
fed conveyer followed by a gate fed conveyer with an oversized gate in fully open position.
40
Conveyer
More general conveyer arrangements are illustrated below.
Fundamentals
Fundamentals
The CCConveyer models a bulk flow device such as a conveyer belt, and simulates the transport
lag, or dead time, between the flow of material being placed onto the conveyer and the material
exiting the unit. This dead time is determined by the length and speed of the conveyer.
The internal compartments of a CCConveyer are called bins, but they are not the same thing as
the CCBin model, which is meant to store solids rather than to move them.
The CCConveyer model power consumption is a simple linear function of the design power and
the ratio between the load and the reference capacity.
Conveyer is a composite model of a holdup model and conductance models on inlet and exit
sides. So, it may be treated as a flow device in the pressure flow topology and may be connected
directly to holdup devices such as bins, sources and sinks. The internal holdup affects the
properties of the material passing through the conveyer. There is an inlet conductance model for
each feed and an exit conductance model for each product. In case of multiple products, the exit
flow is equally divided between all the products.
The exit flow(s) are determined by conveyer speed independent of pressure flow solver for all
configuration options. The conveyer has fixed boundary pressure. The boundary pressure is only
relevant to conveyer performance when gate fed (not self-fed) option is specified.
41
Gate Fed Conveyer
As shown in the figure below a conveyer can be fed anywhere along its length. The feed enters
the appropriate bin on the conveyer. For instance, if the conveyer has six bins, and a feed is
located at 50% down the length of the conveyer, then the feed enters the fourth bin out of six.
In OEV, following parameters are available for sizing of each of the inlet conductance and
control of inlet flow to the gate fed model.
The variable INLETCONDn.FLOWTYPE determines if sizing is gravimetric (0 = mass based)

or volumetric (1=volume based)
The gate fed conveyer sizing relationships are based on these equations.
Wsiz = INLETCONDn.WSIZ=reference mass flow
OR
Qsiz = INLETCONDn.Qsiz = reference volumetric flow
DPsiz = INLETCONDn.DPSIZ = reference delta P
RMasssiz = INLETCONDn.RMASSSIZ=reference mass density
Pos = INLETCONDn.POS= conductance demand
The inlet flow is determined by
F*MW= J * Pos*SqRt(DP * RMass)
J = Wsiz / SqRt(DPsiz * RMasssiz )
DP = INLETCOND n.DP = inlet stream pressure – PB

42
Conveyer
Where
J = = INLETCONDn.J = flow conductance
F =molar flow
MW = molecular weight
RMass = mass density
PB = conveyer boundary pressure
The exit flow is same as sum of inlet flows with a time lag. The time lag is defined by the
conveyer belt speed and belt length.
The sizing parameters can be used to manipulate the conveyer inlet flow capacity. The inlet flow
may be modulated through a flow controller by connecting it to controller output as shown in
following figures.
43
OR
44
Conveyer
Self -Fed Conveyer
In case of self-fed conveyer, inlet flow is controlled the conveyer belt speed and its capacity. If
conveyer is connected to motor then the belt speed is set by motor and you will need a variable
speed motor if modulated flow control is required.
The inlet flow to conveyer is calculated by the following equation:

FI *CONVHOLDUP.MW = CAPACITY * (BELTSPEED/BELTSPEEDREF)
Where
FI = inlet flow to conveyer (k-mol/sec)
BELTSPEED = conveyer belt speed (m/sec)
BELTSPEEDREF = reference belt speed (m/sec)
CAPACITY = capacity of conveyer (kg/sec)
MW = molecular weight of holdup material
Motor Connection
When motor is connected to conveyer then conveyer belt speed and reference belt speed is set by
motor and motor power is calculated based on conveyer capacity as follows:
M.POWER = Power * FX*CONVHOLDUP.MW / CAPACITY
BELTSPEED = M.SPEED* 3.14159* Sqrt(Power/M.SPEED)*0.112/60.0
Where
M = motor connected to conveyer
SPEED = speed of motor
POWER = power of connected motor
Power = rated power of conveyer
45
Time Delay
The conveyer’s exit flow and properties are equal to inlet flow and properties with time delay
where time delay is given by following equation:
Time Delay = BELTLENGTH / BELTSPEED
Where
BELTLENGTH = length of conveyer belt
For example, if the belt is 100 feet long, and the belt speed is 100 feet/min, and starting empty
the inlet flow is 50 lb/hr, you would expect to see the exit flow = 50 lb/hr after one minute.
The belt can also speed up or slow down. If the belt speed was suddenly doubled, then the outlet
flow would = 100 lb/hr for 30 seconds. After that, flow would return to 50 lb/hr. Later, if the
speed is set back to original, then flow would drop to 25 lb/hr for one minute, after which it
would return to 50. The response will look like this:
Belt speeds
up
Belt slows
down
Example
Example 1
This example configures a CCConveyer model. A mixture of solid and liquid wet material flows
from the source CCSRC1 at 150 kPa. The conveyer CCC1 has 6 bins. When the material
reaches the conveyer inlet, it falls into the first bin. When the conveyer starts rotating at one foot
per second, the bins filled with solid materials transfer the materials from the beginning of the
bin to the end. The CCSink unit CCSNK1 maintains boundary pressure at 100 kPa.
46
Conveyer
Source: CCSRC1
OProdStream[0] CCS1
Valve CCXV1.
Valve: CCXV1
OFeedStream CCS1
Source CCSRC1.
OProdStream CCS2
connecting to Conveyer CCC1.
FlowType Mass
TimeOp 10 sec Time to Open
TimeCl 10 sec Time to Close
Conveyer: CCC1
OFeedStream CCS2
CCXV1.
OProdStream CCS3 Product stream connecting from
47

conveyer to sink CCSNK1.
NBins 6 Number of Bins on conveyer belt
Length 3.048 m Length of the conveyer
BeltSpeedSiz 0.50833 m/sec Reference belt speed
Power 3 kW Rated power of conveyer

Capacity 2 kg/sec Capacity of conveyer
Sink: CCSNK1
OFeedStream[0] CCS3
Conveyer CCC1.
Example 2
This example configures a CCConveyer model with inlet flow determined by a Bin filled with
solids. Solid material flows from the source CCSRC2 at 150 kPa to a Bin CCBN1 through a
valve CCXV3. The Bin is operating at 125 kPa. The conveyer CCC4 has 5 bins. The inlet flow
to conveyer is manipulated by a level controller PID4. The controller adjusts the conductance
demand of INLETCOND1 of conveyer to maintain the level in the Bin at 2m. The CCSink unit
CCSNK2 maintains boundary pressure at 100 kPa.
48
Conveyer
Source: CCSRC2
OProdStream[0] CCS1
Valve CCXV1.
Valve: CCXV3
OFeedStream CCS1
Source CCSRC1.
OProdStream CCS2
connecting to Bin CCBN1.
FlowType Mass
Bin: CCBN1
Bin feed stream connecting from
OFeedStream CCS2
Valve CCXV3.
Bin CCBN1 product stream
OProdStream CCS3
connecting to Conveyer CCC4.
Len 5 m Bin length
49

Dia 1 m Bin diameter
Conveyer: CCC4
Feed stream connecting from Bin
OFeedStream CCS3
CCBN1.
OProdStream CCS4
conveyer to sink CCSNK2.
NBins 5 Number of Bins on conveyer belt
Length 3.048 m Length of the conveyer
BeltSpeedSiz 0.50833 m/sec Reference belt speed
Power 3 kW Rated power of conveyer

Capacity 2 kg/sec Capacity of conveyer
Sink: CCSNK2
OFeedStream[0] CCS4
Conveyer CCC4.
Level Controller: PID4

PIDType Level
HI_IN 5 m High limit on input
LO_IN 0.1 m Low limit on input
Action Direct(PV-SV) Controller action
PV CCBN1.S Process variable
SP 5 M Set point
50
Conveyer
Data Entry Window
Conveyer Input
Enter the Number of Bins.
Enter the Length of the Conveyer, in meters.
Enter the Reference speed in meter/sec
Enter the Capacity of Conveyer in kg/sec
Enter the Power of Conveyer in kW
51
Conveyer Feeds
Enter the feed location for each feed in terms of fractional length of conveyer
Conveyer Notes
52
Conveyer
Parameters
Advanced
Class Value Allowed
Pressure
Static
CONVHOLDUP.KDPS dynamics scale 1.0 No
Double
factor
Minimum inlet
pressure (not Static
*CONDn.PIMIN 10 Yes kPa
used by Double
conveyer)
Maximum exitt
*CONDn.PXMAX 30000 Yes kPa
used by Double
conveyer)
Basic
Reverse flow
conductance factor Static
*COND.KJR 0.0 No
(conveyer does not Double
allow reverse flow)
53
Calculated Values
Class Value Allowed
Mass in Bin
This
parameter
represents
the total Dynamic NBINS
Amount No Kg
mass of Double
material in
the internal
bin of
Conveyer.
Speed of Dynamic
Beltspeed No
conveyer belt Double
Pressure
Dynamic kPa
*CONDn.DP drop across No
Double
conductance
Flow Dynamic
*CONDn.J No
conductance Double
Inlet flow kg-
Dynamic
*CONDn.Fi rate to No mol/sec
Double
conductance
Exitt flow kg-
Dynamic
*CONDn.Fx rate from No mol/sec
Double
conductance
Holdup
Dynamic
CONVHOLDUP.LF1 liquid 1 No
Double
fraction
Holdup
Dynamic
CONVHOLDUP.LF2 liquid 2 No
Double
fraction
Dynamic kg-mol
CONVHOLDUP.MT Total holdup No
Double
Holdup fluid kg-
Dynamic
CONVHOLDUP.R molar No mol/m3
Double
density
Holdup
Dynamic
CONVHOLDUP.SF solids No
Double
fraction
54
Conveyer

Class Value Allowed
Holdup
Dynamic
CONVHOLDUP.VF vapor No
Double
fraction
Holdup fluid
Dynamic Defined in
CONVHOLDUP.ZMASS mass No
Double ComponentList
fraction
Dynamic kg-
Fi Inlet flow No
Double mol/sec
Exit Flow
This
parameter
represents
exit flow of
the material Dynamic kg-
Fx in the No
Double mol/sec
CCConveyer.
The model
calculates it
from the belt
speed and in
contents.
External Inputs
Conductance
demand (if
conveyer is not
self-fed then it can
Dynamic
*CONDn.Pos be used to 1.0 No
Double
manipulate the
inlet flow to
conveyer using
controller)
55
Input
Static
BeltSpeedSiz Design belt speed 0.50833 Yes m/sec
Double
Capacity of Static
Capacity 2.0 Yes kg/sec
conveyer Double
Length of conveyer Static
Length 30.5 Yes m
belt Double
Number of Bins
This may not be a
physical
representation of
the unit operation. Static
NBins The series of bins is Integer 5 No
a device for moving
solids along the
length of the
conveyer. Must be
greater than 2.
Static
Pb Boundary pressure 101.325 No kPa
Double
Rated power of Static
Power 3.0 Yes kW
conveyer Double
Flag for self-fed
option Static
SelfFedFlag 0 No
Set it to 1 if Bool
conveyer is self-fed
Static OFEEDSTREAM
FeedLoc Feed location 0 No
Double
56
Conveyer
Outputs
Class Value Allowed
Dynamic
CONVHOLDUP.P Pressure No kPa
Double
Dynamic
CONVHOLDUP.T Temperature No K
Double
Reference Conditions
Class Value Allowed
Reference sizing Graphic
*CONDn.DPsiz 50 Yes kPa
pressure Double
Flow type option
for reference
Static
*CONDn.FlowType sizing flow (0 - 0-Mass No
Int
Mass based, 1-
Volume based)
*CONDn.Qsiz 0.05 Yes m3/sec
volume flow Double
*CONDn.RMASSsiz 999.01 Yes kg/m3
mass density Double
*CONDn.Wsiz 50 Yes kg/sec
mass flow Double
Rotational Sensing Parameters

Class Value Allowed
Rotational Dynamic
Expansion 50 Yes mm
expansion Double
Vibration Dynamic
Vibration 50 Yes 1/sec
frequency Double
57
States
Default Default Equation Array
Parameter Name Description UOM
Class Value Allowed Size
Holdup fluid
molar heat State
CONVHOLDUP.CP capacity No kJ/kg-mol-K
Double
Liquid 1 State kg-mol

CONVHOLDUP.ML1 No
holdup Double
CONVHOLDUP.ML2 No
holdup Double
State kg-mol
CONVHOLDUP.MS Solid holdup No
Double
State kg-mol
CONVHOLDUP.MV Vapor holdup No
Double
Holdup fluid
State
CONVHOLDUP.MW molecular No
Double
weight
Holdup fluid
State
CONVHOLDUP.SPS solids No
Double
particle size
Topology
Parameter
Name
Feed Stream
Product Stream
OProdStream CCSTREAM
58
Conveyer
Parameter
Name
outlet stream, and its associated fluid properties.
This entry must be unique among all other product streams in
stream identifier from another unit. OFeedStream and
Only one product stream can connect from this unit.
Mechanical Stream
This parameter identifies the mechanical stream and its
associated mechanical properties.
This entry can be same as a mechanical stream identifier that
OMechStream connects to another unit. CCSTREAM
When a mechanical stream connects a Shaft to this unit, the
Shaft sets the speed of the unit.
Only one mechanical stream can connect to the unit.
59
FAQ
Q. What is the effect of checking the “self fed conveyer” option in DEW or not checking.
A. If “self fed conveyer” is checked in DEW the flow is proportional to speed at conveyer inlet
and outlet. Self fed conveyers steady sate flow rate is determined by the belt speed and design
capacity.
If “self fed conveyer” is NOT checked then the flow rate is determined by an inlet gate. Gate
fed conveyer belt speed influences exit flow in a transient way but flow must return to steady
state flow incoming through the inlet gate(s).
Q. Will the conveyer pass more than the design capacity flow rate?
A. If “self fed conveyer” is checked in DEW the conveyer may be run at over design speed and
the flow will be higher that design flow by the ratio of speed to design speed.
If gate fed conveyer option is used (“self fed conveyer” is NOT checked) then the flow rate is
determined by an inlet gate. The inlet gate position is limited to 100% or 1.0 and that
establishes the maximum flow rate. If additional flow is required then you must resize the
gate or add another inlet flow.
Q. Can I purge the self fed conveyer so that it has no mass on the belt and exit flow is
delayed at the next startup?
A. There is no way to completely purge self-fed conveyer. You can reduce the capacity to almost
zero (capacity has to be greater than zero) and almost purge the conveyer.
Q. You define how the gate fed inlet flow is determined. How is the gate fed exit flow
determined?
A. The exit flow is same as sum of inlet flows with a time lag. The time lag is defined by the
conveyer belt speed and belt length. In case of multiple products, this exit flow is equally
divided between all products.
60
Header
Introduction
The CCHeader, also called the Tee, mixes any number of mixed-phase feed streams and passes
fluid mixture to any number of product streams. The CCHeader is a pressure node that serves to
model flow mixing, flow splitting, and piping holdup dynamics.
All product streams have the same phase split. The model recalculates the phase split based on
inlet flows, outlet flows and existing holdup.
This unit accounts for heat transfer between the material fluid and the surroundings, using the
imposed heat-transfer parameter Qimp.
The CCHeader takes the form of a cylinder, and therefore has both diameter and length.
Fundamentals
Fundamentals
Material Balance
The model calculates the material balance using these equations:
dML1/dt = Σ(Fi * LF1i) - Σ(Fx * LF1x)
dML2/dt = Σ(Fi * LF2i) - Σ(Fx * LF2x)
dMS/dt = Σ(Fi * SFi) - Σ(Fx * SFx)
dMV/dt = Σ(Fi * VFi) - Σ(Fx * VFx)
61
MT = ML1 + ML2 + MS + MV
Where:
Fi = Flow of inlet stream
Fx = Flow of exit stream
LF1i = Liquid 1 fraction of inlet stream i
LF1x = Liquid 1 fraction of exit stream x
LF2i = Liquid 2 fraction of inlet stream i
LF2x = Liquid 2 fraction of exit stream x
SFi = Solid fraction of inlet stream i
SFx = Solid fraction of exit stream x
VFi = Vapor fraction of inlet stream i
VFx = Vapor fraction of exit stream x
dML1/dt = Derivative of liquid 1 moles in holdup fluid
dML2/dt = Derivative of liquid 2 moles in holdup fluid
dMS/dt = Derivative of solid moles in holdup fluid
dMV/dt = Derivative of vapor moles in holdup fluid
ML1 = Liquid 1 moles in holdup fluid
MV = Vapor moles in holdup fluid
62
Header
Phase Fractions
The model calculates the phase fractions using these equations:
LF1 = ML1 / MT
LF2 = ML2 / MT
SF = MS / MT
VF = MV / MT
Where:
LF1 = Liquid 1 fraction of holdup fluid
LF2 = Liquid 2 fraction of holdup fluid
SF = Solid fraction of holdup fluid
VF = Vapor fraction of holdup fluid
MV = Vapor moles in holdup fluid.
Composition Balance
The model calculates the composition using these equations:
dM/dt = ΣWi – ΣWx
where:
dM/dt = Rate of change of mass inside the holdup,
ΣWi = Sum of inlet mass flows,
ΣWx = Sum of outlet mass flows.
63
The component derivatives are then:
dXc[i]/dt = (ΣWi*Xci[i] - ΣWx*Xc[i] – Xc[i]*dM/dt) / M
where:
dXc[i]/dt = the state rate of change derivative for component I inside the holdup,
Xci[i] = the inlet flow of component i,
Xc[i] = the value of the state variable inside the holdup,
M = the total mass inside the holdup.
And:
ΣXc[i] = 1.0
Holdup
The Medium Fidelity CCHeader model uses simplified holdup calculations similar to those of
the CCDrum model. The calculations estimate the pressure using the fluid bulk modulus of
elasticity, with no flash.
Relationship between Pressure, Fluid Density and Bulk Modulus
The model calculates the relationship between pressure, fluid density and bulk modulus in the
fixed-volume unit using this equation.
ΔP = ΔM * KdPs * Ev / M0
Where:
ΔP = Change in vessel pressure
ΔM = Change in holdup fluid mass
Ev = Bulk modulus of elasticity (for vapors = 1.4 * pressure, for liquids = 2.15E6 kPa)
KdPs = Pressure dynamics scaling factor
M0 = Initial holdup fluid mass
64
Header
Holdup Fluid Temperature
The model calculates the holdup fluid temperature using a simplified weighted average energy
balance:
dT/dt = (Σ((Ti - Th) * Cpi * Fi) + Qimp) / (Mh * Cph)
Where:
dT/dt = Derivative of holdup fluid temperature (K/sec)
Ti = Temperature of the fluid in stream i (K)
Th = Temperature of holdup fluid (K)
Fi = Molar flow of inlet stream i (K)
Mh = Total molar holdup (kg-mole)
Qimp = Duty imposed (kJ/sec)
Cph = Specific molar heat capacity of inlet stream i (kJ/kg-mole-K)
Cph = Specific molar heat capacity of holdup fluid (kJ/kg-mole-K)
Other State Derivatives
The model calculates other state derivatives using molar averages of incoming fluids.
dMW/dt = (Σ((MWi - MWh) * Fi) / Mh
Where:
dMW/dt = Derivative of holdup fluid molecular weight
MWi = Molecular weight of the fluid in stream i
MWh = Molecular weight of holdup fluid
Mh = Total molar holdup in the unit
65
Example
This example configures a pressure let-down Header. The CCHeader CCH1 receives a stream of
high-pressure fluid from CCSource CCSRC1 15850 kPa and 900°K. The CCHeader then splits
the flow into two streams. Pressure controller PC acts on CCValve CCXV1 upstream of the
CCHeader to maintain the CCHeader pressure at 15000 kPa. Fluid flows into the Header at the
rate of 1280 kg/sec. Flow controller FC acts on CCValve CCXV2 to control the flow through
the CCHeader exit stream CCS3 at 220kg/sec.
CCSource: CCSRC1
OProdStream[0] CCS1
CCValve CCXV1
VFB 1 fraction Boundary vapor fraction
LF1B 0 fraction Boundary liquid 1 fraction
Tb 900 K Boundary temperature
SFB 0 fraction Solids fraction
CCValve: CCXV1
CCValve feed stream connecting
OFeedStream CCS1
from CCSource CCSRC1.
CCValve product stream connecting
OProdStream CCS2
to CCHeader CCH1.
FlowType Mass
Wsiz 100 Kg/Sec Mass Flow rate
66
Header

Pressure PID controller output
Op PC.OUT fraction connecting to CCValve opening
parameter
PID: PC
PIDType Pressure
Stream S2 pressure assigned to PV
PV CCS2.P kPa
of PID controller
Set point of the pressure PID
SP 15000 kPa
controller
Kp 0.5 PID controller proportional gain
KI 0.5 PID controller integral gain
Hi_In 20000 kPa High limit on PID controller input
Lo_In 0 kPa Low limit on PID controller input
Hi_Out 1 High limit on PID controller output
Lo_Out 0 Low limit on PID controller output
CCHeader: CCH1
CCHeader feed stream connecting
OFeedStream[0] CCS2
from CCValve CCXV1
CCHeader product stream
OProdStream[0] CCS3
connecting to CCValve CCXV2
CCHeader product stream
OProdStream[1] CCS4
connecting to CCValve CCXV3
PI 101.32 kPa Initial pressure
TI 298.15 kPa Initial temperature
FlowType Mass
Wsiz 50 Kg/sec Mass flow rate
TRESsiz 4 Sec Residence time
CCValve: CCXV2
67

OFeedStream CCS3
from CCHeader CCH1
OProdStream CCS4
to CCSink CCSNK1
FlowType Mass
Flow PID controller output
Op FC.OUT fraction connecting to CCValve opening
parameter
PID: FC
PIDType MassRate
Stream CCS5 mass flow assigned to
PV CCS5.W kg/sec
PV of Flow PID controller
SP 220 kg/sec Set point of the flow PID controller
Kp 0.009 PID controller proportional gain
KI 0.1 PID controller integral gain
Hi_In 250 kg/sec High limit on PID controller input
Lo_In 0 kg/sec Low limit on PID controller input
68
Header
CCSink: CCSNK1
CCSink feed stream connecting
OFeedStream[0] CCS5
from CCValve CCXV2
CCValve: CCXV3
OFeedStream[0] CCS4
from CCHeader H1
OProdStream CCS6
to CCSink CCSNK2
FlowType Mass
CCSink: CCSNK2
OFeedStream[0] CCS6
from CCValve CCXV3
69
Data Entry Window
Header Input
Initial Conditions
Enter the Residence Time in seconds
Enter Mass or Volume flow in kg or m3 per second
70
Header
Header Properties
Enter Mass Density in kilograms per m3.
71
Header Notes
Parameters
Advanced
Parameter Description UOM
Pressure dynamics scale factor.
Increasing KdPs causes
pressure changes to occur Dynamic
KdPs 1.0 No
more rapidly. Decreasing Double
KdPs causes pressure changes
to occur more slowly.
Temperature dynamics scale
factor.
Increasing KdTs causes Dynamic
KdTs temperature changes to occur Double 1.0 No
more slowly. Decreasing
KdPs causes temperature
changes to occur more rapidly.
72
Header

Heat imposed on the fluid, or
lost to ambient.
Dynamic
Qimp This parameter represents the 0 Yes kJ/sec
Double
external heat imposed on the
fluid or lost to ambient.
Ambient heat transfer Static kW/m2-
UL 1.0 Yes
coefficient Double K
Calculated Values
Liquid 1 mole fraction
LF1 This is the ratio of liquid Dynamic 0.5 No Fraction
1 moles over total moles Double
in the CCHeader .
Liquid 2 mole fraction
LF2 This is the ratio of liquid Dynamic 0 No fraction
2 moles over total moles Double
in the CCHeader .
Dynamic
MM Total Metal Mass 1 kg
Double
Total moles of holdup Dynamic
MT 0 Kg-mol
fluid Double
Pressure
Pressure calculated by Dynamic
P Pb No kPa
the Pressure Flow Double
Solver.
Simultaneous Solver Dynamic
POFF 0 kPa
pressure offset Double
Dynamic
Ql Ambient heat loss 0 No kJ/sec
Double
Holdup fluid molar State Kg-
R 55.4534 No
density Double mol/m3
Solids mole fraction
SF This is the ratio of solid Dynamic 0 No fraction
moles over total moles in Double
the CCHeader.
State
T Holdup fluid temperature No
Double
73

Residence Time based Dynamic
TRES No sec
on incoming fluid rate. Double
Vapor mole fraction
VF This is the ratio of vapor Dynamic 0.5 No fraction
moles over total moles in Double
the CCHeader.
Volume of the Dynamic
Vol No m3
CCHeader. Double
CC_CO
MPLIST
Dynamic .NCOM fraction
Zmass Composition Vector No
Double PONEN
TS
Derivatives
Description UOM
Holdup fluid mass fraction Dynamic
dZmass 0 No
derivative Double
Total Holdup fluid heat Dynamic kJ/kg-mol-
DCP 0
capacity derivative Double K/sec
Total Holdup fluid liquid 1 Dynamic
DML1 0 kg-mol/sec
moles derivative Double
Total Holdup fluid liquid 2 Dynamic
DML2 0 kg-mol/sec
Total Holdup fluid solid Dynamic
DMS 0 kg-mol/sec
Total Holdup fluid vapor Dynamic
DMV 0 kg-mol/sec
Total Holdup fluid Dynamic
DMW
molecular weight derivative Double
Total Holdup fluid molar Dynamic kg-
DR 0
density derivative Double mol/m3/sec
Total Holdup fluid solids Dynamic
DSPS 0
particle size derivative Double
Total Holdup Temperature Dynamic
DT 0 K/sec
derivative Double
74
Header
External Inputs
Parameter Description Default Default Equation Array UOM
Ambient
Dynamic
TAMB temperature TAMBIENT K
Double
reference
Initial Conditions
Initial Pressure
Static
Pi The CCHeader initializes to this 101.325 Yes kPa
Double
pressure.
Initial Temperature
Static
Ti The CCHeader initializes to this 298.15 Yes K
Double
temperature.
75
Network Solver
Parameter Description Default Default Equation Arra UO
Class Value Allowed y M
Size
kPa/k
Sensitivity of pressure to Dynamic g-
DPDFL 0
liquid flow Double mol/s
ec
kPa/k
DPDFL2 0
liquid 2 flow Double mol/s
ec
kPa/k
DPDFV 0
vapor flow Double mol/s
ec
Filter for simultaneous Static fracti
KOFF 0.125
solver pressure offset Double on
Number of calls by network Dynamic
NCALLS 0
solver per time step Double
Number of iterations to Dynamic
NITERS 0
converge Double
Network Solver Legacy Only

Parameter Description Default Default Equation Arra UO
Class Value Allowed y Size M
kg-
Explicit / Iterated / Local Dynamic
BAL 0 mol/
Iterated molar flow balance Double
sec
Iterated Nested tolerance Static
CONFAC 0.25
convergence factor Double
kg-
Iterated / Local Iterated last
Dynamic mol/
DFDP iteration sensitivity of flow to 0
Double sec/k
pressure
Pa
kg-
Iterated / Local Iterated
Dynamic mol/
DFDPAVG average sensitivity of flow to 0
Double sec/k
pressure
Pa
76
Header
Iterated network convergence Dynamic

FAILRATE 0
failure rate Double
kg-
Iterated / Local Iterated flow Static
FTOL mol/
convergence tolerance Double
sec
Dynamic
KLFB Local iterated flow band KLFB
Double
MAXNITER Iterated / Local Iterated Static
20
S network maximum iterations Double
Iterated / Local Iterated
Static
PTOL pressure convergence kPa
Double
tolerance
Sizing
Static
Dia Diameter of header 0.16 False M
Double
MASS or VOLUME. This
FlowType is used when SizingMethod Enum MASS No
= RESIDENCE_TIME.
Length of header (When
Sizing Method is
"Residence Time, Length is Graphic
Len calculated.When Sizing 50 No m
Double
Method is Dimensions, Length
is user entered)
Volume flow rate for sizing.
Only used when
Static m3/se
Qsiz SizingMethod = Yes
Double c
RESIDENCE_TIME and
FlowType = VOLUME
Sizing fluid density. Only
used when SizingMethod = Static
Rmasssiz 999.01 Yes kg/m3
RESIDENCE_TIME and Double
FlowType = VOLUME
Used to determine the sizing
method for the header.
RESIDENCE_TIME Uses
FlowType, Wsiz (or Qsiz), RESIDEN
SizingMethod Enum CE_TIME No
Dia and Tressiz to calculate
Vol and Len.
DIMENSIONS. Uses Dia
and Len to calculate Vol.
77

Residence Time value used
to size the header when Static 4
Tressiz Yes sec
SizingMethod = Double
RESIDENCE_TIME
Mass flow rate for sizing.
Only used when
Static 50
Wsiz SizingMethod = Yes kg/sec
Double
RESIDENCE_TIME and
FlowType = MASS
States
Dynamic kJ/k-
Cp Holdup specific heat capacity 0 No
Double mol/K
Dynamic
ML1 Holdup liquid 1 moles 0 No k-mol
Double
Dynamic
ML2 Holdup liquid 2 moles 0 No k-mol
Double
Dynamic
MS Holdup solid moles 0 No k-mol
Double
Dynamic
MV Holdup vapor moles 0 No k-mol
Double
Dynamic kg/k-
MW Holdup molecular weight 0 No
Double mol
Dynamic
SPS Holdup solids particle size 0 No
Double
Status And Control

Parameter Description Default Defaul Equation Arra UOM
Class t y
Allowed Size
Value
Dynami
DISABLEF
Disable flag c 0
LAG
Double
Dynami
Model object viewer
DISPLAY c 0
command
Double
ELAPSEDT Elapsed time since last Dynami 0 sec
78
Header
IME executed c
Double
Static
PERIOD Execution period DELT sec
Double
Dynami
STATUS Object status c 0
Double
Topology
Parameter Description Default Class
Feed Stream
This parameter identifies the feed stream, also called the inlet
stream, and its associated fluid properties. This unit can
connect only from flow devices.
OfeedStream This entry must be unique among all other feed streams in the CCSTREAM
stream identifier from another flow device. OfeedStream and
OprodStream cannot be the same.
Product Stream
OprodStream This entry must be unique among all other product streams in CCSTREAM
stream identifier from another flow device. OfeedStream and
79
FAQ
Q. Does the CCHeader model support external heat inputs?
A. Yes the model supports external heat inputs. You can add heat to or remove heat from the
model. Enter the data in the OEV window, and the changes are implemented after you fully
load the model conditions.
Q. What is the effect of the Compressibility factor in the holdup fluid of the CCHeader
model?
A. The relationship between pressure, fluid density and compressibility is described as
ΔP = ΔM * KdPs * Ev / M0
Where
ΔP = Change in CCHeader pressure
ΔM = Change in holdup fluid mass
Ev = Compressibility factor elasticity (for vapors = 1.4 * pressure, for liquids = 2.15E6
kPa)
KdPs = Pressure dynamics scaling factor
M0 = Initial holdup fluid mass
Therefore, for a constant change in CCHeader pressure, the greater the compressibility factor,
the greater is the holdup volume in the CCHeader model.
80
Mechanical Screen
Introduction
The CCMechScreen serves as a hybrid model in the Medium Fidelity models. The unit is a
pressure device on the inlet side and flow device on the exit side. It has two exit streams: the
Product stream and the Recycle/Reject stream. The CCMechScreen separates solids based on
screen opening size.
The CCMechScreen model has a hold-up model and two conductance models as sub-objects.
The two conductance models represent the Product stream and Recycle/Reject stream. The exit
flow of Product and Reject streams is determined based on user specification of screen size, clog
factor and carry under fraction and not by pressure flow solver.
to be a combined flow device and pressure node.
Fundamentals
Fundamentals
Inlet Particle Size
The model calculates the average inlet particle sizes using this equation:
SPS = (Σ(Fi * SPSi)) / Σ(Fi)
Where:
SPS = average inlet size of particles
Fi = flow of inlet stream i
SPSi = average particle size of inlet stream i
Outlet Particle Size
81
The model calculates the average particle sizes, the fraction of solids that pass through to the
product stream, and the fraction of solids that pass through to the recycle/reject stream using
these equations:
PassThruFrac = Min (1.0, EXP(-Screen_Exp(InletSize – ScreenSize)

Where
PassThruFrac = fraction of solids passing through the screen
Screen_Exp = screen classifying exponent
InletSize = average inlet (feed) particle size
ScreenSize = screen cut size
The average particle size for the Accept flow and Reject flow will be given by
Accept.SPS = MIN(ScreenSize, InletSize)
Reject.SPS = InletSize
Where
SPS = average particle size
Amount going to Accept and Reject Stream
The parameter CarryUnderFrac determines amount of liquid1, liquid2 and vapor going with the
Reject flow. Based on total feed, mass flow and mass fractions of different phases in Accept and
Reject streams are given by following:
Accept Stream:
Solids = Feed.W * Feed.SF * PassThruFrac
Liquid1 = Feed.W * Feed.LF1 * (1.0 – CarryUnderFrac)
Vapor = Feed.W * Feed.VF * (1.0 – CarryUnderFrac)
Waccept = Solids + Liquid1 + Liquid2 + Vapor
SFaccept = Solids / Waccept
LF1accept = Liquid1 / Waccept
VFaccept = Vapor / Waccept
Reject Stream:
Solids = Feed.W * Feed.SF * (1.0 – PassThruFrac)
Liquid1 = Feed.W * Feed.LF1 * CarryUnderFrac
Vapor = Feed.W * Feed.VF * CarryUnderFrac
82
Mechanical Screen
Wreject = Solids + Liquid1 + Liquid2 + Vapor

SFreject = Solids / Wreject
LF1reject = Liquid1 / Wreject
VFreject = Vapor / Wreject
Where
W = mass flow rate of total feeds
SF = solid mass fraction
VF = vapor mass fraction
LF1 = liquid1 mass fraction
Flow_Coeff = Waccept / (Waccept + Wreject)

Where
Flow_Coeff = Accept leg flow coefficient
Example
This example configures a screen model. The material flows from the CCSource CCMSRC1 at
150 kPa through the CCValve CCXV1 and into the CCScreen CCSCR1. The solids that do not
pass through the screen openings flow through the recycled stream outlet to the CCSink
CCSNK2. The product that passes through the screen flows through CCValve CCXV2 and into
CCSink CCSNK1. The boundary pressure of the CCSource CCSRC1 is maintained at 150 kPa,
and the boundary pressures of the CCSinks CCSNK1 and CCSNK2 are maintained at 100 kPa.
83
Source: CCSRC1
OProdStream[0] CCS1
Valve CCXV1.
Valve: CCXV1
OFeedStream CCS1
Source CCSRC1.
OProdStream CCS2
connecting to screen CCSCR1.
FlowType Mass
Screen: CCMSCR1
OFeedStream CCS2
CCXV1.
ORecyStream CCS3
screen to Valve CCSINK1
OProdStream CCS4
screen to Valve CCSINK2
ScreenSize 1 Size of screen opening
ScreenExponent 1 Screen exponent
84
Mechanical Screen

Fraction of vapor and liquid carried
CarryUnderFrac 0.05
with Reject stream
ClogFactor 0 Factor to simulate filter clogging
Sink: CCSNK1
OFeedStream[0] CCS3
valve CCSCR1.
Sink: CCSNK2
OFeedStream[0] CCS3
valve CCSCR1.
85
Data Entry Window
Mechanical Screen Input
Specifications
Enter the Size of screen opening.
Enter the Screen classifying exponent
Enter the Fraction carried by Reject stream
Enter the Clogging Factor
86
Mechanical Screen
Mechanical Screen Notes
Parameters
Advanced
Class Value Allowed
Pressure
Static
CCHOLDUP.KDPS dynamics scale 1.0 No
Double
factor
Minimum inlet
pressure (not
Static
SCR*.PIMIN used by 10 Yes kPa
Double
mechanical
screen)
Maximum exitt
pressure (not
Static
SCR*.PXMAX used by 30000 Yes kPa
Double
mechanical
screen)
87
Basic
Reverse flow
conductance factor
Static
SCR*.KJR (mechanical screen 0.0 No
Double
does not allow
reverse flow)
Calculated Values
Class Value Allowed
Holdup liquid 1 Dynamic
CCHOLDUP.LF1 No
fraction Double
CCHOLDUP.LF2 No
fraction Double
Dynamic kg-mol
CCHOLDUP.MT Total holdup No
Double
Holdup fluid Dynamic kg-mol/m3
CCHOLDUP.R No
molar density Double
Holdup solids Dynamic
CCHOLDUP.SF No
fraction Double
Holdup vapor Dynamic
CCHOLDUP.VF No
fraction Double
Defined
Holdup fluid Dynamic in
CCHOLDUP.ZMASS No
mass fraction Double Compone
ntList
Accept stream Dynamic
FlowCoeff No
flow coefficient Double
Average inlet Dynamic
InletSize 0.0 No
particle size Double
Fraction of
solids that pass Dynamic
PassThruFrac 0.0 No
to product Double
stream
Pressure drop
Dynamic
SCR*.DP across No kPa
Double
conductance
88
Mechanical Screen

Class Value Allowed
Flow Dynamic
SCR*.J No
conductance Double
Inlet flow rate to Dynamic kg-
SCR*.Fi No
conductance Double mol/sec
Exit flow rate to Dynamic kg-
SCR*.Fx No
External Inputs
Conductance Dynamic
SCR*.Pos 1.0 No
demand Double
Input
Fraction of vapor and liquid
Static
CarryUnderFrac carried with Reject stream. 0.05 Yes
Value should be between 0 Double
and 1
Factor to simulate filter Dynamic
ClogFactor clogging. Value should be 0.0 Yes
Double
between 0 and 1
Static
Pb Boundary pressure 101.325 Yes
Double
Static
ScreenSize Size of CCScreen opening 4.0 Yes
Double
Static
ScreenExponent Screen classifying exponent 1.0 Yes
Double
Outputs
Class Value Allowed
Dynamic
CCHOLDUP.P Pressure No kPa
Double
Dynamic
CCHOLDUP.T Temperature No K
Double
89
Class Value Allowed
SCR*.DPsiz 50 Yes kPa
pressure Double
Flow type option
for reference
Static
SCR*.FlowType sizing flow (0 - 0-Mass No
Int
Mass based, 1-
Volume based)
SCR*.Qsiz 0.05 Yes m3/sec
volume flow Double
SCR*.RMASSsiz 999.01 Yes kg/m3
mass density Double
SCR*.Wsiz 50 Yes kg/sec
mass flow Double
90
Mechanical Screen
States
Holdup fluid
molar heat State
CCHOLDUP.CP capacity No kJ/kg-mol-K
Double

CCHOLDUP.ML1 No
holdup Double
CCHOLDUP.ML2 No
holdup Double
State kg-mol
CCHOLDUP.MS Solid holdup No
Double
State kg-mol
CCHOLDUP.MV Vapor holdup No
Double
Holdup fluid
State
CCHOLDUP.MW molecular No
Double
weight
Holdup fluid
State
CCHOLDUP.SPS solids No
Double
particle size
Topology
Parameter
Name
Feed Stream
OFeedStream This entry must be unique among all other feed streams in the CCSTREAM
Only one feed stream can connect to this flow device.
91
Parameter
Name
Product Stream
ORecyStream Recycle/Reject stream CCSTREAM
FAQ
Q. What is the size of the screening?
A. This is a parameter that you use to specify the screen opening. Based on the specification, the
CCMechScreen allows smaller particles to pass through to the Product stream, and sends
larger particles on to the Recycle stream.
92
Mill
Introduction
The CCMill unit models a grinder that reduces solid material to smaller particles.
The CCMill accepts a mixed feed of fluid and solid material. The CCMill product depends on
solid feed, fluid feed, grinding efficiency, and quantity of solid material that accumulates inside
the unit.
Both the CCPulverizer and the CCMill are grinders. The CCPulverizer has screen at the end
which controls size of solids that passes through the unit. This unit is usually powered by Motor.
If you do not attach a Motor, the Design Speed (Speedsiz) parameter sets the unit's speed.
93
Fundamentals
Fundamentals
Grinding
For the unit-operation of grinding, the key state variable is the average particle diameter, and
how that changes with time. The model determines this using the following differential balance:
∂/∂t (MS) = ∑feed (mi)(sfi)(Si) - ∑prod (mx)(sf)(S) + (rgrind)
Where:
M = total mass of rock/solid in grinder (kg)
S = average rock diameter in grinder and leaving grinder (m)
mi = total mass flow rate of stream i into the grinder (kg/sec)
sfi = solids-fraction of stream i into the grinder
Si = average rock diameter for stream i into the grinder (m)
mx = total mass flow rate of stream x leaving the grinder (kg/sec)
sf = solids-fraction inside the grinder and in all exit streams
rgrind = rate of grinding ((kg-m)/sec)
The model defines the rate of grinding using this equation:
rgrind = (M) (sf) min(0, (Sss - S) / τ)
Where:
Sss = average rock diameter in grinder at steady-state, (m)
τ = residence time of the grinder (sec)
94
Mill
Power
The model calculates power using this equation:
Power = IdlePower + PowerFactor * Mass * Speed
Exit Flow of Solids
The exit flow of solids is a function of throughput capacity, holdup mass and the capacity.
ExitSolidsFlow = f(Throughput, holdupMass/Capcity in terms of Mass)
Example
This example shows the flow of solids from the CCSource CCSRC1 through an inlet CCValve
CCVX1 into the CCMill MILL. The product of the CCMill flows through CCValve CCXV2,
which diverts the flow into Sink CCSINK1.
Source: CCSRC1
Product stream from CCSRC1 to inlet of Valve
OProdStream[0] CCS1
CCXV1.
95
Valve: CCVX1
Feed stream connecting outlet of
OFeedStream CCS1
CCSRC1 to CCXV1
Valve Product stream connecting
OProdStream CCS2
MILL CCM1.
FlowType Mass
Mill: CCM1
Mill Feed stream connecting outlet
OFeedStream CCS2
from valve CCXV1
Mill product stream connecting to
OProdStream CCS3
Three way valve CCXV2.
FinalParticleSize 3 Final particle size
Eff 0.8 Efficiency of mill
Thruput 2 Kg/sec Throughput capacity of mill
GrindTau 100 sec Grinding time constant for mill
Dia 2 M Mill diameter
Len 3 M Length
IdlePower 300 kw Idle power
96
Mill
Valve; CCXV2
OFeedStream CCS3 Feed stream from the mill CCM1.
OProductStream CCS4 Product Stream connecting to sink CCSINK1.
FlowType Mass
TimeCl 10 Sec Time to Close
TimeOp 10 Sec Time to Open
ActType Diaphragm Actuator type
Sink: CCSINK1
OFeedStream[0] CCS4
three way valve CC3WXV1.
97
Data Entry Window
Mill Input
CCMill Specification
Enter the Steady State Particle Size in meters.
Enter the Efficiency of the Mill as a percentage.
Enter the Capacity of Mill in kg/sec.
Enter the Grinding Time Constant in seconds.
Geometry Specification
Enter the Mill Diameter in meters.
Enter the Mill Length in meters.
98
Mill
Power Calculation
Enter the Rated Power of the Mill in kilojoules per second.
Mill Notes
Parameters
Advanced
Class Value Allowed
Minimum inlet
Static
FD.PIMIN pressure (not 10 Yes kPa
Double
used by mill)
Maximum exitt
Static
FD.PXMAX pressure (not 30000 Yes kPa
Double
used by mill)
99

Class Value Allowed
Pressure
Static
MILLHOLDUP.KDPS dynamics scale 1.0 No
Double
factor
Proportionality Dynamic
PFactor 2.0 Yes
facctor Double
Basic
Reverse flow Static
FD.KJR 0.0 No
conductance factor Double
Calculated Values
Pressure drop across Dynamic
FD.DP No kPa
conductance Double
FD.Fi No
Exitt flow rate from Dynamic kg-
FD.Fx No
Dynamic
FD.J Flow conductance No
Double
Dynamic kg-
Fi Inlet flow No
Double mol/sec
Dynamic kg-
Fx Exit Flow 0.0 No
Double mol/sec
Dynamic
InletSize Inlet particle size No
Double
MILLHOLD Holdup liquid 1 Dynamic
No
UP.LF1 fraction Double
MILLHOLD Holdup liquid 2 Dynamic
No
UP.LF2 fraction Double
MILLHOLD Dynamic
Total holdup No
UP.MT Double
MILLHOLD Holdup fluid molar Dynamic
No
UP.R density Double
100
Mill

MILLHOLD Holdup solids Dynamic
No
UP.SF fraction Double
MILLHOLD Holdup vapor Dynamic
No
UP.VF fraction Double
Defined
MILLHOLD Holdup fluid mass Dynamic in
No
UP.ZMASS fraction Double Compone
ntList
Power required for Dynamic
Power No kJ/sec
mill Double
Average particle size
Dynamic
SPS of solids in exit No
Double
stream
Dynamic
Vol Volume of mill No m3
Double
Dynamic
WT Holdup solids 0.0 No kg
Double
External Inputs
Conductance Dynamic
FD.Pos 1.0 No
demand Double
101
Input
Static
Dia Diameter of Mill. 2 Yes m
Double
Static
Eff Efficiency of Mill 0.8 Yes
Double
Steady State Solid
Particulate Size
Static
FinalParticleSize Average particulate 3 Yes
Double
size if Mill reaches
steady state.
Grinding time Static
GrindTau 100 Yes sec
constant Double
CCMill Power Static
IdlePower 300 Yes kW
Consumption at Idle Double
Static
Len Length of Mill 3 Yes m
Double
Static
Pb Boundary pressure 101.325 Yes kPa
Double
Power required to
Static
PowerperTPH process one ton per 0.5 Yes kW
Double
hour of material
Static
Speedsiz Design speed 1.0 Yes rpm
Double
Static
Thruput Throughput capacity 2 Yes kg/sec
Double
102
Mill
Outputs
Class Value Allowed
Dynamic
MILLHOLDUP.P Pressure No kPa
Double
Dynamic
MILLHOLDUP.T Temperature No K
Double
Class Value Allowed
FD.DPsiz 50 Yes kPa
pressure Double
Flow type option
for reference
Static
FD.FlowType sizing flow (0 - 0-Mass No
Int
Mass based, 1-
Volume based)
FD.Qsiz 0.05 Yes m3/sec
volume flow Double
FD.RMASSsiz 999.01 Yes kg/m3
mass density Double
FD.Wsiz 50 Yes kg/sec
mass flow Double

Class Value Allowed
Rotational Dynamic
Expansion 50 Yes mm
expansion Double
Vibration Dynamic
frequency Double
States
Holdup fluid State
MILLHOLDUP.CP No kJ/kg-mol-K
molar heat Double
103
capacity
MILLHOLDUP.ML1 No
holdup Double
MILLHOLDUP.ML2 No
holdup Double
State kg-mol
MILLHOLDUP.MS Solid holdup No
Double
State kg-mol
MILLHOLDUP.MV Vapor holdup No
Double
Holdup fluid
State
MILLHOLDUP.MW molecular No
Double
weight
Holdup fluid
State
MILLHOLDUP.SPS solids No
Double
particle size
Topology
Parameter
Name
Feed Stream
Product Stream
104
Mill
Parameter
Name
Mechanical Stream
FAQ
Q. What is the difference between the CCMill and the CCPulverizer?
A. Both models simulate the crushing of solid particles. The CCPulverizer has screen at the end
which controls the solids going out based on particle size.
105
Pipe
Introduction
The CCPipe model simulates the flow in the pipelines. The pipe represents a simple flow
conductance without holdup.
The model calculates the flow through the CCPipe by using flow conductivity equation.
Fundamentals
Fundamentals
Equations for Flow and Flow Conductance
When ΔPsiz is greater than ΔPlin, the model calculates flow conductance using these equations:
J = ( Wsiz / SqRt(ΔPsiz * RMasssiz ) )
When ΔPsiz is less than or equal to ΔPlin, the model calculates flow conductance using these
equations:
J = (Wsiz / ( (ΔPsiz / SqRt(ΔPlin) ) * SqRt(RMasssiz) )
When ΔP is above ΔP lin, the model calculates flow through the device using these equations:
Ff = J * SqRt(ΔP * (R / MW ))
Fr = J * SqRt(ΔP * (R / MW )) * KJr
When ΔP is below ΔP lin, the model calculates flow through the device using these equations:
Ff = J * (ΔP / ΔPlin ) * SqRt(R / MW )
Fr = J * (ΔP / ΔPlin ) * SqRt(R / MW ) * KJr
The model calculates Temperature modification using this equation:
107
T = Ti - ΔTsiz * (ΔP / ΔPsiz)
Where:
ΔP = Pipe pressure drop
ΔPlin = Internal parameter used to smooth Flow – DP relationship (set to 10.0 in code)
ΔPsiz = Sizing delta pressure for conductance and simple temperature effects
ΔTsiz = Sizing delta Temperature for simple temperature effects
Ff = Fluid forward flow
Fr = Fluid reverse flow
J = Forward flow conductance
KJr = Reverse flow conductance factor
MW = Fluid molecular weight
R = Fluid molar density
T = Exit stream temperature
Ti = Inlet stream temperature
ΔTsiz = Sizing temperature difference for simple temperature effects
Wsiz = Sizing mass flow rate
108
Pipe
Example
The following example demonstrates the configuration of flow through the two Pipes PIPE1 and
PIPE2. Liquid at 147 kg/sec and 298.15 K is fed at 215 kPa through the CCHeader CCH1. The
CCHeader splits the flow and sent into PIPE1 and PIPE2. CCValve CCXV1 is open at 50% to
maintain the flow rate into the CCHeader. Boundary pressure is maintained at 100 kPa.
CCSource: CCSRC1
OProdStream[0] CCS1
CCValve CCXV1
CCValve: CCXV1
OfeedStream CCS1
OprodStream CCS2
to CCHeader CCH1.
FlowType Mass
109

OP 0.5 Fraction Open command
CCHeader: CCH1
OFeedStream[0] CCS2 Feed streams
OprodStream CCS3 Product streams
OprodStream CCS5 Product streams
CCPipe: PIPE1
Feed stream connecting from
OfeedStream CCS3
CCHeader CCH1
Product stream connecting to
OprodStream CCS4
CCSink CCSNK1
FlowType Mass
CCValve: PIPE2
Feed stream connecting from
OfeedStream CCS5
CCHeader CCH1
Product stream connecting to
OprodStream CCS6
CCSink CCSNK2
FlowType Mass
110
Pipe
CCSink: CCSNK1
OFeedStream CCS4
from Pipe PIPE1
Pressure 100 kPa. Boundary pressure
CCSink: CCSNK2
OFeedStream[0] CCS6
from CCPipe PIPE2
Data Entry Window
Pipe Input
111
InputSpecification
Sizing Specification
Enter the Mass or Volume Flow in kilograms or m3 per second.
Enter the Pressure Drop in kPa.
Pipe Properties
Enter Mass Density in kilograms per m3.
112
Pipe
Pipe Notes
Parameters
Advanced
Description UOM
Dynamic
Qimp Imposed heat to fluid 0 Yes kJ/sec
Double
Basic
Description UOM
Reverse flow conductance Static
KJr 0 Yes
factor Double
113
Calculated Values
Description UOM
Pressure drop across flow Dynamic
DP 0 No kPa
device Double
Sizing
Description UOM
Sizing delta pressure
This parameter is used to
calculate conductance for the
model.
The model supports a linearized
influence coefficient of the effect Static
DPsiz of pressure change on fluid 50.0 Yes kPa
Double
temperature. You can use this
parameter to approximate the
effect of Joule – Thomson
expansion when needed. This
value must be a positive
number.
Sizing delta temperature
The model supports a linearized
influence coefficient of the effect
of pressure change on fluid
temperature. You can use this Static
DTsiz 0.0 Yes K
parameter to approximate the Double
effect of Joule – Thomson
expansion when needed. This
value must be a positive
number.
Flag to inidicate flow type for
Static 0–
FlowType reference flow (0 – Mass based, No
Int Mass
1- Volume based )
Sizing Volume Flow
This parameter is used to Static
Qsiz calculate conductance for 0.05 Yes m3/sec
Double
CCPipe. This value must be a
positive number.
114
Pipe

Description UOM
Sizing mass density
RMasssiz calculate conductance for 999.01 Yes kg/m3
Double
positive number.
Sizing Mass Flow
Wsiz calculate conductance for 50.0 Yes kg /sec
Double
positive number.
Topology
Parameter
Name
Feed Stream
Product Stream
115
FAQ
Q. Does the CCPipe model support external heat inputs?
A. Yes the model supports external heat inputs. You can add or remove heat from the model.
Enter the data through the Qimp control in the Operator View window. The changes are
implemented after you fully load the model conditions.
Q. How do I model long gas pipelines?
A. The CCPipe can be divided into multiple segments for the simulation of a long gas pipeline.
The number of segments depends on the pressure drop across the pipeline.
Q. Does the CCPipe model support holdup?
A. No. The CCPipe model does not support holdup, because it is a flow device.
116
Pulverizer
Introduction
The CCPulverizer unit models a grinder that reduces solid material to smaller particles.
The CCPulverizer accepts a mixed feed of fluid and solid material. The CCPulverizer product
depends on solid feed, fluid feed, grinding efficiency, and quantity of solid material that
accumulates inside the unit.
Both the CCPulverizer and the CCMill are grinders. The CCPulverizer passes out the solid
material based on particle size.
This unit is usually powered by Motor. If you do not attach a Motor, the Speed Norm parameter
sets the unit's speed to the Default Speed Value.
117
Fundamentals
Fundamentals
Grinding
For the unit-operation of grinding, the key state variable is the average particle diameter, and
how that changes with time. The model determines this using the following differential balance:
∂/∂t (MS) = ∑feed (mi)(sfi)(Si) - ∑prod (mx)(sf)(S) + (rgrind)
Where:
M = total mass of rock/solid in grinder (kg)
S = average rock diameter in grinder and leaving grinder (m)
mi = total mass flow rate of stream i into the grinder (kg/sec)
sfi = solids-fraction of stream i into the grinder
Si = average rock diameter for stream i into the grinder (m)
mx = total mass flow rate of stream x leaving the grinder (kg/sec)
sf = solids-fraction inside the grinder and in all exit streams
rgrind = rate of grinding/pulverizing ((kg-m)/sec)
The model defines the rate of grinding/pulverizing using this equation:
rgrind = (M) (sf) min(0, (Sss - S) / τ)
where:
Sss = average rock diameter in grinder at steady-state, (m)
τ = residence time of the grinder (sec)
118
Pulverizer
Power
The model calculates power using this equation:
Power = IdlePower + PowerFactor * Mass * Speed
Exit Flow of Solids
The exit flow of solids is a function of throughput capacity, holdup mass, the capacity and pass
through fraction
PassThruFraction = f(average particle size, screen size)
ExitSolidsFlow = f(Throughput, holdupMass/Capcity in terms of Mass)
Example
This example configures the CCPulverizer. Solid material flows at 298.15°K and 450 kPa from
CCSource CCSRC1 through CCValve CCXV1 into the CCPulverizer CCPU1. After the
CCPulverizer crushes the solid, it flows through CCValve CCXV2 into CCSink CCSNK1. The
boundary pressure is maintained at 100 kPa.
SOURCE: CCSRC1
Source product stream connecting to the valve
OProdStream[0] CCS1
CCXV1.
VALVE: CCXV1
119

Valve feed stream connecting from Source
OFeedStream CCS1
CCSRC1.
Valve CCXV1 product stream connecting to
OProdStream CCS2
pulverizer CCPU1.
FlowType Mass
OP 0.5 fraction Open command
PULVERIZER: CCPU1
OFeedStream[0] CCS2
connecting to pulverizer CCPU1.
Pulverizer CCPU1 product stream
OProdStream CCS3
connecting to valve CCXV2.
Screensize 3 Screen size
Eff 0.8 fraction Efficiency of Pulverizer
Thruput 2 Kg/sec Throughput capacity of pulverizer
Grinding time constant for
GrindTau 100 sec
pulverizer
Dia 2 m Pulverizer diameter
Len 3 m Length
IdlePower 300 kW Idle power
120
Pulverizer
VALVE: CCXV3
Valve feed stream connecting from pulverizer
OFeedStream CCS3
CCPU1.
Valve CCXV3 product stream connecting to sink
OProdStream CCS4
CCSNK1.
FlowType Mass
SINK: CCSNK1
OFeedStream[0] CCS4 Sink feed stream connecting from valve CCXV2.
121
Data Entry Window
Pulverizer Input
CCPulverizer Specification
Enter the Screen Size.
Enter the Efficiency of the Pulverizer as a fraction.
Enter the Capacity of Pulverizer in kg/sec.
Enter the Pulverizing Time Constant in seconds.
Geometry Specification
Enter the Pulverizer Diameter in meters.
Enter the Pulverizer Length in meters.
Power Calculation
Enter the Rated Horsepower of the Pulverizer in kilojoules per second.
122
Pulverizer
Pulverizer Notes
Parameters
Advanced
Minimum inlet
FD.PIMIN 10 Yes kPa
used by Double
pulverizer)
Maximum
exitt pressure Static
FD.PXMAX 30000 Yes kPa
(not used by Double
pulverizer)
123

Pressure
Static
PULVERIZERHOLDUP.KDPS dynamics 1.0 No
Double
scale factor
Proportionality Dynamic
PFactor 2.0 Yes
facctor Double
Basic
Reverse flow Static
FD.KJR 0.0 No
conductance factor Double
Calculated Values
Parameter Default Equation Array
Description Default Class UOM
Name Value Allowed Size
FD.DP No kPa
conductance Double
FD.Fi No
Exitt flow rate from Dynamic kg-
FD.Fx No
Dynamic
FD.J Flow conductance No
Double
Dynamic kg-
Fi Inlet flow No
Double mol/sec
Dynamic kg-
Fx Exit Flow 0.0 No
Double mol/sec
Dynamic
InletSize Inlet particle size No
Double
Dynamic
Power Power required for mill No kJ/sec
Double
PULVERIZE
Dynamic
RHOLDUP.L Holdup liquid 1 fraction No
Double
F1
PULVERIZE
Dynamic
RHOLDUP.L Holdup liquid 2 fraction No
Double
F2
124
Pulverizer

Description Default Class UOM
Name Value Allowed Size
PULVERIZE
Dynamic
RHOLDUP. Total holdup No
Double
MT
PULVERIZE Holdup fluid molar Dynamic
No
RHOLDUP.R density Double
PULVERIZE
Dynamic
RHOLDUP.S Holdup solids fraction No
Double
F
PULVERIZE
Dynamic
RHOLDUP.V Holdup vapor fraction No
Double
F
Defined
PULVERIZE
Holdup fluid mass Dynamic in
RHOLDUP.Z No
fraction Double Compo
MASS
nentList
Average particle size of Dynamic
SPS No
solids in exit stream Double
Dynamic
Vol Volume of mill No m3
Double
Dynamic
WT Holdup solids 0.0 No kg
Double
External Inputs
Conductance Dynamic
FD.Pos 1.0 No
demand Double
125
Input
Diameter of Static
Dia 2 Yes m
Pulverizer Double
Efficiency of Static
Eff 0.8 Yes
Pulverizer Double
Grinding time Static
GrindTau 100 Yes sec
constant Double
Power Consumption Static
IdlePower 300 Yes kW
at Idle Double
Static
Len Length of Pulverizer 3 Yes m
Double
Static
Pb Boundary pressure 101.325 Yes kPa
Double
Power required to
Static
PowerperTPH process one ton per 0.5 Yes kW
Double
hour of material
Screen classifying Static
ScreenExponent 1.0 Yes
exponent Double
Size of screen Static
ScreenSize 3 Yes
opening Double
Static
Speedsiz Design speed 1.0 Yes rpm
Double
Static
Thruput Throughput capacity 2 Yes kg/sec
Double
Outputs
Class Value Allowed
Dynamic
PULVERIZERHOLDUP.P Pressure No kPa
Double
Dynamic
PULVERIZERHOLDUP.T Temperature No K
Double
Class Value Allowed
126
Pulverizer

FD.DPsiz 50 Yes kPa
pressure Double
Flow type option
for reference
Static
FD.FlowType sizing flow (0 - 0-Mass No
Int
Mass based, 1-
Volume based)
FD.Qsiz 0.05 Yes m3/sec
volume flow Double
FD.RMASSsiz 999.01 Yes kg/m3
mass density Double
FD.Wsiz 50 Yes kg/sec
mass flow Double

Class Value Allowed
Rotational Dynamic
Expansion 50 Yes mm
expansion Double
Vibration Dynamic
frequency Double
States
Holdup fluid
State
PULVERIZERHOLDUP.CP molar heat No kJ/kg-mol-K
Double
capacity
PULVERIZERHOLDUP.ML1 No
holdup Double
PULVERIZERHOLDUP.ML2 No
holdup Double
State kg-mol
PULVERIZERHOLDUP.MS Solid holdup No
Double
Vapor State kg-mol
PULVERIZERHOLDUP.MV No
holdup Double
Holdup fluid
State
PULVERIZERHOLDUP.MW molecular No
Double
weight
127

Holdup fluid
State
PULVERIZERHOLDUP.SPS solids No
Double
particle size
Topology
Parameter
Name
Feed Stream
Product Stream
Mechanical Stream
128
Pulverizer
FAQ
Q. What is the average particle size? Is it the inlet solid particle size?
A. No, the average particle size is the size of the particles after the pulverizing action finishes.
129
Screen
Introduction
The CCScreen serves as a hybrid model in the Medium Fidelity models. The unit is a pressure
device on the inlet side and flow device on the exit side. It has two exit streams: the Product
stream and the Recycle/Reject stream. The CCScreen separates solids based on screen opening
size.
The CCScreen model has a hold-up model and two conductance models as sub-objects. The two
conductance models represent the Product stream and Recycle/Reject stream.
Fundamentals
Fundamentals
130
Screen Filter
Inlet Particle Size
The model calculates the average inlet particle sizes using this equation:
SPS = (Σ(Fi * SPSi)) / Σ(Fi)
Where:
SPS = average inlet size of particles
Fi = flow of inlet stream i
SPSi = average particle size of inlet stream i
Outlet Particle Size
The model calculates the average particle sizes, the fraction of solids that pass through to the
product stream, and the fraction of solids that pass through to the recycle/reject stream using
these equations:
PassThruFrac = Min (1.0, EXP(-Screen_Exp(InletSize – ScreenSize)

Where
PassThruFrac = fraction of solids passing through the screen
Screen_Exp = screen classifying exponent
InletSize = average inlet (feed) particle size
ScreenSize = screen cut size
The average particle size for the Accept flow and Reject flow will be given by
Accept.SPS = MIN(ScreenSize, InletSize)
Reject.SPS = InletSize
Where
SPS = average particle size
Amount going to Reject Stream
The parameter CarryUnderFrac determines amount of liquid1, liquid2 and vapor going with the
Reject flow. Based on total feed, mass flow and mass fractions of different phases in Accept and
Reject streams are given by following:
Accept Stream:
Solids = Feed.W * Feed.SF * PassThruFrac
131
Vapor = Feed.W * Feed.VF * (1.0 – CarryUnderFrac)

Waccept = Solids + Liquid1 + Liquid2 + Vapor
SFaccept = Solids / Waccept
VFaccept = Vapor / Waccept
Reject Stream:
Solids = Feed.W * Feed.SF * (1.0 – PassThruFrac)
Vapor = Feed.W * Feed.VF * CarryUnderFrac
Wreject = Solids + Liquid1 + Liquid2 + Vapor
SFreject = Solids / Wreject
VFreject = Vapor / Wreject
Where
W = mass flow rate of total feeds
SF = solid mass fraction
VF = vapor mass fraction
Flow_Coeff = Waccept / (Waccept + Wreject)

Where
Flow_Coeff = Accept leg flow coefficient
132
Screen Filter
Amount going to Accept Stream
The clogging of filter is simulated by use of ClogFactor. We define Accept leg flow coefficient
as
Accept.W = (1.0 – ClogFactor) * J * (DP*Rmass)1/2
Where
ClogFactor = factor to simulate filter clogging
J = flow conductance
DP = pressure drop across conductance
Rmass = mass density
Adjustment of Phase Fractions
If the flow legs are not balanced (for instance, a valve downstream in the Accept leg is closed or
partially-closed), then the phase fractions for Accept and Reject streams calculated above will
need to be adjusted in order to conserve total mass of each phase fraction. It is done by first
comparing total mass of each phase feeding the screen, and subtracting the mass of each phase
leaving both the Accept and Reject legs. The difference represents the “surplus” that is used to
adjust the phase fractions:
Solids_Surplus = Feed.W * Feed.SF – Accept.W * SFaccept – Reject.W * SFreject
Liquid1_Surplus = Feed.W * Feed.LF1 – Accept.W * LF1accept – Reject.W *

LF1reject
Liquid2_Surplus = Feed.W * Feed.LF2 – Accept.W * LF2accept – Reject.W *

LF2reject
Vapor_Surplus = Feed.W * Feed.VF – Accept.W * VFaccept – Reject.W * VFreject
A mass flow-weighted average is used to calculate how much of the surplus goes to the Accept
leg, and how much to the Reject leg. The corrected phase fractions are given by following
equations:
Accept.SF = (SFaccept*Accept.W + Solids_Surplus*Flow_Coeff) / Accept.W
133
Accept.LF1 = (LF1accept*Accept.W + Liquid1_Surplus*Flow_Coeff) / Accept.W
Accept.LF 2= (LF2accept*Accept.W + Liquid2_Surplus*Flow_Coeff) / Accept.W
Accept.VF = (VFaccept*Accept.W + Vapor_Surplus*Flow_Coeff) / Accept.W
Reject.SF = (SFreject*Reject.W + Solids_Surplus*(1.0 – Flow_Coeff)) / Reject.W
Reject.LF1 = (LF1reject*Reject.W + Liquid1_Surplus*(1.0 – Flow_Coeff)) /

Reject.W
Reject.LF2= (LF2reject*Reject.W + Liquid2_Surplus*(1.0 – Flow_Coeff)) /

Reject.W
Reject.VF = (VFreject*Reject.W + Vapor_Surplus*(1.0 – Flow_Coeff)) / Reject.W
Flow Equations
The model calculates forward and reverse flow using these equations:
Where:
ΔP = Pressure drop across the unit
134
Screen Filter
Example
This example configures a screen model. The material flows from the CCSource CCSRC1 at
150 kPa through the CCValve CCXV1 and into the CCScreen CCSCR1. The solids that do not
pass through the screen openings flow through the recycled stream outlet to the CCSink
CCSNK2. The product that passes through the screen flows through CCValve CCXV2 and into
CCSink CCSNK1. The boundary pressure of the CCSource CCSRC1 is maintained at 150 kPa,
and the boundary pressures of the CCSinks CCSNK1 and CCSNK2 are maintained at 100 kPa.
Source: CCSRC1
Source CCSRC1 product stream
OprodStream[0] CCS1
connecting to the Valve CCXV1.
Valve: CCXV1
Valve feed stream connecting from Source
OfeedStream CCS1
CCSRC1.
Valve CCXV1 product stream connecting
OprodStream CCS2
to screen CCSCR1.
FlowType Mass
135

Actuator Diaphragm Actuator Type
Screen: CCSCR1
OfeedStream CCS2
CCXV1.
Product stream connecting from screen to
OprodStream CCS3
Valve CCSINK1
Product stream connecting from screen to
OprodStream CCS4
Valve CCSINK2
ScreenSize 1 Size of screen opening
ScreenExponent 1 Screen exponent
Fraction of vapor and liquid carried with
CarryUnderFrac 0.05
Reject stream
ClogFactor 0 Factor to simulate filter clogging
SCRPROD.Wsiz 50 Kg/sec Mass Flow Rate
SCRPROD.DPsi
50 kPa Delta Pressure
z
SCRRECY.Wsiz 50 Kg/sec Mass Flow Rate
SCRRECY.DPSi
50 kPa Delta Pressure
z
Sink: CCSNK1
Sink feed stream connecting from valve
OfeedStream[0] CCS3
CCSCR1.
136
Screen Filter
Sink: CCSNK2
Sink feed stream connecting from valve
OfeedStream[0] CCS3
CCSCR1.
Data Entry Window
Screen Filter Input
137
Specifications
Enter the Size of screen opening.
Enter the Screen classifying exponent
Enter the Fraction carried by Reject stream
Enter the Clogging Factor
Sizing
Enter the Product mass flow in kilograms per second.
Enter the Product pressure drop in kPa.
Enter the Recycle mass flow in kilograms per second.
Enter the Recycle pressure drop in kPa.
138
Screen Filter
Screen Filter Notes
Parameters
Advanced
Class Value Allowed
Pressure
Static
CCHOLDUP.KDPS dynamics scale 1.0 No
Double
factor
Minimum inlet
Static
SCR*.PIMIN pressure (not 10 Yes kPa
Double
used by screen)
Maximum xit
Static
SCR*.PXMAX pressure (not 30000 Yes kPa
Double
used by screen)
139
Basic
Parameter Default Default Array
Description Equation Allowed UOM
Name Class Value Size
Reverse flow
conductance factor Static
SCR*.KJR 0.0 No
(screen does not Double
allow reverse flow)
Calculated Values
Class Value Allowed
CCHOLDUP.LF1 No
fraction Double
CCHOLDUP.LF2 No
fraction Double
Dynamic kg-mol
CCHOLDUP.MT Total holdup No
Double
Holdup fluid Dynamic kg-mol/m3
CCHOLDUP.R No
molar density Double
Holdup solids Dynamic
CCHOLDUP.SF No
fraction Double
Holdup vapor Dynamic
CCHOLDUP.VF No
fraction Double
Defined
Holdup fluid Dynamic in
CCHOLDUP.ZMASS No
mass fraction Double Compone
ntList
Accept stream Dynamic
FlowCoeff No
flow coefficient Double
Average inlet Dynamic
InletSize 0.0 No
particle size Double
Fraction of
solids that pass Dynamic
PassThruFrac 0.0 No
to product Double
stream
Pressure drop
Dynamic
SCR*.DP across No kPa
Double
conductance
140
Screen Filter

Class Value Allowed
Flow Dynamic
SCR*.J No
conductance Double
SCR*.Fi No
Exit flow rate to Dynamic kg-
SCR*.Fx No
External Inputs
Conductance Dynamic
SCR*.Pos 1.0 No
demand Double
Input
Fraction of vapor and liquid
Static
CarryUnderFrac carried with Reject stream. 0.05 Yes
Value should be between 0 Double
and 1
Factor to simulate filter Dynamic
ClogFactor clogging. Value should be 0.0 Yes
Double
between 0 and 1
Static
ScreenSize Size of CCScreen opening 4.0 Yes
Double
Static
ScreenExponent Screen classifying exponent 1.0 Yes
Double
141
Outputs
Class Value Allowed
Dynamic
CCHOLDUP.P Pressure No kPa
Double
Dynamic
CCHOLDUP.T Temperature No K
Double
Class Value Allowed
SCR*.Dpsiz 50 Yes kPa
pressure Double
Flow type option
for reference
Static
SCR*.FlowType sizing flow (0 – 0-Mass No
Int
Mass based, 1-
Volume based)
SCR*.Qsiz 0.05 Yes m3/sec
volume flow Double
SCR*.RMASSsiz 999.01 Yes kg/m3
mass density Double
SCR*.Wsiz 50 Yes kg/sec
mass flow Double
States
Holdup fluid
State
CCHOLDUP.CP molar heat No kJ/kg-mol-K
Double
capacity
CCHOLDUP.ML1 No
holdup Double
CCHOLDUP.ML2 No
holdup Double
State kg-mol
CCHOLDUP.MS Solid holdup No
Double
142
Screen Filter

State kg-mol
CCHOLDUP.MV Vapor holdup No
Double
Holdup fluid
State
CCHOLDUP.MW molecular No
Double
weight
Holdup fluid
State
CCHOLDUP.SPS solids No
Double
particle size
Topology
Parameter
Name
Feed Stream
OfeedStream This entry must be unique among all other feed streams in the CCSTREAM
stream identifier from another unit. OfeedStream and
Product Stream
OprodStream This entry must be unique among all other product streams in CCSTREAM
stream identifier from another unit. OfeedStream and
OrecyStream Recycle/Reject stream CCSTREAM
FAQ
Q. What is the size of the screening?
A. This is a parameter that you use to specify the screen opening. Based on the specification, the
CCScreen filter allows smaller particles to pass through to the Product stream, and sends
larger particles on to the Recycle stream.
143
Sink
Introduction
The CCSink sets the outlet boundary pressure conditions for any simulation. It can take any
number of feed streams. You should use a CCSink only when you do not expect any reverse
flow. Upstream flow devices should include a check valve. If you plan to allow reverse flow to
the CCSink, use a CCSource model instead, which can set the composition and energy for the
reversing stream.
Fundamentals
Fundamentals
Boundary Specifications
The CCSink is used for setting outlet boundary pressure in any simulation. The boundary value
sets the pressure for all streams connected to it.
Feed Streams
The CCSink can be used only for setting the outlet boundary conditions. It can take only feed
streams, and any number of those. No product stream can be connected to CCSink.
Reverse Flow
You should use a CCSink only when you do not expect any reverse flow, because you cannot set
composition and energy content during reverse flow. If reverse flow does occur, the CCSink
reflects the feed stream’s composition and enthalpy. For predictable reverse flow calculations,
use a CCSource model with feed streams connected to it. If you do not have to model reverse
flow, set to zero the KJr parameter for a flow device in each flow path that enters the CCSink.
144
Screen Filter
Example
This example configures a CCSink unit to specify a pressure boundary.
The CCSource unit CCSRC1 sets the inlet pressure for the CCValve CCXV1. The CCSource
unit CCSRC2 sets inlet pressures for the CCValve CCXV2 and for the CCPump CCP1. The
CCSource unit CCSRC1 supplies Liquid at 250 kPa and 320°K. The CCSource unit CCSRC2
supplies feed to the CCPump CCP1 and to the CCValve CCXV2 at 250 kPa and 310°K.
The CCSink CCSNK1 sets boundary pressures for the two CCValve units CCXV1 and CCXV2.
The CCSink CCSNK2 sets boundary pressures for the CCPump CCP1.The boundary pressure
of CCSink CCSNK1 is set at 150 kPa, while that of CCSink CCSNK2 is set at 280 kPa.
The CCPump takes liquid from the CCSource unit CCSRC2 and delivers it to the CCSink unit
CCSNK2 at some pressure higher than that of the CCSource CCSRC2.
CCSource: CCSRC1
OprodStream[0] CCS1 CCSource product stream connecting to the
CCValve CCXV1
145
CCSource: CCSRC2
CCValve CCXV2
CCPump CCP1
CCValve: CCXV1
OfeedStream CCS1 CCValve feed stream connecting from CCSource
CCSRC1.
OprodStream CCS2 CCValve product stream connecting to CCSink
CCSNK1.
FlowType Mass
146
Screen Filter
CCValve: CCXV2
OFeedStream CCS3 CCValve feed stream connecting from CCSource
CCSRC2.
CCSNK1.
FlowType Mass
CCPump: CCP1
OFeedStream CCS5 CCPump feed stream connecting from CCSource
CCSRC2
OprodStream CCS6 CCPump product stream connecting to CCSink
CCSNK2.
FlowType Mass
DPsiz 50.0 kPa Delta Pressure
POWERsiz 0.05 kJ/sec Power
RMASSsiz 999.01 kg/m3 Mass Density
Wsiz 1.0 kg/sec Mass Flow Rate
DTsiz 0.0 K Delta Temperature
Speed 3600 rpm Shaft speed
147
CCSink: CCSNK1
OFeedStream[0] CCS2 CCSink feed stream connecting from CCValve
CCXV1.
CCXV2.
CCSink: CCSNK2
OFeedStream[0] CCS6 CCSink feed stream connecting from CCPump
CCP1.
Data Entry Window
Sink Basic
Boundary Conditions
148
Screen Filter
Sink Notes
Parameters
Boundary Conditions
Boundary pressure Static
Pb 100 Yes kPa
Boundary pressure in the CCSink. Double
149
Topology
Parameter Description Default Class
Feed Stream
FAQ
Q. How do I model the correct reverse flow properties from a CCSink?
A. The CCSink model cannot effectively model reverse flow. You must either prevent reverse
flow to the CCSink by setting the KJr parameter of one of the flow devices to zero, or replace
the CCSink with a CCSource model. If you use a CCSource, you can specify the liquid and
vapor fraction of the fluid used for reverse flow, just as you would specify it in any other
CCSource model.
150
Source
Introduction
As the starting point for all flow sheets, the CCSource sets the inlet and outlet boundary
conditions for the simulation model. These boundary conditions include pressure, temperature,
vapor fraction, component molecular weight, and component molar density. The CCSource is an
infinite source of inventory, You can connect any number of feed and product streams to a
CCSource.
You can use a CCSource to model a CCSink where reverse flow may occur. In this case, the
CCSource accepts feed streams. When the feed stream flow reverses, the CCSource sets the feed
stream composition and energy content.
A CCSource cannot model a flow boundary. Instead, you must use a Stream Set to force the flow
at the beginning of a simulation. For this configuration, you must provide a CCSource followed
by a Stream Set followed by a pressure node.
Fundamentals
Fundamentals
Boundary Specifications
The CCSource model assigns the boundary conditions directly to the exit streams, using these
equations:
Px = Pb
Tx = Tb
VFx = VFb
LF1x = LF1b
LF2x = LF2b
151
SFx = SFb
MWx = MWb
Rx = Rb
Cpx = Cpb
ZMASSx[i] = WB[i]
Where:
Px = Exit stream pressure
Pb = Boundary pressure
Tx = Exit stream temperature
Tb = Boundary temperature
VFx = Exit stream vapor fraction
VFb = Boundary vapor fraction
LF1x = Exit stream liquid 1 fraction
LF2x = Exit stream liquid 2 fraction
LF1b = Boundary liquid 1 fraction
LF2b = Boundary liquid 2 fraction
SFx = Exit stream solids fraction
SFb = Boundary solids fraction
MWx = Exit stream molecular weight
MWb = Boundary molecular weight
Rx = Exit stream molar density
Rb = Boundary molar density
Cpx = Exit stream specific heat capacity
152
Source
Cpb = Boundary specific heat capacity
ZMASSx[i] = Exit stream mass composition of component i
WB[i] = Boundary mass composition of component i
Feed and Product Streams
The CCSource is infinite source of inventory. Any number of product streams can be connected
to it. A CCSource can also act as a CCSink, such that it can act as an end point in the Flowsheet.
As a CCSink, it can take any number of feed streams. Because a CCSource is a pressure node,
you can connect only flow devices directly to it.
Reverse Flow
You should use a CCSource in place of a CCSink when you expect reverse flow. The CCSource
sets the user-defined composition and temperature in the inlet stream.
Example
This example configures a CCSource unit to specify the initial conditions for the model.
The CCSource unit CCSRC1 sets the inlet pressure for the CCValve CCXV1. The CCSource
unit CCSRC2 sets inlet pressures for the CCValve CCXV2 and for the CCPump CCP1. The
CCSource unit CCSRC1 supplies Liquid at 250 kPa and 320°K. The CCSource unit CCSRC2
supplies feed to the CCPump CCP1 and to the CCValve CCXV2 at 250 kPa and 310°K.
The CCSink CCSNK1 sets boundary pressures for the two CCValve units CCXV1 and CCXV2.
The CCSink CCSNK2 sets boundary pressures for the CCPump CCP1.The boundary pressure
of CCSink CCSNK1 is set at 150 kPa, while that of CCSink CCSNK2 is set at 280 kPa.
The CCPump takes liquid from the CCSource unit CCSRC2 and delivers it to the CCSink unit
CCSNK2 at some pressure higher than that of the CCSource CCSRC2.
153
CCSource: CCSRC1
CCValve CCXV1
CCSource: CCSRC2
CCValve CCXV2
CCPump CCP1
154
Source
CCValve: CCXV1
CCSRC1.
CCSNK1.
FlowType Mass
CCValve: CCXV2
OFeedStream CCS3 CCValve feed stream connecting from CCSource
CCSRC2.
CCSNK1.
FlowType Mass
155
CCPump: CCP1
OFeedStream CCS5 CCPump feed stream connecting from CCSource
CCSRC2
OprodStream CCS6 CCPump product stream connecting to CCSink
CCSNK2.
FlowType Mass
DPsiz 50.0 kPa Delta Pressure
POWERsiz 0.05 kJ/sec Power
RMASSsiz 999.01 kg/m3 Mass Density
Wsiz 1.0 kg/sec Mass Flow Rate
DTsiz 0.0 K Delta Temperature
Speed 3600 rpm Shaft speed
CCSink: CCSNK1
CCXV1.
CCXV2.
CCSink: CCSNK2
OFeedStream[0] CCS6 CCSink feed stream connecting from CCPump
CCP1.
156
Source
Data Entry Window
Source Basic
Boundary Conditions
Enter the Vapor Fraction as a decimal fraction between 0.0 and 1.0.
Enter the Liquid 1 Fraction as a decimal fraction between 0.0 and 1.0.
Enter the Solids Fraction as a decimal fraction between 0.0 and 1.0.
All the fractions must add up to 1.0.
Enter the Solids Average Particle Size as an integer between 0 and 10.
Enter Reference Source name against Initialization Source field.
157
Source Properties
Bulk Properties
Enter Molecular Weight
Enter Density in kilograms per m3.
Enter Heat Capacity in kilojoules per kilograms per Kelvin
Composition
Enter Mass Composition for each component in kg
158
Source
Source Notes
Parameters
Boundary Conditions
Description UOM
Static
LF1b Boundary liquid 1 fraction 1.0 Yes
Double
Static
LF2b Boundary liquid 2 fraction 0.0 Yes
Double
Static
Pb Boundary pressure 150.0 Yes
Double
Static
SFb Boundary solids fraction 0.0 Yes fraction
Double
Static
SPSb Solids average particle size 1.0 Yes
Double
Static
Tb Boundary temperature 298.15 Yes K
Double
Static
VFb Boundary vapor fraction 0.0 Yes fraction
Double
159
Calculated Values
Description UOM
Dynamic kJ/kg-
Cpb Specific Heat Capacity No mol-K
Double
Dynamic Kg-
Rb Molar density No mol/m3
Double
Initialization
Parameter Equation Array
Name Allowed Size
Initialization Source
This parameter identifies a CC Source
OinitSource that will be used to initialize the CCSOURCE No 1
properties of this CC Source.
Properties
Static kJ/kg-
Cpmassb Specific Heat Capacity 4.1786 Yes K
Double
Static
MWb Molecular weight 18.015 Yes
Double
Static Kg/m3
Rmassb Mass density 999.01 Yes
Double
Un-normalized mass Static Defined by
Wb 0 No ComponentList
composition Double
160
Source
Topology
Parameter Equation Array
Name Allowed Size
Feed Stream
This parameter identifies the feed
stream, also called the inlet stream, and
its associated fluid properties. This unit
can connect only from flow devices.
This entry must be unique among all User
OfeedStream other feed streams in the flowsheet. CCSTREAM No
Specified
However, this entry can be the same as a
product stream identifier from another
flow device. OfeedStream and
Any number of feed streams can connect
to this unit.
Product Stream
This parameter identifies the product
stream, also called the outlet stream,
and its associated fluid properties. This
unit can connect only to flow devices.
This entry must be unique among all User
OprodStream other product streams in the flowsheet. CCSTREAM No
Specified
However, this entry can be the same as a
feed stream identifier from another flow
device. OfeedStream and OprodStream
cannot be the same.
Any number of product streams can
connect from this unit.
161
FAQ
Q. Can I use the CCSource as a CCSink?
A. Yes, the CCSource can act as a CCSink, but not for all purposes. When you want to model
reverse flow, use only a CCSource, because the CCSink unit cannot effectively model reverse
flow. You must either prevent reverse flow to the CCSink by setting the KJr parameter of one
of the flow devices to zero, or replace the CCSink with a CCSource model. If you use a
CCSource, you can specify the liquid and vapor fraction of the fluid used for reverse flow,
just as you would specify it in any other CCSource model.
162
Stream Modify
Introduction
CCStreamModify allows users to modify certain properties in a CCStream in the middle of a

flow sheet. It also allows users to modify holdup properties in a CCDrum, CCTank and
CCGeneralReactor.
The CCStreamModify does not directly affect the pressure-flow network. When connected to a
CCStream (or holdup device), the modified properties may have an impact on the pressure-flow
solution.
Fundamentals
Fundamentals
Forced Parameter Specifications
When connected to a CCStream (through the OstreamModify parameter), the CCStreamModify

model assigns the forced conditions directly to the forward flow properties of the stream. When
connected to a holdup device (CCDrum, CCTank, or CCGeneralReactor), the model converts a
specified amount of holdup material to the forced conditions. The following properties are
available:
Cpmassforce = Bulk Heat Capacity (mass basis)
LF1force = Liquid 1 Fraction
LF2force = Liquid 2 Fraction
Mwforce = Bulk Molecular Weight
Rmassforce = Bulk Density (mass basis)
Sfforce = Solid Fraction
Tforce = Temperature
Vfforce = Vapor Fraction
Wcompforce[i] = Composition Fraction for component i
163
Wforce = Internal Flow Rate (for holdup devices only)
Connected to Streams
When a CCStream.OstreamModify parameter points to a CCStreamModify object, that stream’s

forward flow properties will be replaced by any forced properties that are specified in the
CCStreamModify. If a forced property is not specified (i.e. left blank by the user), then it will
NOT replace the stream property. For normalized properties (phase fraction, composition
fraction), only one of the group of forced properties must be specified to replace all of the
stream’s group properties.
Connected to Holdups
When a holdup device is connected to a CCStreamModify object (through the OstreamModify

parameter vector), an amount of holdup material (Wforce) will be replaced with an equal amount
of material having the forced properties. If a forced property is not specified (i.e. left blank by
the user) the holdup property will remain the same. For normalized properties (phase fraction,
composition fraction), only one of the group of forced properties must be specified to replace all
of the group properties.
Example
This example illustrates the use of stream modify. The source, CCSRC1 feeds material at 200
kPa and 320K through valve CCXV1 to drum CCV1. The vapor product from drum flows
through valve CCXV2 to sink CCSNK1. The liquid product from drum flows through valve
CCXV3 to sink CCSNK2. The flow to drum is manipulated by flow controller PID1 by
controlling the opening of valve CCXV1. The liquid level in drum is manipulated by level
controller PID2 by controlling the valve opening of valve CCXV3. The vapor product from drum
has a vapor fraction 1.0. The stream modify CCSM1 modifies the temperature and phase
fractions of stream going to CCSNK1. The stream modify CCSM2 modifies the vapor fraction in
drum CCV1 by internal recycle flow of 75kg/sec which has vapor fraction of 0.8 and liquid
fraction of 0.2.
CCSource: CCSRC1
164
Strem Modify

CCValve CCXV1
CCValve: CCXV1
CCSRC1.
OprodStream CCS2 CCValve product stream connecting to CCDrum
CCV1.
FlowType Mass
OP PID1.OUT fraction Open command
CCValve: CCXV2
OFeedStream CCS3 CCValve feed stream connecting from CCDrum
CCV1.
CCSNK1.
FlowType Mass
165

CCValve: CCXV3
OFeedStream CCS5 CCValve feed stream connecting from CCDrum
CCV1.
CCSNK2.
FlowType Mass
OP PID2.OUT fraction Open command
CCSink: CCSNK1
CCXV2.
CCSink: CCSNK2
CCXV3.
CCDrum: CCV1
OFeedStream[0] CCS2 Feed streams connecting from CCValve
FV1
OProdVapor CCS3 Vapor-port product stream connecting to
166
Strem Modify
CCValve CCXV2.
OProdLiquid CCS5 Liquid port product stream connecting to
CCValve CCXV3
Psiz 125 kPa Initial pressure
Tsiz 298.15 kPa Initial temperature
Len 5 m Drum Length
Dia 1 m Drum Diameter
DPDTSIZ 1 kPa/K Pressure / Temperature Sensitivity
Orientation Vertical CCDrum Orientation
Boiling Scale 1 Boiling scale factor
Factor
OStreamModify[0] CCSM2 Stream modify object
CCStream: CCS5
OStreamModify CCSM1 Stream modify object
CCStreamModify: CCSM1
Tforce 330 K Forced temperature
LF1force 0.1 Forced liquid 1 fraction
VFforce 0.9 Forced vapor fraction
CCStreamModify: CCSM2
Wforce 75 Kg/sec Internal flow rate
LF1force 0.2 Forced liquid 1 fraction
VFforce 0.8 Forced vapor fraction
167
Data Entry Window
StreamModify Basic
Boundary Conditions
Enter the Vapor Fraction as a decimal fraction between 0.0 and 1.0.
Enter the Solids Fraction as a decimal fraction between 0.0 and 1.0.
All the fractions must add up to 1.0.
Enter the Solids Average Particle Size as an integer between 0 and 10.
168
Strem Modify
Enter the Recycle Flow in kg/sec
Enter Reference Source name against Initialization Source field.
StreamModify Properties
Bulk Properties
Enter the Molecular Weight
Enter the Density in kg/m3
Enter the Heat Capacity in kJ/kg-K
Composition
Enter the Composition
StreamModify Notes
169
Parameters
Calculated Values
Description UOM
Mass fractions of each Dynamic
ZMASS 0 No
component Double
170
Strem Modify
Forced Conditions
Description UOM
Graphic kJ/kg-K
Cpmassforce Forced specific heat capacity 0 Yes
Double
Graphic Fraction
LF1force Forced liquid 1 fraction 0 Yes
Double
Graphic Fraction
LF2force Forced liquid 2 fraction 0 Yes
Double
Graphic
MWforce Forced molecular weight 0 Yes
Double
Graphic Kg/m3
Rmassforce Mass density 0 Yes
Double
Graphic Fraction
SFforce Forced solid fraction 0 Yes
Double
Graphic
SPSforce Forced solid particle size 0 Yes
Double
Graphic K
Tforce Forced temperature 0 Yes
Double
Graphic Fraction
VFforce Forced vapor fraction 0 Yes
Double
Defined
Un-normalized mass Graphic in Kg
WCompforce 0 Yes
composition Double CompList
Internal flow rate (used as
Graphic Kg/sec
Wforce internal recycle when 0 Yes
Double
attached to unit operation)
Initialization
Description UOM
Source initialization object (if
specified then all properties are
OinitSource CCSource No
initialized from specified
CCSource)
171
Stream Receive
Introduction
The CCStream Receive model, when used with the CCStream Send model, allows process
streams to connect across flowsheet boundaries. If the flowsheets are in the same engine, the
CCStream Send/CCStream Receive pair extends the same pressure flow network without a
break. If the flowsheets are in different DYNSIM engines, the CCStream Send/CCStream
Receive pair links the two different networks using an internal transfer of the stream properties
between the engines. A transfer of pressure flow sensitivities also preserves stability at the
network break point.
• Flow sheet connections (local engine)

• Flow sheet connections (remote engine)
The CCStreamReceive model should be configured as a flow device feeding directly into a
pressure node such as a CCDrum or a CCHeader. If a connection is made between engines, the
downstream pressure node should be chosen to have the largest available capacity, because this
will improve dynamic accuracy across the connection. A large compressible volume will
generally give better results than a small incompressible volume. The CCStream Send model
documentation gives further general information.
Fundamentals
Use as a Boundary
If a CCStream Receive model is not connected to a CCStream Send model, it acts as a network
boundary and its behavior will be similar to a StreamSet with a boundary flow specification. In
this case the boundary flow is set by the Fb parameter. The Fb parameter is dynamic and is
saved and loaded with initial conditions. You need not specify an elevation because the elevation
of the connected pressure node is always assumed.
The CCStream Receive may use an initialization CCSource object in a manner similar to
CCStream Send to initialize the forward properties of the outlet stream.
Since a fixed boundary flow is often inconvenient, the Kf parameter may be attached to the Pos
parameter of a standalone CCValve object in order to provide flow adjustment between zero and
Fb.
172
Strem Modify
Making Connections within the Same Engine
If a CCStream Receive model is connected to a CCStream Send model and exists within the
same engine, and the engine is launched, the CCStream Send/CCStream Receive pair acts as
invisible glue joining the sent and received streams together. The flow device upstream of the
CCStream Send becomes directly attached to the pressure node downstream of the CCStream
Receive. In this case, none of the CCStream Send parameters such as PB or the initialization
Source have any effect.
Making Connections between Different Engines
If a CCStream Receive model is connected to a CCStream Send model and exists within a
different DYNSIM engine, and the simulation is launched, a special network connection between
the engines is set up. The CCStream Send acts as a network boundary, but its boundary pressure
is dynamically adjusted to correspond to the remote network state. Likewise, the CCStream
Receive has its boundary flow dynamically adjusted to correspond to the flow entering the
CCStream Send. Additionally, a calculation involving the transfer of pressure and flow
sensitivities is made to preserve stability across the interface. The sensitivity calculation may
lead to some transient time lags in the transmission of pressure and flow through the interface;
the effects of which may be reduced by selecting the largest available pressure difference
upstream of the CCStream Send, and the largest available pressure node (compressible,
preferably) downstream of the CCStream Receive.
When connecting engines, the stream properties in the forward and reverse direction
communicate automatically at each time step, without the need to configure any entries in the
cross-reference table.
In this mode, the CCStream Send elevation reflects the elevation of the remote pressure node in
the other engine, and the elevation parameter will have no effect.
Flow Device Equations
CCStream Receive is a flow device object and implements a dynamic flow calculation in the
pressure-flow network. The details of this calculation depend on the configuration of the
CCStream Receive object.
If the CCStream Receive has no connection to a CCStream Send object, then the flow equation
applied is:
F = Fb x kF
Where:
F = Outlet stream flow (kg-mol/sec)
Fb = Boundary flow (kg-mol/sec)
173
kF = Outlet flow control factor (0 – 1)
The outlet flow control factor kF allows for adjustment of the stream flow at the boundary prior
to model integration. A recommended configuration is to place a CCValve object on the
flowsheet near to the CCStream Receive and connect the Pos parameter of the CCValve to the
Kf parameter of the CCStream Receive. Then you can use the CCValve to adjust the outlet flow
of the CCStream Receive as a fraction of Fb.
If the CCStream Receive is connected to a CCStream Send object, and that CCStream Send
object is not present in the same engine, then the flow device equation is this:
F = Fb + (P – P0)(∂Fremote/∂Plocal)
Where:
Fx = Exit stream flow (kg-mol/sec)
Fb = Boundary flow received from flow device in remote engine (kg-mol/sec)
P = Pressure of attached pressure node (kPa)
P0 = Pressure of attached pressure node at end of previous time step (kPa)
Fremote = Flow through flow device attached to StreamSend in remote engine (kg-
mol/sec)
Plocal = Local pressure transmitted to flow device in remote engine (kPa)
∂Fremote /∂Plocal = Flow sensitivity of flow device received from remote engine (kg-
mol/sec/kPa)
Note that even if the connection to a remote engine is not active, when the CCStream Receive
icon is red, the same equation applies. In this case the values of Fb and ∂Fremote /∂Plocal are
taken from the current snapshot or IC. This allows a simulation to continue from a saved IC
without a bump. However, the values of these parameters should not be manipulated by hand,
other than perhaps to set the dFdP parameter to zero.
If the CCStream Receive has an active connection to a CCStream Send in the same engine, then
the CCStream Send/CCStream Receive pair is eliminated from the pressure-flow network and no
flow equation exists.
174
Strem Modify
Data Transfer
If a CCStream Receive is connected to a CCStream Send in a remote engine, then at each time
step the following parameter values are transferred by internal cross-reference from the local
engine to the remote engine.
StreamSend StreamReceive
Pb ← P
F0 ← Fx
E ← Ei
dPdF ← dPdF
Tr ← Tr
Rr ← Rr
MWr ← MWr
CPr ← CPr
LF1r ← LF1r
LF2r ← LF2r
VFr ← VFr
SFr ← SFr
SPSr ← SPSr
The following parameters are transferred from the remote engine to the local engine:
F → Fb
dFdP → dFdP
Tf → Tf
Rf → Rf
MWf → MWf
CPf → CPf
LF1f → LF1f
LF2f → LF2f
VFf → VFf
SFf → SFf
SPSf → SPSf
175
Where any of the parameters listed are not contained in the CCStream Receive or CCStream
Send models, they are located in the inlet or exit streams.
If a CCStream Receive is connected to a CCStream Send in the same engine, then all stream
properties are mirrored between the inlet stream and the exit stream so that the contents of both
streams remain the same before and after network solution.
Example
This example shows a connection from one flowsheet to another. The Stream Send component
CCSS1 sets its Stream Receive connection to CCSR1, and the Stream Receive component
CCSR1 sets its Stream Send connection to CCSS1.
This symmetrical connection normally happens automatically. The stream from flowsheet FS1
goes to flowsheet FS2.
Stream Send: CCSS1

OstreamReceive CCSR1 Stream Receive object reference
OfeedStream CCS2 Feed stream object reference
Stream Receive: CCSR1

OstreamSend CCSS1 Stream Send object reference
OprodStream CCS3 Product stream object reference
176
Strem Modify
SOURCE: CCSRC1
OprodStream[0] CCS1 Source product stream connecting to
the Valve CCXV1
VFb 0 fraction Boundary vapor fraction
LF1b 1 fraction Boundary liquid 1 fraction
SFb 0 fraction Solids fraction
SPSb 1 Solid Average Particle Size
VALVE: CCXV1
OfeedStream CCS1 Valve feed stream connecting from
Source CCSRC1.
OprodStream CCS2 Valve product stream connecting to
Stream send CCSS1.
FlowType Mass
DPsiz 50 Kpa Delta pressure
Op 0.5 fraction Open Command
ActType Diaphram Actuator Type
177
HEADER: CCH1
OfeedStream[0] CCS3 Header feed stream connecting
from Stream receive CCSR1
OprodStream[0] CCS4 Header product stream connecting
to Valve CCXV2
VALVE: CCXV2
Header CCH1.
Sink CCSNK1.
FlowType Mass
SINK: CCSNK1
OfeedStream[0] CCS5 Sink feed stream connecting from
Valve CCXV2.
178
Strem Modify
Data Entry Window
Stream Receive Basic
Place a CCStream Send model on the target flowsheet and attach it to the other equipment.
Open the Data Entry Window of the Stream Receive unit.
To connect the unit to a Stream Send unit on a different flowsheet, select the Stream Send
object to which to connect this Stream Receive object.
To leave the CCStream Send unit unconnected, enter a value for the Boundary Flow, in
kilogram-moles per second.
179
Stream Receive Notes
180
Strem Modify
Parameters
Basic
Description UOM
Network sensitivity method
0 – NODERIVS
1 – LOCAL
When set to LOCAL (the
default), a local network
sensitivity will be calculated
and sent to the other engine
to stabilize pressure and flow
SensitivityMode calculations. If this is KI 1 No
changed to NODERIVS then
no sensitivity calculations will
be used. The pressures and
flows will match exactly each
time step but oscillations and
instability may occur.
Matching values should be set
at each end of a connection.
Boundary Conditions
Description UOM
Flow sensitivity
Change in calculated flow
when downstream node (kg-
DFDP DD 0 Yes
pressure changes. Used to mol/sec)/kPa
stabilize connection
between networks.
Boundary flow
Boundary flow to be used
FB if this is a stream DD 0 Yes kg-mol/sec
origination. This object
then acts like a StreamSet
with a fixed flow.
181

Description UOM
Fraction of boundary flow
Fraction of FB set to
KF outlet stream when used DD 1 Yes
stand-alone. Use for
temporary flow control
before system integration.
Calculated Values
Connection Status
0 – No connection
configured
1 – Connection in same
ConnectionStatus engine DI 0 No
2 – Connection in
different engine
3 – Attempted
connection failed
Pressure sensitivity
Sensitivity of connected
node pressure to kPa/(kg-
DPDF changes in this flow. DD 0 No
mol/sec)
Sent to StreamSend in
other engine to stabilize
network.
Liquid phase pressure kPa/(kg-
DPDFL DD 0 No
sensitivity mol/sec)
Liquid 2 phase pressure kPa/(kg-
DPDFL2 DD 0 No
Vapor phase pressure kPa/(kg-
DPDFV DD 0 No
Liquid phase mass
DPDWL DD 0 No kPa/(kg/sec)
pressure sensitivity
Liquid 2 phase mass
DPDWL2 DD 0 No kPa/(kg/sec)
Vapor phase mass
DPDWV DD 0 No kPa/(kg/sec)
182
Strem Modify

Calculated exit flow
Fx Exit flow calculated by DD 0 No kg-mol/sec
solver.
Topology
Parameter
Name
Product Stream
OprodStream Outgoing stream, which must be connected to a pressure CCSTREAM
node.
StreamSend object reference
OstreamSend Remote StreamSend object to be linked with this CCSTREAMSEND
StreamReceive object.
183
FAQ
Q. Why is the Flow Boundary parameter in the CCStream Receive model dynamic and not
static as in other models?
A. When a CCStream Receive model is connected with a Stream Send model, the boundary flow
is continually updated with the latest value taken from the remote end of the connection. The
parameter is dynamic so that if the CCStream Receive is disconnected for any reason, for
example, by deleting the remote engine, then the DYNSIM application can still load an initial
condition and run it without a delay or an error.
If the parameter were static, then the current value would reset when you perform a Load Full
operation, which is undesirable.
184
Stream Send
Introduction
The CCStream Send model, when used with the CCStream Receive model, allows process
streams to connect across flowsheet boundaries. If the flowsheets are in the same engine, the
CCStream Send/CCStream Receive pair extends the same pressure flow network without a
break. If the flowsheets are in different DYNSIM engines, the CCStream Send/CCStream
Receive pair links the two different networks using an internal transfer of the stream properties
between the engines. A transfer of pressure flow sensitivities also preserves stability at the
network break point.
The CCStream Send by itself may be configured as a fixed pressure node to allow easier
management of sub-models for later integration.
The CCStream Send is supported only by the simultaneous pressure flow solver. You should not
use it in legacy pressure flow networks.
Configure the CCStream Send model in a manner similar to a pressure node in the pressure-flow
network. The adjacent upstream model must be a flow device. If a connection is made between
engines, the upstream flow device should have a large pressure difference across it, because this
improves dynamic accuracy across the connection.
When the engines are loaded and the CCStream Send model is connected to a CCStream Receive
model, double-clicking on the CCStream Send model brings the CCStream Receive and its
associated flow sheet to the foreground. When the engines are not loaded, double-clicking on the
CCStream Send model brings either its Data Entry Window or its Object Editor Viewer to the
foreground, depending on the Edit/Run environment.
Fundamentals
Use as a Boundary
If a CCStream Send model is not connected to a CCStream Receive model, it acts as a network
boundary similar to a CCSource or CCSink model. In this case the boundary pressure is set by
the Pb parameter. Unlike in a CCSource or a CCSink model, the Pb parameter here is dynamic,
and the model loads it and saves it with initial conditions. You may also specify the elevation,
and the model uses this value when a connection to a CCStream Receive does not exist.
CCStream Send does not offer a means to enter stream properties, but you can configure an
initialization CCSource model for this purpose. The CCSource model provides the stream
composition and other properties for reverse flow out of the CCStream Send.
Making Connections within the Same Engine

185
If a CCStream Receive model is connected to a CCStream Send model and exists within the
same engine, and the engine is launched, the CCStream Send/CCStream Receive pair acts as
invisible glue joining the sent and received streams together. The flow device upstream of the
CCStream Send becomes directly attached to the pressure node downstream of the CCStream
Receive. In this case, none of the CCStream Send parameters such as PB or the initialization
Source have any effect.
Making Connections between Different Engines
If a CCStream Receive model is connected to a CCStream Send model and exists within a
different DYNSIM engine, and the simulation is launched, a special network connection between
the engines is set up. The CCStream Send acts as a network boundary, but its boundary pressure
is dynamically adjusted to correspond to the remote network state. Likewise, the CCStream
Receive has its boundary flow dynamically adjusted to correspond to the flow entering the
CCStream Send. Additionally, a calculation involving the transfer of pressure and flow
sensitivities is made to preserve stability across the interface. The sensitivity calculation may
lead to some transient time lags in the transmission of pressure and flow through the interface;
the effects of which may be reduced by selecting the largest available pressure difference
upstream of the CCStream Send, and the largest available pressure node (compressible,
preferably) downstream of the CCStream Receive.
When connecting engines, the stream properties in the forward and reverse direction
communicate automatically at each time step, without the need to configure any entries in the
cross-reference table.
In this mode, the CCStream Send elevation reflects the elevation of the remote pressure node in
the other engine, and the elevation parameter will have no effect.
Pressure Node
CCStream Send is a pressure node object and implements a dynamic pressure calculation in the
pressure-flow network. The details of this calculation depend on the configuration of the
CCStream Send object.
If the CCStream Send has no connection configured to a CCStream Receive object, then the
pressure equation applied is:
P = Pb
Where:
P = Inlet stream pressure (kPa)
Pb = Boundary pressure (kPa)
186
Stream Send
If the CCStream Send does have a connection configured to a CCStream Receive object, and that
CCStream Receive object is not present in the same engine, then the pressure node equation is
this:
P = Pb + (F – F0)(∂Premote/∂Flocal)
Where:
P = Inlet stream pressure (kPa)
Pb = Boundary pressure received from pressure node in remote engine (kPa)
F = Inlet flow from upstream flow device (kg-mol/sec)
F0 = Balancing flow fed back from remote engine (kg-mol/sec)
Premote = Pressure of node attached to CCStream Receive in remote engine (kPa)
Flocal = - Local flow transmitted to pressure node in remote engine (kg-mol/sec)
∂Premote/∂Flocal = Pressure sensitivity of remote node received from remote engine

(kPa-sec/kg- mol)
F0 is the flow most recently computed by the CCStream Receive in the remote engine. By
feeding back this flow from the remote engine, flow mismatches between the local and remote
engines are reduced.
Note that even if the connection to a remote engine is not active, when the CCStream Send icon
is red, the same equation applies. In this case the values of Pb, F0 and ∂Premote/∂Flocal are
taken from the current snapshot or IC. This allows a simulation to be continued from a saved IC
without a bump. However, the values of these parameters should not be manipulated by hand
other than perhaps to set the dPdF parameter to zero.
If the CCStream Send has an active connection to a CCStream Receive in the same engine, then
the CCStream Send/CCStream Receive pair is eliminated from the pressure-flow network and no
pressure equation exists.
187
Data Transfer
If a CCStream Send is connected to a CCStream Receive in a remote engine, then at each time
step the following parameter values are transferred by internal cross-reference from the local
engine to the remote engine:
F → Fb
dFdP → dFdP
Tf → Tf
Rf → Rf
CPf → CPf
MWf → MWf
VFf → VFf
LF1f → LF1f
LF2f → LF2f
SFf → SFf
SPSf → SPSf
The following parameters are transferred from the remote engine to the local engine:
Pb ← P
F0 ← Fx
E ← Ei
dPdF ← dPdF
Tr ← Tr
Rr ← Rr
CPr ← CPr
MWr ← MWr
VFr ← VFr
LF1r ← LF1r
LF2r ← LF2r
SFr ← SFr
SPSr ← SPSr
188
Stream Send
Where any of the parameters listed are not contained in the CCStream Send or CCStream
Receive models themselves, they are located in the inlet or exit streams.
If a CCStream Send is connected to a CCStream Receive in the same engine, then all stream
properties are mirrored between the inlet stream and the exit stream so that the contents of both
streams remain the same before and after network solution.
Example
This example shows a connection from one flowsheet to another. The Stream Send component
CCSS1 sets its Stream Receive connection to CCSR1, and the Stream Receive component
CCSR1 sets its Stream Send connection to CCSS1.
This symmetrical connection normally happens automatically. The stream from flowsheet FS1
goes to flowsheet FS2.
Stream Send: CCSS1

OstreamReceive CCSR1 Stream Receive object reference
OfeedStream CCS2 Feed stream object reference
Stream Receive: CCSR1

OstreamSend CCSS1 Stream Send object reference
OprodStream CCS3 Product stream object reference
189
SOURCE: CCSRC1
OprodStream[0] CCS1 Source product stream connecting to
the Valve CCXV1
VALVE: CCXV1
Source CCSRC1.
Stream send CCSS1.
FlowType Mass
190
Stream Send
HEADER: CCH1
OfeedStream[0] CCS3 Header feed stream connecting
from Stream receive CCSR1
OprodStream[0] CCS4 Header product stream connecting
to Valve CCXV2
VALVE: CCXV2
Header CCH1.
Sink CCSNK1.
FlowType Mass
SINK: CCSNK1
OfeedStream[0] CCS5 Sink feed stream connecting from
Valve CCXV2.
191
Data Entry Window
Stream Send Basic
Place a CCStream Send model on the CCSource flowsheet, and attach it to the existing
equipment.
Open the Data Entry Window of the Stream Send unit.
To connect the unit to a Stream Receive unit on a different flowsheet, select the Stream Receive
object to which to connect this Stream Send object.
To leave the CCStream Send unit unconnected, enter a value for the Boundary Pressure, in
kPa.
192
Stream Send
Stream Send Notes
Place a CCStream Send model on the CCSource flowsheet, and attach it to the existing
equipment.
Open the Data Entry Window of the Stream Send unit.
To connect the unit to a Stream Receive unit on a different flowsheet, select the Stream Receive
object to which to connect this Stream Send object.
To leave the CCStream Send unit unconnected, enter a value for the Boundary Pressure, in
kPa.
193
Parameters
Basic
Description UOM
Network sensitivity method
0 – NODERIVS
1 – LOCAL
When set to LOCAL (the
default), a local network
sensitivity will be calculated
and sent to the other engine
to stabilize pressure and flow
SensitivityMode calculations. If this is KI 1 No
changed to NODERIVS then
no sensitivity calculations will
be used. The pressures and
flows will match exactly each
time step but oscillations and
instability may occur.
Matching values should be set
at each end of a connection.
Boundary Conditions
Description UOM
Back pressure sensitivity
Change in boundary pressure kPa/(kg-
DPDF when feed flow changes. Used DD 0 Yes
mol/sec)
to stabilize connection
between networks.
Balanced flow from other
network
F0 Balanced flow from other DD 0 No kgl/sec
network (used by internal
calculations).
194
Stream Send

Description UOM
Boundary pressure
Boundary node pressure to be
used if this is a stream
PB DD 101.325 Yes kPa
termination. Note that unlike
a Source or Sink
this is a dynamic parameter.
Calculated Values
Connection Status
0 – No connection
configured
1 – Connection in same
ConnectionStatus engine DI 0 No
2 – Connection in
different engine
3 – Attempted connection
failed
Calculated flow Kg-
DFDP DD 0 No
sensitivity mol/sec
P Calculated pressure DD 101.325 Yes kPa
195
Topology
Parameter Name Description Default Class
Feed Stream
OfeedStream Incoming stream to be transferred to CCSTREAM
StreamReceive object.
StreamReceive object reference
OstreamReceive Remote StreamReceive object to be linked with CCSTREAMRECEIVE
this Stream Send object.
FAQ
Q. Why is the Pressure Boundary parameter in the Stream Send model dynamic and not
static as in other models?
A. When a CCStream Send model connects to a CCStream Receive model, the boundary
pressure is continually updated with the latest value taken from the remote end of the
connection. The parameter is dynamic so that if the CCStream Send is disconnected for any
reason, for example, by deleting the remote engine, then the DYNSIM application can still
load an initial condition and run it without a delay or an error.
If the parameter were static, then the current value would reset when you perform a Load Full
operation, which is undesirable.
196
Valve
Introduction
The CCValve is a flow device that the pressure flow solver uses to regulate forward and reverse
flow in the pipelines, to maintain level in the CCDrum, to control the CCDrum and pipeline
pressure, and to control temperature.
The CCValve has two types of actuators:.
• Diaphragm-actuated valves have a single open input command that sets the position of
the valve and are used for control valve applications.
• Motor-actuated valves have independent open and close commands and are used for
isolation valve applications.
The CCValve has linear, equal percentage, quick opening, butterfly, modified linear, uni-
rotational, counter rotational and custom trims. The CCValve supports direct and reverse actions.
The CCValve can model the actuator only, without any stream connections. In this way, the
CCValve can provide a position or conductance to another model. For example, The CCValve
can provide a position to a CCCompressor inlet guide vane or a conductance to a CCExpander or
CCHeat Exchanger bypass. This configuration is known as graphical CCValve. The
CCExpander FAQ gives more information on the graphical CCValves.
The CCValve executes without any user input, based on default values. To obtain accurate flows,
you must edit Wsiz, DPsiz, and RMasssiz input parameters. To achieve a linearized influence
co-efficient of the effect of pressure change on fluid temperature, you must edit the DTsiz input
parameter.
This unit conserves both mass and phase splits.
to be a flow device.
197
Fundamentals
Fundamentals
Valve Flow Conductance
When ΔPsiz is greater than ΔPlin, the model calculates flow conductance using these equations:
J = (Wsiz / SqRt(ΔPsiz * RMasssiz ) ) * (A / Asiz)
When ΔPsiz is less than or equal to ΔPlin, the model calculates flow conductance using these
equations:
J = (Wsiz / ((ΔPsiz / SqRt(ΔPlin) ) * SqRt(RMasssiz) ) * (A / Asiz)
The model calculates the flow area A as a function of the CCValve Position and the Custom
Trim, using an algorithm that is not easily shown as an equation.
When ΔP is above ΔP lin, the model calculates flow through the device using these equations:
When ΔP is below ΔP lin, the model calculates flow through the device using these equations:
Ff = J * (ΔP / ΔPlin ) * SqRt(R / MW )
Fr = J * (ΔP / ΔPlin ) * SqRt(R / MW ) * KJr
The model calculates Temperature modification using this equation:
T = Ti – Δtsiz * ΔP / ΔPsiz
Where:
A = Valve flow area (based on trim and Valve position)
Asiz = Valve flow area at 50% Valve opening
198
Valve
CusTrim = Chosen trim type (Default = Linear)
ΔP = valve pressure drop
ΔPlin = Internal parameter, set to 10.0, that serves to smooth the relationship between
Flow and ΔP relationship
ΔPsiz = Sizing delta pressure for conductance and simple temperature effects
ΔTsiz = Sizing delta Temperature for simple temperature effects
Pos = CCValve position
T = Exit stream temperature
Ti = Inlet stream temperature
Tsiz = Sizing temperature for simple temperature effects
Wsiz = Sizing mass flow rate
199
Valve Actuator Design
There are two actuator types: Diaphragm and Motor. Both have the following
features
• Open and close times, with a default of 10 seconds

• Custom trim: Area vs. Lift
• Limit and travel switches
• Direct or reverse acting, with the default of direct.
This figure illustrates the sequence of calculations in the actuators to calculate

CCValve position Pos, fractional area A, and finally conductance J. If the trim
is linear, then position Pos and area A are equal.
The CCValve actuator includes a deadband, so the CCValve does not respond
to changes in the open and close command if those changes are smaller than a
user-specified value. The default value of deadband is zero; meaning no
deadband.
Valve Diaphragm Actuator
Diaphragm-actuated Valves only require a single open command to control the

CCValve. If the actuator travel is Linear (Rtype), the following equation
represents what the model uses.
where:
Pos - Position, as a fraction
Op - Open command, as a fraction
TimeOp - Time to open CCValve, in seconds
TimeCl - Time to close CCValve, in seconds
LIMV - Function to limit value between a minimum and maximum
If the actuator travel is first order, the following simplified equation is used.
200
Valve
In this case, TimeOp is the time constant for the first order lag. The CCValve takes
approximately three to four times the value of TimeOp for full travel.
Valve Motor-Operated Valve
Motor-operated Valves require two commands for control. The open command Op causes the
CCValve to open, while a close command Cl causes the CCValve to close. If the actuator travel
is Linear (Rtype), the following simplified equations represent what the model uses.
Where:
Pos - Position, as a fraction
Op - Open command, as a fraction
TimeOp - Time to open CCValve, in seconds
TimeCl - Time to close CCValve, in seconds
LIMV - Function to limit value between a minimum and maximum
Typically either Op or Cl has a value of 1, but both at the same time do not. If the actuator travel
is first-order, then the following equation is used.
Motor-operated Valves can be pulse modulated such that they only travel when Op or Cl have a
value. Alternatively, a full travel relay option is provided such that the CCValve will travel fully
if FTRelay is set to true.
Custom Trim
The relationship between control valve capacity and valve stem travel is known as the Flow
Characteristic of the control valve.
Trim design of the valve affects how the control valve capacity changes as the valve moves
through its complete travel. Because of the variation in trim design, many valves are not linear in
nature. Valve trims are instead designed, or characterized, in order to meet the large variety of
control application needs. Many control loops have inherent non linearities, which may be
possible to compensate selecting the control valve trim.
201
There are seven standard Valve trims (lift vs. area) available, in addition to the user defined trim.
The default is linear (lift = area). The standard Valve trims available are shown in the following
graph.
There are seven standard CCValve trims (lift vs. area) available, in addition to the user-defined
trim. The default is linear (lift = area). The standard CCValve trims available are shown in the
following graph.
Inherent Control Valve Flow Characteristics
The most common characteristics are shown in the figure above. The percent of flow through the
valve is plotted against valve stem position. The curves shown are typical of those available from
valve manufacturers. These curves are based on constant pressure drop across the valve and are
called inherent flow characteristics.
• Linear - flow capacity increases linearly with valve travel.

• Equal percentage - flow capacity increases exponentially with valve trim travel. Equal
increments of valve travel produce equal percentage changes in the existing Cv.
• Modified Linear - incremental valve travel near full closed and full open positions result
in less flow capacity changes than similar incremental changes in the middle of the travel
range. This allows for more precise control in the low and high flow regions for the
valve.
• Quick opening provides large changes in flow for very small changes in lift. It usually
has too high a valve gain for use in modulating control. So it is limited to on-off service,
such as sequential operation in either batch or semi-continuous processes.
• Butterfly - incremental flow capacity curve is approximately midway between linear and
equal-percentage characteristics. It provides fine throttling at low flow capacity and
approximately linear characteristics at higher flow capacity.
• Unirotational Louver - flow capacity curve is similar to modified linear, but quicker to
open. These are typically dampers used to control air flow.
202
Valve
• Counter Rotational - flow capacity curve is similar to modified linear, but quicker to open
(not as quick as Unirotational Louvers). These are typically dampers used to control air
flow.
Malfunctions
The Valve model supports nine different malfunctions. These malfunctions can be divided into
two categories, Analog and Discrete. Analog malfunctions can take any numerical value between
the high and low limit. Discrete malfunctions have either one or two states.
Analog Malfunctions
Fail to Position
The Fail to Position malfunction when activated will result in the Valve to fail to the specified
position. Allowable values range from 0 to 100% Valve position.
Positioner Bias
This malfunction introduces bias on the Valve position demand by the Mature Value. The
demand may be biased from full open to full closed. This malfunction will have no effect on
MOV Valves. It results in increase of flow for a positive bias and decrease in flow for a negative
bias. Allowable values range from –100 to 100% Valve position.
Valve Blockage
This malfunction creates a blockage in the Valve. It is similar to the Positioner Bias except that it
does not alter the Valve position. It results in decrease in the flow through the Valve. Allowable
values range from 0 to 100% Valve position.
Valve Leakage
This malfunction creates a leakage in the Valve. It is exactly opposite to the Valve Blockage. It
results in increase of flow through Valve when the opening is small or zero. At higher openings
of the Valve, leakage does not have any effect in flow. Allowable values range from 0 to 100%
Valve position.
Valve Travel Rate
This malfunction scales the Valve travel rate by the Mature Value. Allowable values range from
0 to 1000% of normal movement rate. A value above 100% results in an increase in the normal
movement rate. A value below 100% results in a decrease in the normal movement rate.
203
Dead Band
This malfunction creates a positioner deadband with magnitude given by the Mature Value.
When the position error is less than deadband (|position demand - position| < Mature Value) the
Valve will freeze. This malfunction will have no effect on MOV Valves. Allowable values range
from 0 to 100% Valve position.
Discrete Malfunctions
Broken Valve Stem
This malfunction will decouple Valve lift from Valve stem position. When triggered, flow
through the Valve will not change with change in position.
Open Limit Switch
This malfunction will decouple the open limit switch from Valve position.
• Switch stuck off (Ls0 = 0 regardless of Valve position where LS0 stands for Limit Switch
at 0% position)
• Switch stuck on (Ls0 = 1 regardless of Valve position).
Closed Limit Switch
This malfunction will decouple the closed limit switch from Valve position.
• Switch stuck off (Ls1 = 0 regardless of Valve position where LS1 stands for Limit Switch
at 100% position)
• Switch stuck on (Ls1 = 1 regardless of Valve position).
204
Valve
Example
This example configures a linear Valve FCV1 for flow control. Liquid at 300 kPa pressure and
298.15°K temperature is fed to a CCSink CCSNK1 at 100 kPa. Flow control CCValve FC1
maintains the flow at 20 kg/sec.
CCSource: CCSRC1
OProdStream[0] CCS1
CCValve FCV1
CCValve: FCV1
OFeedStream CCS1
OProdStream CCS2
to CCSink CCSNK1.
FlowType Mass
Flow controller FC1 output
Op FC1.OUT fraction connecting to CCValve(FCV1)
opening parameter
205

PID: FC1
PIDType MassRate
Stream CCS2 flow assigned to PV
PV CCS2.W Kg/sec
of flow controller FC1.
SP 20 Kg/sec Set point of the flow controller FC1.
Kp 0.1 Flow controller proportional gain
KI 0.1 1/sec Flow controller integral gain
Hi_In 50 Kg/sec High limit on PID controller input
Lo_In 0 Kg/sec Low limit on PID controller input
CCSink: CCSNK1
OFeedStream[0] CCS2
from CCValve FCV1.
206
Valve
Importance of Parameters
To understand how the parameters work, change their values and see how the model responds, as
shown in these examples.
When you vary the sizing parameters, the rate of material flow through the valve changes.
This example shows how the valve runs with default sizing parameters of 50 Kg/sec and 50 kPa.
This example shows how the valve runs when the mass flow rate increases to 100 Kg/sec. You
can see the increase in conductance, which leads to increased flow through the valve.
207
This example shows how the valve runs when the mass flow rate decreases to 30 Kg/sec. You
can see the decrease in conductance, which leads to decreased flow through the valve.
This example shows how the valve runs when the pressure drop across the valve decreases. You
can see that the lower the pressure drop across the valve, the higher the flow through the valve.
208
Valve
This example shows how the valve runs when the pressure drop across the valve increases. You
can see that the higher the pressure drop across the valve, the lower the flow through the valve.
209
Data Entry Window
Valve Sizing
Sizing
Enter the Mass Flow or Volumetric Flow in kilograms or m3 per second.
Enter the Pressure Drop in kPa.
Enter Valve Position in decimal fraction.
The Mass flow control corresponds to the Wref parameter. If Wref is not specified, the CCValve
inlet stream mass flow is used for calculation of Cv
The Pressure drop control corresponds to the DPref parameter. The default value is 50 kPa.
210
Valve
Valve Actuator
Actuator
Enter the Time to Open in seconds.
Enter the Time to Close in seconds.
The Time to open control corresponds to the TimeOp parameter. The default value is 30
seconds, which is appropriate for most cases. Use a low value (1 to 5 sec) for fast opening and
trip valves.
The Time to close control corresponds to the TimeCl parameter. The default value is 30 seconds,
which is appropriate for most cases. Use a low value (1 to 5 sec) for fast closing and trip valves.
Actuator Type
Select whether the type of Actuator is a diaphragm or a motor.
211
Valve Properties
Enter Mass Density in kilograms per m3
212
Valve
Valve Notes
Parameters
Actuator
Description Default Value UOM
Name Class Allowed Size
Action flag
Allowable values are
0 = REVERSE
Static
Action 1 = DIRECT DIRECT Yes
Integer
Reverse action
reverses direction of
valve travel.
Actuator type
Allowable values are Static
ActType DIAPHRAGM No
0 = DIAPHRAGM Integer
1 = MOTOR.
213

Description Default Value UOM
Name Class Allowed Size
Static
FTRelay Full travel relay 0 Yes
Bool
Failure position with Static
PosNoMP 0 Yes
no motive power Double
Type of rate travel
Allowable values are Static
Rtype LINEAR No
0 = LINEAR Integer
1 = FIRST_ORDER
Time to open
Static
TimeOp Time from full closed 10.0 Yes sec
Double
to full open.
Time to close Static
TimeCl Time from full open Double 10.0 Yes sec
to full closed.
Advanced
Description UOM
Custom trim table (A Vs L)
Predefined custom trim
types include
0 = LINEAR
1 = EQUALPERCENT
2 = QUICKOPEN
3 = BUTTERFLY Static
CusTrim LINEAR No
4 = MODLIN Integer
5 = UNIROT
6 = COUNTERROT
7 =USER
If you select User, you must
also provide a
CusTrimTable
214
Valve

Description UOM
Custom trim table (A vs. L)
Custom trim table for user
defined trim type. Create a
standalone STATIC
DOUBLE function table that
defines the desired valve
characteristic. Give it a
name such as
VALVETRIMCURVE. A
typical table may look like
this:
Static User
CusTrimTable 6 -999 0 Yes
Double Specified
0.0 0.0
0.2 0.3
0.4 0.5
0.6 0.9
0.8 0.95
1.0 1.0
Refer to this curve as
VALVETRIMCURVE[0]. Be
sure to use the trailing zero
to indicate that it is a vector.
Positioner deadband (valve
will not for input signal Static
DeadBand 0.0 Yes
changes smaller than Double
deadband)
215
Basic
Description UOM
Reverse flow conductance
factor
fraction of the forward flow Static
KJr 1 Yes fraction
conductance available for Double
reverse flow. If this parameter
is set to zero, the conductance
device acts like a check valve.
Calculated Values
Description UOM
DP 0 No kPa
CCValve Double
Valve stem position
(measured)
This corresponds to the Static
Pos measured stem position 0.5 No fraction
Double
You must explicitly
request to use it for
control cross referencing
Travel Status of full travel relay Static Int 0 No
216
Valve
External Inputs
Description UOM
Close command
Used for motor-operated
valves with separate open and
close commands. When equal Static
Cl 0 Yes fraction
to one, the Valve moves to the Double
closed position. The Valve only
moves while Cl is set to one
unless FTRelay is set to one
Dynamic
MP Normalized motive power INSTAIR Yes
Double
Open command
Open command is the only Static
Op 0.5 Yes fraction
input signal for DIAPHRAGM Double
actuators.
Stop Command
This is the command to stop Static
Stop
the travel of a motor-operated Integer
Valve if FTRelay is set to one.
Limit Switches
Description UOM
Closed limit switch
Set to one to create a closed limit
Ls0 switch. 1 No
0 = Open Limit Switch
1 = Closed Limit Switch
Open limit switch
Set to one to create an open limit
Ls1 switch. 0 No
0 = Closed Limit Switch
1 = Open Limit Switch
Sizing
217

Description UOM
Sizing delta pressure
The model supports a
linearized influence coefficient
of the effect of pressure
change on fluid temperature. Static
DPsiz 50.0 Yes kPa
You can use this parameter to Double
approximate the effect of Joule
– Thomson expansion when
needed. This value must be a
positive number.
Sizing delta temperature
The model supports a
linearized influence coefficient
of the effect of pressure
change on fluid temperature. Static
DTsiz 0.0 Yes K
You can use this parameter to Double
approximate the effect of Joule
– Thomson expansion when
needed. This value must be a
positive number.
Flow type for reference sizing
Static
FlowType flow (0 – Mass based, 1 – 0-Mass No
Int
Volume based)
Static
POSsiz Valve stem position 0.5 No
Double
Sizing Volumetric Flow
approximate a CCValve Static
Qsiz 0.05 Yes M3/sec
conductance (at 50% CCValve Double
area). This value must be a
positive number.
Sizing mass density
RMasssiz 999.01 Yes kg/m3
positive number.
218
Valve

Description UOM
Sizing Mass Flow
Wsiz 50.0 Yes kg /sec
positive number.
Topology
Parameter
Name
Feed Stream
flow sheet. However, this entry can be the same as a product
Product Stream
the flow sheet. However, this entry can be the same as a feed
FAQ
Q. What is the difference between a CCValve diaphragm and motor actuator?
A. A diaphragm-actuated has a single input command called Op. A motor actuator has two input
commands, Op for open and Cl for close. OTS applications require two input signals for open
and close because these are the signals from the DCS.
Q. Does the CCValve model support reverse flow?
A. Yes, the CCValve supports reverse flow. You can model the reverse flow by setting the KJr
parameter to 1. If you do not want to model reverse flow, set KJr to 0.
219
Q. Can you explain the sizing parameters Mass flow and Pressure drop?
A. The mass flow and pressure drop decide the conductance of the valve. To increase or decrease
the flow through the valve, you must increase or decrease the conductance. Conductance is
increased or decreased by varying the two sizing parameters Mass Flow and Pressure Drop.
To see what happens when the Mass Flow and Pressure Drop change, see the CCValve
Example.
220
Invensys Systems, Inc.
26561 Rancho Parkway South
Lake Forest, CA 92630
United States of America
http://iom.invensys.com
Global Customer Support

Inside U.S.: 1-866-746-6477
Outside U.S.: 1-508-549-2424 or contact your
local Invensys Representative.
Email: [email protected]
Website: http://support.ips.invensys.com

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Schneider Electric Software, LLC

Additional Reading ................................................................................................................. 1

Why Dynamic Simulation for Control Checkout?...................................................................... 2

How Medium Fidelity Simulation Saves Project Cost ........................................................... 3

Medium Fidelity Suitability for Operator Training ................................................................ 3

Pressure-Flow Solver .................................................................................................................. 4

Flow Paths ............................................................................................................................... 5

Flow Path Parameters WLin and DPLin ................................................................................. 5

Internal Units of Measure ........................................................................................................... 6

Process Equipment Model Types................................................................................................ 7

Pressure Node Attributes ........................................................................................................ 7

Flow Device Attributes ........................................................................................................... 8

Basic Unit Operations ................................................................................................................. 8

Definition of Reference State...................................................................................................... 9

Modeling Philosophy .................................................................................................................. 9

Configuring and Parameterizing Models .............................................................................. 10

Checkout Equipment Material Characterization ................................................................... 10

Flow Networks ...................................................................................................................... 11

Project Considerations .............................................................................................................. 12

Tuning to the Process Flow Diagram........................................................................................ 13

Process Stream .............................................................................................................................. 18

Bin Fundamentals ..................................................................................................................... 22

Fundamentals General .......................................................................................................... 22

Bin Fundamentals Material Balance ..................................................................................... 22

Bin Fundamentals Phase Fractions ....................................................................................... 23

Bin Fundamentals Temperature ............................................................................................ 24

Bin Fundamentals Other State Derivatives ........................................................................... 24

Data Entry Window .................................................................................................................. 27

Bin Input ............................................................................................................................... 27

Bin Notes .............................................................................................................................. 29

Component List ............................................................................................................................. 34

Data Entry Window .................................................................................................................. 36

Component List Input ........................................................................................................... 36

Component List Notes .......................................................................................................... 37

Gate Fed Conveyer ............................................................................................................... 42

Self -Fed Conveyer ............................................................................................................... 45

Motor Connection ................................................................................................................. 45

Data Entry Window .................................................................................................................. 51

Conveyer Feeds ..................................................................................................................... 52

Conveyer Notes ..................................................................................................................... 52

Material Balance ................................................................................................................... 61

Phase Fractions ..................................................................................................................... 63

Composition Balance ............................................................................................................ 63

Relationship between Pressure, Fluid Density and Bulk Modulus ....................................... 64

Holdup Fluid Temperature .................................................................................................... 65

Other State Derivatives ......................................................................................................... 65

Data Entry Window .................................................................................................................. 70

Header Properties .................................................................................................................. 71

Header Notes ......................................................................................................................... 72

Mechanical Screen ........................................................................................................................ 81

Inlet Particle Size .................................................................................................................. 81

Outlet Particle Size ............................................................................................................... 81

Amount going to Accept and Reject Stream......................................................................... 82

Data Entry Window .................................................................................................................. 86

Mechanical Screen Input....................................................................................................... 86