Simple Manual Method for Settle Out Condition Estimation

Compression system shutdown, block-in, settle out follow by system blowdown is common in any oil and gas, refinery and
LNG production facilities. A methodology using HYSYS simulation software has been presented in "Simple Method For
Compressor Settle Out (Vapor Only) Using HYSYS" and this method is particularly applicable to vapor only system. In
order to handle system contains vapor and liquid, the method has been extended "Adjusted Method For Compressor
Settle Out (with Vapor & Liquid) Using HYSYS". Some engineers asked a question, this method is applicable during
detailed design. Nevertheless, is there any simpler and manual method that may be used for quick estimation during
proposal and/or conceptual stage ? Yes... Following is a simple manual method may be considered.
This method is utilising universal gas law (PV=znRT) with the following basis and assumption :

Vapor only system

No condensation during the process

Compressibility factor assumed same for condition before and after settle-out and assumed (z=1)

Limited fluid with molecular weight is similar range. Higher the different, higher the deviation

A system consists of n-section with pressure (Pi, kPag), temperature (Ti, K), Molecular weight (MW i), physical volume
(Vi,m3)
for
i-section.
Number of mole in each i-section (before settle-out),
ni = (Pi x Vi) / (zi x R x Ti).....[1]
Total mole (after settle-out),
ns = Sum (n1 + n2 + n3...).....[2]
Total volume (after settle-out),
Vs = Sum (V1 + V2 + V3...).....[3]
Volume at normal condition (Pi,n = 1.01325 bar & Ti,n = 273.15 K) for each i-section (before settle-out)
Vi,n = (Pi x Vi / Ti) /(Pi,n / Ti,n)......[4]
Total volume at normal condition (after settle-out)
Vs,n = Sum (V1,n + V2,n + V3,n...).....[5]
ni x Ti for each i-section (before settle-out),
ni x Ti = (Pi x Vi) / (zi x R).....[6]
Total ns x Ts (after settle-out),
ns x Ts = Sum (n1 x T1 + n2 x T2 + n3 x T3 +...).....[7]
Thus, From [7] and [2],
Settle-out temperature (Ts),
Ts = Sum (n1 x T1 + n2 x T2 + n3 x T3 +...) / ns .....[8]

Settle-out pressure (Ps),

Case Study
A methane compression system with the following conditions.
Suction :
Pressure, P1 = 5 barg
Temperature, T1 = 50 degC
Molecular weight, MW = 16.0429
Physical Volume, V1 = 1 m3
Compressor discharge (Hot) :
Pressure, P2 = 15 barg
Temperature, T2 = 150 degC
Molecular weight, MW = 16.0429
Physical Volume, V2 = 1 m3
Cooler discharge (Cool) :
Pressure, P3 = 15 barg
Temperature, T3 = 50 degC
Molecular weight, MW = 16.0429
Physical Volume, V3 = 1 m3
Using method as proposed in "Simple Method For Compressor Settle Out (Vapor Only) Using HYSYS", the settle out
pressure and temperature are 11.73 barg and 86.3 degC. (see below image).

Using manual method as proposed above (program in Excel), the settle out pressure and temperature are 11.67 barg and
85.7 degC. (see below image).

The percentage error are 0.5% and 0.7% for pressure and temperature respectively.
This shown the method is reasonable.

Simple Method For Compressor Settle Out Using HYSYS

Compressor emergency blowdown is commonly initiated after compressor system shutdown. The compressor shutdown
will also lead to Compressor System Suction shutdown valve (SDV) and Discharge SDV to shut close and the anti-surge
and/or capacity control valve open. Compressor discharge with high pressure and hot, air cooler and downstream high
pressure and cold and suction vessel low pressure and cold will be settled-out prior to blowdown.
How to estimate the settle out condition ?
Settle-out of compressor system can be conducted using HYSYS. The main concept is constant mass and volume
before and after settle-out. It is assumed the settle out is carried out adiabatically.
Following are some steps can be used to obtain the settle-out condition. Let start with following image.

Step 1 : Calculate physical volume of Compressor Suction (V1), Compressor Discharge (V2) and Air Cooler Downstream
(V3).
Step 2 : Setup the system as per above image by correct Compressor Suction, Compressor Discharge and Air Cooler
Downstream operating condition and composition.
Step 3 : Adjust Compressor Suction, Compressor Discharge and Air Cooler Downstream Mass flow until the respective
Actual Volumetric Flow same as V1, V2 and V3.
Step 4 : Set Balance (BAL-1) for Mole & Heat
Step 5 : Adjust Settle-out Cond stream pressure until the Actual Volumetric Flow same as V1+V2+V3.
Thus, the settle out condition can be extracted from the Settle-out Cond stream.
Do you aware of other method ? Why not share with us ?

Adjusted Method For Compressor Settle Out (with Vapor & Liquid)
Using HYSYS

Since the release of "Simple Method For Compressor Settle Out Using HYSYS", some readers of Chemical & Process
Technology raised a question. The proposed method has considered all in VAPOR, how shall this method apply in case of
present of VAPOR and LIQUID in Compressor Suction drum and Air Cooler Downstream ?
It is correct that the simple method is simplified version for VAPOR only Settle out condition. Nevertheless, minimum
adjustment to the method enable the method to be used for condition with VAPOR and LIQUID. First refer to following
image.

Step 1 : Compressor Suction. Estimate physical volume of vapor (Vv1) and liquid (Vl1).
Step 2a : Compressor Suction. Separate Compressor Suction Inlet (stream 1) with 2-phases (vapor & Liquid) with
Separator unit operation.
Step 2b : Copy Compressor Suction Inlet Vapor (stream 2) condition and composition to a new stream Actual Compressor
Suction Inlet Vapor ((stream 4). Adjust Mass flow of this stream until the Actual Volumetric Flow equal to Vv1.
Step 2c : Copy Compressor Suction Inlet Liquid (stream 3) condition and composition to a new stream Actual Compressor
Suction Inlet Liquid (stream 5). Adjust Mass flow of this stream until the Actual Volumetric Flow equal to Vl1.
Step 2d : Mix Actual Compressor Suction Inlet Vapor (stream 4) and Actual Compressor Suction Inlet Liquid (stream 5) to
form Compressor Suction (stream 6).
Normally the Compressor Discharge stream is superheated and no liquid is expected.
Step 3 : Air Cooler Downstream. Estimate physical volume of vapor (Vv3) and liquid (Vl3).
Step 4a : Air Cooler Downstream. Separate Air Cooler Downstream Outlet (stream 7) with 2-phases (vapor & Liquid) with
Separator unit operation.
Step 4b : Copy Air Cooler Downstream Outlet Vapor (stream 8) condition and composition to a new stream Actual Air
Cooler Downstream Outlet Vapor (stream 9) . Adjust Mass flow of this stream until the Actual Volumetric Flow equal to Vv3.
Step 4c : Copy Air Cooler Downstream Outlet Liquid (stream 10) condition and composition to a new stream Actual Air
Cooler Downstream Outlet Liquid (stream 11). Adjust Mass flow of this stream until the Actual Volumetric Flow equal to Vl3.
Step 4d : Mix Actual Air Cooler Downstream Outlet Vapor (stream 9) and Actual Air Cooler Downstream Outlet Liquid
(stream 11) to form Air Cooler Downstream (stream 12).
The remaining steps are same as "Simple Method For Compressor Settle Out Using HYSYS" by adjusting Settle Out
Cond Actual Volumetric Flow same as Vv1+Vl1+V2+Vv3+Vl3.